Professional Documents
Culture Documents
Skid-Steer Loader
S/N AT6311001 & Above
S/N B3BW11001 & Above
7252384enUS (12-17) (C) Printed in U.S.A. ©2017 Bobcat Company. All rights reserved.
T4-B S4-B
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
FW SSL-0617 SM
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.
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
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.
SI SSL-1016 SM
SI SSL-1016SM
SI SSL-1016 SM
Fire Extinguishers
SI SSL-1016 SM
Figure 1 1
P121092A
1
P100390E
Figure 2
Module 2 - Production
Sequence (Series)
Figure 4
NA3106
2 20
1 11
3
19
4 12
5 18
13
10
14
6
9
7 8 17
15
16
NA9749
NA9752
[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.
Procedure
Figure 10-10-1
P-85425
P-85423
Figure 10-10-3
WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807 P-85424
Read the Removal And Installation, Disassembly And Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the struts [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tracks. Make sure the tracks clear the floor or
any obstacles.
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.
Figure 10-20-1
P109924
Start the engine and raise the lift arms all the way up.
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised P-90567B
unless supported by an approved lift arm
support. Replace if damaged. Have a second person install the lift arm support device
D-1009-0409
over the rod of one of the lift cylinders [Figure 10-20-3].
Remove attachment from the loader. The lift arm support device must be tight against the
cylinder rod.
Figure 10-20-2
Figure 10-20-4
P100399
P107247A P100009
P100398
DANGER
P-90328
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.
P109924
Description
Level I
Level II
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
Raising WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See Installing on Page • STOP ENGINE before raising or lowering cab.
10-20-2.) W-2758-0908
Figure 10-30-3
P107247
Figure 10-30-2
P100235A P100236A
Figure 10-30-5
P100953 P-90565A
Figure 10-30-6
P-68116B
Figure 10-30-7
NA3275
Figure 10-30-8
NA1026
Figure 10-30-10
NA1819
P100984
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can P107245A P107253A
Figure 10-40-1
P100727D
P107246A P-85599C
1
P100728D 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.
Procedure
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC-
10-2.)
Figure 10-60-1
1
P16117
Figure 10-60-3
2 2
1
1
P114629
Remove the service tool harness (Item 1) from the cover Connect the service tool harness to the ACD connector
(Item 2) [Figure 10-60-3]. and the loader harness connector.
P-85729
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
Figure 10-60-8
1
1
P114631
Figure 10-60-11
P-85729
Figure 10-60-9 2
P114632
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the Remote Start Tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped). NOTE: The key switch on the right-hand side
operator panel must be in the OFF position or
the Remote Start Tool Kit will not operate.
WARNING
2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in P16118
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock The traction lock switch (Item 1) [Figure 10-60-13] is
the keypad with a unique password (keyless) or used to turn traction lock ON or OFF. Push the switch to
otherwise disable the starter before working in the OVERRIDE position. The switch will illuminate to
the engine area. indicate traction lock OVERRIDE, in this position the
W-2457-1110 wheels are able to turn.
Figure 10-60-12 The maximum flow / variable flow switch (Item 2) [Figure
10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when testing pressures and flow rate.
WARNING
P16116
AVOID INJURY OR DEATH
• Use traction lock override switch for service work
with seat bar raised.
The Remote Start Tool (Item 1) [Figure 10-60-12] has
• Traction lock is engaged when light is OFF.
three rocker switches.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209
Figure 10-60-14
P-85311
Description
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.
1 1
P114629
2
The Loader Service Tool Harness (Item 1) [Figure 10- When the remote start procedure is completed, replace
61-3] is used to connect the Remote Start Tool (Service the loader connector cap (Item 1) [Figure 10-61-4] or
Tool) (Item 2) [Figure 10-61-3] to the electrical system on reconnect the attachment control harness to the loader
the loader. harness [Figure 10-61-5].
1
2
3
P-85729 P114632
Loaders without an attachment control harness, remove NOTE: The Remote Start Tool (Service Tool)
the loader harness cap (Item 1) [Figure 10-61-4] and connection harness has two connectors (Item
connect the Loader Service Tool Harness from the 1) and (Item 3). The main connector (Item 1)
Remote Start Tool (Service Tool). [Figure 10-61-6] is always used for connection
to the loader harness.
WARNING
AVOID INJURY OR DEATH
• 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
Figure 10-61-7
2
P-76450
WARNING
1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
P-85729
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area. Loaders without an attachment control harness, remove
W-2457-1110 the loader harness cap (Item 1) [Figure 10-61-9] and
connect the Loader Service Tool Harness from the
The tool listed will be needed to do the following Remote Start Tool (Service Tool).
procedure:
NOTE: When using a Remote Start Tool (Service tool)
7217666: Remote Start Tool (Service Tool) Kit harness on loaders not equipped with an
attachment control device, the Remote Start
Figure 10-61-8 Tool (Service Tool) harness attachment
control device connector must be capped.
Figure 10-61-10
1
P-76450
2
Figure 10-61-12
1 2
5 3
6 4
P114632
1
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-11] is always used for P-76439
connection to the loader harness.
The second connector (Item 3) [Figure 10-61- The Remote Start Tool (Service Tool) (Item 1) [Figure
11] is used for attachment ACD upgrades or 10-61-12] has five buttons.
attachment operational diagnostics only. This
connector has a cap attached to it to prevent The STOP button (Item 2) [Figure 10-61-12] is used to
damage or corrosion when not in use. stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
Connect the Remote Start Tool (Service Tool) connector
(Item 1) to the loader harness connector (Item 2) and the The RUN button (Item 3) [Figure 10-61-12] is used to
other Remote Start Tool (Service Tool) connector to the turn the Remote Start Tool (Service Tool) on and
ACD harness connector (Item 3) [Figure 10-61-11]. activates the loader electrical system. The button will
illuminate to indicate the service tool is active.
NOTE: The key switch must be in the OFF position or
the Remote Start Tool (Service Tool) will not The START button (Item 4) [Figure 10-61-12] is used to
operate. start the loader engine.
Figure 10-61-13
1 2
P106657
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.
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.
• Battery – Check cables, connections, and electrolyte level; add distilled water as needed.
• Engine Oil and Filter – Perform every 100 hours when operating under severe conditions. Replace oil and filter.
• 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.
• Diesel Exhaust Fluid (DEF) / AdBlue® Filter – Replace the diesel exhaust fluid (DEF) / AdBlue® filter.
Replacing Filters
Figure 10-80-1
1
3
P121219
NA3271
P121218A
Inner Filter
P121220
Install new inner filter. Push in until the filter contacts the
base of the housing.
Check the cooling system every day to prevent over- See the SERVICE SCHEDULE for the correct service
heating, loss of performance, or engine damage. interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Figure 10-90-1
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
Figure 10-90-2
P107266
1
A maintenance platform [Figure 10-90-1] is available to
facilitate access when cleaning the engine cooling
system.
3
P121169B
Loaders With Air Conditioning Return the support bar to storage position and lower the
air conditioning condenser.
Figure 10-90-3
Figure 10-90-5
1
1
2 2
P121216B
P121162
P121217D
Figure 10-90-6 2
3
1
1
P121216D
The area between the fuel cooler and the hydraulic fluid
Use low air pressure or low water pressure to clean the cooler and radiator assembly will require occasional
top of the hydraulic fluid cooler and radiator assembly cleaning. Remove the bolt (Item 2) and lift the fuel cooler
(Item 1) [Figure 10-90-6]. up while sliding out of the brackets (Item 1) [Figure 10-
90-7].
Install the fuel cooler into the brackets. Install and tighten
the bolt [Figure 10-90-7].
WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907
Stop the engine, open the rear door, and remove the rear
grille. (See Removing on Page 50-60-1.)
1
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine P121163
is hot. You can be seriously burned.
W-2607-0804
Pinch off the coolant hose attached to the engine oil
cooler using a locking hose pinching plier (Item 1)
NOTE: This procedure requires the use of a spare [Figure 10-90-10] or similar tool.
19 mm (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
P121221A P121164
Remove the coolant fill cap (Item 1) [Figure 10-90-9]. Remove the clamp (Item 2) and disconnect the hose
(Item 3) from the engine oil cooler fitting (Item 1) [Figure
10-90-11].
1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Install the coolant hose (Item 2) onto the engine oil cooler
fitting and install the clamp (Item 1) [Figure 10-90-13].
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 5% biodiesel mixed with ultra used:
low sulfur petroleum based diesel. This
biodiesel blend fuel is commonly marketed as • Ensure the fuel tank is as full as possible at all times
B5 blended diesel fuel. B5 blended diesel fuel to prevent moisture from collecting in the fuel tank.
must meet ASTM specifications.
• Ensure that the fuel tank cap is securely tightened.
E.U. Standard (EN590)
• Biodiesel blend fuel can damage painted surfaces,
Use only clean, high quality diesel fuel that meets the remove all spilled fuel from painted surfaces
EN590 specifications listed below: immediately.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10 • Drain all water from the fuel filter daily before
ppm) sulfur maximum. operating the machine.
• Diesel fuel with cetane number of 51.0 and above. • Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain • Before machine storage; drain the fuel tank, refill with
no more than 7% biodiesel mixed with ultra 100% petroleum diesel fuel, add fuel stabilizer, and
low sulfur petroleum based diesel. This operate the engine for at least 30 minutes.
biodiesel blend fuel is commonly marketed as
B7 blended diesel fuel. B7 blended diesel fuel NOTE: Biodiesel blend fuel does not have long term
must meet EN590 specifications. stability and should not be stored for more
than 3 months.
WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
1 100-1].
P121465
WARNING
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Fuel Filter See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Removing Water
Stop the engine and open the rear door.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-100-4
1 2
P121903
Loosen the fuel filter head (Item 3) from the fuel filter
Loosen the drain (Item 1) [Figure 10-100-3] at the element (Item 1) [Figure 10-100-4]. Do NOT remove the
bottom of the filter to remove trapped water from the filter. hoses from the fuel filter head.
Securely tighten the drain. Loosen the clamps (Item 4) [Figure 10-100-4].
Remove the fuel filter element (Item 1) from the fuel filter
head (Item 3) [Figure 10-100-4].
WARNING
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Put clean oil on the two new fuel filter element O-rings,
sparks or lighted tobacco away from fuel and oil.
install the element, and tighten to 13,5 N•m (10 ft-lb)
Failure to use care around combustibles can cause
torque.
explosion or fire.
W-2103-0508
Install the fuel filter assembly into the clamps and tighten.
Connect the electrical connector [Figure 10-100-4].
Close the rear door.
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-4.)
Fuel Filter (Cont’d) After replacing the filter element or if the fuel tank has run
out of fuel, the air must be removed from the fuel system
Replacing Element (Cont’d) before starting the engine.
WARNING WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames, AVOID INJURY OR DEATH
sparks or lighted tobacco away from fuel and oil. Diesel fuel or hydraulic fluid under pressure can
Failure to use care around combustibles can cause penetrate skin or eyes, causing serious injury or
explosion or fire. death. Fluid leaks under pressure may not be visible.
W-2103-0508 Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
Close the rear door.
from a physician familiar with this injury.
W-2072-0807
Start the engine and allow to operate for one minute.
Figure 10-100-5
WARNING
AVOID INJURY OR DEATH 1
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do 2
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807 P121904
Stop the engine and check for leaks at the filter. Open the air vent plug (Item 1) [Figure 10-100-5] on the
fuel filter assembly three full turns.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
The engine exhaust system is equipped with a selective NOTE: The engine must be stopped with the key
catalytic reduction (SCR) system. The SCR is an switch in the STOP position when filling the
emissions reduction system that removes nitrogen oxides DEF / AdBlue® tank.
from the exhaust gases.
Figure 10-101-1
The machine will periodically perform a process to clean
sulfur oxides from the SCR system. This process is
called DeSOX. (See DeSOX Process on Page 70-30-3.)
Check the engine oil level every day before starting the ENGINE CRANKCASE OIL
engine for the work shift. Recommended SAE Viscosity Number
Figure 10-110-1
Figure 10-110-3
P-90498A
P109762A
P109086B
Return the oil drain hose to the storage location on top of
the fuel tank [Figure 10-110-4].
The oil drain hose is located behind a cover (Item 2) Install the cover and the cover mounting bolts [Figure 10-
under the right rear corner of the loader (Inset) [Figure 110-3]. Tighten both bolts.
10-110-3].
Figure 10-110-4
P121158
Add oil as needed if oil level is not at the top mark on the
Remove the oil filter (Item 3) [Figure 10-110-6] and clean dipstick. Install the dipstick and close the rear door.
the filter base.
Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filter only. WARNING
Remove the oil fill cap (Item 1) [Figure 10-110-6].
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Put oil into the engine and replace the oil fill cap. (See
sparks or lighted tobacco away from fuel and oil.
Capacities on Page SPEC-10-5.) Do not overfill.
Failure to use care around combustibles can cause
explosion or fire.
Start the engine and allow to operate for several minutes.
W-2103-0508
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.
Figure 10-120-1
Figure 10-120-2
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
1 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P121074A
Install the fill cap [Figure 10-120-2] and install the rear
grille.
Figure 10-120-6
1
1
2
P121074A
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.
Figure 10-120-7
P121073A
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.)
Stop the engine and remove the rear grille. (See NOTE: The filter cap O-rings are not the same size.
Removing on Page 50-60-1.) Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and bolts. Alternate tightening the
Figure 10-120-8 bolts to draw the cap down evenly. Tighten the bolts to 27
– 41N•m (20 – 30 ft-lb) torque.
WARNING
1 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
2 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Figure 10-120-9
WARNING
1 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
2 death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
1 Install the right side access cover and bolts [Figure 10-
120-10].
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
P100007
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Remove the right side access cover bolts (Item 1) Use a piece of cardboard or wood to find leaks. Do
[Figure 10-120-10] and remove the access cover. (Lift not use your bare hand. Wear safety goggles. If fluid
arms shown raised for visual clarity.) enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Figure 10-120-11 W-2072-0807
P121104
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.
Figure 10-120-12
P121074A
P-31233A NA3098
The levers and wedges must move freely. 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.
WARNING Figure 10-130-3
NA13065S
Figure 10-131-1 2
P-31233A NA3098
WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
9 10
11
2
3 5
6
7
P107399B
Figure 10-140-4 5
3
P109928
Figure 10-140-5
P107292
P100908
Figure 10-140-8
7
P107960
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].
Lubrication Locations (Cont’d) The track rollers and idlers have sealed bearings and do
not require lubrication.
Figure 10-140-12
11
P107959
Figure 10-150-1
P107293A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure
10-150-1].
Storage After the Bobcat loader has been in storage, perform the
procedures below to return the loader to service:
You may decide to store your Bobcat loader for an
extended period of time. Perform the procedures below • Check the engine oil and hydraulic fluid levels; check
for storage: coolant level.
• Thoroughly clean the loader including the engine • Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• 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 • Lubricate the loader.
on the ground.
• Check track condition and remove blocks from under
• Put blocks under the frame to remove weight from the frame.
tires.
• Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods.
Perform the following steps if the DEF / AdBlue®
• Put fuel stabilizer in the fuel tank and operate the
storage limit has been exceeded:
engine a few minutes to circulate the stabilizer to the
pump and fuel injectors. 1. Remove the fluid from the DEF / AdBlue® tank and
refill with new fluid.
If biodiesel blend fuel has been used, perform the
following:
2. Replace the DEF / AdBlue® filter if the machine was
Drain the fuel tank, refill with 100% petroleum diesel stored for more than nine months.
fuel, add fuel stabilizer, and operate the engine for at
least 30 minutes. 3. See your Bobcat dealer for service if the machine
displays any codes related to the SCR system that do
• Drain and flush the cooling system. Refill with not clear within 15 minutes of engine run time.
premixed coolant.
• Start the engine and operate for a few minutes while
• Fill the DEF / AdBlue® tank. The maximum DEF / observing the instrument panels and systems for
AdBlue® storage limit is two months in ambient correct operation.
temperatures of -40 – +40°C (-40 – +104°F) or four
months in -40 – +25°C (-40 – +77°F). • Operate machine, check for correct function.
• Replace all fluids and filters (engine, hydraulic / • Stop the engine and check for leaks. Repair as
hydrostatic). needed.
Figure 10-170-3
P107184
P-85737A P-85735A
Engage the parking brake.
Figure 10-170-2 Exit the loader using grab handles, safety tread, and
steps (maintaining a three-point contact) [Figure 10-170-
3].
1 1
WARNING
AVOID INJURY OR DEATH
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
P-90688A P-90214C
the ground.
• Stop the engine.
• Engage the parking brake.
Turn the key switch to the STOP position (Item 1) [Figure • Raise the seat bar.
10-170-2]. • Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
NOTE: If the loader lights are ON, they will remain ON drive functions are deactivated.
for approximately 90 seconds after turning
the loader OFF. The seat bar system must deactivate these functions
when the seat bar is up. See your Bobcat dealer for
NOTE: The cooling fans in the rear door may service if controls do not deactivate.
continue to operate for several minutes. W-2463-1110
The front opening on the operator cab and rear window provide exits.
Rear Window Identification There are two different procedures for removing the rear
window from your machine:
Figure 10-180-1
1. This window is equipped with latches [Figure 10-180-
Latches Rubber Cord 1].
—————————————————————————————————————————————————————
P-85309A P-64994C
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.
P-90676 P-90676
Exit through the rear of the operator cab [Figure 10-180- Exit through the rear of the operator cab [Figure 10-180-
3]. 5].
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
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.
Figure 10-180-10
1
1
P-90685
P-85781A 1
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 the clip into the hole in the gas
spring socket. Rotate the clip to lock into position [Figure
10-180-11].
P-85588A P-85589A
WARNING 3
Male
DRIVE MOTOR 27
Male
L
30
29
31 Female
32
Z
10
A
10
33 B
Auxiliary Spool
TILT CYLINDERS
7A
42 11 BICS CONTROL VALVE
HYDROSTATIC PUMP 8
38 Tilt Spool
8 13
M4
M
11
3
D C 14 LIFT CYLINDERS)
12
39 39 Lift Spool
20
40 11 16
B A
15
IN 18
2
M2 M1 7 16
6
17
19
39 1
39 Oil Cooler
38 41
3 HYDRAULIC RESERVOIR
T 2 (VENTED)
4
1
37
36 5
25
23
26 WORKING CIRCUIT
BRAKE VALVE -
SPRING APPLIED CHARGE
PRESSURE RELEASE
B
33 PRESSURE
(SAPR) A
DRAIN / RETURN
24 21
3
Z
P DR 22
45 2
44 32
44
1
DRAIN/RETURN MANIFOLD Printable Version Click Here
43
HYDRAULIC/HYDROSTATIC SCHEMATIC
28 MANUAL WITH NO OPTIONS
31 29
30
T770 (S/N AT6311001 & ABOVE)
L
T770 (S/N B3BW11001 & ABOVE)
DRIVE MOTOR
(PRINTED JUNE 2015)
7194314 (F)
PRINTED IN U.S.A.
- AT6313226)
- B3BW12382)
(PRINTED DECEMBER 2017)
V-1612legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 36 CHARGE PUMP - 57 RESTRICTOR - 0,8 mm (0.031 in)
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (SCREEN) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 58 LOAD SHUTTLE VALVE - BLEED OFF
17 CHECK VALVE - With 100 kPa (1,0 bar) HYDRAULIC PUMP . . . . . . . Gear Type
37
2 SIGHT GUAGE (14.5 psi) Spring 87,1 L/min (23.0 U.S. gpm) at High Engine Idle SOLENOID ACTIVATED DIRECTIONAL
59
VARIABLE CAPACITY DISPLACEMENT CONTROL VALVE - Female
3 18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 38
DIFFERENTIAL PRESSURE SWITCH: BIDIRECTIONAL HYDROSTATIC PUMP SOLENOID ACTIVATED DIRECTIONAL
103 kPa (1,03 bar) (15 psi) 60
19 PULL BUTTON ACTIVATED CONTROL VALVE - Male
Normally Closed 39 RELIEF/REPLENISHING VALVE - HIGH
DIRECTIONAL CONTROL VALVE - LIFT PRESSURE: 36500 kPa (365 bar) (5294 psi)
4 61 SOLENOID ACTIVATED DIRECTIONAL
FILTER - HYDRAULIC (CANISTER) ARM BY-PASS
CONTROL VALVE - BUCKET POSITION
5 SPRING LOADED FILTER BY-PASS 20 LIFT CYLINDER SPOOL - MADE TO 40 RELIEF VALVE - CHARGE INLET: VALVE (ON/OFF)
VALVE: 172 kPa (1,7 bar) (25 psi) RESTRICT FLOW DURING BOOM 3447 kPa (34,5 bar) (500 psi) at High 62 FLOW DIVIDER ADJUSTMENT VALVE
DOWN BUT NOT DURING BOOM UP Engine Idle With 60 ° C (140 ° F) Fluid
6 DIAGNOSTIC COUPLER PILOTED ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE 63
41 CHECK VALVE – COLD WEATHER BY-PASS CONTROL VALVE - FLOW CONTROL
7 RELIEF VALVE - MAIN: With 345 kPa (3,45 bar) (50 psi) Spring SPOOL
22 PROPORTIONAL RELIEF VALVE –
23787 - 24476 kPa (238 - 245 bar)
(Fan Speed Regulator): 10797 – 12300 kPa 42 FILL PORT – Factory hydraulic Oil 64 CHECK VALVE - BUCKET POSITION
(3450 - 3550 psi) at Front Quick Couplers
(108 - 123 bar) (1566 - 1784 psi) VALVE
RELIEF VALVE – MAIN (OPTIONAL): 23 SPRING LOADED FILTER BY-PASS VALVE: PILOT ACTIVATED DIRECTIONAL CONTROL
43 65 PILOTED ACTIVATED DIRECTIONAL
25855 – 26545 kPa (259 - 265 bar) 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) VALVE – HYDRAULIC POWERED BOB-TACH CONTROL VALVE - UNLOADING
(3750 - 3850 psi) at Diagnostic Coupler 6 24 FIXED CAPACITY DISPLACEMENT With Build-up Valve 275 kPa (2,75 bar) (40 psi) SPOOL
HYDRAULIC MOTOR 44 FILTER - BOB-TACH VALVE 66 HIGH FLOW HYDRAULIC PUMP Gear Type
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 51,1 L/min (13.5 U.S. gal) at High Engine Idle
25 FILTER - HYDRAULIC (CANISTER)
23787 – 24476 kPa (238 - 245 bar) 45 RESTRICTION - 1,17 mm (0.46 in)
(3450 - 3550 psi) at Diagnostic Coupler 6 67 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
26 SENSOR – CHARGE PRESSURE – 46 SOLENOID ACTIVATED DIRECTIONAL
8 Fan Filter CONTROL VALVE (TWO COIL) 68 DUMP VALVE – ON / OFF
RELIEF/ANTICAVITATION VALVE -
PORT: 27579 kPa (276 bar) (4000 psi) 27 FRONT AUXILIARY MANUAL PRESSURE 47 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) 69 CHECK VALVE - With 34,5 kPa (0,34 bar)
BLEED-OFF VALVE (5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - 48 CHECK VALVE
28 SENSOR – HYD. TEMPERATURE 70 SOLENOID ACTIVATED DIRECECTIONAL
PORT (OPTIONAL): 27579 kPa
CONTROL VALVE – BRAKE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in) 49 RESTRICTION - 0,25 mm (0.10 in)
71 FILTER – BRAKE VALVE
10 SOLENOID ACTIVATED DIRECTIONAL
30 CHECK VALVE - With 1379 kPa 13,8 bar 50 NOT USED FOR THIS MODEL
CONTROL VALVE - AUXILIARY 72 NOT USED ON THIS MODEL
11 (200 psi) Spring
LOAD CHECK VALVE
51 NOT USED FOR THIS MODEL 73 SOLENOID ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
12 ANTICAVITATION VALVE CONTROL VALVE – 2 Speed Shift
52 NOT USED FOR THIS MODEL
13 PILOTED ACTIVATED DIRECTIONAL 32 FIXED CAPACITY DISPLACEMENT 74 NOT USED ON THIS MODEL
BIDIRECTIONAL HYDROSTATIC MOTOR 53 NOT USED FOR THIS MODEL
CONTROL VALVE - TILT CONTROL
33 HYDRAULIC BRAKE – SPRING APPLIED – 75 RIDE CONTROL VALVE
14 PILOTED ACTIVATED DIRECTIONAL 54 PILOT ACTIVATED DIRECTIONAL
PRESSURE RELEASE (SAPR)
CONTROL VALVE - LIFT CONTROL CONTROL VALVE - REAR AUXILIARY 76 HIGH PRESSURE CHAMBER
15 SOLENOID ACTIVATED DIRECTIONAL 34 PILOT ACTIVATED DIRECTIONAL 55
CONTROL VALVE – 2 Speed RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) 77 LOW PRESSURE CHAMBER
CONTROL VALVE - BICS CONTROL
35 FIXED CAPACITY DISPLACEMENT 56 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE - TWO COIL springs have NO significant
Printed in U.S.A. pressure value. V-1612legend (12-5-17)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
B A
A Male
TWO SPEED DRIVE MOTOR (OPTIONAL) B B A
B
L
30 B A
27 P B
A B A
A A Male
29 B B A
A
A
31
A A
69
B A P B B A
A
A
P T
B
Female
A A A B B A
A
B B B
A B
A B
A
A
B A
A B B
RIDE CONTROL (OPTIONAL)
X T1 P T2 A
0
B B
77 76 LIFT CYLINDERS)
1
1 A
B
A A
A B
B B
32 B A B
A A
34 A B
A B
REAR AUXILIARY COUPLERS (OPTIONAL)
9
35 C 10
B B A
FEMALE A A
MALE A
A A
A B 75 1
B A A
B
A A A
B
A B
C
A
A
A
B
A
B A
10
Z B B B B
Auxiliary Spool
A
A
B
B
AA
B
58 A
B
B A A BA CA
0
A A
33
B
A B T T
42 B
B A
P A
A A
A PA B B
A B A B B A A B A
P P
B B
T1 P T2
60
A A A A
B A B
B A A A C B B
A AB
59 7A A
A B
56 A A
B B
A
A
AA BA
11 BICS CONTROL VALVE
B
BUCKET POSITIONING
HYDROSTATIC PUMP A B
B
8 VALVE (OPTIONAL)
A B
A A
B A
A
A P T
E1 E2 A1 A2
A C
A
A
B
57 B
A A E3
A P
A
B
B
B
A
A
Tilt Spool A B 61
38 A B
A
A
A B
A
B
1 2B 3B 4
B
8
B A B P A
P A 55 0 6
A
5
B
13 A
B A
B
A A
A
B B
B 62
M4 A
M
A 11 B B
P A T
63
A B B A A
3
A
54 A
A
B
64
C C
REAR AUXILIARY A
A A
B
B
A
A A
D C VALVE (OPTIONAL) B
B
14 A B
D2
2-SPEED & SAPR
BRAKE VALVE B A A B
P in
B P out
A
T B A 12 A B
(OPTIONAL) 73
B
B
A
A
B
A B
P T
70 B
64
T 39 39 B A P B A A A A
71 A 1 2 3
Lift Spool
A
A
POWER BOBTACH CYLINDER
B
65 A
A (OPTIONAL) 8 A
A B
C2
B A T
B B
A
T AB
A
A A
P A
A
B BA A
POWER BOBTACH 0 5
A
4 P A
C1 D1
B P B B A
A BB AB B
VALVE (OPTIONAL)
20
B B
BA
P A
A
A
40 A
11
B
B
47 B 16
B1
A
A1
B
A
48 B A
B B A A B A A B B
15 A
71
B
B
C C IN
B A
2 18
M2 M1 7 16
6
A
A A
A B B A
A
46 A
49 2 5 17 A
B B
A
P
1 4 3
A
19 TILT CYLINDERS
39 1 B
39 D A
Oil Cooler
38 41 45 A B
A B
A
44 RESERVOIR
3
2
A B
A
T A
4 (VENTED)
37
A
A
B A
A
1
A
43
A
A
36
A B
5 A
C P
25
A B
B
B
23
A
A
WORKING CIRCUIT
26 A
B
CHARGE
A
PRESSURE
C 2
B
33 A
B
DRAIN / RETURN
A
A
A
C A
Z
AA B 24 1
21
A
B
B
A B A
35 C
B
P DR 22
A B
34
A
B B 32
AA BA
1
1 DRAIN/RETURN MANIFOLD
A
X
0
T1 P T2
A A
B
A
A
A
1
28
A
A
HYDRAULIC/HYDROSTATIC SCHEMATIC
B
A A
B
A
B
B
MANUAL WITH ALL OPTIONS
T770 (S/N AT6311001 - AT6313226)
A
B P T B B
A B A A
L
(PRINTED DECEMBER 2017)
A B
7194314 (H)
PRINTED IN U.S.A.
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
T770 (S/N AT6313227 AND ABOVE)
(S/N B3BW12383 AND ABOVE)
(PRINTED DECEMBER 2017)
V-1657legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 36 CHARGE PUMP - 57 RESTRICTOR - 0,8 mm (0.031 in)
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (SCREEN) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 58 LOAD SHUTTLE VALVE - BLEED OFF
17 CHECK VALVE - With 100 kPa (1,0 bar) HYDRAULIC PUMP . . . . . . . Gear Type
37
2 SIGHT GUAGE (14.5 psi) Spring 87,1 L/min (23.0 U.S. gpm) at High Engine Idle SOLENOID ACTIVATED DIRECTIONAL
59
VARIABLE CAPACITY DISPLACEMENT CONTROL VALVE - Female
3 18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 38
DIFFERENTIAL PRESSURE SWITCH: BIDIRECTIONAL HYDROSTATIC PUMP SOLENOID ACTIVATED DIRECTIONAL
103 kPa (1,03 bar) (15 psi) 60
19 PULL BUTTON ACTIVATED 39 CONTROL VALVE - Male
Normally Closed RELIEF/REPLENISHING VALVE - HIGH
DIRECTIONAL CONTROL VALVE - LIFT
4 PRESSURE: 36500 kPa (365 bar) (5294 psi) 61 SOLENOID ACTIVATED DIRECTIONAL
FILTER - HYDRAULIC (CANISTER) ARM BY-PASS
CONTROL VALVE - BUCKET POSITION
5 SPRING LOADED FILTER BY-PASS 20 LIFT CYLINDER SPOOL - MADE TO 40 RELIEF VALVE - CHARGE INLET: VALVE (ON/OFF)
VALVE: 172 kPa (1,7 bar) (25 psi) RESTRICT FLOW DURING BOOM 3447 kPa (34,5 bar) (500 psi) at High 62 FLOW DIVIDER ADJUSTMENT VALVE
DOWN BUT NOT DURING BOOM UP Engine Idle With 60 ° C (140 ° F) Fluid
6 DIAGNOSTIC COUPLER PILOTED ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE 63
41 CHECK VALVE – COLD WEATHER BY-PASS CONTROL VALVE - FLOW CONTROL
7 RELIEF VALVE - MAIN: With 345 kPa (3,45 bar) (50 psi) Spring SPOOL
22 PROPORTIONAL RELIEF VALVE –
23787 - 24476 kPa (238 - 245 bar)
(Fan Speed Regulator): 10797 – 12300 kPa 42 FILL PORT – Factory hydraulic Oil 64 CHECK VALVE - BUCKET POSITION
(3450 - 3550 psi) at Front Quick Couplers
(108 - 123 bar) (1566 - 1784 psi) VALVE
RELIEF VALVE – MAIN (OPTIONAL): 23 SPRING LOADED FILTER BY-PASS VALVE: 43 PILOT ACTIVATED DIRECTIONAL CONTROL PILOTED ACTIVATED DIRECTIONAL
65
25855 – 26545 kPa (259 - 265 bar) 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) VALVE – HYDRAULIC POWERED BOB-TACH CONTROL VALVE - UNLOADING
(3750 - 3850 psi) at Diagnostic Coupler 6 24 FIXED CAPACITY DISPLACEMENT With Build-up Valve 275 kPa (2,75 bar) (40 psi) SPOOL
HYDRAULIC MOTOR 44 FILTER - BOB-TACH VALVE HIGH FLOW HYDRAULIC PUMP Gear Type
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 66
25 FILTER - HYDRAULIC (CANISTER) 51,4 L/min (13.6 U.S. gal) at High Engine Idle
23787 – 24476 kPa (238 - 245 bar) 45 RESTRICTION - 1,17 mm (0.46 in)
(3450 - 3550 psi) at Diagnostic Coupler 6 67 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
26 SENSOR – CHARGE PRESSURE – SOLENOID ACTIVATED DIRECTIONAL
46
8 Fan Filter CONTROL VALVE (TWO COIL) 68 DUMP VALVE – ON / OFF
RELIEF/ANTICAVITATION VALVE -
PORT: 27579 kPa (276 bar) (4000 psi) 27 FRONT AUXILIARY MANUAL PRESSURE 47 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) 69 CHECK VALVE - With 34,5 kPa (0,34 bar)
BLEED-OFF VALVE (5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - 48 CHECK VALVE
28 SENSOR – HYD. TEMPERATURE 70 SOLENOID ACTIVATED DIRECECTIONAL
PORT (OPTIONAL): 27579 kPa
CONTROL VALVE – BRAKE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in) 49 RESTRICTION - 0,25 mm (0.10 in)
71 FILTER – BRAKE VALVE
10 SOLENOID ACTIVATED DIRECTIONAL
30 CHECK VALVE - With 1379 kPa 13,8 bar 50 NOT USED FOR THIS MODEL
CONTROL VALVE - AUXILIARY 72 FAN REVERSING VALVE (OPTIONAL)
11 (200 psi) Spring
LOAD CHECK VALVE
51 NOT USED FOR THIS MODEL 73 SOLENOID ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
12 ANTICAVITATION VALVE CONTROL VALVE – 2 Speed Shift
52 NOT USED FOR THIS MODEL
13 PILOTED ACTIVATED DIRECTIONAL 32 FIXED CAPACITY DISPLACEMENT 74
SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC MOTOR 53 NOT USED FOR THIS MODEL CONTROL VALVE – Ride Control (OPTIONAL)
CONTROL VALVE - TILT CONTROL
33 HYDRAULIC BRAKE – SPRING APPLIED – 75 ACCUMULATOR – Ride Control (OPTIONAL)
14 PILOTED ACTIVATED DIRECTIONAL 54 PILOT ACTIVATED DIRECTIONAL
PRESSURE RELEASE (SAPR)
CONTROL VALVE - LIFT CONTROL CONTROL VALVE - REAR AUXILIARY 76 ORIFICE WITH CHECK VALVE:
15 SOLENOID ACTIVATED DIRECTIONAL 34 PILOT ACTIVATED DIRECTIONAL 55 2,54 mm (0.10 in)
CONTROL VALVE – 2 Speed RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE - BICS CONTROL 77 ORIFICE: 1,60 mm (0.063 in)
35 FIXED CAPACITY DISPLACEMENT 56 SOLENOID ACTIVATED DIRECTIONAL
NOTE: Unless otherwise specified springs have
BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE - TWO COIL
NO significant pressure value.
Printed in U.S.A. V-1657legend (12-4-17)
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
Male
TWO SPEED DRIVE MOTOR (OPTIONAL)
L
34 27
Male
29
31
69
Female
T
76 LIFT CYLINDERS)
32 77
34 REAR AUXILIARY COUPLERS (OPTIONAL)
9
35 10 P
FEMALE MALE
74
10
Z Auxiliary Spool
58 CR2 CR CB
A 33 B
42
60
59 7A
56
11 BICS CONTROL VALVE
BUCKET POSITIONING
HYDROSTATIC PUMP 8 VALVE (OPTIONAL)
E1 E2 A1 A2
57 E3
Tilt Spool 61
38
8 B
55 13
62
M4
M
11 63
54 64
REAR AUXILIARY
D C VALVE (OPTIONAL) 14 D2
2-SPEED & SAPR
BRAKE VALVE P in P out T 12
(OPTIONAL) 73
B A
70 64
71
T
39 39 Lift Spool
POWER BOBTACH CYLINDER 65
(OPTIONAL) 8 C2
POWER BOBTACH C1 D1
VALVE (OPTIONAL)
P 20
40 11
47 16
B1 A1 A
48
B
15
71
7
IN
2 18
M2 M1 16
46 6
49 17
19 TILT CYLINDERS
39 39 D Oil Cooler
1
38 41 45
44 RESERVOIR
3 2
T 4 (VENTED)
37
43 1
36 5
X
Printable Version Click Here
28 HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH ALL OPTIONS
T770 (S/N AT6313227 & ABOVE)
30 29
31 T770 (S/N B3BW12383 & ABOVE)
L
(PRINTED DECEMBER 2017)
TWO SPEED DRIVE MOTOR (OPTIONAL)
7194314 (H)
PRINTED IN U.S.A.
Printable Version Click Here
Male
27
DRIVE MOTOR Male
L
30
Female
29
31 HYDRAULIC CONTROL VALVE
OUT
32
10
43
10
Z
Auxiliary Spool
A B
7A
TILT CYLINDERS
42
11
BICS CONTROL VALVE
R
HYDROSTATIC PUMP 33 8
T
37
X1 38 Tilt Spool
36
13
X2 8
34 34 11
14 LIFT CYLINDERS
MA 38 12
MB
A B
MG
Lift Spool
35
8
G
A B
MB 20
16
MA 38 11
15
IN
7 16 2 18
34 6
34
X2 17
36
X1 Oil Cooler
1 19
38
33 37
39 HYDRAULIC RESERVOIR
T 3 (VENTED)
4 2
R
40 1
41
5
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
HYDRAULIC FILTER
25
WORKING CIRCUIT
BRAKE VALVE - 26 23 CHARGE
SPRING APPLIED
PRESSURE RELEASE 43 PRESSURE
(SAPR)
DRAIN / RETURN
B A
3
Z 21
24
2
45 22
P DR
44 44 32
1 Printable Version Click Here
DRAIN/RETURN MANIFOLD
46
HYDRAULIC/HYDROSTATIC SCHEMATIC
28
SJC WITH NO OPTIONS
31
29
T770 (S/N AT6311001 & ABOVE)
30
T770 (S/N B3BW11001 & ABOVE)
L
DRIVE MOTOR
(PRINTED JUNE 2015)
7194315 (F)
PRINTED IN U.S.A.
- AT6313226)
- B3BW12382)
(PRINTED DECEMBER 2017)
V-1614legend Printable Version Click Here
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 38 VARIABLE CAPACITY DISPLACEMENT 62 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE - Female
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 39 SOLENOID ACTIVATED DIRECTIONAL
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) RELIEF/REPLENISHING VALVE - HIGH 63
2 SIGHT GUAGE PRESSURE: 36500 kPa (365 bar) (5294 psi) CONTROL VALVE - Male
19 PULL BUTTON ACTIVATED 64 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT 40 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - BUCKET POSITION
103 kPa (1,03 bar) (15 psi) ARM BY-PASS 3447 kPa (34,5 bar) (500 psi) at High VALVE (ON/OFF)
Normally Closed 20 LIFT CYLINDER SPOOL - MADE TO Engine Idle With 60 ° C (140 ° F) Fluid
65 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM 41 SERVO PISTON – Swash Plate
PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP SOLENOID ACTIVATED DIRECTIONAL 66
5 SPRING LOADED FILTER BY-PASS 42 CONTROL VALVE - FLOW CONTROL
21 ANTICAVITATION VALVE CONTROL VALVE – FORWARD/REVERSE SPOOL
VALVE: 172 kPa (1,7 bar) (25 psi)
43 FILTER
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa 44 CHECK VALVE – COLD WEATHER BY-PASS VALVE
7 RELIEF VALVE - MAIN: (108 - 123 bar) (1566 - 1784 psi) With 345 kPa (3,45 bar) (50 psi) Spring 68 PILOTED ACTIVATED DIRECTIONAL
23787 - 24476 kPa (238 - 245 bar) 23 SPRING LOADED FILTER BY-PASS VALVE: CONTROL VALVE - UNLOADING
45 FILL PORT – Factory Hydraulic Oil
(3450 - 3550 psi) at Front Quick Couplers 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) SPOOL
46 PILOT ACTIVATED DIRECTIONAL CONTROL HIGH FLOW HYDRAULIC PUMP Gear Type
RELIEF VALVE – MAIN (OPTIONAL): 24 FIXED CAPACITY DISPLACEMENT 69
VALVE – HYDRAULIC POWERED BOB-TACH 51,1 L/min (13.5 U.S. gal) at High Engine Idle
25855 – 26545 kPa (259 - 265 bar) HYDRAULIC MOTOR
With Build-up Valve 207 kPa (2,07 bar) (30 psi)
(3750 - 385 psi) at Diagnostic Coupler 6 25 FILTER - HYDRAULIC (CANISTER) 70 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
47 FILTER - BOB-TACH VALVE
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 26 SENSOR – CHARGE PRESSURE – 71 DUMP VALVE – ON / OFF
48 RESTRICTION - 2,08 mm (0.08 in)
23787 – 24476 kPa (238 - 245 bar) Fan Filter
72 CHECK VALVE - With 34,5 kPa (0,34 bar)
(3450 - 3550 psi) at Diagnostic Coupler 6 27 FRONT AUXILIARY MANUAL PRESSURE 49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
BLEED-OFF VALVE CONTROL VALVE (TWO COIL) SOLENOID ACTIVATED DIRECECTIONAL
8 RELIEF/ANTICAVITATION VALVE - 73
28 SENSOR – HYD. TEMPERATURE 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) CONTROL VALVE – BRAKE
PORT: 27579 kPa (276 bar) (4000 psi)
29 RESTRICTION - 1,5 mm (0.06 in) 51 CHECK VALVE - With 552 kPa) (5,5 bar) 74 FILTER – BRAKE VALVE
9 RELIEF/ANTICAVITATION VALVE - (80 psi) Spring
PORT (OPTIONAL): 27579 kPa 30 CHECK VALVE - With 1379 kPa 13,8 bar 52 SHUTTLE VALVE 75 NOT USED ON THIS MODEL
(276 bar) (4000 psi) (200 psi) Spring 53 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 76 SOLENOID ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE – 2 Speed Shift
54 CHECK VALVE - With 2068 kPa (20,7 bar) (300
CONTROL VALVE - AUXILIARY 77
psi) Spring And With 0,40 mm (0.016 in) Orifice NOT USED ON THIS MODEL
11 LOAD CHECK VALVE 32 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR 55 RESTRICTION - 0,51 mm (0.020 in)
12 ANTICAVITATION VALVE 78 RIDE CONTROL VALVE
33 HYDRAULIC BRAKE – SPRING APPLIED – 56
PRESSURE RELEASE (SAPR) RESTRICTION - 0,51 mm (0.020 in)
13 PILOTED ACTIVATED DIRECTIONAL 79 HIGH PRESSURE CHAMBER
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL 57
CONTROL VALVE – 2 Speed CONTROL VALVE - REAR AUXILIARY 80 LOW PRESSURE CHAMBER
14 PILOTED ACTIVATED DIRECTIONAL 58 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE - LIFT CONTROL 35 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR 59 SOLENOID ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
CONTROL VALVE - BICS CONTROL 36 CHARGE PUMP - NOTE: Unless otherwise specified
51,1 L/min (13.5 U.S. gpm) at High Engine Idle 60 RESTRICTOR - 0,8 mm (0.031 in)
16 FILTER - BICS CONTROL VALVE springs have NO significant
(SCREEN) HYDRAULIC PUMP . . . . . . . Gear Type 61 LOAD SHUTTLE VALVE - BLEED OFF pressure value.
37
Printed in U.S.A. 87,1 L/min (23.0 U.S. gpm) at High Engine Idle V-1614legend (6-1-15)
INTEGRATED COUPLER BLOCK
L
30 27
Male
29 31
72
Female
X
RIDE CONTROL (OPTIONAL)
LIFT CYLINDERS
80 79
34
35 REAR AUXILIARY COUPLERS (OPTIONAL) 9
FEMALE MALE
10
78
33
Z 32 10
Auxiliary Spool
A
61
B
45
63
62
7A
59 11
BICS CONTROL VALVE
R BUCKET POSITIONING
HYDROSTATIC PUMP 38 8 VALVE (OPTIONAL)
T
E1 E2 A1 A2
60 E3
42
X1 43 Tilt Spool TILT BICS VALVE
B
41
13
X2
8
58 65
39 39 11
REAR AUXILIARY 64 67
VALVE (OPTIONAL) 14
76 57
D2
B A MA 43 P in P out T
12
73 MB 66
T A B
MG
67
Lift Spool
40 68 C2
POWER BOBTACH CYLINDER 8
G (OPTIONAL)
C1 D1
P A B
POWER BOBTACH
MB VALVE (OPTIONAL) 20
B1 A1 16
MA 43 11
51 50
74 15
IN
7 16 2 18
39 6
39
X2 49 17
52
41 TILT CYLINDERS
X1 Oil Cooler
1 19
D
43
38 42
44 48
HYDRAULIC RESERVOIR
T 47 4 3
(VENTED)
2
R
37 1
46
5
36
25
WORKING CIRCUIT
26 23 CHARGE
PRESSURE
DRAIN / RETURN
B 33 A
Z 21
24
P DR
22
35 32
34
DRAIN/RETURN MANIFOLD
31
L
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH ALL OPTIONS
T770 (S/N AT6313227 AND ABOVE)
(S/N B3BW12383 AND ABOVE)
(PRINTED DECEMBER 2017)
V-1614legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 38 VARIABLE CAPACITY DISPLACEMENT 62 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 9,5 L (2.5 U.S. gal) (14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE - Female
System Capacity . . . . . . . 36 L (9.5 U.S. gal) 39 SOLENOID ACTIVATED DIRECTIONAL
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) RELIEF/REPLENISHING VALVE - HIGH 63
2 SIGHT GUAGE PRESSURE: 36500 kPa (365 bar) (5294 psi) CONTROL VALVE - Male
19 PULL BUTTON ACTIVATED 64 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT 40 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - BUCKET POSITION
103 kPa (1,03 bar) (15 psi) ARM BY-PASS 3447 kPa (34,5 bar) (500 psi) at High VALVE (ON/OFF)
Normally Closed 20 LIFT CYLINDER SPOOL - MADE TO Engine Idle With 60 ° C (140 ° F) Fluid
65 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM 41 SERVO PISTON – Swash Plate
PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP SOLENOID ACTIVATED DIRECTIONAL 66
5 SPRING LOADED FILTER BY-PASS 42 CONTROL VALVE - FLOW CONTROL
21 ANTICAVITATION VALVE CONTROL VALVE – FORWARD/REVERSE SPOOL
VALVE: 172 kPa (1,7 bar) (25 psi)
43 FILTER
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa 44 CHECK VALVE – COLD WEATHER BY-PASS VALVE
7 RELIEF VALVE - MAIN: (108 - 123 bar) (1566 - 1784 psi) With 345 kPa (3,45 bar) (50 psi) Spring PILOTED ACTIVATED DIRECTIONAL
68
23787 - 24476 kPa (238 - 245 bar) 23 SPRING LOADED FILTER BY-PASS VALVE: CONTROL VALVE - UNLOADING
45 FILL PORT – Factory Hydraulic Oil
(3450 - 3550 psi) at Front Quick Couplers 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) SPOOL
46 PILOT ACTIVATED DIRECTIONAL CONTROL HIGH FLOW HYDRAULIC PUMP Gear Type
RELIEF VALVE – MAIN (OPTIONAL): 24 FIXED CAPACITY DISPLACEMENT 69
VALVE – HYDRAULIC POWERED BOB-TACH 51,4 L/min (13.6 U.S. gal) at High Engine Idle
25855 – 26545 kPa (259 - 265 bar) HYDRAULIC MOTOR
With Build-up Valve 207 kPa (2,07 bar) (30 psi)
(3750 - 385 psi) at Diagnostic Coupler 6 25 FILTER - HYDRAULIC (CANISTER) 70 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
47 FILTER - BOB-TACH VALVE
7A RELIEF VALVE – AUXILIARY (OPTIONAL): 26 SENSOR – CHARGE PRESSURE – 71 DUMP VALVE – ON / OFF
48 RESTRICTION - 2,08 mm (0.08 in)
23787 – 24476 kPa (238 - 245 bar) Fan Filter
72 CHECK VALVE - With 34,5 kPa (0,34 bar)
(3450 - 3550 psi) at Diagnostic Coupler 6 27 FRONT AUXILIARY MANUAL PRESSURE 49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
BLEED-OFF VALVE CONTROL VALVE (TWO COIL) SOLENOID ACTIVATED DIRECECTIONAL
8 RELIEF/ANTICAVITATION VALVE - 73
28 SENSOR – HYD. TEMPERATURE 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) CONTROL VALVE – BRAKE
PORT: 27579 kPa (276 bar) (4000 psi)
29 RESTRICTION - 1,5 mm (0.06 in) 51 CHECK VALVE - With 552 kPa) (5,5 bar) 74 FILTER – BRAKE VALVE
9 RELIEF/ANTICAVITATION VALVE - (80 psi) Spring
PORT (OPTIONAL): 27579 kPa 30 CHECK VALVE - With 1379 kPa 13,8 bar 52 SHUTTLE VALVE 75 SOLENOID ACTIVATED DIRECTIONAL
(276 bar) (4000 psi) CONTROL VALVE – 2 Speed Shift
(200 psi) Spring 53 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 76 FAN REVERSING VALVE (OPTIONAL)
10 SOLENOID ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE
54 CHECK VALVE - With 2068 kPa (20,7 bar) (300
CONTROL VALVE - AUXILIARY 77 SOLENOID ACTIVATED DIRECTIONAL
psi) Spring And With 0,40 mm (0.016 in) Orifice
11 LOAD CHECK VALVE 32 FIXED CAPACITY DISPLACEMENT CONTROL VALVE – Ride Control (OPTIONAL)
BIDIRECTIONAL HYDROSTATIC MOTOR 55 RESTRICTION - 0,51 mm (0.020 in)
12 ANTICAVITATION VALVE 78 ACCUMULATOR – Ride Control (OPTIONAL)
33 HYDRAULIC BRAKE – SPRING APPLIED – 56 RESTRICTION - 0,51 mm (0.020 in)
13
PRESSURE RELEASE (SAPR) 79 ORIFICE WITH CHECK VALVE:
PILOTED ACTIVATED DIRECTIONAL PILOT ACTIVATED DIRECTIONAL 2,54 mm (0.10 in)
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL 57
CONTROL VALVE – 2 Speed CONTROL VALVE - REAR AUXILIARY 80 ORIFICE: 1,60 mm (0.063 in)
14 PILOTED ACTIVATED DIRECTIONAL 58 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE - LIFT CONTROL 35 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC MOTOR 59 SOLENOID ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL
CONTROL VALVE - BICS CONTROL 36 CHARGE PUMP - NOTE: Unless otherwise specified
51,1 L/min (13.5 U.S. gpm) at High Engine Idle 60 RESTRICTOR - 0,8 mm (0.031 in)
16 FILTER - BICS CONTROL VALVE springs have NO significant
(SCREEN) HYDRAULIC PUMP . . . . . . . Gear Type 61 LOAD SHUTTLE VALVE - BLEED OFF pressure value.
37
Printed in U.S.A. 87,1 L/min (23.0 U.S. gpm) at High Engine Idle V-1658legend (12-5-17)
INTEGRATED COUPLER BLOCK
L
30 27
Male
29 31
72
Female
T 79 LIFT CYLINDERS
80
FEMALE MALE 10
77
33
Z 32 10
Auxiliary Spool CR2 CR CB
61
A B 45
63
62
7A
11
59 BICS CONTROL VALVE
R BUCKET POSITIONING
HYDROSTATIC PUMP 38 T
8 VALVE (OPTIONAL)
E1 E2 A1 A2
60 E3
42
X1 43 Tilt Spool TILT BICS VALVE
B
41
13
X2
8
58 65
39 39 11
REAR AUXILIARY 64 67
VALVE (OPTIONAL) 14
75 57
D2
B A MA 46 P in P out T
12
MB 66
73 A B
T
MG
67
Lift Spool
40 68 C2
POWER BOBTACH CYLINDER 8
G (OPTIONAL)
C1 D1
P A B
POWER BOBTACH
MB VALVE (OPTIONAL) 20
B1 A1 16
MA
43 11
51 50 15
74
IN
7 16
2 18
39 6
X2
39 49 17
52
41 TILT CYLINDERS
X1 Oil Cooler
1 19
D
47
38 42
44 48
HYDRAULIC RESERVOIR
T 47 4 3 (VENTED)
2
R
37 1
46
5
36
VARIABLE SPEED HYDRAULIC FAN
MOTOR W/ INTEGRATED FILTER
(Shown With OPTIONAL Reversing Valve)
HYDRAULIC FILTER
69 70
71
25 23
WORKING CIRCUIT
CHARGE
26 PRESSURE
1 4 DRAIN / RETURN
B 33 A
3 2
Z 21
24
76 22
35 32 DR P
34
DRAIN/RETURN MANIFOLD Printable Version Click Here
X
HYDRAULIC/HYDROSTATIC SCHEMATIC
28
SJC WITH ALL OPTIONS
T770 (S/N AT6313227 & ABOVE)
29
T770 (S/N B3BW12383 & ABOVE)
30
31
L
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
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).
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
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
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 posi- 4
tion
The lift arms come down with the pedal in NEUTRAL position 4, 9, 10, 11
Lift Arm Bypass Control valve stuck 12
Lift Arm Bypass Control valve stem bent or broken 13
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.
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].
WARNING
P-90616 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
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
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
Figure 20-20-5
P-90602A
Figure 20-20-6
P-90611
DANGER
1
P-90605
P-90328
2
WARNING 1
P-90823
Figure 20-20-9
P-90827
1
With a slide hammer, remove the pin (Item 1) [Figure 20-
20-11] from the base end of the lift cylinder.
Figure 20-20-12
P-90834
P-90825
Parts Identification
1. Plug
2. O-ring
3. Tubeline
4. Tube
5. Clamp
6. Nut
7. O-ring
8. Seal
9. Piston
10. Spacer 1
2
11. Wear Ring
12. Seal
13. O-ring
14. Head
15. Seal 4
16. Wiper 1
17. Rod 2
18. Grease Fitting 5
3
6
7
8
9
10
11
12
13
14
15
16
17
18
NA6139S
Disassembly
2
Use the following tools to disassemble the cylinder:
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
1
Remove the back-up ring (Item 1) and O-ring (Item 2)
[Figure 20-20-15] from the piston.
Figure 20-20-16
1
2
P-48033
Figure 20-20-14
4
3
2
P101716
1
Remove the O-ring (Item 1). Remove the Seal (Item 2)
[Figure 20-20-16] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].
P-81036
Figure 20-20-18 Wash the cylinder parts in solvent and air dry them.
Install the new seal on the tool and slowly stretch it until it
2
fits the piston [Figure 20-20-19].
Assembly (Cont’d)
Figure 20-20-20
1
2
P7425
P-48041 P-48042
Install the wiper seal with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 23].
Install the rod seal on the rod seal tool [Figure 20-20-21].
Assembly (Cont'd)
Figure 20-20-24 1
2
3
1 4
P-48036
Install the head (Item 1), spacer (Item 2) piston (Item 3),
P-81027 and nut (Item 4) [Figure 20-20-26].
Figure 20-20-27
P101716
Assembly (Cont'd)
Figure 20-20-28
P-81039
Testing
Figure 20-21-1 1
P85552
Engage the parking brake. Lower the seat bar. Start the
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.
Figure 20-21-3
2
1
1
P-85562
Cap and plug the hoses and the fittings on the cylinder.
Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward Remove the base end pivot bolt and washer (Item 3)
[Figure 20-21-5].
Stop the engine. Raise the seat bar.
Figure 20-21-6
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
3] from the rod end pivot pin.
P-85648
Figure 20-21-7
P-85564
Slide the cylinder from the base pin and remove the
cylinder from the loader [Figure 20-21-7].
Figure 20-21-8
P-85567
1
Inspect pivot pin and replace as needed [Figure 20-21-
P-85565 10].
Figure 20-21-9
P-85566
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Parts Identification
1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. Piston 5
10. Collar 6
11. Head
12. Wiper
13. Rod
14. Bushing 4 2
3
7
8
1
9
4
3 10
8
4
11
12
13
14
NA8189S
Disassembly
2
4
Use the following tools to disassemble the cylinder:
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. 1
3
Put the base end of the cylinder in a vise.
Figure 20-21-11
P109554
Remove the nut (Item 1), piston (Item 2), collar (Item 3),
and head (Item 4) [Figure 20-21-13].
1
Figure 20-21-14
P-85651B
Figure 20-21-12
P109555
P106021
Disassembly (Cont'd)
Figure 20-21-15
1
1
P-48042
Figure 20-21-16
P-48040
Assembly
Lubricate all O-rings and seals with hydraulic fluid during Install the seal (Item 1) [Figure 20-21-19] and on the
installation. cylinder piston.
P7424 N-22358
Install the new seal on the tool and slowly stretch it until it Use a ring compressor to compress the seal to the
fits the piston [Figure 20-21-18]. correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-21-20].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
Assembly (Cont'd)
Figure 20-21-21 2
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
P-48043 P7427 1) toward the outside of the head (Item 2) [Figure 20-21-
23].
Install the rod seal on the rod seal tool [Figure 20-21-21]. Figure 20-21-24
Figure 20-21-22
P109556
P7425
3
1 1
4
2
P109554 P106021
NOTE: Lube chamfer on shaft with oil or grease Using an adjustable gland nut wrench, lightly lubricate
before installing the collar. with grease and tighten the head (Item 1) [Figure 20-21-
26] to 373 N•m (275 ft-lb) torque.
Install the head (Item 1), collar (Item 2), piston (Item 3)
and nut (Item 4) [Figure 20-21-25]. Figure 20-21-27
P-85651B
Testing
WARNING
1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
P-85570
from a physician familiar with this injury.
W-2072-0807
Figure 20-22-1 2
P-85568
Engage the parking brake. Lower the seat bar. Start the
engine.
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].
Figure 20-22-5
1
1
P-85569
Parts Identification
1. Tube
2. Nut
3. Seal
4. O-ring
5. Piston
6. Spacer
7. Head
8. Back-up Ring
9. Rod
2
3
4
5
4
7
4
8 3
3
NA2603SA
Disassembly 3 2 1
Figure 20-22-6
P16295
Figure 20-22-9
Use the following tools to disassemble the cylinder:
Hold the hydraulic cylinder over a drain pan and move the
2
rod in and out slowly to remove the fluid from the cylinder.
1
Put the base end of the cylinder in a vise.
Figure 20-22-7
N-20611
2
4 3 1
Remove the wiper seal (Item 1), rod seal (Item 2), back-
up ring (Item 3), O-ring (Item 4), and the O-ring (Item 5)
[Figure 20-22-9] from the head.
P16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.
Assembly
3 1
2
Figure 20-22-10
P16295
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Assembly (Cont’d)
1
Figure 20-22-13
P-48039
Install the O-ring (Item 1). Install the O-ring (Item 2) and
N-20613 back-up ring (Item 3) [Figure 20-22-15] onto the cylinder
head.
Rotate the handles to collapse the rod seal [Figure 20- Figure 20-22-16
22-13].
3
Figure 20-22-14 2 4
1
P16294
P7425 Install the head (Item 1) and spacer (Item 2) [Figure 20-
22-16].
Install the rod seal in the head [Figure 20-22-14]. Install the piston (Item 3) [Figure 20-22-16].
Install the wiper seal with the wiper toward the outside of Grease the piston where the nut contacts the piston. Do
the head. do not get grease on the threads. Install the new nut
(Item 4) [Figure 20-22-16].
Assembly (Cont'd)
Figure 20-22-17
P-85647
Description
Figure 20-30-1
P107749A
Testing
1 3
WARNING
When the engine is running during service, the
driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
2
cause injury or death.
W-2006-1209
MEL1355-3 - Pressure gauge 34474 kPa (345 bar) (5000 Install the gauge (Item 1) and coupler (Item 2) to the test
psi) hose (Item 3) [Figure 20-30-2].
MEL1723 - Coupler
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased Raise the operator cab. (See Raising on Page 10-30-2.)
locally. Must be rated for pressures above 34474 kPa
(345 bar) (5000 psi). Figure 20-30-3
WARNING 1
Testing (Cont’d) The auxiliary relief valve setting is 23787 - 24476 kPa
(238 - 245 bar) (3450 - 3550 psi).
Enter the loader and engage the parking brake. Start the
engine. Figure 20-30-4
Increase the engine speed to full rpm and make sure the
hydraulic fluid is at 60°C (140°F).
Testing Main Relief Pressure If Equipped With Auxiliary Press the auxiliary hydraulics button (Item 1) [Figure 20-
Relief Valve 30-4] to activate the auxiliary hydraulics.
If equipped with the optional auxiliary relief valve, the NOTE: The auxiliary indicator (Item 2) [Figure 20-30-
main relief valve setting is 25,5 - 26,2 mPa (255 - 262 4] will illuminate when activated.
bar) (3700 - 3800 psi).
Figure 20-30-5
Power loader lift arms down on the stops and monitor the
Right
test gauge for the relief pressure setting. Steering
Lever
If the relief pressure is not correct, stop the engine and Control
adjust the relief valve. (See Main Relief Valve Adjustment
on Page 20-30-4.)
P107006B
Figure 20-30-6
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2
Raise the operator cab. (See Raising on Page 10-30-2.)
P107743
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 20-30-8 is located in the same place on all of the
loaders.
Figure 20-30-9
1 2
P107745A 1
Clean the relief valve in clean solvent. Use air pressure to Loosen the locknut (Item 1) [Figure 20-30-9].
dry the valve.
Turn the adjustment screw (Item 2) [Figure 20-30-9] in or
Install a new O-ring (Item 1) and back-up rings (Item 2) out until the pressure is correct. Turning the screw in will
[Figure 20-30-8]. Install the main relief valve and tighten. increase pressure.
Installation: Tighten the relief valve to 51 - 62 N•m (38 - NOTE: If the correct pressure can not be reached,
45 ft-lb) torque. replace the auxiliary relief valve. Test the
pressure setting of the new auxiliary relief
Test the relief valve. (See Testing on Page 20-30-2.) valve.
IMPORTANT 2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1
P107627
Raise the operator cab. (See Raising on Page 10-30-2.)
Clean the area around the control valve. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-30-11] 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 20-30-10 [Figure 20-30-11]. Install the relief valve and tighten.
P107746
Description
Figure 20-40-1
P107871
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-110-2.)
WARNING 2
Figure 20-40-3
1
1
P122356
2
1
1 1
P122354 P-90269
Move the hose clamp (Item 1) to the middle of the hose Disconnect the wire harness connectors (Item 1) [Figure
(Item 2) [Figure 20-40-4] and place the fuel inlet 20-40-6] from the control valve.
assembly off to the side. Plug the fuel tank inlet.
Disconnect the hose (Item 2) [Figure 20-40-6] that
routes from the control valve to the drain manifold.
Figure 20-40-7
2 2
2
1
P-90272
Figure 20-40-8
1
1
P122357
P-90271
Figure 20-40-11
1 1
1
P-90276
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.
Figure 20-40-15
P-90280
Figure 20-40-16
P-90279
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
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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.
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
Figure 20-40-21 1
2
1 4
2
3
P107624
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
20]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-23
P107628
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.
Remove the spring (Item 1) and poppet (Item 2) [Figure
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.
poppet to make sure it is not plugged.
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.
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
Remove the O-ring (Item 1) [Figure 20-40-30] from the
port relief / anti-cavitation relief valve.
Remove the O-ring (Item 1) [Figure 20-40-28] from the
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-40-26] for wear or damage and replace as
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Figure 20-40-31
P107628
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
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.
Figure 20-40-35
P107628
Remove the port relief plug (Item 1) [Figure 20-40-35] Figure 20-40-38
from the auxiliary circuit of the control valve.
Figure 20-40-36
1
1
2
P107629
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 20-40-36] from the port relief plug.
Figure 20-40-39
P107632
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-39].
Figure 20-40-40
1
P107633
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
Figure 20-40-44
1
2
1 P107666
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
Figure 20-40-49
P107775
Figure 20-40-50
P107846
Figure 20-40-51
1
P107845A
P107778
NOTE: If removed, use the following for correct
installation: for a radius lift pattern machine,
Remove the spool centering block (Item 1) [Figure 20- align the radius side (Item 1) [Figure 20-40-53]
40-51]. so it faces the opening of the spool centering
block when seated. For a vertical lift pattern
Remove the O-ring (Item 2) [Figure 20-40-51]. machine, align the vertical side (Item 2)
[Figure 20-40-53] so it faces the opening when
seated. Install retaining ring over detent
sleeve.
Figure 20-40-54
2
P107739
1
P107790 Clamp the linkage end of the spool in a vise [Figure 20-
40-56].
Remove the lift spool assembly (Item 1) and O-ring (Item NOTE: Protect spool before clamping in vise.
2) [Figure 20-40-54] from the control valve.
Figure 20-40-55
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-57
1
2
P107757A
1
Remove the lift spool seal (Item 1) [Figure 20-40-55]
from the linkage end of the valve.
P107674A
4
2
P107676
1
Remove spring tool (Item 1) from the spring assembly
(Item 2) [Figure 20-40-60].
Figure 20-40-61
2
P107674
2 1
3
Remove the spring assembly / spring tool (Item 1) from 4
the spool (Item 2) [Figure 20-40-58].
Figure 20-40-59
P107677
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-61].
P107675
Figure 20-40-62
0.60 inch
(15,2 mm)
B-14712B
N-18918 Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-63].
Remove the stud from the end of the spool [Figure 20-
40-62]. Figure 20-40-64
N-18967
Figure 20-40-65 1
3
2
1 P107675
Figure 20-40-66
P107674
NOTE: The collar and the detent adapter are held NOTE: The adapter must fit in the center of the
together by spring pressure when assembled washer.
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
Figure 20-40-69 1
1 P107679A
P107775
P107779
Figure 20-40-73
1
1
P107666
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.
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].
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
Figure 20-40-80
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-77] from the tilt spool.
Figure 20-40-78
P107780
Figure 20-40-81
1
P107647
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].
Figure 20-40-85
1
3 2
4
1
2
4
P107783
P107784
Figure 20-40-88 1
2
1
2
2
P107798
1
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].
Figure 20-40-90
1
1
2
P107876
Remove the nut (Item 1) [Figure 20-40-90] from the Figure 20-40-93
solenoid stem.
N-18694
Figure 20-40-94
2
1
1
P107937
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
Figure 20-40-98
2
1
P107937
Figure 20-40-101
Remove the lift spool lock solenoid (Item 1) [Figure 20-
40-98].
Figure 20-40-99
P107767
P107789
Figure 20-40-102
P107787
1
Remove the fitting (Item 1) [Figure 20-40-102] from the Figure 20-40-105
valve.
Figure 20-40-103
1
2
P-51463
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
103].
Figure 20-40-106
P107693
Figure 20-40-109
P107870
Figure 20-40-107 1
P107786
P107627
Figure 20-40-110
P107625
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
P107847
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
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
Figure 20-41-2
3
1
P122354
P121154
Figure 20-41-5 2
1
P107219
Figure 20-41-6 1
P-90271
2
Figure 20-41-9
1 1
2 2
1 1
P-90274
Figure 20-41-12
Remove the tubeline clamp (Item 1) [Figure 20-41-9].
Figure 20-41-10
P-90275
Figure 20-41-13
P-90276
Figure 20-41-14
P-90278
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-41-14].
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.
W-2059-0598
P-54587
1 2
P-54566
P-90330
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
P107803
Pull the actuator away from the control valve [Figure 20-
41-20].
1
P107804
1
Remove the two mount bolts (Item 1) [Figure 20-41-23]
from the lift actuator.
Figure 20-41-22
1
1
P107805
P-54340 Pull the actuator away from the control valve [Figure 20-
41-24].
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 (Item 1) [Figure 20-41-27].
and the tilt spool.
Figure 20-41-26
P-54340
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
1 Figure 20-41-31
P-90280
Figure 20-41-30 1
2 P107848
P100202
Figure 20-41-32
1
1
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41-
34].
Remove the lift load check valve (Item 1) [Figure 20-41-
32] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-41-34].
tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
NOTE: The tilt and auxiliary load check valves are
Figure 20-41-33 interchangeable.
Figure 20-41-35
1
5
1
2
2
3 4 4
P107716
3
P107624
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-33].
Remove the spring (Item 1) and poppet (Item 2) [Figure
Inspect the spring (Item 3) and the free movement in the 20-41-35].
load check valve (Item 4) [Figure 20-41-33].
Inspect the orifice (Item 3) [Figure 20-41-35] in the
Inspect the orifice to make sure it is not plugged (Item 5) poppet to make sure it is not plugged.
[Figure 20-41-33].
Installation: Install a new O-ring (Item 4) [Figure 20-41-
35] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-41-36
P107628
Figure 20-41-37
1
2
2
1
4
P107952
3
P107624
Remove the O-ring (Item 1) [Figure 20-41-39] from the
port relief / anti-cavitation relief valve.
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-37]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-26] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-41-37] in the needed.
poppet to make sure it is not plugged.
Installation: Tighten the port relief / anti-cavitation relief
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.
Figure 20-41-40
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anit-cavitation seat (Item 1) [Figure 20-41-42]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-40] from the base end of the tilt section. Figure 20-41-43
Figure 20-41-41
2
1 1
P107952
P107629
Remove the O-ring (Item 1) [Figure 20-41-43] from the
port relief / anti-cavitation relief valve.
Remove the O-ring (Item 1) [Figure 20-41-41] from the
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-43] for wear or damage and replace as
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Figure 20-41-44
P107628
Remove the port relief plug (Item 1) [Figure 20-41-44] Figure 20-41-47
from the auxiliary circuit of the control valve.
Figure 20-41-45
2
P107629
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 20-41-45] from the port relief plug.
Figure 20-41-48
P107628
Remove the port relief plug (Item 1) [Figure 20-41-48] Figure 20-41-51
from the auxiliary circuit of the control valve.
Figure 20-41-49
1
1
2
P107629
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 20-41-49] from the port relief plug.
Figure 20-41-52
P107632
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-52].
Figure 20-41-53
1
P107633
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-6.) Remove the end cap block from the control valve [Figure
20-41-56].
Figure 20-41-56
Figure 20-41-58
1 2 P107851
P107853
Remove the two end cap block mount screws (Item 2) Installation: Replace the O-ring, and lubricate lightly
[Figure 20-41-56]. with oil before installation of the end cap block.
Figure 20-41-57
1
P107753
1
Figure 20-41-60
1
P107756
Figure 20-41-61
P107757
2
P107855
Figure 20-41-64
1
P107647
Figure 20-41-65
3
4 1
1
P-51776B
P107646
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-41-67].
Install the spring tool (Item 1) [Figure 20-41-65] over the
centering spring.
Figure 20-41-68 2
P107769
2 Figure 20-41-71
P107856
Figure 20-41-69
P107770
P107769
N-18944B
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-41-74].
P107646
Put the actuator end of the spool in the vise [Figure 20-
41-72].
Figure 20-41-73
P107647
Figure 20-41-75
2
1
2 P107760
Figure 20-41-76
1
2
P107761
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-78] from the auxiliary spool.
P107759
Figure 20-41-79
1
2 2
1
1
P107847
Remove the auxiliary spool (Item 1) [Figure 20-41-79]. Remove the solenoids (Item 2) [Figure 20-41-80].
Figure 20-41-81
P107798
Figure 20-41-82 1
P107857
Remove the nut (Item 1) [Figure 20-41-82] from the Figure 20-41-85
solenoid stem.
N-18694
Figure 20-41-86
1 2 P107937
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
Figure 20-41-90
1 P107937
P107767
Figure 20-41-93
1
1 P107862
Figure 20-41-96
Remove the fitting (Item 1) [Figure 20-41-93] from the
valve.
1
Figure 20-41-94
1 2
P107745A
Figure 20-41-97
1 1
P107848
Figure 20-41-100
Remove the auxiliary relief valve (Item 1) [Figure 20-41-
97].
Figure 20-41-98
1
2
P107864
1
Remove the check valve fitting (Item 1) [Figure 20-41-
P107627 100] from the hydraulic control valve.
Figure 20-41-101
P107625
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.
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.
can cause lift arms to drop.
• 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) [Figure 20-50-2] from the
support. Replace if damaged. valve shaft.
D-1009-0409
Figure 20-50-3
WARNING
2
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.
W-2059-0598
P-85671
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.
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 25511 kPa (255 bar) (3700
supplies flow to the hydraulic fan motor and charge psi).
pressure to the hydrostatic pump.
Turn the restrictor control (Item 2) [Figure 20-60-1] on
A seal kit is available to service the hydraulic pump. If any the tester counterclockwise to obtain free flow, the flow
of the main components of the pump are damaged, the should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
entire pump must be replaced. gpm). Start turning the restrictor clockwise, causing more
restriction on the flow. The L/min (U.S. gpm) should drop
Pump Test At Quick Couplers off slightly until the pressure reaches approximately
21374 kPa (214 bar) (3100 psi). At approximately 21374
The tools listed will be needed to do the following kPa (214 bar) (3100 psi) the flow should start decreasing
procedure: rapidly until the pressure reaches 23787 - 24132 kPa
(238 - 241 bar) (3450 - 3500 psi). At 23787 - 24132 kPa
MEL10003 or MEL1744 - Hydraulic Tester (238 - 241 bar) (3450 - 3500 psi) the flow should be at 0
MEL10006 - Fitting Kit L/min (0 U.S. gpm). Turn the restrictor (Item 2) [Figure
20-60-1] counterclockwise to free flow. Shut the auxiliary
Figure 20-60-1 hydraulics off.
P106632
WARNING 1
P106429
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 Disconnect the OUTLET hose (Item 1) that comes from
fall or move and cause injury or death. the gear pump and connects to the control valve fitting
W-2017-0286
(Item 2) [Figure 20-60-2].
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)
WARNING 2
1
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.)
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*.
WARNING
P122351
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 Disconnect the inlet hose (Item 1) [Figure 20-60-4].
fall or move and cause injury or death.
W-2017-0286
Figure 20-60-5
2
1
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
P106631
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-5] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-4]
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-5] from the tester to the inlet fitting on the fan (Item
Tester to prevent any contamination to the 1) [Figure 20-60-4].
Hydrostatic Pumps.
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
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*.
1
1
DANGER 1
P-90180
IMPORTANT 1
Figure 20-60-8
3 1
2
1
P-43940 P-43938A
Figure 20-60-9
P106594
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-11 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
P100685
Figure 20-60-12
P100352
Parts Identification
Figure 20-60-13
1. Bolt
2. Charge Pump End Section
3. Section Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
13. Auxiliary Pump Center Section
14. Auxiliary Pump End Section
15. Shaft Seal
7
8
9 4
10 3
2
3
4
6 5
8
7
11 8
10
11
14 3
3 12
4
6 9
4 8
15
P-66540
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The L/min (U.S. gpm) should drop
off slightly until the pressure reaches approximately
The tools listed will be needed to do the following 21374 kPa (214 bar) (3100 psi). At approximately 21374
procedure: kPa (214 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23787 - 24132 kPa
MEL10003 or MEL1744 - Hydraulic Tester (238 - 241 bar) (3450 - 3500 psi). At 23787 - 24132 kPa
MEL10006 - Fitting Kit (238 - 241 bar) (3450 - 3500 psi) the flow should be at 0
L/min (0 U.S. gpm). Turn the restrictor (Item 2) [Figure
Figure 20-61-1 20-61-1] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
1
2 If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)
P106632
WARNING 1
P106429
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 Disconnect the OUTLET hose (Item 1) that comes from
fall or move and cause injury or death. the gear pump and connects to the control valve fitting
W-2017-0286
(Item 2) [Figure 20-61-2].
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)
WARNING 2
1
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.)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool Kit
tester, the hoses are connected wrong. With the hoses MEL10003 or MEL1744 - Hydraulic Tester
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.
%= HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 Raise the lift arms and install an approved lift arm
FREE FLOW (L/min [U.S. gpm]) support device. (See Installing on Page 10-20-2.)
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*.
P106631
Never work on a machine with the lift arms up unless Figure 20-61-6
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.
W-2059-0598
1
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-90186
Figure 20-61-7 NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700
psi).
Open the restrictor control and record the free flow (L/min
1 [U.S. gpm]) at full rpm. Increase the restriction and the
flow should drop to 0 L/min (0 U.S. gpm) between 24132
kPa (241,3 bar) (3500 psi) and 25511 kPa (255,1 bar)
(3700 psi).
2
1
P106631
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.
1 1
1
1
1
P-90352 P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-9] NOTE: [Figure 20-61-11] shows adjusting the relief
from the access cover and remove the cover from the screw on a wheeled machine for photo clarity.
loader.
If the pump reaches 25,5 kPa (255,1 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned counterclockwise 1/4 turn and retested with the
procedure above.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to 1
fall or move and cause injury or death.
W-2017-0286
Remove the track from the right side of the loader. (See P-64022
Track Removal And Installation on Page 40-20-4.) or
(See Track Removal And Installation on Page 40-21-4.)
Locate the high flow relief valve through rear door along
Figure 20-61-12 the right side of the engine.
1
1 1 1
P-90352 3
P-45459
Inspect the relief valve and replace the two O-rings (Item
1) and back-up ring (Item 2) [Figure 20-61-14].
Figure 20-61-15
P-45461
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 2) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow
pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb) torque.
Figure 20-61-16
Figure 20-61-18
P-45460
P-45462
DANGER 1
1
P-90184
Figure 20-61-20
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
IMPORTANT P-90185
Figure 20-61-21
1
P106594
3
2
1
P114353
P-43940 P-43938A
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.
P100685
Figure 20-61-26
P100352
Parts Identification
Figure 20-61-27
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
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.
W-2059-0598
P122067
Figure 20-70-4
1
P122360 1
Figure 20-70-2
P122362
1
Remove the two bolts (Item 1) [Figure 20-70-4].
P122361
Description
2
The hydraulic fluid reservoir is a storage container for the
loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.
Remove the rear grille, side panels and shield. (See Remove the hydraulic fluid reservoir from the loader.
Removing on Page 50-60-1.)
Installation: Tighten the mount bolts and nuts to 21,7 -
Drain the fluid from the reservoir. (See Removing And 24,4 N•m (16 - 18) torque.
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-80-1
P122344
Figure 20-80-3
P121073A
Description
The oil cooler and radiator are removed from the loader
as a unit. (See Radiator Removal And Installation on
Page 70-60-1.)
Description
When repairing hydrostatic and hydraulic systems, Remove the two bolts (Item 2) and reposition the fuel
clean the work area before disassembly and keep all filter assembly (Item 3) [Figure 20-100-1].
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-100-2
damage the system.
I-2003-0888
DANGER
1
P122353
P-90328
Solenoid Removal And Installation (Cont’d) NOTE: Electric fuel pump removed for photo clarity.
1
3
P122355 1 P101161
Remove the hose (Item 1) [Figure 20-100-3]. Disconnect the wire harness connector (Item 1) [Figure
20-100-5] from the bucket position shut-off solenoid.
Figure 20-100-4
Disconnect and cap the two tubelines (Item 2) [Figure
20-100-5].
2 Remove the solenoid nut, coil, and stem (Item 3) from the
bucket positioning valve [Figure 20-100-5].
Figure 20-100-6
P122354
N-18191
Solenoid Testing
DANGER
P122353
Figure 20-100-9
P-90328
1
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Figure 20-100-7
Remove the hose (Item 1) [Figure 20-100-9].
2
1
P121154
Figure 20-100-10
1
2
1 4 3
P101157
Disconnect and cap the tilt base inlet hose (Item 1), the
P122354 tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-12]
that route from the control valve.
Reposition the clamp (Item 1) and remove the fuel fill
hose (Item 2) [Figure 20-100-10] from the tank. Figure 20-100-13
Cover the fuel tank inlet.
Figure 20-100-11
2
1
P-90189A
Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-13]
from the valve block.
1 P101161
Figure 20-100-14
2
1 3
2
2
1 P-90192
P-90197A
Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-16].
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2) Assembly: Tighten the nut to a maximum of 8 N•m (6 ft-
[Figure 20-100-14] that route from the lift cylinders. lb) torque. Overtightening may cause valve failure.
Figure 20-100-15 Assembly: Put oil on O-rings and back-up rings and
tighten the solenoid stem to 40,7 - 54,2 N•m (30 - 40 ft-lb)
torque.
Figure 20-100-17
1
1
P101159
Figure 20-100-18
3
1
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
2), and plug (Item 3) [Figure 20-100-18]. Inspect for
wear and replace as needed.
Figure 20-100-19
1
2 3
P-90193
Remove the plug (Item 1), spring (Item 2), and unloading
spool (Item 3) [Figure 20-100-19]. Inspect for wear and
replace as needed.
Description
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
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
can cause lift arms to drop. Figure 20-110-6
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
1
Put jack stands under the rear corners of the loader.
Figure 20-110-4
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-6] from the main harness.
P-90583
Removal And Installation (Cont’d) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-7 assembly.
Figure 20-110-8
P-90581
1
1
P-48751
Figure 20-110-9
P-48752
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-48755
Figure 20-110-10
1 Figure 20-110-13
2
2
P-48755
1
Figure 20-110-11
3
P-48757
P-48756
Figure 20-110-14
P-48759
1
Figure 20-110-17
P-48753
Figure 20-110-15
1
2 2
P-48760
Assembly: Put oil on O-ring and back-up rings. Tighten Remove the spacer (Item 2) and solenoid valve coils
to 27 - 34 N•m (20 - 25 ft-lb) torque. (Item 3) [Figure 20-110-17].
Figure 20-110-18
1
1
P-48762
Figure 20-110-20
P-48761
P-48763
Figure 20-110-21
P-48765
1 2
1
P-48764 P-48766
Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-21] and [Figure 20-110-22] and replace the O-rings 24] for dirt and debris.
and back-up rings (Item 2) [Figure 20-110-22].
Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
Assembly: Put oil on O-rings and back-up rings. Tighten torque.
to 41 - 47 N•m (30 - 35 ft-lb) torque.
Figure 20-110-25
1
1
P-48758
Remove the plug (Item 1) [Figure 20-110-25]. Inspect cartridges, check valves, solenoid valves, and
sealing washers for contamination or damage. Wash all
Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up rings.
Figure 20-110-26
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
P-48786
Description
WARNING 1
Figure 20-120-3
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508 1
Figure 20-120-1
P122238
Engage the parking brake. Lower the seat bar. Start the
engine.
Figure 20-120-4
P122229
Figure 20-120-5
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. 1
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
IMPORTANT P122161
When repairing hydrostatic and hydraulic systems, Disconnect the two wire connectors (Item 1) [Figure 20-
clean the work area before disassembly and keep all 120-5] from the solenoid coils.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-120-6
2 2
P122162
Figure 20-120-7
1 1
1
1
P122157
IMPORTANT
3
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 2
4 P122197
Figure 20-120-8
Remove plug (Item 1), spring (Item 2), and spool (Item 3)
[Figure 20-120-9] and inspect. Replace damaged parts
as needed.
1 Figure 20-120-10
P122196
P122198
3 P122201
Figure 20-120-14
Remove the first solenoid coil (Item 1), the spacer (Item
2), and the second solenoid coil (Item 3) [Figure 20-120-
11].
Figure 20-120-12
2
1
P122202
Figure 20-120-15
P122206
1
P122205
Figure 20-120-19
2
3
1
2 P122209
Remove the O-ring (Item 1), the spring (Item 2), and the Figure 20-120-22
check ball (Item 3) [Figure 20-120-23]. Inspect and
replace as needed.
Figure 20-120-20
1
P122210
Figure 20-120-23
P122212
Figure 20-120-24
P122213
1
P115535
P115534A
All Models
1
IMPORTANT 2
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
1
1
1
P-85281
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
2
2 1
2
2 1
2
1 P-34665
Figure 20-130-8
P-34664
2 1
1 2
2
1
2
1
P115529B
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-15].
Figure 20-130-16
2
1
P115531
Description
WARNING W-2103-0508
Figure 20-140-1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure 3
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
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.
parts clean. Always use caps and plugs on hoses,
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
Figure 20-140-2 2
P122354
P128342
P122355
1
1
P128335
Figure 20-140-7
P128339
Figure 20-140-9
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
P128321
Figure 20-140-10 1
2
1
P128489
Loosen the Allen plug (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.
1
P128488
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
P128322
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present. Loosen the Allen plug (Item 1) [Figure 20-140-14]
• Engine is running. approximately 1/4 turn.
• Tools are being used.
W-2505-0604
Figure 20-140-15
WARNING 1
Figure 20-140-13 Install the tool / gauge (Item 1) [Figure 20-140-15] onto
the accumulator.
P128321
2
1
P128491
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) 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.
P128327
Description
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
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
P-90680B
Figure 30-20-2
DANGER
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
P100811
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised Remove the mounting bolts (Item 1) [Figure 30-20-2]
unless supported by an approved lift arm from the access cover and remove the cover from the
support. Replace if damaged. loader.
D-1009-0409
Figure 30-20-3 1 1
1
P-85991
Figure 30-20-4
2 3
4 1
P100901
Parts Identification
10
9
8
7
6
5
4 25
3 24
2 12
23
22
21
11
10
1 20
14
13
17 15
16 63
18
16 54
15 53
46
52
51
19 38 50
49
48
40
27 3332 31
29 35 39 47 61
30 33
26
28
34
42
41
36 37
60
44
43 59
45 55
58
57
56
62
MS2290S
N-18296
P100796
Figure 30-20-7
P100799
Figure 30-20-9
1
2
P100798
1
Inspect the piston surface (Item 1) and the bushing
P100804 surface (Item 2) [Figure 30-20-11] in the brake shaft.
Figure 30-20-10
2
P100801
Figure 30-20-12
2 1
3
N-18347
1
Assembly: Clamp the disc pack in a vise and measure
1
P100795 the disc pack height [Figure 30-20-13].
Remove the snap ring and inner piston seal (Item 3) NOTE: Brake pack height is for reference only.
[Figure 30-20-12].
Figure 30-20-14
NOTE: Install seal with metal case end towards the
brake pack.
Figure 30-20-15
1
2
3
N-18301
1
Disassembly: Remove the brake discs (Item 1) [Figure
P100805 30-20-17] and shims from the brake shaft.
Assembly: Assemble the brake discs into a pack making Figure 30-20-18
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 30-20-15] and
the base of the pack.
1
Figure 30-20-16
2
2
N-18302
Figure 30-20-19
1
2
1 1
P-48686
1 1
Remove and replace with a new O-ring (Item 1) [Figure
P-48684 30-20-21].
Figure 30-20-20
1
1
N-18318
Figure 30-20-23
1
1
P100794
2
Remove the springs from the distributor (Item 1) [Figure Figure 30-20-26
30-20-23].
4
Remove and replace the two seals and back-up rings
(Item 2) [Figure 30-20-23] under the seals, from the 3
distributor.
N-18315
Remove the spring (Item 1), spool (Item 2), washer (Item
2 3), and rear spring (Item 4) [Figure 30-20-26].
P100812
Figure 30-20-27 2
N-18312
Remove the plug (Item 1) [Figure 30-20-27]. Assembly: Apply Loctite® activator 7649 to the plug
threads. Allow ten seconds for the activator to dry. Apply
Figure 30-20-28 Loctite® 243 to the plug threads. Install the plug (Item 1)
[Figure 30-20-30] and tighten to 60 N•m (44 ft-lb) torque.
Figure 30-20-30
1
N-18311
Assembly: Apply Loctite® activator 7649 to the plug Remove the plug (Item 1) [Figure 30-20-30].
threads. Allow ten seconds for the activator to dry. Apply
Loctite® 243 to the plug threads. Install the plug (Item 1)
[Figure 30-20-28] and tighten to 85 N•m (63 ft-lb) torque.
4
1
3
2
P-48688
Figure 30-20-32
1
2
1
P-48690
Figure 30-20-35
P-48694
Figure 30-20-36
P-48695
1
P-48689
Lift the retaining ring (Item 1) [Figure 30-20-38].
Remove the snap ring (Item 1) [Figure 30-20-36] from Use low air pressure and remove the roller / piston
the top side of the rotating group. assembly (Item 2) [Figure 30-20-38] from the cylinder
block.
N-18345
Figure 30-20-40 Assembly: Install the split ring (Item 3) [Figure 30-20-
41] and with a feeler gauge measure the distance
between the split ring and the top of the bearing inner
race.
N-18343
Figure 30-20-42
2
2
1 1
P13083
P0123
Figure 30-20-46
1
P100802A
Figure 30-20-47
1
3
P0126
The hydrostatic drive motors are driven by the hydrostatic Park the loader so that the plug in the hydrostatic drive
pump. Machines equipped with SJC / SCPA are motor is at the bottom.
monitored by a sensor mounted onto the hydrostatic
pump. The sensor is used for detection of motion and for Remove the plug and let the fluid drain from the
rate of speed for the SJC / SCPA options. hydrostatic drive motor.
P100737A
DANGER
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P100811
Figure 30-21-3 2 3
4 1
5
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 30-21-4]. Torque all bolts to 34 N•m (25 ft-lb) in
P109063 the same sequence.
Installation: Fill the main drive hose ports on the motor P-85991
with new hydraulic fluid before installing the drive hoses.
With an arm hoist support the hydrostatic motor.
Parts Identification
10
9
8
65 7
6
5
4
3
12
2 23
11 22
65
21
10
20
1
14
40
39
17
18
38
13 36 37
15 41
16
36
19 42
16 29 42
15 35 30
31
43
34 64
24 32 44 36
25 33
26 31
28 45
27 46
47
48
49 50
51 63
52
53 62
61
55 54 60
59
58
57 NA2870s
56
Figure 30-21-6
N-18296
P100869
Remove the disc spring (Item 1) [Figure 30-21-8] from
the brake housing.
NOTE: Mark the motor, brake, and motor housings
for proper alignment during assembly [Figure NOTE: Mark the top side of the disc spring for proper
30-21-6]. 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)
[Figure 30-21-6], these serial numbers may be needed
when ordering replacement parts.
Figure 30-21-7
P100799
Figure 30-21-9
1
2
P100868
Figure 30-21-10
2
P100801
Figure 30-21-12
N-18347
3
2
Assembly: Clamp the disc pack in a vise and measure
the disc pack height [Figure 30-21-13].
1 P100866
Assembly: The correct disc pack reference
specifications is 37,7 mm (1.48 in).
Remove the five mounting bolts (Item 1) [Figure 30-21-
12] and washers from the brake housing. Assembly: Extra outer discs are used to reduce the
number of required shims [Figure 30-21-13] to make up
Remove the brake housing (Item 2) [Figure 30-21-12] the required thickness for the brake pack.
from the rear housing.
NOTE: Brake pack height is for reference only.
Remove the snap ring and inner piston seal (Item 3)
[Figure 30-21-12]. Figure 30-21-14
Figure 30-21-15
1
2
3
P100858
Figure 30-21-18
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 30-21-15] and
the base of the pack.
1
Figure 30-21-16
2
2
P100859
Figure 30-21-19
P100872
Figure 30-21-20
1 2
P100871
2
4
3 Remove the spool (Item 1) [Figure 30-21-22].
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 30-21-20].
1 Figure 30-21-25
2 4 3
Later
Models
1
1 1
2 2
N-22504
1
Remove the spring (Item 1), washer (Item 2), and rear
P100861A
spring (Item 3) from the spool (Item 4) [Figure 30-21-23].
Inspect all parts and replace as needed. Remove the eight mounting bolts (Item 1) [Figure 30-21-
25] from the rear housing.
Figure 30-21-24
Early Remove the two cam ring mount bolts (Item 2) [Figure
Models 30-21-25].
1
1 Turn the housing, cam ring, and rotating group assembly
1
over and place on a stand.
P100861
Figure 30-21-26
1
P100856
Remove and replace with a new O-ring (Item 1) [Figure Assembly: Apply a small amount of grease to the
30-21-26]. springs to hold them in place during installation.
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
Figure 30-21-30
P100873
1
Figure 30-21-31
1
P100875
P100874
4
1
3
2
P100924
Figure 30-21-35
2
1
1
P-48690
Figure 30-21-38
P100927
Remove the retainer ring (Item 1) [Figure 30-21-38] from Figure 30-21-41
the bottom side of the rotating group.
Figure 30-21-39
2
1
P100928
1
P100932
P100931
Figure 30-21-45
2
1
2
P13083
Figure 30-21-46
P100941
Figure 30-21-49 2 1
2
1
P100940
Remove and replace the face seal (Item 1) [Figure 30- Figure 30-21-51
21-49] on the front housing.
P100930
The hydrostatic drive motors are driven by the hydrostatic Figure 30-22-1
pump. The hydrostatic drive motors contain a spring
applied pressure release braking system. In addition
there is a separate fluid chamber in the motor that is filled
with drive motor fluid for maximum durability, this fluid has
a recommended service interval. (See SERVICE
SCHEDULE on Page 10-70-1.)
P127598B
Remove the plugs and let the fluid drain from the
hydrostatic drive motor.
Removal And Installation Remove the sprocket. (See Sprocket Removal And
Installation (Later Models With Eight Track Sprocket
Bolts) on Page 40-22-14.) or (See Sprocket Removal And
Installation (Later Models With Eight Track Sprocket
IMPORTANT Bolts) on Page 40-23-15.).
Figure 30-22-2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
DANGER
P133296
Figure 30-22-3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm 1
support. Replace if damaged.
D-1009-0409
WARNING P133342
Never work on a machine with the lift arms up unless Remove the mounting bolts (Item 1) [Figure 30-22-3]
the lift arms are secured by an approved lift arm and the access cover.
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.
W-2059-0598
Figure 30-22-4 2
1
1
P133254
Figure 30-22-7
2
P133255
Figure 30-22-5
P133258
4 1
P100901
4
8
18
19
13
21
15
6
20
14
22
11
25
16 12
32
17
23
28 30
24 9 31
29
31
30
7
3
11 5
26 10
2 49 50
27 59 35 53
48
51
22 33
36
40 52
42
48
43
41
45 55 54
46 58
44 56
57
34
54
53
36
NA14530S
4
43
51
1
52
44
9
50
10
6 49
12
47
14
11 58 48
17 46
21
56
17
13 19
20
18
20
19
15 7
5 3
41
45 42
2 16 34 37
33
38
22
26
35
57 36
28 36
29 39 32
27
25
31
30
40
23 54 8
53
24 55
NA14128S
P127424
Figure 30-22-11
3 4 2 1
P127415
parts.
Figure 30-22-9 Remove the spring (Item 1), washer (Item 2), and rear
spring (Item 3) from the spool (Item 4) [Figure 30-22-11].
P127398
Figure 30-22-12
P127390
Figure 30-22-13
4 2 3
1
P127391
Figure 30-22-16
1
1 1
1
P127434
1
1 1 Remove and inspect the alignment stop pin (Item 1)
[Figure 30-22-18].
P127393
Figure 30-22-19
Remove the 12 mounting bolts (Item 1) [Figure 30-22-
16] from the rear housing. (Eight bolts on the single
speed motor).
Figure 30-22-17
P127407
P127394
Figure 30-22-20
2
2
P127407
1
Figure 30-22-23
Remove the five seals (Item 1), and five back-up rings
(Item 2) [Figure 30-22-20] from the rear housing.
Figure 30-22-21
1
P127408
Figure 30-22-24
1
2
P127395
Figure 30-22-25
2
2
1
1
P127396
3 4
P127410
Remove the cam ring (Item 1) [Figure 30-22-27] from the
front housing assembly.
Inspect the two-speed spool (Item 1) (if equipped with
two-speed), the spring (Item 2), washer (Item 3), and the Inspect the cam ring inside surface for wear and
retaining ring (Item 4) and replace as needed [Figure 30- scratches.
22-25].
Assembly: Align the marks (Item 2) [Figure 30-22-27]
NOTE: The two-speed spool (Item 1) [Figure 30-22- on the cam rings to the front housing.
25] has an internal make-up spool, which is
not serviceable. The spool will be damaged if
disassembled.
Figure 30-22-28
1
1
P127401
Figure 30-22-29
1
P127402
1
P127400
Figure 30-22-32
P127406
P127404
P127413
Use low air pressure and remove the roller / piston Disassembly: With a hammer and punch remove the
assembly (Item 1) [Figure 30-22-33] from the cylinder split ring and the preload washer located under the split
block. ring (Item 1) [Figure 30-22-35].
1
2
3
P127416
P127423
Figure 30-22-40
2
1
P127431
Turn the housing over and remove the mounting bolts NOTE: Brake pack height is for reference only.
(Item 1) and the brake retaining plate (Item 2) [Figure 30-
22-40].
P127425
Figure 30-22-44
3 2
1
P127433
Figure 30-22-46
1
1
P127426
Figure 30-22-48
Remove the O-ring (Item 1) [Figure 30-22-46] from the
seal ring.
Install the seal installation tool on the seal ring and O-ring
assembly. 1
P127445
Figure 30-22-50 NOTE: When installing the face seal, apply a layer of
good quality lithium grease to the mating
surfaces of the face seal.
1
Figure 30-22-52
P127429
Figure 30-22-53
P103863
Assembly: Install a new bearing (Item 1) [Figure 30-22- NOTE: Do not get any oil on the rubber O-ring.
54] onto the shaft.
Remove the seal installation tool. Measure the assembly
height at four places 90° apart. The assembled height
must be uniform.
Figure 30-22-56
P127406
Description
Testing
1
The tools listed will be needed to do the following
procedure:
Figure 30-30-1
Assemble the gauge (Item 1), hose (Item 2) and the
correct test coupler (Item 3) [Figure 30-30-2]. Tighten all
fittings.
1 3
WARNING
Never work on a machine with the lift arms up unless
2 the lift arms are secured by an approved lift arm
4 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.
W-2059-0598
P121789
Raise the loader lift arms and install an approved lift arm
Test ports have changed on the Main valve. If your test support device. (See Installing on Page 10-20-2.)
port looks like (Item 2) use test coupler (Item 1). If your
test port looks like (Item 4) Use test coupler (Item 3) Raise the operator cab. (See Raising on Page 10-30-2.)
[Figure 30-30-1].
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
2
P109149B
Figure 30-30-4
P122351
P107933
Adjusting
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
N-17231
I-2003-0888
Figure 30-30-6 Remove the plug, spring and poppet [Figure 30-30-7].
Figure 30-30-8
P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-6].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
(30 - 50 ft-lb) torque.
There are several different thickness of the shims (Item 1)
[Figure 30-30-8] and are used to adjust the charge
pressure.
Adjusting (Cont’d)
SJC Machines
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P-64435
I-2003-0888
Figure 30-30-9 Inspect the poppet and spring for wear or damage.
Description
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.
clean the work area before disassembly and keep all
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
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two mounting bolts and nuts (Item 1) [Figure
ft-lb) torque 30-40-3].
Figure 30-40-4
P-66670
1
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.
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
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
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
Disassembly (Cont'd)
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.
Figure 30-40-11
1
1
N-17197
Disassembly (Cont'd)
3 3
Figure 30-40-14
1 1
3 2
3
2
N-17200
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.
Disassembly (Cont'd)
Figure 30-40-18
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-40-20] from
N-17481 the pump housing and remove the drive shaft and
bearing from the housing.
Remove the drive shaft key (Item 1) the snap ring (Item Figure 30-40-21
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
Disassembly (Cont’d)
Figure 30-40-22
N-17244
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.
Disassembly (Cont’d)
Figure 30-40-26
1
2
1 N-17250
1
Figure 30-40-29
Inspect the dust seal on the pintle shaft.
Figure 30-40-27
N-17248
N-17247
Disassembly (Cont’d)
1
Figure 30-40-30
N-17252
2
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
Figure 30-40-36
Install the lower bearing (Item 1) [Figure 30-40-33] on
the swash plate.
Figure 30-40-34
N-17248
Assembly (Cont’d)
Figure 30-40-37
1 N-17245
Figure 30-40-40
N-17247
Figure 30-40-38
1
N-17244
N-17246
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].
Figure 30-40-42
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
40-44].
Assembly (Cont’d)
1
1
Figure 30-40-45
1
1 3
1 2
N-17200
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
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
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
N•m (35 - 45 ft-lb) torque.
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].
Figure 30-40-54 1
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-40-56].
Assembly (Cont’d)
Figure 30-40-57
N-19570
Figure 30-40-58
1
P-43858
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
Place the loader on jackstands. (See Procedure on Page Disconnect the wire harness (Item 1) [Figure 30-41-3]
10-10-1.) from both sides of the hydrostatic pump.
WARNING IMPORTANT
Put jackstands under the front axles and rear corners When repairing hydrostatic and hydraulic systems,
of the frame before running the engine for service. clean the work area before disassembly and keep all
Failure to use jackstands can allow the machine to parts clean. Always use caps and plugs on hoses,
fall or move and cause injury or death. tubelines and ports to keep dirt out. Dirt can quickly
W-2017-0286 damage the system.
I-2003-0888
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 30-41-4
Figure 30-41-2
1
1
1
P-90208
P-90207
Figure 30-41-5
3
2
1
4
P-90210
Figure 30-41-6
2 2
P-90209
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-41-8] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
clean the work area before disassembly and keep all
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 30-41-7 Remove the pump pulley from the pump drive shaft.
Figure 30-41-9
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-41-7] on the
hydrostatic pump drive shaft.
Remove the two bolts and nuts (Item 1) [Figure 30-41-9].
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque. Installation: Tighten the bolts and nuts to 88 - 95 N•m
(65 - 70 ft-lb) torque.
Figure 30-41-10
P-90226
Parts Identification
1. O-ring 3
2. Bolt 4 1
1
3. End Housing
4. Right Rotating Assembly
5. Timing Pin 6
5
6. Bearing 7
7. Spacer/Coupler
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer
12. Steel Cover 9
13. Hydraulic Controller 8 2
14. High Pressure Relief 1
15. Case Housing 1
10
16. Plug
17. Dowel Pin 11
18. Charge Pressure Relief 2
19. Left Servo 12
20. Right Servo
21. Left Rotating Assembly 16 2
2 14
22. End Housing 16 17
15
13
17
13
18 20
14
22 19
5
2 6
21
8 1 1
9 1
11
10
2
12 2
P-90240
Figure 30-41-11
1
1
P-64437
4
3
2 1
P-64436
1 P-64435
Disassembly
Figure 30-41-16 1
2
P-90228
P-90226
Figure 30-41-17
3 3
2 2 P-90218
1 1
Remove the O-ring (Item 1) [Figure 30-41-19].
3
3
P-90227
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-41-17] from both sides.
Disassembly (Cont'd)
Figure 30-41-20
P-64464
1
Remove the end housing / rotating group assembly
P-64445 [Figure 30-41-22] from both ends of the pump.
Figure 30-41-23
Remove the bolts (Item 1) from the right end housing
(Item 2) [Figure 30-41-20] 1
Figure 30-41-21
P-64465
1
Remove O-ring (Item 1) [Figure 30-41-23].
P-64447
Remove the four bolts (Item 1) from the left end housing
(Item 2) [Figure 30-41-21].
Disassembly (Cont'd)
Figure 30-41-24
RIGHT SIDE
B25012
Figure 30-41-27
Remove valve plate (Item 1) [Figure 30-41-24] from the
right side pump.
Figure 30-41-25
LEFT SIDE
B25011
P-64501
Disassembly (Cont'd)
1
Figure 30-41-28
P-64471
Figure 30-41-31
Remove the pistons (Item 1) [Figure 30-41-28] from the
rotating block.
1
Figure 30-41-29
1
P-64472
Disassembly (Cont'd)
1 1
Figure 30-41-32
3
1
2
P109266
Figure 30-41-35
P109265
Figure 30-41-33 2
P109268
P109269
Disassembly (Cont'd)
Figure 30-41-36
LEFT SIDE
1
P-76742
Figure 30-41-39
Figure 30-41-37
RIGHT SIDE 1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-41-36] and a rubber mallet.
[Figure 30-41-37] from the end housing.
Remove the snap ring (Item 1) and remove the bearing
(Item 2) [Figure 30-41-39].
Disassembly (Cont'd)
Figure 30-41-40
P-90231
Figure 30-41-41
1 1
P-90237
Disassembly (Cont'd)
Figure 30-41-44 1
2
1 2
P-64496
1
P-64497
P-64495
Disassembly (Cont'd)
Figure 30-41-48
1
2
P-64498
Figure 30-41-49
2
1
P-64502
Inspection
Figure 30-41-50
P-64477
Figure 30-41-53
Inspect the valve plates (Item 1) [Figure 30-41-50] for
scratches or scoring. Replace a valve plate if the 1
scratches are deep enough to catch with a fingernail. 1
Figure 30-41-51
P-64472
1
Inspection (Cont’d)
Figure 30-41-54
P109265
Figure 30-41-57
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-41-54].
2
Figure 30-41-55
2
1
3
P-64482
Inspection (Cont’d)
Figure 30-41-58 1
1
P-64498
Figure 30-41-61
Inspect bearing surfaces (Item 1) [Figure 30-41-58] for
scratches or scoring.
Figure 30-41-59
1
2
3 1
P109268
Inspection (Cont’d)
Figure 30-41-62
P-64437
Assembly
Figure 30-41-63
P-64497
2
Figure 30-41-64
1
1
2
P-64496
P-64498
Assembly (Cont’d)
Figure 30-41-67
P-90237
Figure 30-41-68
1
1
2
1
2 P-64466
Align the servo piston with the guide slot (Item 1) [Figure
30-41-70] parallel to the drive shaft center line.
P-64493
1 1
P-64456
Figure 30-41-75
P-90232
LEFT SIDE
Install the bolts (Item 1) [Figure 30-41-71].
1
Tighten the bolts to 10,4 N•m (7.7 ft-lb) torque. 2
Figure 30-41-72
RIGHT SIDE
P-64503
1
2
P-64502
2
1
P-76743
Figure 30-41-77
LEFT SIDE
P-64486
Assembly (Cont’d)
Figure 30-41-79 1 1
2
2 2
1 P-64480A
Install the swash plate assembly over the shaft and into
P109266 the end cap housing. The locating wires (Item 1) must
engage the holes (Item 2) [Figure 30-41-81] of the end
cap housing.
Install the positioning pin (Item 1). Install the bearing
races with the tall edge (Item 2) [Figure 30-41-79] of the Figure 30-41-82
race towards the outside of the housing.
Figure 30-41-80
2
2 1
P109273
4 3
P109271 Install the positioning wire (Item 1) into the positioning pin
(Item 2) [Figure 30-41-82].
Assembly (Cont’d)
Figure 30-41-83
2
1 1
P-64476
Figure 30-41-86
The swash plate (Item 1) must move smoothly on the
bearings. Install the feedback link (Item 2) [Figure 30-41-
83] on the swash plate.
1
Figure 30-41-84
P-64475
Assembly (Cont’d)
Figure 30-41-87
1
1
P-64466
Figure 30-41-88
1 2
1
P-64463
P-64465
Align the dowel pin (Item 1) with the hole in the case
(Item 2) [Figure 30-41-90] as the end cap is installed.
Install the O-ring (Item 1) [Figure 30-41-88].
Assembly (Cont’d)
1
Figure 30-41-91
1 1
1 1 P-90218
Figure 30-41-92
1 1
2
1 1
P-64476
P-64447
Install the swash plate angle sensor (Item 1) into the slot
of the positioning pin (Item 2) [Figure 30-41-94].
Install the bolts (Item 1) [Figure 30-41-91] and [Figure
30-41-92]. Tighten the bolts to 130 N•m (96 ft-lb) torque.
Assembly (Cont’d)
Figure 30-41-95
P-90228
Figure 30-41-96
2 2
1 1
2 2
P-90227
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-64973
Raise the lift arms, and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Connect a hydraulic hose (Item 1) [Figure 30-41-97]
Raise the operator cab. (See Raising on Page 10-30-2.) between port X1 and port X2 on each side of the
hydrostatic pump to equalize the pressures on both ends
Connect the Remote Start Tool. (See REMOTE START of the servo pistons.
TOOL KIT - MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 30-41-98
7217666 on Page 10-61-1.)
P-90242
Figure 30-41-99
P-90226
Start the loader using the Remote Start Tool and run at
Remove the plugs (Item 1) [Figure 30-41-99] from the idle.
MA ports on the bottom of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.
Figure 30-41-102
P115932
Figure 30-41-103
P-90238
1
Turn the adjustment screw (Item 1) [Figure 30-41-103] Shut the loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the hydraulic hose from the X1 and X2 ports on
adjustment screw. the pump. Install the plugs and tighten to 25 N•m (18 ft-
lb) torque.
Figure 30-41-104
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
P-90238
1
WARNING
2
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
P-90226
Raise the lift arms, and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Remove the X1 plug (Item 1) and X2 plug (Item 2)
Raise the operator cab. (See Raising on Page 10-30-2.) [Figure 30-41-107] from the side of the hydrostatic pump
being adjusted.
Connect the Remote Start Tool. (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.)
Figure 30-41-108
P-90236
Figure 30-41-109
1
1
P-90236
P-90236
Turn the adjustment screw (Item 1) [Figure 30-41-111]
counterclockwise, until the other gauge registers an
Loosen the screw (Item 1) [Figure 30-41-109]. increase in system pressure. Mark the position of the
adjustment screw.
Start the loader using the Remote Start Tool and run at
an idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
Figure 30-41-112
P-90236
Figure 30-41-113
1
2
P-90236
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
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].
Figure 30-50-4
Later Models
1
P121107A
2
Figure 30-50-2
P126273
P115668
Belt Replacement
1
Stop the engine and open the rear door.
Figure 30-50-5
2
P109783
P121086
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.
P121188
1 1
P115669
Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
P121086
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
NOTE: 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
P107206
1 P114387
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].
P114384
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].
P126277
P126274
Figure 30-50-19
1 2
P126284
Description
Figure 30-60-1
P122392
DANGER 1
P122392
P-90328
AVOID DEATH Remove the steering shocks (Item 1), the bolts (Item 2)
• Disconnecting or loosening any hydraulic [Figure 30-60-2] and set the steering levers to the side.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Mark all hydraulic hoses for proper installation.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Figure 30-60-3
support. Replace if damaged.
D-1009-0409
WARNING
Never work on a machine with the lift arms up unless 2
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. 1
W-2059-0598
P122393
Figure 30-60-4
1
2 2
P122394
Figure 30-60-5
1
1
1
P107100
Figure 30-60-8
Remove the hydraulic fittings (Item 1) [Figure 30-60-5]
from the valve block.
Figure 30-60-6
1
2
P107101
3
Figure 30-60-9
P107104
Figure 30-60-10
1
1
2 2 2
P107103
Description
IMPORTANT 1
Figure 30-70-1
P-90484
Remove and plug all hoses from the drain manifold (Item
1) [Figure 30-70-1].
Description
WARNING
Figure 40-10-1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 40-10-2
P-85426
DANGER
1 P-85428
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Figure 40-10-3
1
2
P-85431
P-85427
Loosen the electrical brake solenoid nut (Item 1) and the
three fittings (Item 2)[Figure 40-10-5].
Disconnect and cap the tubeline (Item 1) [Figure 40-10-
3] from the rear of the brake valve. Assembly: Tighten the solenoid nut to 5,4 - 6,8 N•m (48 -
60 in-lb) torque.
Figure 40-10-4
Figure 40-10-6
2
2
1
1
1 3
1
P-85430
P-85429
Figure 40-10-7
P-85432
Description
Figure 40-11-1
P-90668E
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].
Checking Tension
Figure 40-20-4
Track
13 - 16 mm Roller
(1/2 - 5/8 in)
1
P-85243C
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
about 76 mm (3 in) off the ground [Figure 40-20-2]. 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 13 - 16 mm (1/2 - 5/8 in)
jackstands do not touch the tracks. bolt, dowel or block to measure the gap [Figure 40-20-3]
and [Figure 40-20-4].
Measure the track sag at the 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
Figure 40-20-5
2 1
P-76326A
1
2
P109765
2 1
Install the bleed tool (MEL1560) on the bleed fitting (Item
P-76325A
1), adjust and tighten the collar (Item 2) [Figure 40-20-6]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-20-5]. Figure 40-20-7
WARNING P-85416
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 track assembly until all
support device. Failure to use an approved lift arm track tension has been released [Figure 40-20-8].
support device can allow the lift arms or attachment
to fall and cause injury or death. Tighten the bleed fitting using the MEL1560 tool (Item 1)
W-2059-0598 [Figure 40-20-8].
With pry bars, pry the track up and over the front idler
[Figure 40-20-9].
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].
Figure 40-20-11
P-73967
P-76843
Figure 40-20-12
P-76051
Figure 40-20-14
P-76325
Figure 40-20-15
1 2
P-76850
Figure 40-20-17
WRONG
2
2
1
P-85014A
Figure 40-20-18
WRONG
P-85014
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
AVOID INJURY OR DEATH the grease tube.
• Spring loaded components under pressure can
cause serious injury or death. Installation: Apply oil to new O-ring, back-up ring, seal,
• Do not disassemble the coil spring assembly and wear ring before installation.
W-2617-1004
Installation: Apply grease to area between seal and O-
Figure 40-20-20 ring before installing.
P-85036
WARNING
1 2 3 4 5 6 7
P-85019
P-85372
Figure 40-20-24
1
1
1
1
2 P-85421
2
Align the holes in the housing with the holes in the shaft.
P100737A
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
(300 - 330 ft-lb) torque.
Figure 40-20-30
P-85409
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].
Checking Tension
Figure 40-21-4
Track
13 mm Roller
(1/2 in)
P100726A
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
about 76 mm (3 in) off the ground [Figure 40-21-2]. 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 13 mm (1/2 in) bolt, dowel
jackstands do not touch the tracks. or block to measure the gap [Figure 40-21-3] and
[Figure 40-21-4].
Measure the track sag at either middle track roller (Item
1) [Figure 40-21-2]. The correct gap is 13 mm (1/2 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
Adjusting Tension
Figure 40-21-5
2 1
1
2
P109765
WARNING P-85380
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 track housing assembly
support device. Failure to use an approved lift arm until all track tension has been released [Figure 40-21-
support device can allow the lift arms or attachment 8].
to fall and cause injury or death.
W-2059-0598 Tighten the bleed fitting using the MEL1560 tool (Item 1)
[Figure 40-21-8].
Decrease the track tension. (See Adjusting Tension on
Page 40-21-3.)
Figure 40-21-9
P-85369
With a chain hoist, lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-21-10].
Figure 40-21-11
P-73967
Figure 40-21-12
P-76051
Figure 40-21-14
1 2
P-76850
Figure 40-21-16
P-76844
Figure 40-21-17
WRONG
2
2
1
P-85014A
Figure 40-21-18
WRONG
P-85014
WARNING 4
3
2
1
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
AVOID INJURY OR DEATH the grease tube.
• Spring loaded components under pressure can
cause serious injury or death. Installation: Apply oil to new O-ring, back-up ring, seal,
• Do not disassemble the coil spring assembly and wear ring before installation.
W-2617-1004
Installation: Apply grease to area between seal and O-
Figure 40-21-20 ring before installing.
P-85036
WARNING
1 2 3 4 5 6 7
P-85019
P-85372
Figure 40-21-24
1
1
1
2 P-85374
2
Align the holes in the housing with the holes in the shaft.
Figure 40-21-26
1
3
P-76930
Figure 40-21-27
P-76027
The upper and lower leaf spring mounts are wider on one
1 side to prevent the leafs from rubbing on the track
housing during operation.
P100737A
Figure 40-21-32
At the rear of the loader remove the two mount bolts
(Item 1) [Figure 40-21-33].
Figure 40-21-34
P-85422
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].
Description (Cont’d)
Figure 40-22-2
SOLID-MOUNTED UNDERCARRIAGE
P121538B
Figure 40-22-4
P107800
Figure 40-22-7
Track
19 – 22 mm Roller
(3/4 – 7/8 in)
1
P121538B
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
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]
and [Figure 40-22-7].
Measure the track sag at the middle track roller (Item 1)
[Figure 40-22-5]. The correct gap is 19 – 22 mm (3/4 – 7/
8 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
Figure 40-22-8
1
2
P115662
1 2
Loosen the access cover bolts and pivot the access cover Figure 40-22-10
open [Figure 40-22-8].
Figure 40-22-11
1
2
P115662A
1
Loosen the access cover bolts and pivot the access cover Figure 40-22-13
open [Figure 40-22-11].
WARNING P115667
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].
support device can allow the lift arms or attachment
to fall and cause injury or death. Tighten the bleed fitting using the MEL1560 tool (Item 1)
W-2059-0598 [Figure 40-22-8] and lower the track.
Figure 40-22-15
P120890
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].
Figure 40-22-19
P120877
With a chain hoist, lift the track clear of the drive sprocket
and rear idler. Remove the track from the loader [Figure
40-22-19].
Put the track on the front idler wheel using the same
procedure as removing the track.
Figure 40-22-20
P120892
Figure 40-22-21
1 1
P122303
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
WARNING
P120897
P-62574
Remove the O-ring (Item 1) [Figure 40-22-28].
Figure 40-22-27
2 1
2
1
P106695
P120896
Figure 40-22-30
1
2
3
4
P120897
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
Figure 40-22-32
P120902
1
Remove the bolts (Item 1) [Figure 40-22-33] from the
P120901 roller shaft. (Both ends of the roller shaft.)
Figure 40-22-34 1
P127282A
Figure 40-22-35
D F
1 G C
1
P127598A
P122661
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].
Description (Cont’d)
Figure 40-23-2
SOLID-MOUNTED UNDERCARRIAGE
P121538A
Figure 40-23-4
P107800
Figure 40-23-7
Track
19 – 22 mm Roller
(3/4 – 7/8 in)
P121536A
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
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]
and [Figure 40-23-7].
Measure the track sag at either middle track roller (Item
1) [Figure 40-23-5]. The correct gap is 19 – 22 mm (3/4
– 7/8 in).
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
Figure 40-23-8
1
2
P115662
1 2
Loosen the access cover bolts and pivot the access cover Figure 40-23-10
open [Figure 40-23-8].
Figure 40-23-11
1
2
P115662A
1
Loosen the access cover bolts and pivot the access cover Figure 40-23-13
open [Figure 40-23-11].
WARNING P121200A
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 40-23-14].
support device can allow the lift arms or attachment
to fall and cause injury or death. Tighten the bleed fitting using the MEL1560 tool (Item 1)
W-2059-0598 [Figure 40-23-2] and lower the track.
Figure 40-23-15
P120890
Figure 40-23-18
P120888
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
With a pry bar, pry the track over the front idler [Figure
40-23-18].
P122263
Figure 40-23-19
P120877
With a chain hoist, lift the track clear of the drive sprocket
and rear idler. Remove the track from the loader [Figure
40-23-19].
Put the track on the front idler wheel using the same
procedure as removing the track.
Figure 40-23-20
P122300
Figure 40-23-21
1 1
P122303
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
WARNING
P120897
P-62574
Remove the O-ring (Item 1) [Figure 40-23-28].
Figure 40-23-27
2 1
2
1
P106695
P120896
Figure 40-23-30
1
2
3
4
P120897
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
Figure 40-23-32
P122302
1
Figure 40-23-34
P122299
P122301
Figure 40-23-35
P122302
Figure 40-23-37 1
P127282A
Figure 40-23-38
D F
G C
1
P127598A
P120903
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.
Figure 40-30-1
Move Sprockets to opposite sides of the loader
P-3864
Remove track
Reinstall 180° Figure 40-30-3
P-85440
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.
Prevention:
Damage:
Figure 40-30-5
Excessive Wear
PI-13037A
Track Rotation:
Figure 40-30-7
Idler
Rubber
track
PI-13039
PI-13040
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.)
Figure 40-30-12
Good
Separation of
bonded rubber
cover
PI-13043
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
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:
Figure 40-30-14
PI-13045
Construction sites
Demolition sites
Concrete ridges
Stumpy fields
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:
P-4380
Damage:
Replacement:
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 (0.2 in).
Prevention:
Figure 40-30-19
Lug abrasion
PI-13049
Damage:
Replacement:
No replacement is required.
PI-13051
PI-13053
Prevention:
Figure 40-30-24
PI-13056
PI-13055
Damage:
Replacement:
Figure 40-30-27
Cut
Tear
PI-13057
Prevention:
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-3
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
Figure 50-10-1
1
P-90021
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Figure 50-10-2
P122374
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].
5
4 8
3
2
1
P-90028
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.
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
Figure 50-20-1
2
1
1 3
P-85652A
Remove the retaining clip (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
Lift the cab with the hoist to release the pressure on the
gas spring(s).
Gas Spring Bracket Disassembly And Assembly Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
Figure 50-20-4 2.)
Figure 50-20-5
3
2
1
1
1
2
P-85661
P100756
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-
20-4]. Unhook the four fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-20-5].
Installation: Apply a small amount of threadlocker on the
threads of the gas spring rod before installing the clevis Installation: (See Installing on Page 80-150-1.)
(Item 1) [Figure 50-20-4].
Figure 50-20-6
WARNING 1
AVOID INJURY 2
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only 1
qualified service personnel can remove the cylinder.
W-2112-0987
1
P100879A
1
1
1 P107406
Figure 50-20-9
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].
Cap and plug the hoses and expansion valve fittings with
proper A/C caps and plugs.
WARNING 1
Figure 50-20-10
P-85662
Using a strap and a hoist, remove the cab from the loader
[Figure 50-20-10].
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.
Figure 50-30-3
3 1
P101250
Remove the seat belt. Installation: Tighten the mounting bolts to torque.
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)
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
P-85770
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
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.
1 1
P-85775
Shock Removal And Installation Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
P-85784
1 3
1
P-85788
Figure 50-31-14
P-85787
P-85554
Figure 50-40-2
P-85649
Figure 50-40-3
1 P-31405
Figure 50-40-6
Remove the snap ring (Item 1) [Figure 50-40-3] from the
Bob-Tach pivot pin grease plug (both sides).
Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug (Item 1) [Figure 50-40-4] out of
the Bob-Tach (both sides).
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Figure 50-40-10
Figure 50-40-8
P127544
Figure 50-40-11
P-85667
Figure 50-40-12
P-85666
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.
replace the damaged parts as needed.
Figure 50-40-16
2 1
P-85669
Figure 50-40-17
3
NA5472
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-41-1].
Figure 50-41-2
1 1
P-31402
Figure 50-41-5
Remove the retainer bolt and nut (Item 1) [Figure 50-41-
2] from the rod end pivot pin.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug (Item 1) [Figure 50-41-5] out of
the Bob-Tach (both sides).
P-85649
Figure 50-41-6
P-31406
1
Remove the retainer bolt (Item 1) [Figure 50-41-8] from
P-31405 the Bob-Tach pivot pin (both sides).
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).
1 1
P127544
Remove the washers and bolts (Item 1) [Figure 50-41- Figure 50-41-13
10] from the cylinder (both ends).
Figure 50-41-11
1
2
P-85665
1
Remove the washer and spring (Item 1) and the lever
assembly (Item 2) [Figure 50-41-13].
P-85664
Figure 50-41-14 4
1
1 2
2
P19287
P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise. Remove the bolt (Item 1) [Figure 50-41-16] and
Use a punch and hammer to remove the roll pin (Item 1) replace the damaged parts as needed.
[Figure 50-41-14] from the Bob-Tach wedge and spring
clevis. Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-41-16], tighten to 125 - 135
Remove the spring clevis assembly (Item 2) [Figure 50- N•m (90 - 100 ft-lb) torque.
41-14].
Later Design
Figure 50-41-15
Figure 50-41-17
3
P-85667 2
P121303
Figure 50-41-18
2 1
P-85669
Figure 50-41-19
3
NA5472
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].
Figure 50-50-4
P-90592A
Figure 50-50-2
P-31595
P-90593
P-90594
1
1
P-90598
P-90597
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
Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
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].
Figure 50-50-11
P-90599
Figure 50-50-12
P-90611
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
Figure 50-50-16
1
2
P-90609
2
Remove the retaining bolt and nut (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).
Figure 50-50-17
P-90605
Figure 50-60-1
1 P109931
Insert the front tab of the two hood covers into the slots in
P121151A
the loader frame and lower [Figure 50-60-3]. (Left side
shown.)
Remove the clamping knob (Item 1). Lift using the handle Figure 50-60-4
(Item 2) [Figure 50-60-1] and pull the rear grille
backward to remove from the loader.
Figure 50-60-2
P109722
Insert the edge of the rear grille under the loader frame
P121215A
and slide rear grille in while lowering [Figure 50-60-4].
Figure 50-60-5
P122118
Figure 50-70-1
1 1
P122494
P122491
Figure 50-70-2
P122492
2 2
P115841
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-80-1] from the main frame harness.
[Figure 50-80-3].
Remove both rear lights (Item 2) [Figure 50-80-1] from
Installation: Tighten the mounting bolts and nuts to 34 -
the door. (See Rear Removal And Installation on Page
38 N•m (25 - 28 ft-lb) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-80-2
flat on the floor.
1 2
1
P115840
Figure 50-80-4
WARNING
1
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-80-6
1
1
P85698B
Close the rear door. (This will align the striker assembly
to the correct position.)
P106584
Open the door.
Remove the bolt (Item 2), spacer (Item 3) and roller (Item Close the rear door.
4) from the bracket (Item 5) [Figure 50-80-5].
Figure 50-80-7
1
2
1
P109094
Figure 50-80-8
2
1
P109093
1
2
P121146
1 1
1
2
1 1
P121145 P121147
Remove the 12 nuts (Item 1) [Figure 50-80-11]. Remove the nuts and bolts (Item 1)and the tailgate fan
(Item 2) [Figure 50-80-13] from the rear door.
WARNING
W-2103-0508
Figure 50-90-3
4
2
P114311
2 3
Remove the fuel vent hose (Item 1) and the fuel inlet
hose (Item 2) [Figure 50-90-1].
1
P-85708
Removal And Installation (Cont'd) Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Figure 50-90-4
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-15.)
2 1
Figure 50-90-6
1
1
P-85710
Figure 50-90-7
1 1
2
P-85709
Lift the fuel tank and remove it from the loader frame.
Inspect the fuel level sender and replace if worn or
NOTE: When installing the fuel tank, avoid striking damaged [Figure 50-90-7].
the tank with heavy objects to prevent
damage.
Figure 50-90-8
1
1
P122354
Figure 50-90-9
1
1
P122375
Description
WARNING P100782
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-100-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598
Figure 50-100-2
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
DANGER
1
P100783
P-90328 Remove the two nuts (Item 1) [Figure 50-100-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Figure 50-100-3
1
1
2
P-85679
2
1
P-85681
P-85680
1
2
1
P100782 P100783
Remove the bolt (Item 1) [Figure 50-100-7] and nut from Loosen the two mounting bolts (Item 1) [Figure 50-100-
the pedal linkage. 9] from the pedal mounting bracket.
Figure 50-100-8
1
1
2
P100782
P-85675A
Loosen the bolt (Item 1) [Figure 50-100-10] and nut on
the pedal linkage.
Remove the bolt (Item 1) [Figure 50-100-8] and nut from
the pedal linkage. Inspect the bushing in the pedal for wear and replace as
needed.
Remove the linkage (Item 2) [Figure 50-100-8].
Tilt the pedal back and forth until an acceptable
Pedal (Adjusting) “NEUTRAL” angle is achieved on the pedal.
After installing the pedal, adjust the pedal angle so that Tighten the two nuts (Item 2) and pivot bolt (Item 1)
there is clearance under the rear of the pedal. The valve [Figure 50-100-10] on the pedal assembly to standard
spool must travel full stroke without the pedal hitting the torque.
floor panel.
Figure 50-100-11
1
1
P-85859 P-85860
Figure 50-100-12
1 1
P-85858
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.
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-101-1] and nut from
the pedal linkage.
Never work on a machine with the lift arms up unless
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.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 50-101-2
W-2059-0598
DANGER 1
P-85676
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-101-3 spool must travel full stroke without the pedal hitting the
floor panel.
Figure 50-101-5
1 1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
101-3] from the foot sensor.
Figure 50-101-4
P-85676
Figure 50-101-6
1
1
P-90981
2
Figure 50-101-7
1
1
P-85859 P-85860
Figure 50-101-8
1 1
P-85858
Description
Figure 50-110-1
NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the NEUTRAL or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set NEUTRAL of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
2
DANGER
1
P-85846
P-90328
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
P-85847
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. Disconnect the control harness connectors (Item 1) and
W-2059-0598
the back-up alarm wires (Item 2) [Figure 50-110-2] and
[Figure 50-110-3] from the control levers.
WARNING
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
Figure 50-110-4
2
1
P-90612
Figure 50-110-5
3 2 3
3 3 P-85848
Figure 50-110-6
1
1 1
P-85861
2
2 Remove the bolts and nuts (Item 1), steering link, (Item
2), and washers (Item 3) [Figure 50-110-7] and [Figure
50-110-8].
1 1
P-85864 Installation: Verify correct orientation of components
[Figure 50-110-7] and [Figure 50-110-8].
Remove the nuts (Item 1) and the steering stabilizers Figure 50-110-9
(Item 2) [Figure 50-110-6].
1
Figure 50-110-7
2 2
2 2
1 1
1 1
1
3 1 3 3
3
P-85867
Figure 50-110-10
2
2
4
3
1
1
2
P126301
P126310
1
Figure 50-110-11 4
3
1 1
2
1
P126303
P126302 Inspect the shaft (Item 1), bellcrank (Item 2), four
bushings (Item 3) and the two torsion bushings (Item 4)
[Figure 50-110-13] for wear and replace as needed.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death. 2
W-2017-0286 P-48631
Lift and block the loader. (See Procedure on Page 10-10- Remove the nut (Item 1) from the end of the centering
1.) spring shoulder bolt (Item 2) [Figure 50-110-15].
Raise the lift arms and install an approved lift arm Remove the bolt / spring assembly.
support device. (See Installing on Page 10-20-2.)
Installation: Tighten the centering spring bolt and a
Raise the operator cab. (See Raising on Page 10-30-2.) NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
1
2
1
P-90612 P-48632
Scribe a mark across the top of the steering linkage bars Slide the centering plate (Item 1) [Figure 50-110-16] to
(Item 1) [Figure 50-110-14] which are connected to the the right to remove it from the hydrostatic pumps.
steering shaft on the control panel.
NOTE: Directions are shown and stated as if you
Remove the four steering linkage mounting bolts, nuts were sitting in the operator’s seat.
and rubber isolators (Item 2) [Figure 50-110-14].
Figure 50-110-17
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Inspect the wear on the centering blocks (Item 1) [Figure
P-48630 50-110-18].
4 Bushing Spacer NOTE: If the centering blocks are worn, they can be
5 Spring removed and rotated 180 degrees and
6 Locknut reinstalled.
7 Centering Plate
8 Guide Bushings
Figure 50-110-19
2
2
1
P-54615
3
Remove the bolts and washers (Item 1) [Figure 50-110- Figure 50-110-22
19] from the pintle.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-110-19].
Figure 50-110-20 2
1 3
1
2 P-48659
4
3 NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-110-22].
2
4
3 1
2
3
1 P-48619
P-54624
Inspect the torsion bushing (Item 4) [Figure 50-110-23] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-110-25] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-110-24 arm should be the same.
4
2
P-54626
Lift and block the loader. (See Procedure on Page 10-10- P-85845
1.)
Figure 50-110-26 Loosen the bolt / nut (Item 1) [Figure 50-110-27] only
until the tension is released from the torsion bushing.
3
Figure 50-110-28
2
1
P-48450A
To make this tool use a locking grip C-Clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-110-28].
[Figure 50-110-26] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-110-26] is torsion bushing (Item 2) [Figure 50-110-28] to
also needed. The centering block can be placed as turn freely between the torsion bushing and
shown and welded to the C-clamp if desired. the steering linkage bar.
WARNING
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
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.
[Figure 50-110-29] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine startup to reduce
adjusting the right centering block, the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-110-30
Tighten bolts (Item 3) [Figure 50-110-30] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-110-29] and
[Figure 50-110-30].
1
P-48451
Figure 50-110-31
1 1
2
P-54610
Figure 50-110-33
2 1
2 1
P-48632
WARNING
P-85845
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 Loosen the bolt / nut (Item 1) [Figure 50-110-34] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
to fall and cause injury or death.
W-2059-0598
Figure 50-110-35
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service. 2
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Preload tension in the torsion bushings must be removed The bolts must be loose enough to allow the torsion
before adjusting the steering linkage. bushing (Item 2) [Figure 50-110-35] to turn freely
between the torsion bushing and the linkage bar.
Figure 50-110-36
2
1
1 3
P-51132
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-110-37]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-110-39].
Figure 50-110-40
1
1
1
P-51132
Figure 50-110-41
P-54613
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-110-
41]. Use a locking plier, clamp the two linkage bars
together.
WARNING
1
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
Tighten the two bolts and nuts (Items 1) [Figure 50-110- If the drift is excessive to the right, turn the left
44] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bellcranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the back-up alarm must be inspected. (See
Inspection on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-110-45 prevent overcorrection and excessive
reduction in travel speed.
P-85877
Figure 50-110-47
1 2
P-85845
WARNING
Put jackstands under the front axles and rear corners
1
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
P-85879
Figure 50-111-2
1
1
1
2
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. 3
1 1
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
P-85881
support. Replace if damaged.
D-1009-0409
WARNING Remove the lift arm bypass knob and rubber washer
(Item 2) [Figure 50-111-2].
Never work on a machine with the lift arms up unless Remove the control panel (Item 3) [Figure 50-111-2].
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.
W-2059-0598
Description
Figure 50-120-1
2
3
P-85882
Figure 50-120-2
P-85883A
Figure 50-121-1 1
P-85882
P-21879
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator, or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-121-1] that are Loosen the nuts (Item 1) [Figure 50-121-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator’s
panel. seat.
Figure 50-121-3
1 P-21860
Figure 50-121-4
5
1 2
4
1 P-21862
P-21878
1 Figure 50-121-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-121-7] from the handle sensor.
Figure 50-121-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, inspect the routing of the switch handle
4 wire harness (Item 1) [Figure 50-121-9] and [Figure 50-
3 121-10] to assure proper return of the control handle to
7 NEUTRAL and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-121-9] and
2
P-21882 [Figure 50-121-10] as shown away from stop
strap (Item 3) [Figure 50-121-9] and [Figure 50-
121-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-121-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-121-8] sensor, actuator, or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Figure 50-121-11
1
1
N-17384
Figure 50-121-14
Remove the handle sensor (Item 1) [Figure 50-121-11].
(See Handle Sensor Removal And Installation on Page
50-121-1.)
Figure 50-121-12 1
1 2
N-17385
Figure 50-121-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-121-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-121-15] from the handle.
Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-121-17] used to mount the control lever.
N-22796
Figure 50-121-18
P-85883A
Description
Joystick Testing
Figure 50-122-1
P-85891
P-85890
Figure 50-122-2
1
1
P-85889
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Installation on Page 50-100-1.)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-100-1.) Figure 50-130-2
Figure 50-130-1
1 1
1
1 2
3
2
3
P-85677A
P100732
Remove the four bolts (Item 1), washer (Item 2), and
remove the right access panel (Item 3) [Figure 50-130-
Remove the four bolts (Item 1), washer (Item 2), and 2].
remove the left access panel (Item 3) [Figure 50-130-1].
Figure 50-131-1
2 2
1
P106589
P100731
Remove the two mounting nuts (Item 1) and remove the
foot rest (Item 2) [Figure 50-131-3].
Remove the two nuts (Item 1) and remove the foot rest
(Item 2) [Figure 50-131-1]. Figure 50-131-4
Figure 50-131-2
1 1
2
P106590
2
P100732
NOTE: Mark the location of the foot pedal before
removal for correct assembly.
Remove the four bolts (Item 1), and remove the access
panel (Item 2) [Figure 50-131-2]. Loosen the bolt (Item 1) and remove the engine speed
control foot pedal (Item 2) [Figure 50-131-4].
Figure 50-131-5
2
1
1
P106591
Remove the four bolts (Item 1) and lay the right inside
access panel (Item 2) [Figure 50-131-5] down.
Figure 50-131-6
P107707
1
P-85309B P-64994G
—————————————————————————————————————————————————————
P-85309A P-64994F
Turn both latches (Item 1) [Figure 50-140-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 50-140-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
P-90676 P-90676
Exit through the rear of the operator cab [Figure 50-140- Exit through the rear of the operator cab [Figure 50-140-
3]. 5].
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 50-140-6
Figure 50-140-8
1
P-90669A
P13982
OR
Figure 50-140-7
P-90669C
Figure 50-141-1
1 1
P107298A
1 1
1 1
1 1
2
P-85807
P-85807
Figure 50-141-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-141-5].
P-90586
1 3 4 5
2
P-85819
Description
Figure 50-150-1
P-85828
Figure 50-150-4
2 1
P-85781A
Figure 50-150-2
2
3
2 1
1 P-85837
4
3
1
1
1
P-85834
1 2
Figure 50-150-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-150-5].
2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Figure 50-150-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-150-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-150-
8].
1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-150-6].
1 1
4
3 P106381
4
P-85836
Figure 50-150-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-150-9].
Figure 50-150-10
1 1
3
P106382
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-150-11] between the
door and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-150-10]. After verifying alignment inspect for proper operation.
(See Checking Operation on Page 50-150-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-150-10].
Figure 50-150-13
2
1
P-85413F
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-150-13] and LOADER button (Item 1) [Figure 50-150-15].
adjust the latch as needed.
Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-150-14 [Figure 50-150-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-150-15] will go out and the display will return
to machine hours.
P106587
Description
Figure 50-160-1
P-90837
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 50-160-2
P-90845
P-90835
Figure 50-160-3
P-90836
Figure 50-160-5
1
1
P-90840
Figure 50-160-8
1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-160-5].
Figure 50-160-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-160-8].
1 1
P-90839
Figure 50-160-9
3 1 1
2 2
1 P-90844
Remove the two nuts (Item 1) and the slide rail (Item 2)
P100825 [Figure 50-160-11] from the armrest mount.
7 4
6 3
5 2
1
P100824
Figure 50-170-1
1
1
1 1
P-90863 P-90856
1
P-90867
Figure 50-170-5
2
1 1
P-90858
Figure 50-170-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-170-5].
Figure 50-170-6
2 1
1
P-90852
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-170-6]. harness.
Figure 50-170-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-170-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-170-9] (if equipped). Figure 50-170-11
P-90865
Figure 50-170-12
1 1
1
1
P-90866
Figure 50-170-13
P-90864
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-180-3].
Figure 50-180-2
1 P106595
1
1 Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-180-4].
P-90869
Figure 50-180-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-180-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-180-5] power port from the right side lower panel.
rear out and away from the side of the cab.
NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new lock washer when it has been
side of the cab far enough to access the wire removed.
harness.
Figure 50-180-8
Figure 50-180-6
2 1
1
2 P-90877
1
P-90881
P-90873
Figure 50-180-9
P-90875
Figure 50-180-10
1
1
1
1
P-90876
Figure 50-190-1
1 1
1
P-90895
2
1
1
2
1 P-90896
Remove the air duct (Item 1) [Figure 50-190-2] (if NOTE: Replace the retainers if needed.
equipped).
Figure 50-200-1
P122398
Figure 50-200-4
1
1
P122396
Figure 50-200-2
P122399
P122397
Figure 50-200-5
3 2
P122400
Remove the bolt (Item 1) and move the hose (Item 2) out
of panel slot (Item 3) [Figure 50-200-5].
Figure 50-200-6
1
2
P122401
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
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
TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-2
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C607 POWER BOBTACH CLOSE 2 17 T17 LEFT REAR WORK LIGHT (+) 1 15
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C610 HVAC DUCT FAN 2 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C611 BLOWER MOTOR 4 16 T19 BACKUP ALARM 1 14
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C630 THERMOSTAT 3 16 T20 BACKUP ALARM (GND) 1 14
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C635 HEATER VALVE 6 16 T26 FUSE 150 AMP 1 9
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C667 DOOR HARNESS 6 13 T27 PRE HEATER CONTACTOR PWR 1 9
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C670 EXTERIOR BEACON HARNESS 6 17 T29 BATTERY 1 9
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C676 RADIO 6 17
T32 ECU CASE GND 1 6
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15,
T31 PREHEATER 1 9
16
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 J1A GATEWAY CONTROLLER 34 5,9,11,12, T33 DCU CASE GND 1 10
14,15,16,17
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 1 13
T37 DOME LIGHT +
VALVE 12,14,13,17
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J2A AUX CONTROLLER 34 11,14,17 1 13
T38 DOME LIGHT -
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 9
T42 PREHEATER FDBK
14,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 SW1 BRAKE SWITCH 6 12
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 SW2 BEACON SWITCH 6 17
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 SW3 HAZARD SWITCH 6 17
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW5 POWER BOBTACH SWITCH 6 17
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW6 BUCKET POSITION SWITCH 6 17
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW9 TRAVEL CONTROL SWITCH 6 12
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW10 BLOWER SWITCH 5 16
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW11 AC SWITCH 3 16
C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW12 DPF SWITCH 10 12
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 1 of 18
Printable Version Click Here
24
25
26
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29
33
T4
SHEET 9
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 16
FUSE 3 30 A FRC1 HVAC RELAY
1310 RED 1360 RED/WHT SHEET 11
FRC 1 TRACTION LOCK RELAY
FUSE 1 15 A 1320 RED/WHT
SHEET 15
1350 RED/WHT FRC1 REAR LIGHT RELAY
FUSE 2 20 A SHEET 15
1340 RED 1330 RED/WHT
SP26 SHEET 15 FRC1 FRONT LIGHT RELAY
FRC1 FRONT LIGHT RELAY
C404
1720 RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
3380 LBL 4
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
T770 (S/N AT6311001 - AT6311908)
1920 RNG/WHT 9 1920 RNG/WHTSP37 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK T770 (S/N B3BW11001 - B3BW12166)
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK Sheet 5 of 18
Printed In U.S.A.
7226989 (B)
(PRINTED DECEMBER 2016)
Printable Version Click Here
2320 BRN
SHEET 11
GROUND
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 2001 BLK SHEET 11
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 9
C405 AIR FILTER SWITCH
T32 2004 BLK
ECU CASE GND SHEET 9 2690 BRN
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10
C120 SCR-MFR CONN
2430 BRN 18
SHEET 9
SHEET 7 2080 BLK
ENGINE TEMP GND
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL SHEET 15
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SP3 SHEET 16
2960 BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
2250 BLK GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
SHEET 12 C408 CAB-MFR CONN (ACCESSORIES)
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SP47 1 SP28
2830 BLK 2900 BLK 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650 BLK
SP51 2600 BLK 2390 BLK 10
T20 BU ALARM B 2600 BLK T1 2015 BLK T10
2640 BLK BATT GND SHEET 9 ENGINE
SHEET 15 2400 BLK 14 SP6
SHEET 9 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2455 BLK
2630 BLK SHEET 17
SHEET 15 C423 BKT POSITION SOLENOID
T18 LH REAR LIGHT 2710 BLK 2300 BLK
SHEET 7
C426 REMOTE RUN, ACD SP27
2715 BLK
SHEET 8
C169 ENGINE CAN
2290 BLK
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
SHEET 6 RIGHT JOYSTICK
9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
AUX CTRLR SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
9280 PUR 8 9300 PUR/WHT 3
SHEET 14
9180 PUR/WHT 9 9400 PUR 4
J2B C426
AUX CTRLR Remote Run Tool, ACD
CAN HI
20
14 9500 PUR/WHT
9600 PUR
A
B
WIRING SCHEMATIC
CAN LO
(MANUAL MACHINE)
J1B
T770 (S/N AT6311001 - AT6311908)
GWY CTRLR
T770 (S/N B3BW11001 - B3BW12166)
21 3090 LBL D
C
REMOTE RUN KEY
Sheet 7 of 18
1735 RNG/WHT E
SHEET 5 SWITCHED POWER Printable Version Click Here
1165 RED/WHT F
SHEET 4 UNSWITCHED POWER
2710 BLK G
SHEET 6 GROUND (PRINTED DECEMBER 2016)
Printed In U.S.A. 7226989 (B)
J7A
ECU CNTRLR
ENGINE CAN BUS C121
DOSING CONTROL UNIT
SP81 SP90
47 9200 PUR 9215 PUR 9415 PUR 9210 PUR SP67 9265 PUR SP71 9275 PUR SP70 9245 PUR 65
CAN LO 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205 PUR
NOx PRETREATMENT
9105 PUR/WHT 14
9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1
87
ENGINE 8200 TAN
3560 LBL
C111
MFR-BCT HARN CONN
A
B
8220 TAN
3560 LBL
STARTER
S
R
M
B SHEET 4
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK SHEET 5 1800 RNG/WHT
FUSE 12
7 8210 TAN B
22 ALTERNATOR G
3560 LBL 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND AIR FILTER 2015 BLK
SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
FRC1
TAILGATE FANS FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 C171 LEFT TAILGATE
87 TAILGATE FANS CONN
A B
FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
30 LEFT
SHEET 4 TAILGATE 2400 BLK 14 2 2400 BLK 14 B
2295 BLK 18 85 86 FANS GND SHEET 68105 TAN 14 3 8105 TAN 14 FUSE 15 A
TAILGATE FANS RELAY GND
4 C113
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 2405 BLK 14
SHEET 6 C172 RIGHT TAILGATE
TAILGATE A B
J1B FAN CONN
C355 FANS GND
GWY CTRLR FUEL HARN 8135 TAN 14 A
C406
B
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
10 2180 BRN D 2180 BRN B GND
3690 LBL SHEET 6 (30 - 270 OHM)
C100
(MANUAL MACHINE)
9
34
3865 LBL
2865 BRN
1
2
SIG WATER IN FUEL SENSOR
(FUEL FILTER)
T770 (S/N AT6311001 - AT6311908)
GND
56 T770 (S/N B3BW11001 - B3BW12166)
C118
28 8013 TAN ENG-CROSSOVER Sheet 9 of 18
1511 RNG/WHT 1
35 8014 TAN SHEET 5 Printable Version Click Here
8013 TAN 2 FREQ
8014 TAN 3 TEMP (PRINTED DECEMBER 2016)
3420 LBL 4
Printed In U.S.A. T42 7226989 (B)
DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4
2975 BLK T33
DCU CASE GND
85 86
2915 BLK
C121
DOSING CONTROL UNIT
SP62
1230 RED/WHT 1245 RED/WHT 5 93 8310 TAN
SHEET 4 1265 RED/WHT 6
71 C123
1255 RED/WHT 73 HOSE 1 HEATER
67
2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
SHEET 6 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 SP88 8330 TAN 30
8140 TAN
SHEET 8 72 8340 TAN
Nox Ground 87 2955 BLK SP86
2870 BLK 2855 BLK 29
C124
SHEET 8 85 86 HOSE 2 HEATER
22 2145 BRN
8020 TAN
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 2135 BRN SP85
C155
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 8260 TAN 8250 TAN 30
SP89 87 2965 BLK
C156 C125
2140 BRN 85 86 HOSE 3 HEATER
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 8350 TAN 2
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
CATALYST TEMPERATURE
2 2025 BRN 61 2125 BRN 85 86
SCR INLET
28 8600 TAN
C158
1 8520 TAN 62
CATALYST TEMPERATURE
C122
SCR OUTLET 2 2160 BRN 84
SUPPLY MODULE WIRING SCHEMATIC
C159 11
ENVIRONMENTAL TEMPERATURE
1 8800 TAN 31
4 1690 RNG/WHT
12
HEATER BATT+ (MANUAL MACHINE)
3 8650 TAN
2 9 HEATER SIGNAL
2050 BRN
55 1695 RNG/WHT
3
PUMP MOTOR BATT +
T770 (S/N AT6311001 - AT6311908)
C160 2
CATALYST TEMPERATURE
1 8530 TAN 18 TXL 34
76 8700 TAN
4
PUMP MOTOR CONTROL SIGNAL T770 (S/N B3BW11001 - B3BW12166)
54 2095 BRN PUMP MOTOR GND
DOC INLET 2 2075 BRN 18 TXL 12
77 1680 RNG/WHT 5
PURGING PUMP BATT +
Sheet 10 of 18
78 6 Printable Version Click Here
8750 TAN PURGING PUMP SIGNAL
10
17 1685 RNG/WHT PRESSURE SENSOR BATT+ (PRINTED DECEMBER 2016)
39 9
Printed In U.S.A.
3000 LBL PRESSURE SENSOR SIGNAL 7226989 (B)
40 2085 BRN 8
PRESSURE SENSOR GND
PWR 30
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
C425
B C308
BRAKE
SHEET 4 1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG
HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
WIRING SCHEMATIC
J2A 18 2 FRONT ROD
AUX CTRLR
2330 BRN
4330 LGN 1
GND
SIG SOLENOID (MALE) (MANUAL MACHINE)
3.3 OHM PWM
C419 T770 (S/N AT6311001 - AT6311908)
1 2340 BRN 2 GND FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM
T770 (S/N B3BW11001 - B3BW12166)
Sheet 11 of 18
19 13 Printable Version Click Here
7040 WHT
T13
BUZZER (+)
T2
LEFT PANEL
BUZZER
C479
CAB DISPLAY C499
Press To Operate Loader
(PTOL)
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408
2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 14
SHEET 6 LEFT PANEL (GRAY) 3040 LBL 3040 LBL 4
GWY CTRLR RUN/ENTER SWITCH
3620 LBL 12
SHEET 13 DOOR SIGNAL
11 1950 RNG/WHT 5
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
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
8060 TAN 1 6
3
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 12 of 18
Printable Version Click Here
CAB
(ACS)
H/ISO
(SJC, AWS)
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3
C438 2060 BLK 5 6
SHEET 13
(DK GRAY)
CAB-MFR HARN CONN 3
4 * DLX CAB HARN 7253375 ONLY
7 4235 LGN (NOT IN STD CAB HARN)
8 4275 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
* T37
DOME LIGHT (+)
SHEET 4 1390 RED/WHT
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
GWY CTRLR
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR WIRING SCHEMATIC
HARNESS WASHER PUMP
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 TILT SPOOL LOCK 20 4640 LGN D
SIG
2 7.8 OHM 12V 28 4840 LGN C
22 4830 LGN B SKI CTRL
C422 12 4820 LGN G
2 2990 BRN 3 11 4810 LGN F SIDE SHIFT
GND
4990 LGN 1 LIFT SPOOL LOCK 1520 RNG/WHT A
SIG SHEET 5
7.8 OHM 12V J
2
H
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 14 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7226989 (B)
Printable Version Click Here
LIGHTS
C434-1
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts
C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
2760 BLK B GND WORK LIGHT
FRC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - J C435-2
(DK GRAY)
6130 PNK A SIG
CAB-MFR HARN CONN 3 RIGHT FRONT
2705 BLK B GND WORK LIGHT
SHEET 4 1350 RED/WHT 30
87 6610 PNK 13 50.00 Watts
6610 PNK
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SP10 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 15 of 18
Printable Version Click Here
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
SHEET 6
2290 BLK 2280 BLK
GND
(COMPRESSOR) T770 (S/N B3BW11001 - B3BW12166)
D4
Sheet 16 of 18
Printable Version Click Here
E 4470 LGN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
11 4470 LGN
#
OPTIONS
DLX FUEL HARN 7266824 ONLY
POWER BOB 2 B
GND 2470 BLK 2770 BLK 2770 BLK
CLOSE SHEET 6
SW5
4480 LGN
(NOT IN STD FUEL HARN 7149219)
*POWER 2 1
# C606 BOBTACH 3
POWER BOB
GND 2 2480 BLK SWITCH 5 4
6
* DLX CAB HARN 7253375 ONLY
SIG 1 4480 LGN F 4480 LGN 10
OPEN
6010 PNK 13 6010 PNK
(NOT IN STD CAB HARN)
1380 RED/WHT
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
* FLASHER
T3
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 *BUCKET
SW6
6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
106
123
TEMP SENSOR 2
SENSOR RETURN 2
2
1
EXHAUST GAS
TEMP SENSOR
BEFORE TURBO
HARNESS WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
C136 BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1 EGR VREF3 164 TO C113 PIN 3
4 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
See Sheet 9 of 18
5 POSITION SIGNAL 116 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
120 SENSOR GROUND 3
EGR VALVE 3 172 MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
POSITION RETURN MAF
DC MOTOR 137 5V 2 HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
6 H BRIDGE POS 192 SENSOR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
TO C113 PIN 2 1
2 H BRIDGE NEG 193 LIGHTS 6000 THROUGH 6999 PINK PNK
See Sheet 9 of 18
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
ENGINE 8000 THROUGH 8999 TAN TAN
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SCHEMATIC INDEX
COOLANT TEMP 1 COOLANT TEMP SENSOR 109 OVERVIEW PAGE 1-3
SENSOR
165 VREF3 OIL PRESSURE POWER PAGE 4-5
2 COOLANT RETURN 145
111 OIL TEMPERATURE SENSOR OIL PRESSURE & GROUND PAGE 6
TEMPERATURE CAN BUS PAGE 7
148 RETURN GRD SENSOR
FUEL TEMP 1 FUEL TEMP SENSOR 110 ENGINE PAGE 8-9
SENSOR 104 OIL TEMPERATURE SENSOR HYDRAULICS PAGE 10
2 FUEL RETURN 146
CAB DISPLAY PAGE 11
CAB PAGE 12
2 SENSOR SIGNAL 131 MANUAL CONTROLS PAGE 13
ENGINE BLOCK
ACCELEROMETER 1 LIGHTS PAGE 14
1 SENSOR RETURN 130
HVAC PAGE 15
SHIELD 128
OPTIONS PAGE 16
LEGEND
2 SENSOR SIGNAL 132
ENGINE BLOCK . PARTIAL CONNECTOR
ACCELEROMETER 2 1 SENSOR RETURN 133 169 1
RETURN INTAKE
SIGNAL 129 MANIFOLD
194 SENSOR 2
TEMPERATURE
RAIL PRESSURE
1 RAIL PRESS URE SENSOR 135 WIRING SCHEMATIC
2 SENSOR RETURN 119
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA 1 (MANUAL MACHINE)
CYL 1
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C610 HVAC DUCT FAN 2 16 T16 RIGHT REAR WORK LIGHT(-) 1 15
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C676 RADIO 6 17 T27 PRE HEATER CONTACTOR PWR 1 9
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15, T29 BATTERY 1 9
16
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 J1A GATEWAY CONTROLLER 34 5,9,11,12,
T31 PREHEATER 1 9
14,15,16,17
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11
T32 ECU CASE GND 1 6
VALVE 12,13,14,17
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J2A AUX CONTROLLER 34 11,14,17 T33 DCU CASE GND 1 10
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 13
T37 DOME LIGHT +
14,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9 1 13
T38 DOME LIGHT -
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 RC1 FRONT WORK-LIGHTS RELAY 4 15 T42 PREHEATER FDBK 1 9
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 RC2 FRONT WORK-LIGHTS RELAY 4 15
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 SW1 BRAKE SWITCH 6 12
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 SW2 BEACON SWITCH 6 17
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW3 HAZARD SWITCH 6 17
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW5 POWER BOBTACH SWITCH 6 17
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW6 BUCKET POSITION SWITCH 6 17
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW9 TRAVEL CONTROL SWITCH 6 12
C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW10 BLOWER SWITCH 5 16
C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 SW11 AC SWITCH 3 16
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 1 of 18
Printable Version Click Here
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281509
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN (BASE) B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL A-4 RIGHT BLINKER RELAY B-4
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5
A-6 B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK A-7 B-7
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE A-10 REAR AUX (M) RETURN B-10
A-11 AC SENSE B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL A-12 RH PADDLE LEFT B-12
A-13 TRACTION PULL FDBK RELAY- D B-13 BICS HYD LOCK HOLD A-13 RH RIGHT ROCKER UP B-13 FRONT AUX (F) (BASE)
A-14 B-14 CAN HI 2 A-14 B-14 CAN HI 2
A-15 B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR A-17 B-17 RH PWM LO
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-19 PTOL LED B-19 HYD FAN OUTPUT A-19 B-19 FRONT AUX (M) (ROD)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 FLOAT B-20 CAN LO 2
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY A-21 B-21 RH TRIGGER RETURN
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED PWR
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 RH PWM HI
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 RIGHT FAN FDBK RELAY - C B-25 TWO SPEED MAKEUP A-25 B-25
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED MAKE-UP RETURN A-27
A-28 REAR LIGHT FDBK RELAY - E A-28 LH RIGHT ROCKER UP
A-29 A-29
A-30 HVAC FDBK RELAY - B A-30 RH LEFT ROCKER UP
A-31 FRONT LIGHTS FDBK RELAY - K A-31 RH LEFT ROCKER DOWN
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 FOOT THROTTLE A-33
A-34 HYD OIL FILTER SW1 A-34
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 3 of 18
Printable Version Click Here
T4
SHEET 9
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 16
FUSE 3 30 A FRC1 HVAC RELAY
1310 RED 1360 RED/WHT SHEET 11
FRC 1 TRACTION LOCK RELAY
FUSE 1 15 A 1320 RED/WHT
SHEET 15
FRC1 REAR LIGHT RELAY
FUSE 2 20 A 1350 RED/WHT
1340 RED SHEET 15
SP26 1330 RED/WHT FRC1 FRONT LIGHT RELAY
SHEET 15
FRC1 FRONT LIGHT RELAY
FUSE 20 5 A
1335 RED 1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
1325 RED FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
SHEET 5
FRC 1 ENGINE ECU RELAY
1445 RED/WHT SHEET 9
FUSE 18 25 A FRC1 PRE HEATER RELAY
1190 RED 1165 RED/WHT SHEET 7
C426 REMOTE RUN, ACD
C404
1720 RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
3380 LBL 4
J1A
GWY CTRLR (LT GRAY) T770 (S/N B3BW12167 - B3BW12255)
CAB-MFR HARN CONN 2
2370 BRN
C408 CAB-MFR CONN (SEATBAR SENSOR)
J1B
GWY CTRLR
8 9260 PUR 9230 PUR SP31 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
SHEET 6 RIGHT JOYSTICK
9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
AUX CTRLR SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
9280 PUR 8 9300 PUR/WHT 3
SHEET 14
9180 PUR/WHT 9 9400 PUR 4
J2B C426
AUX CTRLR Remote Run Tool, ACD
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
WIRING SCHEMATIC
J1B
(MANUAL MACHINE)
GWY CTRLR
T770 (S/N AT6311909 - AT6312719)
21 3090 LBL D
C
REMOTE RUN KEY
T770 (S/N B3BW12167 - B3BW12255)
1735 RNG/WHT E
SHEET 5 SWITCHED POWER
SHEET 4
1165 RED/WHT
2710 BLK
F
G UNSWITCHED POWER Sheet 7 of 18
SHEET 6 GROUND Printable Version Click Here
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1
5
6
9720 PUR/WHT
9820 PUR
82 CAN HI
60
WIRING SCHEMATIC
CAN LO
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 8 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281509
Printable Version Click Here
1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M C111
MFR-BCT HARN CONN
STARTER
ENGINE
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK SHEET 5 1800 RNG/WHT
FUSE 12
7 8210 TAN B
22 ALTERNATOR G
3560 LBL 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND AIR FILTER 2015 BLK
SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
FRC1
TAILGATE FANS FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 C171 LEFT TAILGATE
87 TAILGATE FANS CONN
A B
FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
30 LEFT
SHEET 4 TAILGATE 2400 BLK 14 2 2400 BLK 14 B
2295 BLK 18 85 86 FANS GND SHEET 68105 TAN 14 3 8105 TAN 14 FUSE 15 A
TAILGATE FANS RELAY GND
4 C113
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 2405 BLK 14
SHEET 6 C172 RIGHT TAILGATE
TAILGATE A B
J1B C355 FAN CONN
FANS GND
GWY CTRLR FUEL HARN 8135 TAN 14 A
C406
B
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
10 2180 BRN D 2180 BRN B GND (30 - 270 OHM)
3690 LBL SHEET 6
2915 BLK
C121
DOSING CONTROL UNIT
SP62
1230 RED/WHT 1245 RED/WHT 5 93 8310 TAN
SHEET 4 1265 RED/WHT 6
71 C123
1255 RED/WHT 73 HOSE 1 HEATER
67
2310 BRN
1275 RED/WHT 51 68 SP87 1
7998 WHT 8120 TAN
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
SHEET 6 2825 BLK 2935 BLK 2 HOSE 1 HEATER
7 SP88 8330 TAN 30
8140 TAN
SHEET 8 2945 BLK 72 8340 TAN
Nox Ground 87 2955 BLK SP86
2870 BLK 2855 BLK 29
C124
SHEET 8 85 86 HOSE 2 HEATER
22 2145 BRN
8020 TAN
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 SP85
C155 2135 BRN
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 30
8260 TAN 8250 TAN
SP89 87 2965 BLK
C156 C125
2140 BRN 85 86 HOSE 3 HEATER
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 8350 TAN 2
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
CATALYST TEMPERATURE
2 61 85 86
SCR INLET 2025 BRN 2125 BRN
28 8600 TAN
C158
1 8520 TAN 62
CATALYST TEMPERATURE
2 84 C122
SCR OUTLET 2160 BRN
SUPPLY MODULE
C159 11
ENVIRONMENTAL TEMPERATURE
1 8800 TAN 31
4 1690 RNG/WHT
12
HEATER BATT+ WIRING SCHEMATIC
3 8650 TAN
2 9 HEATER SIGNAL
2050 BRN
55 1695 RNG/WHT 3
PUMP MOTOR BATT +
(MANUAL MACHINE)
C160 2
CATALYST TEMPERATURE
1 8530 TAN 18 TXL 34
76 8700 TAN
4
PUMP MOTOR CONTROL SIGNAL T770 (S/N AT6311909 - AT6312719)
54 2095 BRN PUMP MOTOR GND
DOC INLET 2 2075 BRN 18 TXL 12
77 1680 RNG/WHT
5
PURGING PUMP BATT +
T770 (S/N B3BW12167 - B3BW12255)
6
78 8750 TAN PURGING PUMP SIGNAL Sheet 10 of 18
17 10
1685 RNG/WHT
9
PRESSURE SENSOR BATT+ (PRINTED DECEMBER 2016)
39 3000 LBL PRESSURE SENSOR SIGNAL
Printed In U.S.A. 40 2085 BRN 8 7281509
PRESSURE SENSOR GND
Printable Version Click Here
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)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
8 4110 LGN
13 3430 LBL
C108
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 2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
4330 LGN
3.3 OHM PWM
C419
(MANUAL MACHINE)
1 2 GND
2340 BRN
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) T770 (S/N AT6311909 - AT6312719)
3.3 OHM PWM
T770 (S/N B3BW12167 - B3BW12255)
19 13 Sheet 11 of 18
J2B
AUX CTRLR (PRINTED DECEMBER 2016)
Printed In U.S.A. 7281509
Printable Version Click Here
SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
LEFT PANEL
BUZZER
C479
CAB DISPLAY C499
Press To Operate Loader
(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 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
SHEET 13 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
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
8060 TAN 1 6
3
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 12 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281509
Printable Version Click Here
*SW4
HAND/FOOT
(ACS)
CAB
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C438 2060 BLK 5 6
SHEET 13
(DK GRAY) 4
CAB-MFR HARN CONN 3 * DLX CAB HARN 7253375 ONLY
7
8
4235 LGN
4275 LGN
(NOT IN STD CAB HARN)
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
*POWER
C212
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
* DOME
T37
LIGHT (+)
SHEET 4 1390 RED/WHT
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * DOME
T38
LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1 WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
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
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR
HARNESS WASHER PUMP
WIRING SCHEMATIC
SHEET 9 5690 YEL 7253378
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
* C252 A 7310 WHT
C253
1
PWR
WASHER T770 (S/N B3BW12167 - B3BW12255)
MOTOR
2845 BLK B 2845 BLK 2 GND Sheet 13 of 18
Printable Version Click Here
J2A
2530 BLK K
SHEET 6
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
OPTIONS DWG) BACK UP
4920 LGN E 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 7.8 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 SHEET 5
7.8 OHM 12V J
2
H
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 14 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281509
Printable Version Click Here
C434-1
LIGHTS
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts
C435-1
8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
6000 PNK
2760 BLK B GND WORK LIGHT
RC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - 1 C435-2
(DK GRAY)
6130 PNK A SIG
CAB-MFR HARN CONN 3 RIGHT FRONT
6620 PNK SP23 2705 BLK B GND WORK LIGHT
SHEET 4 1350 RED/WHT 30
87 13 6610 PNK 50.00 Watts
6610 PNK
RC2
FRONT WORK
LIGHTS RELAY - 2 C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SP10 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK 6630 PNK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
WIRING SCHEMATIC
(MANUAL MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 15 of 18
Printable Version Click Here
HVAC
GND HVAC DUCT
7440 WHT 1 SIG FAN
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
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 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY
6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * 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 DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
J1B 26
5.1 OHM 12 V
OPTIONS DWG) T770 (S/N B3BW12167 - B3BW12255)
GWY CTRLR
Sheet 17 of 18
Printable Version Click Here
SUPPLIED
1 POSITION SENSOR 161 123 TEMP SENSOR
SENSOR RETURN 2
WASTE GATE BEFORE TURBINE
2 POSITION FEEDBACK 113
POSITION C132
3 POSITION GND 121 107 TEMP SENSOR 3 EXHAUST GAS
124 TEMP SENSOR
C151 SENSOR RETURN 3
BEFORE DOC
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 EXHAUST GAS
EGR VALVE
3 172 169 TEMP SENSOR
DC MOTOR POSITION RETURN SENSOR RETURN 4
AFTER DPF
6 H BRIDGE POS 192
C134
2 H BRIDGE NEG 193 166 VREF2 EG DPS 1
C150 108 PRESSURE SENSOR 3 EXHAUST GAS
AIR SENSOR 114 144 2 PRESSURE SENSOR
AMBIENT AIR
SENSOR RETURN
TEMP SENSOR AIR RETURN 171
C135
C149 184 5
H BRIDGE POS
1 COOLANT TEMP SENSOR 109
COOLANT TEMP 183 H BRIDGE NEG 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
163 VREF 3 THROTTLE POSITION 1
C148 170 POSITION SENSOR GND 3
1 FUEL TEMP SENSOR 110 115 2
FUEL TEMP POSITION FEEDBACK ANALOG
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
132 C137
1 SENSOR SIGNAL
ENGINE BLOCK 156 UN 6
ACCELEROMETER 2 2 SENSOR RETURN 133 O2 SENSOR
129 157 VM 2
SHIELD & HEATER
154 IA 5
C145 155 1
160 IP
CRANK SENSOR POS SHEET ?
VR CRANK 182 O2 HEATER 3
SENSOR CRANK SENSOR NEG 136
4
C144
C138
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESS B
CAM SHAFT 2 159
POS SENSOR 112 A
SENSOR INTAKE PRESS SENSOR INLET TEMP
3 VREF1 CAM 140
C143
167
134
INTAKE PRESS RETURN
INTAKE AIR TEMP SENSOR
D
C
PRESSURE
SENSOR WIRING SCHEMATIC
RAIL PRESSURE
1
2
RAIL PRESSURE SENSOR
SENSOR RETURN
135
119
168 INTAKE AIR TEMP RETURN ? (MANUAL MACHINE)
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA
C139
T770 (S/N AT6311909 - AT6312719)
C141 126 CYL 1
FUEL INJECTOR LSD1A
CYL 3
FUEL INJECTOR HSDB 151
C140
T770 (S/N B3BW12167 - B3BW12255)
FUEL INJECTOR LSD1B 175
C142
150
174
FUEL INJECTOR HSDB
FUEL INJECTOR LSD2B CYL 2 Sheet 18 of 18
FUEL INJECTOR HSDA 103 Printable Version Click Here
CYL 4 C154
FUEL INJECTOR LSD2A 125 (PRINTED DECEMBER 2016)
Printed In U.S.A. 177 PWM 2
INLET METERING
1 VALVE 7281509
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
4 SH04 - GROUND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
5 SH05 - CAN BUS
6 SH06 - ENGINE CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
7 SH07 - ENGINE
8 SH08 - ENGINE CONTROL UNIT BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
9 SH09 - DOSING CONTROL UNIT LEGEND
10 SH10 - HYDRAULICS BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
11 SH11 - CAB DISPLAY CONNECTOR
12 SH12 - CAB BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
13 SH13 - MANUAL CONTROLS 1 1
14 SH14 - LIGHTS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
15 SH15 - HVAC
PARTIAL CONNECTOR
16 SH16 - OPTIONS 1
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
17 SH17 - OPTIONS 2
1 1
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HARNESS PART NUMBER LGN
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN 1 1
LF MFR MAN 7300237
DLX CAB 7301237 * CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
DLX FUEL 7266824 SHT1/F2
WIRE BREAK
SHT1/F2
BCT ENG 7242470 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
TAILGATE DOM 7267103 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
SUSP JSTK 7163706
WHL 2 SPD ADP 7159366 ENGINE 8000 THROUGH 8999 TAN TAN
TRK 2 SPD ADP 7243409 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
DEF JUMPER 7305995
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
1310 RED 1360 RED/WHT
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
SP26 1340 RED 1330 RED/WHT
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
FUSE 20 5 A SHT14/F8
1335 RED 1345 RED/WHT
20A 20B SHT3/G8
FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
1190 RED 1165 RED/WHT
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
1095 RED 1100 RED/WHT
25A 25B SHT9/H8
FUSE 26 15A
1220 RED 1230 RED/WHT
26A 26B SHT9/G8
FUSE 10 30A
1045 RED 1105 RED/WHT
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
22A 22B SHT16/F7
SP24
FUSE 24 25 A
SP60 1290 RED 1370 RED/WHT
24A 24B SHT12/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT7/H8
86 85
G4
SP73
1508 RNG/WHT
3
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/E1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT 1511 RNG/WHT
21A 21B SHT7/B7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
1790 RNG/WHT 1550 RNG/WHT
12A 12B SHT16/G7
1700 RNG/WHT
1520 RNG/WHT SHT11/C8
SHT13/D3 1705 RNG/WHT
SHT11/B8
1530 RNG/WHT 1620 RNG/WHT
SHT13/G3 SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
FUSE 14 5 A SHT11/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT11/D8
SP11 1960 RNG/WHT
J2B SHT11/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT12/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT11/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT11/E4
SP42 1565 RNG/WHT
SHT17/E4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
GND
86 85
BUS BAR
A5 A2 1725 RNG/WHT
SHT6/D7
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT12/F8
FUSE 23 15 A
1815 RNG/WHT 1800 RNG/WHT
23A 23B SHT7/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
SP37
1920 RNG/WHT 1920 RNG/WHT 1840 RNG/WHT
9 9 SHT5/D3
1830 RNG/WHT
SHT5/E3
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
2003 BLK SHT10/F7 GATEWAY CTRLR
6 2370 BRN
SHT12/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT10/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT17/F5 SHT10/D7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
2150 BRN
SHT7/G7
2430 BRN
SHT7/C7
2080 BLK
SHT5/D3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT11/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10
2960 BLK
SHT11/E4
2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT14/C4 B B
SP51
2610 BLK
SHT14/E4 2400 BLK AUX CTRLR
SHT7/E4
2630 BLK 2185 BRN
SHT14/B4 2405 BLK SHT17/E7 SP58 2995 BRN
SHT7/D4 2195 BRN 17 SENSOR GROUND
SHT13/G3
2455 BLK
J2B
SHT16/D6
2715 BLK
SHT6/D7
2290 BLK
SHT15/B8
2505 BLK
SHT17/G4
2045 BLK 2295 BLK
SHT14/B8 SHT7/D7
2035 BLK
SHT10/G8
SP55 SP5 2000 BLK
2115 BLK 2105 BLK
SHT14/D8
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8
C503
RH DLX PANEL
9440 PUR TP-06
4 CAN LO
9340 PUR/WHT
2 CAN HI
TP-11
C503
* C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9320 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
9420 PUR 9660 PUR CAN LO
AUX CTRLR 4 4 4 4
TP-11
9280 PUR
8 CAN LO
9180 PUR/WHT
9 CAN HI * C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
J2B 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2080 BLK 2080 BLK GND
SHT4/G8 2 2 2 2
9300 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
9400 PUR 9640 PUR CAN LO
4 4 4 4
9600 PUR
CAN LO 20 B B CAN LO
J2B
3095 LBL
REMOTE RUN KEY 24
J2A
GATEWAY CTRLR
J1B
C C
9105 PUR/WHT
C163
9205 PUR
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR TP-27
3
GATEWAY CTRLR 9195 PUR/WHT
4
2870 BLK 2875 BLK
TP-19 SHT9/F8 5
20 ENG CAN LO SP78
C163
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
TP-25
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
B
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR TP-23 TP-31
9225 PUR
TP-31
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
9255 PUR
ENG CAN LO 4
TP-29 TP-29
CAN HI DCU DIAGNOSTIC 9720 PUR/WHT
5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
CAN LO DCU DIAGNOSTIC 6 60 CAN LO DCU DIAGNOSTIC
C169
C121
C405
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12
SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113
T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
C144 FUEL INJECTOR #3 HSDB 51 1
C154
J7B
J7B
SHT2/D1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2985 BLK
4 92 94 86 85
2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGEN VALVE HIGH
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 HOSE 2 RELAY FB
49 HOSE 2 HEATER
RED AGENT SHIELD SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET 8250 TAN
C125
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
2 9 ENV TEMP GND 8370 TAN 8360 TAN
ENVIRONMENTAL HOSE 3 RELAY FB 27 30
TEMPERATURE T SP61 87
8800 TAN
1 31 ENV TEMP SIG 8600 TAN C122
HOSE 3 HEATER 28 86 85 SUPPLY MODULE
C159
2075 BRN RL013 RL013
CATALYST 2 12 CAT TEMP DOC INLET
TEMPERATURE DOC 1690 RNG/WHT HEATER BATT+
T SM HEATER BATT 4 11
INLET 8530 TAN CAT TEMP DOC INLET 8650 TAN HEATER SIGNAL
1 34 SM HEATER SIGNAL 3 12
1695 RNG/WHT PUMP MOTOR BATT +
C160 +5V POWER 55 3
SM PUMP MOTOR CONTROL 8700 TAN PUMP MOTOR CONTROL SIGNAL
76 2
SIGNAL
2095 BRN PUMP MOTOR GND
SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122
13
23
6
TRACTION SOLENOID
OUTPUT
HYDRAULIC FAN
SIGNAL
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR
DWG. NO.Sheet 10 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
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 10 / 17
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7300236
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1940 RNG/WHT 1
LEFT PANEL BUZZER CAB DISPLAY
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT16/F4 8 START ENGINE 24 2 2 2
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
SW12
DESOX INHIBIT SWITCH(OPT KIT)
DWG. NO.Sheet 11 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
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SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
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.
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11 / 17
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SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
* DLX CAB HARN 7301237 ONLY
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT12/D1 5
4
SW4 3
SW4
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
7 7
4275 LGN
8 8
9 9
4550 LGN *
2795 BLK GND
1850 RNG/WHT 1850 RNG/WHT 1
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT16/C2
1885 RNG/WHT
SHT16/B3
2885 BLK
SHT16/B3
2060 BLK
SHT12/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
2690 BRN
(SEE ADDITIONAL
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 3620 LBL
SENSOR SHT11/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND SHT2/G1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR 2 2 WIPER MOTOR GROUND
C
5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
DWG. NO.Sheet 12 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
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 12 / 17
Printable
7300236
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MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8
T20
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
4820 LGN
7
C410
TRIGGER
GATEWAY CTRLR
DWG. NO.Sheet 13 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
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.
SHTPrintable
13 / 17
7300236
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6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
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
6630 PNK
6320 PNK
RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR SHT4/D8 2
RELAY SIGNAL 5
C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK 31
DWG. NO.Sheet 14 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
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 Printable
14 / 17
7300236
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2440 BLK GND
* HVAC
2
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
SW11
1
3
C
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
DWG. NO.Sheet 15 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
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.
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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
(NOT IN STD FUEL HARN 7149219)
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
3500 LBL
T3
SHT11/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 SHT11/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK
*
2970 BLK 6700 PNK
C423 6 5 SHT17/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT17/D4 D D
6440 PNK BEACON/FLASHER
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C676 C C
LEFT SPEAKER
* * RADIO CONN A A
DWG. NO.Sheet 16 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
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B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
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 Printable
16 / 17
7300236
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*SW7
AUX CTRLR
3410 LBL
C438
MFR HARN CONN 3 (DK GRAY)
14 14
3410 LBL
RIDE CONTROL
1 2
2890 BLK
OPTIONS 2
RIDE CONTROL SWITCH AUTO 23 SHT4/E8
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIG 7 RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL
FRC1 FRC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428 *
SW13
REVERSING FAN
MFR HARN CONN 2 (LT GRAY)
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIG 16 7 7 3
C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR 10 C
PRESSURE SENSOR
5105 YEL
+5V PWR 24 B
J2B
* SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8
DWG. NO.Sheet 17 of 17
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
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B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN 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.
SHTPrintable
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7300236
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Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
4 SH04 - GROUND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
5 SH05 - CAN BUS
6 SH06 - ENGINE CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
7 SH07 - ENGINE
8 SH08 - ENGINE CONTROL UNIT BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
9 SH09 - DOSING CONTROL UNIT LEGEND
10 SH10 - HYDRAULICS BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
11 SH11 - CAB DISPLAY CONNECTOR
12 SH12 - CAB BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
13 SH13 - MANUAL CONTROLS 1 1
14 SH14 - LIGHTS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
15 SH15 - HVAC
PARTIAL CONNECTOR
16 SH16 - OPTIONS 1
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
17 SH17 - OPTIONS 2
1 1
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HARNESS PART NUMBER LGN
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN 1 1
LF MFR MAN 7322239
DLX CAB 7329485 * CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
DLX FUEL 7266824 SHT1/F2
WIRE BREAK
SHT1/F2
BCT ENG 7242470 LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
SHT1/F2 SHT1/F2
TAILGATE DOM 7267103 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
SUSP JSTK 7163706
WHL 2 SPD ADP 7159366 ENGINE 8000 THROUGH 8999 TAN TAN
TRK 2 SPD ADP 7243409 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
DEF JUMPER 7305995
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
1310 RED 1360 RED/WHT
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
SP26 1340 RED 1330 RED/WHT
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
FUSE 20 5 A SHT14/F8
1335 RED 1345 RED/WHT
20A 20B SHT3/G8
FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
1190 RED 1165 RED/WHT
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
1095 RED 1100 RED/WHT
25A 25B SHT9/H8
FUSE 26 15A
1220 RED 1230 RED/WHT
26A 26B SHT9/G8
FUSE 10 30A
1045 RED 1105 RED/WHT
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
22A 22B SHT16/F7
SP24
FUSE 24 25 A
SP60 1290 RED 1370 RED/WHT
24A 24B SHT12/F8
FRC1 FRC1
1200 RED
SHT3/C8
1050 RED
SHT3/D8
1030 RED
SHT7/H8
86 85
G4
SP73
1508 RNG/WHT
3
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/E1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT 1511 RNG/WHT
21A 21B SHT7/B7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
1790 RNG/WHT 1550 RNG/WHT
12A 12B SHT16/G7
1700 RNG/WHT
1520 RNG/WHT SHT11/C8
SHT13/D3 1705 RNG/WHT
SHT11/B8
1530 RNG/WHT 1620 RNG/WHT
SHT13/G3 SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
FUSE 14 5 A SHT11/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT11/D8
SP11 1960 RNG/WHT
J2B SHT11/F8
C428 1785 RNG/WHT
SHT12/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT11/F4
FRC1 SWITCHED 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT11/E4
POWER RELAY - A SP42 1565 RNG/WHT
SHT17/E4
86 85 2055 BLK
A5 A2 GND 1725 RNG/WHT
SHT6/D7
FRC1 FRC1 FUSE 8 25 A
1585 RNG/WHT 1580 RNG/WHT
8A 8B SHT12/F8
FUSE 23 15 A
1815 RNG/WHT 1800 RNG/WHT
23A 23B SHT7/G8
3390 LBL
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
SP37
1920 RNG/WHT 1920 RNG/WHT 1840 RNG/WHT
9 9 SHT5/D3
1830 RNG/WHT
SHT5/E3
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
2003 BLK SHT10/F7 GATEWAY CTRLR
6 2370 BRN
SHT12/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT10/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT17/F5 SHT10/D7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
2150 BRN
SHT7/G7
2605 BLK 2430 BRN
SHT5/E7 SHT7/C7
2080 BLK
SHT5/D3
2070 BLK
SHT5/E3
2960 BLK
SHT11/E4
T6
2250 BLK 2510 BLK SP3 2110 BLK 1 BATT GND
SHT11/D4 16
GATEWAY CTRLR 2500 BLK
15
2765 BLK
SHT14/H8
J1B
2745 BLK
SHT15/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT12/D8
2860 BLK 16
SHT17/D4
AUX CTRLR SHT16/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT17/H4 15
2065 BLK SP28 2730 BLK
SHT11/C8 J2B SHT12/E8
2930 BLK C428
SHT11/E8 MFR HARN CONN 2 (LT GRAY)
2830 BLK 2900 BLK 2900 BLK
SHT16/D5 1 1
2700 BLK SP47
SHT11/F8
2785 BLK 2770 BLK
SHT16/B7 SHT16/H6 T10
SHT7/F3
2015 BLK 1
ALTERNATOR
2200 BLK
SHT10/H4 GROUND
2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT14/C4 B B
SP51
2610 BLK
SHT14/E4 2400 BLK AUX CTRLR
SHT7/E4
2630 BLK 2185 BRN
SHT14/B4 2405 BLK SHT17/E7 SP58 2995 BRN
SHT7/D4 2195 BRN 17 SENSOR GROUND
SHT13/G3
2455 BLK
J2B
SHT16/D6
2715 BLK
SHT6/D7
2065 BLK
SHT3/C6 2290 BLK
2505 BLK SHT15/B8
SHT17/G4
2045 BLK 2295 BLK
SHT14/B8 SHT7/D7
2035 BLK
SHT10/G8
SP55 SP5 2000 BLK
2115 BLK 2105 BLK
SHT14/D8
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8
C479
Z3 C408
GATEWAY CTRLR MFR HARN CONN 1 (BLACK) Z4 LEFT PANEL
120 OHM 0.5 W RESISTOR SP18 120 OHM 0.5 W RESISTOR (BLACK)
SP31 SP39 SP35
9260 PUR 9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR
CAN LO 8 4 4 4
J1B C479
C503
AUX CTRLR RH DLX PANEL
9280 PUR 9440 PUR
8 CAN LO 4 CAN LO
J2B
C503
* C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
TELEMATICS 9320 PUR/WHT 9560 PUR/WHT CAN HI
3 3 3 3
1305 RED/WHT 9420 PUR 9660 PUR CAN LO
PWR 10 SHT2/G1 4 4 4 4
2605 BLK
GND 11 SHT4/G8
C448
Z5 MFR HARN CONN 4 (BLACK)
120 OHM 0.5 W RESISTOR SP104
CAN HI 3
9515 PUR/WHT 9505 PUR/WHT
9500 PUR/WHT
9510 PUR/WHT
7 7 * C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
9 9 1840 RNG/WHT 1840 RNG/WHT +12V PWR
9610 PUR SHT3/B1 1 1 1 1
9615 PUR 9605 PUR 10 10 2080 BLK 2080 BLK GND
CAN LO 4 9600 PUR SHT4/G8 2 2 2 2
8 8 9300 PUR/WHT 9540 PUR/WHT CAN HI
C481 SP103 3 3 3 3
9400 PUR 9640 PUR CAN LO
4 4 4 4
J2B
3615 LBL CAN SELECT
CAN SELECT 25 C C
3095 LBL
REMOTE KEY 24
J2A
GATEWAY CTRLR
J1B
1735 RNG/WHT SWITCHED POWER
SHT3/D1 E E
J7A C121
C163
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR
3
GATEWAY CTRLR 9195 PUR/WHT
4
2870 BLK 2875 BLK
9205 PUR SHT9/F8 5
20 ENG CAN LO SP78
C163
9105 PUR/WHT
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
B
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR 9225 PUR
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
9155 PUR/WHT
ENG CAN HI 3
9255 PUR
ENG CAN LO 4
9820 PUR
CAN LO DCU DIAGNOSTIC 6 60 CAN LO DCU DIAGNOSTIC
C169
C121
C405
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12
SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113
1 64 VREF 3 EGR
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
C148
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
C144 FUEL INJECTOR #3 HSDB 51 1
C154
J7B
J7B
SHT2/D1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2985 BLK
4 92 94 86 85
2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGEN VALVE HIGH
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 HOSE 2 RELAY FB
49 HOSE 2 HEATER
RED AGENT SHIELD SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET C125
8250 TAN
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
2 9 ENV TEMP GND 8370 TAN 8360 TAN
ENVIRONMENTAL HOSE 3 RELAY FB 27 30
TEMPERATURE T SP61 87
8800 TAN
1 31 ENV TEMP SIG 8600 TAN C122
HOSE 3 HEATER 28 86 85 SUPPLY MODULE
C159
2075 BRN RL013 RL013
CATALYST 2 12 CAT TEMP DOC INLET
TEMPERATURE DOC 1690 RNG/WHT HEATER BATT+
T SM HEATER BATT 4 11
INLET 8530 TAN CAT TEMP DOC INLET 8650 TAN HEATER SIGNAL
1 34 SM HEATER SIGNAL 3 12
1695 RNG/WHT PUMP MOTOR BATT +
C160 +5V POWER 55 3
SM PUMP MOTOR CONTROL 8700 TAN PUMP MOTOR CONTROL SIGNAL
76 2
SIGNAL
2095 BRN PUMP MOTOR GND
SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122
13
6
TRACTION SOLENOID
OUTPUT
HYDRAULIC FAN
SIGNAL
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT16/F4 8 START ENGINE 24 2 2 2
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
SW12
DESOX INHIBIT SWITCH(OPT KIT)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
* DLX CAB HARN 7301237 ONLY
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT12/D1 5
4
SW4 3
SW4
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
7 7
4275 LGN
8 8
9 9
4550 LGN *
2795 BLK GND
1850 RNG/WHT 1850 RNG/WHT 1
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT16/C2
1885 RNG/WHT
SHT16/B3
2885 BLK
SHT16/B3
2060 BLK
SHT12/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
2690 BRN
(SEE ADDITIONAL
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 3620 LBL
SENSOR SHT11/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND SHT2/G1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR 2 2 WIPER MOTOR GROUND
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
SHT10/D7
5190 YEL * C252
7253378
2845 BLK GND
B B 2
5690 YEL WASHER
SHT7/D4
MOTOR
7310 WHT PWR
A A 1
C253
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8
T20
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
4820 LGN
7
C410
TRIGGER
GATEWAY CTRLR
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
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
6630 PNK
6320 PNK
RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR SHT4/D8 2
RELAY SIGNAL 5
C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK 31
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
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
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
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
(NOT IN STD FUEL HARN 7149219)
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
3500 LBL
T3
SHT11/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
6010 PNK 3400 LBL
6510 PNK
6410 PNK
B SHT11/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK
1 2
2890 BLK
OPTIONS 2
RIDE CONTROL SWITCH AUTO 23 SHT4/E8
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIG 7
FRC1 SWITCHED
POWER RELAY - L
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL
FRC1 FRC1
COIL COIL
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428 *
SW13
REVERSING FAN
MFR HARN CONN 2 (LT GRAY)
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIG 16 7 7 3
C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR 10 C
PRESSURE SENSOR
5105 YEL
+5V PWR 24 B
J2B
* SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8
C103 TAILGATE HARNESS 8 6,14,15,17 C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 SW11 AC SWITCH 3 16
C104 TAILGATE FANS 4 9 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW12 DPF SWITCH 10 12
C105 HYD CHARGE PRESSURE 3 11 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 T1 BATT GROUND 1 6
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6 T2 BUZZER GROUND 1
12
C111 MFR-BCT ENG HARN CONN 3 9 C350 AC EVAPORATOR SWITCH 2 16 C492 ACS/SJC/AWS-MFR 8 5,7,13 T3 FLASHER 2 17
C112 HYD OIL FILTER SWITCH 2 11 C355 FUEL HARNESS 6 9,17 C493 ACS/SJC/AWS-MFR 4 4,6 T4 MEGAFUSE 1 4
C113 RIGHT TAILGATE FAN CONN 2 9 C404 BACK UP ALARM 2 5,14 C497 SJC HORN/BLINKER 3 17 T6 BATT GROUND 1 6
C114 HAND THROTTLE 6 9 C405 AIR FILTER SWITCH 2 9 C499 PTOL 4 12 T8 BATT GROUND 1 6
C115 FOOT THROTTLE 6 9 C406 FUEL SENDER 2 9 C500 RH KEY SWITCH 6 12 T10 ENGINE SYSTEM GROUND 1 6
C116 FOOT THROTTLE INTMD 3 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C503 RH DLX PANEL 6 7,12 T13 BUZZER POWER 1 12
15,17
C118 ENG-CROSSOVER 4 9 C409 RIGHT HANDLE 10 14 C602 LEFT REAR TAIL LIGHT 2 15 T14 PRE HEATER 1 9
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C603 RIGHT REAR TAIL LIGHT 2 15 T15 RIGHT REAR WORK LIGHT(+) 1 15
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C606 POWER BOBTACH OPEN 2 17 T16 RIGHT REAR WORK LIGHT(-) 1 15
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C607 POWER BOBTACH CLOSE 2 17 T17 LEFT REAR WORK LIGHT (+) 1 15
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C610 HVAC DUCT FAN 2 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C611 BLOWER MOTOR 4 16 T19 BACKUP ALARM 1 14
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C630 THERMOSTAT 3 16 T20 BACKUP ALARM (GND) 1 14
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C635 HEATER VALVE 6 16 T26 FUSE 150 AMP 1 9
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C667 DOOR HARNESS 6 13 T27 PRE HEATER CONTACTOR PWR 1 9
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 C670 EXTERIOR BEACON HARNESS 6 17 T29 BATTERY 1 9
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 C676 RADIO 6 17
T32 ECU CASE GND 1 6
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15,
T31 PREHEATER 1 9
VALVE 16
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J1A GATEWAY CONTROLLER 34 5,9,11,12, T33 DCU CASE GND 1 10
14,15,16,17
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 1 13
T37 DOME LIGHT +
12,14,13,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J2A AUX CONTROLLER 34 11,14,17 1 13
T38 DOME LIGHT -
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 9
T42 PREHEATER FDBK
14,17
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 SW1 BRAKE SWITCH 6 12
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 SW2 BEACON SWITCH 6 17
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW3 HAZARD SWITCH 6 17
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW5 POWER BOBTACH SWITCH 6 17
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW6 BUCKET POSITION SWITCH 6 17
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW9 TRAVEL CONTROL SWITCH 6 12
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 1 of 20
Printable Version Click Here
WIRING SCHEMATIC
HARNESS PART NUMBER
LF MFR CTRL 7267009 (ACS/SJC MACHINE)
DLX CAB 7253375
DLX FUEL 7266824 T770 (S/N AT6311001 - AT6311908)
BCT ENG 7242470
TAILGATE DOM 7267103 T770 (S/N B3BW11001 - B3BW12166)
SUSP JSTK 7163706
BRAKE ADAPTER 7234968 Sheet 2 of 20
WHL 2 SPD ADP 7159366 Printable Version Click Here
TRK 2 SPD 7243409
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7226988 (B)
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
ENGINE CONTROLLER
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7-8
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 9-10 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 11
3 SW POWER
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 12
4 GND HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 13
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CONTROLS PAGE14 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 15 (TWO WIRE BREAKS
6 GND
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 16
ENGINE 8000 THROUGH 8999 TAN TAN
OPTIONS PAGE 17 SHEET #
SIGNAL
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
14
15
24
25
26
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29
33
34 WATER FUEL SENSOR
GROUND
35 MASS AIR FLOW (MAF)
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 3 of 20
Printable Version Click Here
1050 RED
(ACCESSORIES) Sheet 4 of 20
SHEET 5 Printable Version Click Here
FRC1 SWITCHED PWR RELAY
1030 RED
SHEET 9 (PRINTED DECEMBER 2016)
FRC1 STARTER RELAY
Printed In U.S.A. 7226988 (B)
FRC1
ENGINE ECU
1525 RNG
SCR INTERCONNECT
SHEET 8 SWITCHED POWER J7A ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP54
87 1540 RNG/WHT SP73 1545 RNG/WHT 1507 RNG/WHT 3
C404
1720 RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
3380 LBL 4
J1A
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
T770 (S/N AT6311001 - AT6311908)
1920 RNG/WHT 9 1920 RNG/WHTSP37 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK
T770 (S/N B3BW11001 - B3BW12166)
C492
1740 RNG/WHT 6 ACS/SJC/AWS-MFR HARN
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 20
(8 PIN)
Printable Version Click Here
GROUND
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 2001 BLK SHEET 11
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 9
C405 AIR FILTER SWITCH
T32 2004 BLK
ECU CASE GND SHEET 9 2690 BRN
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10 2695 BRN
SHEET 9
C120 SCR-MFR CONN C115 FOOT THROTTLE
2430 BRN 18
2080 BLK C493 3 2235 BLK SHEET 9
SHEET 7 ACS/SJC/AWS-MFR HARN ENGINE TEMP GND
C449 LH JOYSTICK 4 2240 BLK T6
2070 BLK (4 PIN)
SHEET 7 C408 BATT GND
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SP4 SHEET 15
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SHEET 16
2960 BLK 16 SP3 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
2250 BLK GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
SHEET 12 C408 CAB-MFR CONN (ACCESSORIES)
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650 BLK
SP51 2600 BLK 2390 BLK 10
T20 BU ALARM B 2600 BLK T1 2015 BLK T10
2640 BLK BATT GND SHEET 9 ENGINE
SP6
SHEET 15 2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2455 BLK
2630 BLK SHEET 17
SHEET 15 C423 BKT POSITION SOLENOID
T18 LH REAR LIGHT
2710 BLK 2300 BLK
SHEET 7
C426 REMOTE RUN, ACD SP27
2715 BLK
SHEET 8
C169 ENGINE CAN
SHEET 16
2290 BLK WIRING SCHEMATIC
SHEET 15 2045 BLK D4 COMPRESSOR DIODE
FRC1 REAR LIGHT RELAY
SHEET 11 2035 BLK SHEET 9
2295 BLK 18 (ACS/SJC MACHINE)
FRC1 TRACTION LOCK RELAY TAILGATE FANS RELAY GND
SHEET 15
FRC1 FRONT LIGHT RELAY
2115 BLK SP55 2105 BLK SP5 2000 BLK T770 (S/N AT6311001 - AT6311908)
2520 BLK
SHEET 14
SHEET 5 2055 BLK
FRC1 SWITCHED POWER RELAY
C410 LEFT HANDLE
2530 BLK
T770 (S/N B3BW11001 - B3BW12166)
SHEET 14
SHEET 16 2030 BLK C409 RIGHT HANDLE Printable Version Click Here
FRC1 HVAC RELAY
2005 BLK
SHEET 9
FRC1 STARTER RELAY Sheet 6 of 20
SHEET 15
2120 BLK (PRINTED DECEMBER 2016)
Printed In U.S.A. FRC1 FRONT LIGHT RELAY 7226988 (B)
J1B
GWY CTRLR
C408
(BLACK)
CAN BUS
CAB-MFR HARN CONN 1
8 9250 PUR 9220 PUR 9220 PUR SP18 SP39 9430 PUR SP35 9450 PUR 9460 PUR
9260 PUR 9230 PUR SP31 SP79 9270 PUR SP19 4 9410 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP80 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR C492 RESISTOR
ACS/SJC/AWS-MFR HARN
(8 PIN) 9440 PUR 4
C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
9290 PUR 7
9190 PUR/WHT 8
1830 RNG/WHT 1
SHEET 5 C450
9240 PUR 1 2070 BLK 2
SHEET 6 RIGHT JOYSTICK
9140 PUR/WHT 4 9320 PUR/WHT 3 SHEET 14
9420 PUR 4
J2B
1840 RNG/WHT 1
AUX CTRLR SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
9280 PUR 8 9300 PUR/WHT 3
SHEET 14
9180 PUR/WHT 9 9400 PUR 4
J2B C426
AUX CTRLR Remote Run Tool, ACD
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
21 3090 LBL D
(ACS/SJC MACHINE)
REMOTE RUN KEY
SHEET 5
1735 RNG/WHT
C
E
T770 (S/N AT6311001 - AT6311908)
SWITCHED POWER
1165 RED/WHT F
SHEET 4
SHEET 6
2710 BLK G UNSWITCHED POWER
GROUND
T770 (S/N B3BW11001 - B3BW12166)
Sheet 7 of 20
Printable Version Click Here
Printed In U.S.A.
(PRINTED DECEMBER 2016)
7226988 (B)
J7A
ECU CNTRLR
ENGINE CAN BUS SP81 SP90
C121
DOSING CONTROL UNIT
47 9200 PUR 9215 PUR 9415 PUR 9210 PUR SP67 9265 PUR SP71 9275 PUR SP70 9245 PUR 65
CAN LO 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205 PUR
NOx PRETREATMENT
9105 PUR/WHT 14
9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1
2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1
FRC1
TAILGATE FANS
25 3105 LBL 18 RELAY - C FUSE 15 A
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 1 A
30 LEFT 8110 TAN 14 8110 TAN 14 8125 TAN 14
SHEET 4 2 B
TAILGATE 2400 BLK 14 2400 BLK 14
TAILGATE FANS RELAY GND 2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14
9 8100 TAN 18 SHEET 6 RIGHT 2405 BLK 14 4 2405 BLK 14
TAILGATE SHEET 6 FUSE 15 A
C113
J1B C355 FANS GND RIGHT TAILGATE
GWY CTRLR FUEL HARN C172
C406 A B FAN CONN
12 3180 LBL C 3180 LBL A SIG 8135 TAN 14 A
FUEL SENDER
2180 BRN D 2180 BRN B GND B
10 3690 LBL SHEET 6 (30 - 270 OHM)
19 8008 TAN
WIRING SCHEMATIC
C100
9 3865 LBL 1
SIG WATER IN FUEL SENSOR
(ACS/SJC MACHINE)
34 2865 BRN 2 (FUEL FILTER)
56
GND
T770 (S/N AT6311001 - AT6311908)
C118
ENG-CROSSOVER
T770 (S/N B3BW11001 - B3BW12166)
28 8013 TAN
TO MAF - Pin 1
Sheet 9 of 20
See Sheet 18 of 20 Printable Version Click Here
8014 TAN 3 TEMP TO MAF - Pin 4
See Sheet 18 of 20
4
T42 3420 LBL TO GLOW PLUG - ECU Pin 179
See Sheet 18 of 20
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7226988 (B)
DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4
2975 BLK T33
DCU CASE GND
85 86
2915 BLK
C121
DOSING CONTROL UNIT
SP62
1230 RED/WHT 1245 RED/WHT 5 93 8310 TAN
SHEET 4 1265 RED/WHT 6
71 C123
1255 RED/WHT 73 67 HOSE 1 HEATER
2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1
8320 TAN 2
89
2880 BLK SP63 2925 BLK 1
90 7999 WHT
SHEET 6 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 SP88 8330 TAN 30
8140 TAN
SHEET 8 72 8340 TAN
Nox Ground 87 2955 BLK SP86
2870 BLK 2855 BLK 29
C124
SHEET 8 85 86 HOSE 2 HEATER
22 2145 BRN
8020 TAN
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 2135 BRN SP85
C155
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE
8150 TAN
4 8540 TAN 92 49 8260 TAN 8250 TAN 30
SP89 87 2965 BLK
C156 C125
2140 BRN 85 86 HOSE 3 HEATER
1 8850 WHT 80
2985 BLK
REDUCTION AGENT
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 8350 TAN 2
59
HOSE 3 HEATER
27 8370 TAN SP61 8360 TAN 30
C157
87
1 8900 TAN 83
CATALYST TEMPERATURE
2 61 85 86
SCR INLET 2025 BRN 2125 BRN
28 8600 TAN
C158
1 8520 TAN 62
CATALYST TEMPERATURE
2 84 C122
SCR OUTLET 2160 BRN
SUPPLY MODULE
C159
4 1690 RNG/WHT 11 WIRING SCHEMATIC
1 8800 TAN 31 HEATER BATT+
ENVIRONMENTAL TEMPERATURE
2 2050 BRN 9
3 8650 TAN 12
HEATER SIGNAL (ACS/SJC MACHINE)
55 1695 RNG/WHT 3
C160 76 8700 TAN 2
PUMP MOTOR BATT +
T770 (S/N AT6311001 - AT6311908)
1 PUMP MOTOR CONTROL SIGNAL
8530 TAN 18 TXL 34
CATALYST TEMPERATURE
DOC INLET 2 2075 BRN 18 TXL 12
54 2095 BRN 4
PUMP MOTOR GND T770 (S/N B3BW11001 - B3BW12166)
77 5
1680 RNG/WHT
78 8750 TAN 6
PURGING PUMP BATT +
Sheet 10 of 20
PURGING PUMP SIGNAL
Printable Version Click Here
17 1685 RNG/WHT 10
PRESSURE SENSOR BATT+
39 3000 LBL 9 (PRINTED DECEMBER 2016)
PRESSURE SENSOR SIGNAL
Printed In U.S.A.
40 2085 BRN 8
PRESSURE SENSOR GND 7226988 (B)
PWR 30
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
C425
B C308
BRAKE
1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
SHEET 4 87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
GND 85 86 12 V
2035 BLK OPTIONS DWG)
SHEET 6 WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG
HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
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
T770 (S/N AT6311001 - AT6311908)
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM T770 (S/N B3BW11001 - B3BW12166)
Sheet 11 of 20
19 13 Printable Version Click Here
J2B
AUX CTRLR (PRINTED DECEMBER 2016)
Printed In U.S.A. 7226988 (B)
CAB DISPLAY
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 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 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 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
SHEET 13 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 7 C503
DESOX INHIBIT SWITCH (OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
1 6
3 8060 TAN
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 12 of 20
Printable Version Click Here
SHEET 5
1785 RNG/WHT
2060 BLK
(ACS)
H/ISO
(SJC, AWS)
SWITCH
2 1
5
3
6
CAB
C492
ACS/SJC/AWS-MFR HARN
SHEET 14 4230 LGN
C438
(DK GRAY)
SHEET 13
4 * DLX CAB HARN 7253375 ONLY
(8 PIN) CAB-MFR HARN CONN 3
5
SHEET 14 4240 LGN
4220 LGN 4235 LGN 7 4235 LGN
(NOT IN STD CAB HARN)
3 4275 LGN SP29 8 4275 LGN
9
2 4550 LGN
1850 RNG/WHT 2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
* T37
DOME LIGHT (+)
SHEET 4 1390 RED/WHT
DOME
SP41 LIGHT
C129 2010 BLK
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 4 2370 BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
+5V
24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR WIRING SCHEMATIC
SHEET 9 5690 YEL
HARNESS WASHER PUMP
7253378
(ACS/SJC MACHINE)
SHEET 9 5695 YEL
T770 (S/N AT6311001 - AT6311908)
* C252
A
C253
1
PWR T770 (S/N B3BW11001 - B3BW12166)
7310 WHT WASHER
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 TILT SPOOL LOCK 20 4640 LGN D
SIG
2 7.8 OHM 12V 28 4840 LGN C
22 4830 LGN B SKI CTRL
C422 12 4820 LGN G
2 2990 BRN 3 GND 11 4810 LGN F SIDE SHIFT
4990 LGN 1 LIFT SPOOL LOCK 1520 RNG/WHT A
SIG SHEET 5
7.8 OHM 12V J
2
4240 LGN H
SHEET 13
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 14 of 20
Printable Version Click Here
LIGHTS
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts
C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
2760 BLK B GND WORK LIGHT
FRC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - J C435-2
(DK GRAY)
6130 PNK A SIG
CAB-MFR HARN CONN 3 RIGHT FRONT
2705 BLK B GND WORK LIGHT
1350 RED/WHT 30
SHEET 4 87 6610 PNK 13 50.00 Watts
6610 PNK
6630 PNK
FRC1
FRONT WORK
LIGHTS RELAY - K C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK SP10 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 15 of 20
Printable Version Click Here
2560 BLK
* C483
C BLK
POTENTIOMETER
* DLX CAB HARN 7253375 ONLY 7420 WHT
7425 WHT
A
B
DBL
WHT
(TEMP CONTROL
SWITCH)
(NOT IN STD CAB HARN) C635
* D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
C486
WIRING SCHEMATIC
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
(ACS/SJC MACHINE)
2290 BLK 2280 BLK
SHEET 6
D4 T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 16 of 20
Printable Version Click Here
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 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK D
SHEET 6 2420 BLK BEACON/FLASHER
C423
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 DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
C131
106 TEMP SENSOR 2 EXHAUST GAS
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4
EGR VALVE INTAKE
DC MOTOR 3 POSITION RETURN 172 169 SENSOR RETURN 4 MANIFOLD TEMP
6 H BRIDGE POS 192
2 H BRIDGE NEG 193
C145
CRANKSHAFT CRANK POSITION SENSOR 160
POSITION 136
CRANK SENSOR NEG
SENSOR
C144
C138
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESS B
CAM SHAFT 2 159
POS SENSOR 112 A
SENSOR INTAKE PRESSURE SENSOR INLET TEMP
3 VREF1 CAM TO C118 - Pin 1
167 INTAKE PRESSURE RETURN D PRESSURE
C143
See Sheet 9 of 20 SENSOR WIRING SCHEMATIC
1 RAIL PRESS URE SENSOR 135
RAIL PRESSURE
SENSOR
2 SENSOR RETURN 119 (ACS/SJC MACHINE)
3 138 C139
VREF 1 SENSOR 127 FUEL INJECTOR HSDA
CYL 1
T770 (S/N AT6311001 - AT6311908)
C141 126 FUEL INJECTOR LSD1A
CYL 3
FUEL INJECTOR HSDB
FUEL INJECTOR LSD1B
151
175 C140
T770 (S/N B3BW11001 - B3BW12166)
150 FUEL INJECTOR HSDB
C142 174 FUEL INJECTOR LSD2B CYL 2 Sheet 18 of 20
FUEL INJECTOR HSDA 103
Printable Version Click Here
CYL 4 125 C154
FUEL INJECTOR LSD2A
177 PWM 2
INLET METERING (PRINTED DECEMBER 2016)
TO C118 - Pin 1 1 VALVE
Printed In U.S.A. See Sheet 9 of 20 7226988 (B)
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS 7164144
K TILT PEDAL K TILT MOTOR 2
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170 RED/WHT C409 C466
C492 C493 J3-ACS K A
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
B 1740 RNG/WHT 6 2 SOLENOID D
A PWM
+5V
5970 YEL 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GRD LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
5750 YEL A A HALL SENSOR 2980 BRN 1 GND
+5V PWR
3980 LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660 BRN GND
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
WIRING SCHEMATIC
H
E
3980 LBL
3990 LBL
(ACS/SJC MACHINE)
T770 (S/N AT6311001 - AT6311908)
T770 (S/N B3BW11001 - B3BW12166)
Sheet 19 of 20
Printable Version Click Here
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7226988 (B)
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
HARNESS PART NUMBER 13 LF ANGLE
SJC 7234953 LIFT 14 RF ANGLE
C429 ACTUATOR
A22 PUMP 7198705 15 LR ANGLE
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 17 RR ANGLE
2980 BRN 1 GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
3980 LBL 2 SIG 20 R JOYSTICK X
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR
22 CAN LOW
33
C428 23 R QUAD A DRIVE
34 TILT ACTUATOR
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL 4 25 TWO SPEED 1
5970 YEL
3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
6 27 GROUND
23 2990 BRN 1 GND
24 28 GROUND
4290 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN BRN 4 2810 BRN 1 GND
31 L REV DRIVE
8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860 YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1710 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H 49 SPARE PWN COIL 6
C544 C
21 4270 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A
C474 1 1830 RNG/WHT 1 +12V PWR
D 2 2
26 4210 LGN A 2070 BLK GND
J3-ACS
F 4 9660 PUR 4 CAN LO RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1 JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI
C100 WATER IN FUEL SENDER 2 9 C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 SW6 BUCKET POSITION SWITCH 6 17
C103 TAILGATE HARNESS 8 6,14,15,17 C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 SW9 TRAVEL CONTROL SWITCH 6 12
C104 TAILGATE FANS 4 9 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW10 BLOWER SWITCH 5 16
C105 HYD CHARGE PRESSURE 3 11 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 SW11 AC SWITCH 3 16
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6 SW12 DPF SWITCH 10 12
C111 MFR-BCT ENG HARN CONN 3 9 C350 AC EVAPORATOR SWITCH 2 16 C492 ACS/SJC/AWS-MFR 8 5,7,13 T1 BATT GROUND 1 6
C112 HYD OIL FILTER SWITCH 2 11 C355 FUEL HARNESS 6 9,17 C493 ACS/SJC/AWS-MFR 4 4,6 T2 BUZZER GROUND 1 12
C113 RIGHT TAILGATE FAN CONN 2 9 C404 BACK UP ALARM 2 5,14 C497 SJC HORN/BLINKER 3 17 T3 FLASHER 2 17
C114 HAND THROTTLE 6 9 C405 AIR FILTER SWITCH 2 9 C499 PTOL 4 12 T4 MEGAFUSE 1 4
C115 FOOT THROTTLE 6 9 C406 FUEL SENDER 2 9 C500 RH KEY SWITCH 6 12 T6 BATT GROUND 1 6
C116 FOOT THROTTLE INTMD 3 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C503 RH DLX PANEL 6 7,12 T8 BATT GROUND 1 6
15,17
C118 ENG-CROSSOVER 4 9 C409 RIGHT HANDLE 10 14 C602 LEFT REAR TAIL LIGHT 2 15 T10 ENGINE SYSTEM GROUND 1 6
C119 LEFT TAILGATE FAN CONN 2 9 C410 LEFT HANDLE 10 14 C603 RIGHT REAR TAIL LIGHT 2 15 T13 BUZZER POWER 1 12
C120 ENGINE TEMP SENSOR 2 9 C411 LEFT HANDLE 5 WAY 5 17 C606 POWER BOBTACH OPEN 2 17 T14 PRE HEATER 1 9
C121 DOSING CONTROL UNIT 94 8,10 C412 LEFT HANDLE 2 WAY 2 17 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C122 SUPPLY MODULE 12 10 C415 HIGH FLOW SOLENOID 2 17 C610 HVAC DUCT FAN 2 16 T16 RIGHT REAR WORK LIGHT(-) 1 15
C123 HOSE 1 HEATER 2 10 C418 FRONT ROD 2 11 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C124 HOSE 2 HEATER 2 10 C419 FRONT BASE 2 11 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C125 HOSE 3 HEATER 2 10 C420 HYD LOCK 2 11 C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
C126 HORN 2 17 C421 TILT SPOOL LOCK 3 14 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14
C129 CAB ACCESSORY 3 13 C422 LIFT SPOOL LOCK 3 14 C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
C155 TANK HEATING VALVE 4 10 C423 BUCKET POSITION 2 17 C676 RADIO 6 17 T27 PRE HEATER CONTACTOR PWR 1 9
C156 REDUCTION AGENT METERING 2 10 C425 BRAKE SOLENOID 3 11 FRC1 FUSE RELAY CENTER 112 4,5,9,11,15, T29 BATTERY 1 9
VALVE 16
C157 CATALYST TEMP SCR INLET 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 J1A GATEWAY CONTROLLER 34 5,9,11,12, T31 PREHEATER 1 9
14,15,16,17
C158 CATALYST TEMP SCR OUTLET 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 T32 ECU CASE GND 1 6
12,13,14,17
C159 ENVIRONMENTAL TEMP 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 J2A AUX CONTROLLER 34 11,14,17 T33 DCU CASE GND 1 10
C160 CATALYST TEMP DOC INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 J2B AUX CONTROLLER 26 4,5,6,7,11, T37 DOME LIGHT + 1 13
14,17
C161 DEF TANK 4 8 C435-1 RIGHT FRONT LIGHT (37W) 2 15 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9 T38 DOME LIGHT - 1 13
C163 NOx PRETREATMENT 5 8 C435-2 RIGHT FRONT LIGHT (50W) 2 15 RC1 FRONT WORK-LIGHTS RELAY 4 15 T42 PREHEATER FDBK 1 9
C164 NOx POST TREATMENT 5 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,15,16,17 RC2 FRONT WORK-LIGHTS RELAY 4 15
C169 ENGINE CAN DIAGNOSTIC 6 8 C441 TWO SPEED SOLENOID 2 17 SW1 BRAKE SWITCH 6 12
C171 INLINE FAN FUSE LEFT 2 9 C446 HYDRAULIC FAN SOLENOID 2 11 SW2 BEACON SWITCH 6 17
C172 INLINE FAN FUSE RIGHT 2 9 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW3 HAZARD SWITCH 6 17
C212 POWER SOCKET 2 13 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW4 HAND/FOOT, H/ISO SWITCH 6 13
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 SW5 POWER BOBTACH SWITCH 6 17
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 1 of 20
Printable Version Click Here
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 3 of 20
Printable Version Click Here
1335/RED FUSE 20 5 A
1345/RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
1325/RED FUSE 16 25 A
SP1 1300/RED 1035/RED/WHT
SHEET 5
1445/RED/WHT FRC 1 ENGINE ECU RELAY
SHEET 9
FUSE 18 25 A FRC1 PRE HEATER RELAY
1190/RED 1165/RED/WHT SHEET 7
C426 REMOTE RUN, ACD
1050/RED
(ACCESSORIES) Sheet 4 of 20
SHEET 5 Printable Version Click Here
FRC1 SWITCHED PWR RELAY
1030/RED
SHEET 9 (PRINTED OCTOBER 2017)
FRC1 STARTER RELAY
Printed In U.S.A. 7281506 (A)
FRC1
ENGINE ECU
1525/RNG
SCR INTERCONNECT
SHEET 8 SWITCHED POWER J7A ENGINE ECU
+12V RELAY - G
PWR 1506/RNG/WHT 1
SHEET 4 1035/RED/WHT 30 SP54
87 1540/RNG/WHT SP73 1545/RNG/WHT 1507/RNG/WHT 3
1535/RNG/WHT 1508/RNG/WHT 5
85 86
8005/TAN 45
C404
1720/RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 6 25 A 1850/RNG/WHT
1760/RNG/WHT SHEET 13 C408 CAB-MFR CONN (FR WIPER)
1700/RNG/WHT SHEET 12 SW12 DPF SWITCH
1705/RNG/WHT SHEET 12 SW12 DPF SWITCH
FUSE 12 15 A
1790/RNG/WHT 1550/RNG/WHT 1620/RNG/WHT
SHEET 17 C408 CAB-MFR CONN (BKT POSITION) SHEET 12 C479 LH PANEL
1940/RNG/WHT
1520/RNG/WHT SHEET 12 T13 LH PANEL BUZZER
SHEET 14 C410 LEFT HANDLE 1930/RNG/WHT
SHEET 12 C499 RH PANEL PTOL
1530/RNG/WHT SHEET 14 C409 RIGHT HANDLE 1775/RNG/WHT
SHEET 12 SW1 BRAKE SWITCH
C428 1960/RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 12 SW9 TRAVEL CONTROL SWITCH
1805/RNG/WHT 1570/RNG/WHT SP11
1560/RNG/WHT 22 1785/RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 13 SW4 H/ISO SWITCH
1950/RNG/WHT
SHEET 12 C500 RH PANEL KEY SWITCH
1660/RNG/WHT 2 1660/RNG/WHT SP42 1590/RNG/WHT
SHEET 12 C503 RH DELUXE PANEL
1765/RNG/WHT SP25 1795/RNG/WHT FUSE 7 25 A
1730/RNG/WHT SP65 1735/RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725/RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN
POWER RELAY - A FUSE 8 25 A
+12V 1580/RNG/WHT
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR 30
SHEET 4 1050/RED
87 1815/RNG/WHT
FUSE 23 15 A 1800/RNG/WHT
SHEET 9 ALT EXCITATION
WIRING SCHEMATIC
SHEET 6 2055/BLK GND 85 86
(ACS/SJC MACHINE)
3450/LBL 21
3380/LBL 4
J1A
GWY CTRLR
C428
(LT GRAY)
CAB-MFR HARN CONN 2
T770 (S/N AT6311909 - AT6312719)
1920/RNG/WHT 9 1920/RNG/WHTSP37 1840/RNG/WHT SHEET 7
C449 LH JOYSTICK
T770 (S/N B3BW12167 - B3BW12255)
1740/RNG/WHT 6
C492
ACS/SJC/AWS-MFR HARN
1830/RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 20
(8 PIN)
Printable Version Click Here
2370/BRN
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220/BRN SP12 2230/BRN
J1B
GWY CTRLR
17
SHEET 11
C108 HYD TEMP SENDER
2190/BRN
2 SHEET 11
2001/BLK C105 HYD CHG PRESSURE SENDER
4 2002/BLK SP53 2820/BLK SP75 2805/BLK 2180/BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003/BLK C355 FUEL HARN (FUEL SENDER)
2150/BRN
SHEET 9
C405 AIR FILTER SWITCH
T32 2004/BLK
ECU CASE GND SHEET 9 2690/BRN
2880/BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10 2695/BRN
SHEET 9
C120 SCR-MFR CONN C115 FOOT THROTTLE
2430/BRN/18
2080/BLK C493 3 2235/BLK SHEET 9
SHEET 7 ACS/SJC/AWS-MFR HARN ENGINE TEMP GND
C449 LH JOYSTICK 4 2240/BLK T6
2070/BLK (4 PIN)
SHEET 7 C408 BATT GND
C450 RH JOYSTICK (BLACK)
2920/BLK CAB-MFR HARN CONN 1
SHEET 12 2765/BLK
C479 LH PANEL (BLACK) SP4 SHEET 15
2940/BLK 2950/BLK 10 2950/BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
2745/BLK
C499 PTOL SHEET 16
2960/BLK 16 SP3 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510/BLK 2110/BLK
C500 RH PANEL KEY SWITCH J1B 2790/BLK T8
GWY CTRLR 15 2500/BLK SHEET 13 BATT GND
2250/BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 12
C503 RH DELUXE PANEL 2780/BLK
2065/BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540/BLK
SW12 DPF SWITCH SP28 2730/BLK
2930/BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 AUX CTRLR
2550/BLK 2090/BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2830/BLK SP47 2900/BLK 1 2900/BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700/BLK 2770/BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785/BLK 2200/BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620/BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720/BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650/BLK
SP51 2600/BLK 2390/BLK/10
T20 BU ALARM B 2600/BLK T1
2015/BLK T10
2640/BLK BATT GND SHEET 9 ENGINE
SHEET 15 SP6
2400/BLK/14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610/BLK 2405/BLK/14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2455/BLK
2630/BLK SHEET 17
SHEET 15 C423 BKT POSITION SOLENOID
T18 LH REAR LIGHT
2710/BLK 2300/BLK
SHEET 7
C426 REMOTE RUN, ACD SP27
2715/BLK
SHEET 8
C169 ENGINE CAN WIRING SCHEMATIC
2290/BLK
SHEET 15
FRC1 REAR LIGHT RELAY
2045/BLK
SHEET 16
D4 COMPRESSOR DIODE (ACS/SJC MACHINE)
2295/BLK/18
SHEET 11
FRC1 TRACTION LOCK RELAY
2035/BLK SHEET 9
TAILGATE FANS RELAY GND T770 (S/N AT6311909 - AT6312719)
2115/BLK SP55 2105/BLK SP5 2000/BLK
T770 (S/N B3BW12167 - B3BW12255)
SHEET 15
FRC1 FRONT LIGHT RELAY 2520/BLK
SHEET 14
2055/BLK
SHEET 5 C410 LEFT HANDLE
FRC1 SWITCHED POWER RELAY 2530/BLK Printable Version Click Here
SHEET 14
SHEET 16 2030/BLK C409 RIGHT HANDLE
FRC1 HVAC RELAY
SHEET 9 2005/BLK Sheet 6 of 20
FRC1 STARTER RELAY
SHEET 15
2120/BLK (PRINTED OCTOBER 2017)
Printed In U.S.A. FRC1 FRONT LIGHT RELAY
7281506 (A)
J1B
C408
(BLACK)
CAN BUS
GWY CTRLR CAB-MFR HARN CONN 1
8 9250/PUR 9220/PUR 4 9220/PUR SP18 9410/PUR SP39 9430/PUR SP35 9450/PUR 9460/PUR
9260/PUR 9230/PUR SP31 SP79 9270/PUR SP19 4
CAN LO C479
9 9160/PUR/WHT 9130/PUR/WHT 9150/PUR/WHT 9170/PUR/WHT SP20 9120/PUR/WHT 3 9120/PUR/WHT 9310/PUR/WHT 9330/PUR/WHT 9350/PUR/WHT 9360/PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP80 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR C492 RESISTOR
ACS/SJC/AWS-MFR HARN
(8 PIN) 9440/PUR 4
C503
9340/PUR/WHT 2 RIGHT DELUXE PANEL
9290/PUR 7
9190/PUR/WHT 8
1830/RNG/WHT 1
SHEET 5 C450
9240/PUR 1 2070/BLK 2
SHEET 6 RIGHT JOYSTICK
9140/PUR/WHT 4 9320/PUR/WHT 3 SHEET 14
9420/PUR 4
J2B
1840/RNG/WHT 1
AUX CTRLR SHEET 5 C449
2080/BLK 2
SHEET 6 LEFT JOYSTICK
9280/PUR 8 9300/PUR/WHT 3
J2B C426 SHEET 14
9180/PUR/WHT 9 9400/PUR 4
AUX CTRLR Remote Run Tool, ACD
14 9500/PUR/WHT A
CAN HI
20 9600/PUR B
CAN LO
J1B
GWY CTRLR
21 3090/LBL D
C
REMOTE RUN KEY WIRING SCHEMATIC
1735/RNG/WHT E
SHEET 5
SHEET 4
1165/RED/WHT F
SWITCHED POWER
UNSWITCHED POWER
(ACS/SJC MACHINE)
2710/BLK G
SHEET 6 GROUND
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 7 of 20
Printable Version Click Here
Printed In U.S.A.
(PRINTED OCTOBER 2017)
7281506 (A)
ENGINE CAN BUS C121
J7A
ECU CNTRLR DOSING CONTROL UNIT
SP81 SP90
47 9200/PUR 9215/PUR 9415/PUR 9210/PUR SP67 9265/PUR SP71 9275/PUR SP70 9245/PUR 65
CAN LO 120 Ohm Terminator
48 9100/PUR/WHT 9115/PUR/WHT 9315/PUR/WHT 9110/PUR/WHT SP68 9165/PUR/WHT SP72 9175/PUR/WHT SP69 9145/PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR
20 C163
9205/PUR NOx PRETREATMENT
9105/PUR/WHT 14
9295/PUR 3
9195/PUR/WHT 4
2835/BLK 2
2875/BLK 5
1
SHEET 10 2870/BLK
NOx GROUND SP78 C164
NOx POST TREATMENT
2815/BLK 2
9285/PUR 3
9185/PUR/WHT 4
5
1635/RNG/WHT 1
1525/RNG 1645/RNG/WHT
SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
C169
1640/RNG/WHT 4
ENGINE CAN
9225/PUR 1
1 1725/RNG/WHT 2
SHEET 5 9125/PUR/WHT
2 2715/BLK 2825/BLK 3
SHEET 6 SHEET 10
3 9155/PUR/WHT
4 9255/PUR C121
DOSING CONTROL UNIT
FRC1
TAILGATE FANS
25 3105/LBL/18 RELAY - C FUSE 15 A
12 3100/LBL/18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105/RED/WHT/10 87A 1 A
30 LEFT 8110/TAN/14 8110/TAN/14 8125/TAN/14
SHEET 4 2 B
TAILGATE 2400/BLK/14 2400/BLK/14
TAILGATE FANS RELAY GND 2295/BLK/18 85 86 FANS GND SHEET 6 8105/TAN/14 3 8105/TAN/14
9 8100/TAN/18 SHEET 6 RIGHT 2405/BLK/14 4 2405/BLK/14
TAILGATE SHEET 6 FUSE 15 A
C113
J1B C355 FANS GND RIGHT TAILGATE
GWY CTRLR FUEL HARN C172
C406 A B FAN CONN
12 3180/LBL C 3180/LBL A SIG 8135/TAN/14 A
FUEL SENDER
10 2180/BRN D 2180/BRN B GND (30 - 270 OHM) B
3690/LBL SHEET 6
19 8008/TAN
WIRING SCHEMATIC
C100
9 3865/LBL 1
SIG WATER IN FUEL SENSOR
(ACS/SJC MACHINE)
34 2865/BRN 2 (FUEL FILTER)
56
GND
T770 (S/N AT6311909 - AT6312719)
C118
ENG-CROSSOVER
T770 (S/N B3BW12167 - B3BW12255)
28 8013/TAN
T42 3420/LBL 4
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7281506 (A)
DOSING CONTROL UNIT HOSE HEATER MAIN
1100/RED/WHT 30
87 8090/TAN
SHEET 4
2975/BLK T33
85 86
DCU CASE GND
2915/BLK
C121
DOSING CONTROL UNIT
SP62
1230/RED/WHT 1245/RED/WHT 5 93 8310/TAN
SHEET 4 1265/RED/WHT 6
71 C123
1255/RED/WHT 73 67 HOSE 1 HEATER
1
2310/BRN
1275/RED/WHT 51 68 7998/WHT SP87 8120/TAN
8320/TAN 2
89
2880/BLK SP63 2925/BLK 1
90 7999/WHT
SHEET 6 2825/BLK 2935/BLK 2 HOSE 1 HEATER
SHEET 8 2945/BLK 7 72 SP88 8330/TAN 30
8140/TAN
8340/TAN
Nox Ground 87 2955/BLK SP86
2870/BLK 2855/BLK 29
C124
SHEET 8 85 86 HOSE 2 HEATER
22 2145/BRN
8020/TAN
94 1
SHEET 9 8550/TAN
8240/TAN 2
53 2135/BRN SP85
C155
1 2170/BRN 75 HOSE 2 HEATER
TANK HEATING VALVE 4 92 30
8150/TAN
8540/TAN 49 8260/TAN 8250/TAN
SP89 87 2965/BLK
C156 C125
2140/BRN 85 86 HOSE 3 HEATER
1 8850/WHT 80
2985/BLK
REDUCTION AGENT
50 8560/TAN 1
METERING VALVE 2 8950/BLK 58
2165/BLK 2
8350/TAN
59
HOSE 3 HEATER
27 8370/TAN SP61 8360/TAN 30
C157
87
1 8900/TAN 83
CATALYST TEMPERATURE
2 61 85 86
SCR INLET 2025/BRN 2125/BRN
28 8600/TAN
C158
1 8520/TAN 62
CATALYST TEMPERATURE
2 84 C122
SCR OUTLET 2160/BRN SUPPLY MODULE
C159
4 1690/RNG/WHT 11 WIRING SCHEMATIC
1 8800/TAN 31 HEATER BATT+
ENVIRONMENTAL TEMPERATURE
2 2050/BRN 9
3 8650/TAN
12
HEATER SIGNAL (ACS/SJC MACHINE)
55 3
C160 76
1695/RNG/WHT
8700/TAN
2
PUMP MOTOR BATT +
T770 (S/N AT6311909 - AT6312719)
1 34 PUMP MOTOR CONTROL SIGNAL
CATALYST TEMPERATURE
DOC INLET 2
8530/TAN/18/TXL
2075/BRN/18/TXL 12
54 2095/BRN 4
PUMP MOTOR GND T770 (S/N B3BW12167 - B3BW12255)
77 5
Sheet 10 of 20
1680/RNG/WHT PURGING PUMP BATT +
78 8750/TAN 6
PURGING PUMP SIGNAL
Printable Version Click Here
17 10
1685/RNG/WHT PRESSURE SENSOR BATT+
39 3000/LBL
9 (PRINTED OCTOBER 2017)
PRESSURE SENSOR SIGNAL
Printed In U.S.A.
40 2085/BRN 8
PRESSURE SENSOR GND 7281506 (A)
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS C425
B C308
4100/LGN BRAKE
1360/RED/WHT PWR 30
SHEET 4 4200/LGN A 4200/LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200/BLK C 2200/BLK B 9.8 OHM
SHEET 6 ADDITIONAL
2035/BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
8 4110/LGN
13 3430/LBL
C108
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
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
T770 (S/N AT6311909 - AT6312719)
4340/LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM T770 (S/N B3BW12167 - B3BW12255)
Sheet 11 of 20
19 13 Printable Version Click Here
J2B
AUX CTRLR (PRINTED OCTOBER 2017)
Printed In U.S.A. 7281506 (A)
T13
CAB DISPLAY
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 19 2380/BRN 12 2380/BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500/LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700/BLK 2 3 3650/LBL 7 24 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 3040/LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040/LBL RUN/ENTER SWITCH
GWY CTRLR
3620/LBL 12
SHEET 13 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 7 C503
DESOX INHIBIT SWITCH (OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700/RNG/WHT 7 9 8050/TAN 4 1590/RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705/RNG/WHT 10 8 8055/TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240/RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065/BLK 2 4 8070/TAN
SHEET 6 DESOX INHIBIT 2250/BLK 3
1 SHEET 6 GROUND
1 6
3 8060/TAN
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 12 of 20
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7281506 (A)
Printable Version Click Here
CAB
*
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 5 3
C492 C438 SHEET 13 2060/BLK 5 6 * DLX CAB HARN 7253375 ONLY
ACS/SJC/AWS-MFR HARN 4230/LGN (DK GRAY) 4
(8 PIN) SHEET 14
SHEET 14 4240/LGN
CAB-MFR HARN CONN 3
(NOT IN STD CAB HARN)
5 4220/LGN 4235/LGN 7 4235/LGN
3 4275/LGN SP29 8 4275/LGN
2 4550/LGN
1850/RNG/WHT
9
2
4550/LGN
1850/RNG/WHT
*POWER
C212
SHEET 5 SOCKET
2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370/RED/WHT 7 1370/RED/WHT SP45
* DOME
T37
LIGHT (+)
SHEET 4 1390/RED/WHT
DOME
SP41 LIGHT
C129 2010/BLK
CAB ACCESSORY
1210/RED/WHT A +12V BATT PWR * DOME
T38
LIGHT (-)
1580/RNG/WHT 5 1580/RNG/WHT SP8 1865/RNG/WHT B +12V SW PWR
SHEET 5
2800/BLK C GND
1510/RNG/WHT
SHEET 17
1885/RNG/WHT SHEET 17
SP44 2210/BLK SHEET 17
2730/BLK 11 2730/BLK 2885/BLK
SHEET 6 SHEET 17
2060/BLK SHEET 13
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790/BLK 14 2790/BLK
SHEET 6
1850/RNG/WHT 1 WIPER SWITCH, MOTOR SWITCHED POWER
3620/LBL 4
SHEET 12 DOOR SIGNAL
1400/RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B SENSOR 7310/WHT 3
2370/BRN 4 2370/BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
+5V
24 5100/YEL SP13 5370/YEL 3 5370/YEL C +5V PWR WIRING SCHEMATIC
SHEET 9 5690/YEL
HARNESS WASHER PUMP
7253378
(ACS/SJC MACHINE)
SHEET 9 5695/YEL
T770 (S/N AT6311909 - AT6312719)
* C252 A C253
1
PWR T770 (S/N B3BW12167 - B3BW12255)
7310/WHT WASHER
J2A
2530/BLK K
SHEET 6
AUX CTRLR SHEET 13 4230/LGN 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
OPTIONS DWG) 4920/LGN E DETENT FLOW
BACK UP
2650/BLK ALARM 13 4910/LGN F
SHEET 6 TWO SPD
4310/LGN C
T20 TERMINAL (-) 4320/LGN D
PWM
4300/LGN B
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR K
J1A 10 2980/BRN 3 GND
GWY CTRLR 4980/LGN 1 SIG TILT SPOOL LOCK 20 4640/LGN D
2 7.8 OHM 12V 28 4840/LGN C
22 4830/LGN B SKI CTRL
C422 12 4820/LGN G
2 2990/BRN 3 11 4810/LGN F SIDE SHIFT
GND
4990/LGN 1 LIFT SPOOL LOCK 1520/RNG/WHT A
SIG SHEET 5
7.8 OHM 12V J
2
4240/LGN H
SHEET 13
2520/BLK E
SHEET 6
7 5
J1B
GWY CTRLR
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 14 of 20
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7281506 (A)
Printable Version Click Here
C434-1
2735/BLK B GND LEFT FRONT
C408
6100/PNK A SIG WORK LIGHT
(BLACK)
LIGHTS
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765/BLK 9 2765/BLK SP14 2750/BLK B GND
SHEET 6 LEFT FRONT
6110/PNK A SIG WORK LIGHT
50.00 Watts
C435-1
8 6000/PNK SP15 6120/PNK A SIG RIGHT FRONT
2760/BLK B GND WORK LIGHT
RC1 37.00 Watts
FRONT WORK C438
LIGHTS RELAY - 1 C435-2
(DK GRAY)
6130/PNK A SIG
CAB-MFR HARN CONN 3 RIGHT FRONT
6620/PNK SP23 2705/BLK B GND WORK LIGHT
SHEET 4 1350/RED/WHT 30
87 6610/PNK 13 6610/PNK 50.00 Watts
2120/BLK 85 86 SP64
SHEET 6
6630/PNK
6000/PNK
RC2
FRONT WORK
LIGHTS RELAY - 2 C103
+12V TAILGATE HARN C603
PWR 2610/BLK 2 GND
1330/RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340/PNK SP10 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115/BLK C602
SHEET 6
6330/PNK 1 SIG
2640/BLK 2 LEFT REAR
GND
SHEET 6 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
WIRING SCHEMATIC
(ACS/SJC MACHINE)
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 15 of 20
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7281506 (A)
Printable Version Click Here
HVAC 2440/BLK
7440/WHT
* C610
2
1
GND
SIG
HVAC DUCT
FAN
2560/BLK * C483
C BLK
7420/WHT A DBL POTENTIOMETER
(TEMP CONTROL
* DLX CAB HARN 7253375 ONLY 7425/WHT B WHT SWITCH)
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
*
C630
THERMOSTAT
3
AC EVAPORATOR C350 2570/BLK 2
SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT
C486
WIRING SCHEMATIC
7025/WHT 1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
(ACS/SJC MACHINE)
2290/BLK 2280/BLK
SHEET 6
D4 T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Sheet 16 of 20
Printable Version Click Here
POWER BOB
SIG
GND
1
2
4470/LGN
2470/BLK 2770/BLK
E
B
4470/LGN
2770/BLK
11 4470/LGN (NOT IN STD FUEL HARN 7149219)
CLOSE SHEET 6 4480/LGN
*POWER
SW5
2 1
* DLX CAB HARN 7253375 ONLY
# C606 BOBTACH 3
4
POWER BOB
GND
SIG
2
1
2480/BLK
4480/LGN F 4480/LGN 10
SWITCH 5
6 (NOT IN STD CAB HARN)
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
* FLASHER
T3
6570/PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415/PNK 6400/PNK 3 6400/PNK
D2 6430/PNK SWITCH
2725/BLK 6
C103 SHEET 12
3400/LBL
*HAZARD
SW3
2
1
6700/PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410/PNK (PINS 3 & 6 2850/BLK
6
* C670E
(SEE ADDITIONAL D 6510/PNK INTERNALLY
OPTIONS DWG) INSULATED)
2780/BLK 4 2780/BLK 2780/BLK 2420/BLK D
C423 SHEET 6 BEACON/FLASHER
6440/PNK F
*
3 SW6 EXTERIOR HARNESS
SIG A 4450/LGN D3 4455/LGN 5 4455/LGN 1
BUCKET 2 BUCKET 6540/PNK B (SEE ADDITIONAL
POSITION 4 C OPTIONS DWG)
2830/BLK 5 POSITION
SOLENOID GND B 2450/BLK 2455/BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
* C676
*+
(BLACK) C126 C279 RADIO CONN
CAB-MFR HARN CONN 1 SHEET 6
LEFT HANDLE C412 2785/BLK B GND LEFT 1 7820/WHT 3
*
(HORN) 2 WAY HORN C277
B 7210/WHT 13 7210/WHT A SIG SPEAKER 2 7830/WHT 4
(SEE ADDITIONAL - 1
A 1460/RED/WHT
SHEET 4 2
*-
OPTIONS DWG) C278 AIR RIDE
C497 2 7810/WHT 6 3 SEAT
SJC RIGHT
5 7200/WHT C SPEAKER 1 7800/WHT 5 1510/RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420/PNK A + 1885/RNG/WHT 1 2210/BLK 5 GND
(SEE ADDITIONAL SHEET 13 SHEET 13
J2A 3 6520/PNK B OPTIONS DWG) 2885/BLK 2 6
SHEET 13
AUX CTRLR
C415
26 2460/BRN B GND HIGH FLOW
A SIG SOLENOID
4460/LGN
J2B
26
7.5 OHM 12 V
WIRING SCHEMATIC
AUX CTRLR
(ACS/SJC MACHINE)
C441
J1A
GWY CTRLR
26 2350/BRN 2
1
GND
SIG
TWO SPEED
SOLENOID
TRACK 2 SPEED
ADAPTER
T770 (S/N AT6311909 - AT6312719)
4350/LGN (SEE ADDITIONAL
J1B 26
5.1 OHM 12 V
OPTIONS DWG) T770 (S/N B3BW12167 - B3BW12255)
GWY CTRLR
Sheet 17 of 20 Printable Version Click Here
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7281506 (A)
ENGINE
T14 PRE HEATER 179 J7B
PRE HEATER C130
ENG ECU CTRLR 105 TEMP SENSOR 1
C153 EXHAUST GAS
(DOOSAN HARNESS)
1 122 TEMP SENSOR
SENSOR RETURN 1
WASTE GATE BEFORE DPF
2 186
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
SUPPLIED
1 POSITION SENSOR 161 123 TEMP SENSOR
SENSOR RETURN 2
WASTE GATE BEFORE TURBINE
2 POSITION FEEDBACK 113
POSITION C132
3 POSITION GND 121 107 TEMP SENSOR 3 EXHAUST GAS
124 TEMP SENSOR
C151 SENSOR RETURN 3
BEFORE DOC
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 EXHAUST GAS
EGR VALVE
3 172 169 TEMP SENSOR
DC MOTOR POSITION RETURN SENSOR RETURN 4
AFTER DPF
6 H BRIDGE POS 192
C134
2 H BRIDGE NEG 193 166 VREF2 EG DPS 1
C150 108 PRESSURE SENSOR 3 EXHAUST GAS
AIR SENSOR 114 144 2 PRESSURE SENSOR
AMBIENT AIR
SENSOR RETURN
TEMP SENSOR
AIR RETURN 171
C135
C149 184 5
H BRIDGE POS
1 COOLANT TEMP SENSOR 109
COOLANT TEMP 183 H BRIDGE NEG 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
163 VREF 3 THROTTLE POSITION 1
C148 170 POSITION SENSOR GND 3
1 FUEL TEMP SENSOR 110 115 2
FUEL TEMP POSITION FEEDBACK ANALOG
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
132 C137
1 SENSOR SIGNAL
ENGINE BLOCK 156 UN 6
ACCELEROMETER 2 2 SENSOR RETURN 133 O2 SENSOR
129 157 VM 2
SHIELD & HEATER
154 IA 5
C145 155 1
160 IP
CRANK SENSOR POS SHEET ?
VR CRANK 182 O2 HEATER 3
SENSOR CRANK SENSOR NEG 136
4
C144
C138
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESS B
CAM SHAFT 2 159
POS SENSOR
SENSOR
3 VREF1 CAM 140
112
167
INTAKE PRESS SENSOR
INTAKE PRESS RETURN
A
D
INLET TEMP
PRESSURE
WIRING SCHEMATIC
(ACS/SJC MACHINE)
134 SENSOR
C143 INTAKE AIR TEMP SENSOR C
1 RAIL PRESSURE SENSOR 135 168 ?
INTAKE AIR TEMP RETURN
T770 (S/N AT6311909 - AT6312719)
RAIL PRESSURE 2 119
SENSOR RETURN
SENSOR
3 138 C139
VREF 1 SENSOR 127 FUEL INJECTOR HSDA
C141
151
126 FUEL INJECTOR LSD1A CYL 1 T770 (S/N B3BW12167 - B3BW12255)
FUEL INJECTOR HSDB
CYL 3
FUEL INJECTOR LSD1B 175
150 FUEL INJECTOR HSDB
C140
Sheet 18 of 20
C142 174 CYL 2 Printable Version Click Here
FUEL INJECTOR LSD2B
FUEL INJECTOR HSDA 103
CYL 4
FUEL INJECTOR LSD2A 125 C154 (PRINTED OCTOBER 2017)
177 2
Printed In U.S.A. PWM
INLET METERING
7281506 (A)
1 VALVE
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION HARNESS PART NUMBER
ACS 7164144 EXMF, LF
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
ACS 7190593 MF
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 CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
CONTROLS
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
K TILT PEDAL K TILT MOTOR 2
J1-ACS
CONTROLLER
H 2280/BLK
2280/BLK
2240/BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170/RED/WHT C409 C466
C492 C493 J3-ACS K A
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 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 5980/YEL 3 +5V PWR
SIG TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2660/BRN 2 GND C428 TILT ACTUATOR
C
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660/YEL
2990/BRN
2980/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 4
GND
K 4760/LGN 3 5990/YEL 3 +5V PWR
SIG TILT PEDAL
5760/YEL 1 HALL SENSOR 2990/BRN 1 GND
+5V PWR
3990/LBL 2 SIG
5750/YEL
5650/YEL 5980/YEL WIRING SCHEMATIC
5970/YEL 5990/YEL
(ACS/SJC MACHINE)
H
E
3980/LBL
3990/LBL
T770 (S/N AT6311909 - AT6312719)
T770 (S/N B3BW12167 - B3BW12255)
Printed In U.S.A. Sheet 19 of 20
Printable Version Click Here
SJC
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION
PIN FUNCTION PIN FUNCTION PIN FUNCTION
1 SAFETY IN
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
CONTROLS
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
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
HARNESSES 7159325, 7159458 ONLY K TILT PEDAL K TILT MOTOR 2
11 L FWD RETURN
12 CAN HIGH
LIFT
C429 ACTUATOR 13 LF ANGLE
4600/LGN 5 14 RF ANGLE
J5 - DRIVE 4610/LGN
6
8
15 LR ANGLE
16 H PAT LITE
CONTROLLER 2980/BRN 1
4
GND
17 RR ANGLE
# C454 3980/LBL 2 SIG 18 L JOYSTICK X
29 2890/BRN 2880/BRN 3 GND 7 19 L JOYSTICK Y
5880/YEL 1 +5V PWR 5980/YEL 3 +5V PWR 20 R JOYSTICK X
LEFT SPEED
33 3880/LBL 2 SIG SENSOR 21 L FWD DRIVE
34 3885/LBL 4 SIG C428 TILT ACTUATOR 22 CAN LOW
5990/YEL 3 +5V PWR
40 5890/YEL # C453 4 23 R QUAD A DRIVE
+5V
5970/YEL
5870/YEL 1 +5V PWR 3990/LBL 2 24 R QUAD B DRIVE
SIG
2870/BRN 3 GND 6 25 TWO SPEED 1
23 3870/LBL 2 RIGHT SPEED
SIG 2990/BRN 1 GND 26 BRAKE LIGHT OUTPUT
SENSOR
24 3875/LBL 4 SIG 4640/LGN 5 27 GROUND
7
C536 28 GROUND
4650/LGN 8
2970/BRN
5810/YEL 2 C543 A22 PUMP HARNESS
29 SENSOR GROUND
2810/BRN 4 2810/BRN 1 GND
RIGHT 30 SENSOR SUPPLY 2 +5V
8 3810/LBL 3 3810/LBL 3 SIG
1710/RNG/WHT 1 1710/RNG/WHT 2 SWASHPLATE K 31 L REV DRIVE
+12V PWR
J 32 CAN SHIELD
J2-ACS
C537
E 33 L QUAD A DRIVE
5860/YEL 2 C542
H 34 L QUAD B DRIVE
2860/BRN 4 2860/BRN 1 GND
LEFT F 35 SAFETY OUT
7 3860/LBL 3 3860/LBL 3 SIG SWASHPLATE G
1770/RNG/WHT 1 1770/RNG/WHT 2 +12V PWR 36 BACKUP ALARM
C
C546 D
37 R JOYSTICK Y
C501
43 4260/LGN 1 4260/LGN 1 B 38 SPARE ANALOG 1
RIGHT FORWARD DRIVE
42 2660/BRN 2 2660/BRN 2 A 39 SPARE PWM COIL 7
ACS CONTROLLER
40 SENSOR SUPPLY 1 +5V
C547 41 L REV RETURN
44 4250/LGN 3 4250/LGN 1 A
RIGHT REVERSE DRIVE +5V 42 R FWD RETURN
45 2650/BRN 4 2650/BRN 2 G
43 R FWD DRIVE
J1-ACS
F
C545 44 R REV DRIVE
9240/PUR E
31 4280/LGN 5 4280/LGN 1 D 45 R REV RETURN
9140/PUR/WHT
41 2680/BRN 6 2680/BRN 2 LEFT REVERSE DRIVE 46 TWO SPEED 2
1760/RNG/WHT B
2280/BLK H 47 UNSWITCHED BATTERY
C544 C 48 UNSWITCHED BATTERY
21 4270/LGN 7 4270/LGN 1
LEFT FORWARD DRIVE 49 SPARE PWN COIL 6
11 2670/BRN 8 2670/BRN 2
50 SWITCHED BATTERY
K
TO SJC BRAKE A
C474
HARNESS D
26 4210/LGN A
J3-ACS
(SEE ADDITIONAL OPTIONS F
SHEET) SUSP SEAT JOYSTICK HARNESS
2270/BLK H
2260/BLK J
C492
1180/RED/WHT C C460
12 9190/PUR/WHT 8 1 1830/RNG/WHT 1
1190/RED/WHT B +12V PWR
22 9290/PUR 7 C450 2 2
E 2070/BLK GND
4 4550/LGN 2
G RIGHT JOYSTICK 4 9660/PUR 4 CAN LO RIGHT
6 4220/LGN 5 (TO DLX CAB HARNESS) JOYSTICK
16 4275/LGN 3 3 3
9560/PUR/WHT CAN HI
9140/PUR/WHT 4
9240/PUR 1
50 1750/RNG/WHT 1740/RNG/WHT 6
MAINFRAME C459
HARNESS 1 1840/RNG/WHT 1 +12V PWR
27 2470/BLK C493 C449 2 2080/BLK 2 GND
28 2490/BLK 2235/BLK 3 LEFT JOYSTICK LEFT
(TO DLX CAB HARNESS) 4 9640/PUR 4 CAN LO
47 1250/RED/WHT 1235/RED/WHT 2 JOYSTICK
48 1260/RED/WHT 1170/RED/WHT 1 3 9540/PUR/WHT 3 CAN HI
2240/BLK 4
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
1310 RED 1360 RED/WHT
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
SP26 1340 RED 1330 RED/WHT
2A 2B SHT14/D8
1350 RED/WHT
1325 RED
FUSE 20 5 A SHT14/F8
1335 RED 1345 RED/WHT
20A 20B SHT3/G8
FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
1190 RED 1165 RED/WHT
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
1095 RED 1100 RED/WHT
25A 25B SHT9/H8
FUSE 26 15A
1220 RED 1230 RED/WHT
26A 26B SHT9/G8
FUSE 10 30A
1045 RED 1105 RED/WHT
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
22A 22B SHT16/F7
SP24
FUSE 24 25 A
SP60 1290 RED 1370 RED/WHT
24A 24B SHT12/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT7/H8
86 85
G4
SP73
1508 RNG/WHT
3
POWER
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT 1511 RNG/WHT
21A 21B SHT7/B7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
1790 RNG/WHT 1550 RNG/WHT
12A 12B SHT16/G7
1700 RNG/WHT
1520 RNG/WHT SHT10/C8
SHT12/D3 1705 RNG/WHT
SHT10/B8
1530 RNG/WHT 1620 RNG/WHT
SHT12/G3 SHT10/G8
1940 RNG/WHT
SHT10/H8
1930 RNG/WHT
FUSE 14 5 A SHT10/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT10/D8
SP11 1960 RNG/WHT
J2B SHT10/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT11/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT10/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT10/E4
SP42 1565 RNG/WHT
SHT16/E4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
GND
86 85
BUS BAR
A5 A2 1725 RNG/WHT
SHT6/D7
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT12/F8
FUSE 23 15 A
1815 RNG/WHT 1800 RNG/WHT
23A 23B SHT7/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
SP37
1920 RNG/WHT 1920 RNG/WHT 1840 RNG/WHT
9 9 SHT5/D3
1830 RNG/WHT
SHT5/E3
C492
1740 RNG/WHT
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
2003 BLK SHT9/F7 GATEWAY CTRLR
6 2370 BRN
SHT11/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT9/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT16/F4 SHT9/D7
J1B
2880 BLK 2180 BRN
SHT8/F8 SHT7/D7
C493
2150 BRN
ACS/SJC/AWS CONN 2 SHT7/G7
2235 BLK 2695 BRN
2080 BLK 3 3 SHT7/F7
SHT5/D3 2430 BRN
2240 BLK SHT7/C7
2070 BLK 4 4
SHT5/E3
C493 T6
2920 BLK 1 BATT GND
SHT10/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT10/G4 10 10
2960 BLK
SHT10/E4
2650 BLK
SHT12/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT13/C4 B B
SP51
2610 BLK
SHT13/E4 2400 BLK
SHT7/E4 AUX CTRLR
2630 BLK
SHT13/B4 2405 BLK 2195 BRN
SHT7/D4 SHT12/G3 SP58 2995 BRN
2185 BRN 17 SENSOR GROUND
SHT16/D7
2455 BLK
SHT15/D6 J2B
2715 BLK
SHT6/D7
2005 BLK
SHT7/G7
2120 BLK
SHT13/E8
C503
TP-15 RH DLX PANEL
9440 PUR TP-06
C492 4 CAN LO
ACS/SJC/AWS-MFR HARN (8 PIN)
9340 PUR/WHT
9290 PUR TP-15 2 CAN HI
TP-11 TP-13 7 7 CAN LO
9180 PUR/WHT
9 CAN HI * C449 C459 C449
LEFT JOYSTICK
LEFT JOYSTICK CONN LEFT JOYSTICK
J2B 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/B1 1 1 4 4
2080 BLK 2080 BLK GND
SHT4/G8 2 2 3 3
9300 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 2 2
9400 PUR 9640 PUR CAN LO
4 4 1 1
SUSP SEAT JOYSTICK HARNESS
C426
AUX CTRLR
Remote Run Tool, ACD
TP-30 9500 PUR/WHT TP-30
CAN HI 14 A A CAN HI
9600 PUR
CAN LO 20 B B CAN LO
J2B
3095 LBL
REMOTE RUN KEY 24
J2A
GATEWAY CTRLR
J1B
C C
9105 PUR/WHT
C163
9205 PUR
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR TP-27
3
GATEWAY CTRLR 9195 PUR/WHT
4
2870 BLK 2875 BLK
TP-19 SHT9/F8 5
20 ENG CAN LO SP78
C163
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
TP-25
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
B
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR TP-23 TP-31
9225 PUR
TP-31
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
TP-21 9155 PUR/WHT
ENG CAN HI 3
9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT
TP-29 TP-29
9720 PUR/WHT
CAN HI DCU DIAGNOSTIC 5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
CAN LO DCU DIAGNOSTIC 6 60 CAN LO DCU DIAGNOSTIC
C169
C121
1800 RNG/WHT
SHT2/F7
1800 RNG/WHT
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
STARTER RELAY SIGNAL 7 1
3560 LBL FOOT THROTTLE T11
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN GND FOOT THROTTLE 1
SHT4/G3 B HARNESS
AIR FILTER 7217683 T12
3150 LBL SWITCH (NC) C116 D 2015 BLK
AIR FILTER SENDER SIGNAL 16 A SIG
E SHT4/E3
FOOT THROTTLE INTDM F
C405 5695 YEL
5695 YEL +5V PWR
SHT12/C8 C C C
3695 LBL 3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A
2695 BRN 2695 BRN GND
SHT4/G3 B B B
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25 C115
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12
J1A SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113
T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
C144 FUEL INJECTOR #3 HSDB 51 1
C154
J7B
J7B
SHT2/C1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2985 BLK
4 92 94 86 85
2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGEN VALVE HIGH
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 RED AGENT SHIELD
49 HOSE 2 HEATER
HOSE 2 RELAY FB SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET C125
8250 TAN
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
2 9 ENV TEMP GND 8370 TAN 8360 TAN
ENVIRONMENTAL HOSE 3 RELAY FB 27 30
TEMPERATURE T SP61 87
8800 TAN
1 31 ENV TEMP SIG 8600 TAN C122
HOSE 3 HEATER 28 86 85 SUPPLY MODULE
C159
2075 BRN RL013 RL013
CATALYST 2 12 CAT TEMP DOC INLET
TEMPERATURE DOC 1690 RNG/WHT HEATER BATT+
T SM HEATER BATT 4 11
INLET 8530 TAN 8650 TAN
CAT TEMP DOC INLET HEATER SIGNAL
1 34 SM HEATER SIGNAL
3 12
1695 RNG/WHT PUMP MOTOR BATT +
C160 +5V POWER 55 3
SM PUMP MOTOR CONTROL 8700 TAN PUMP MOTOR CONTROL SIGNAL
76 2
SIGNAL
2095 BRN PUMP MOTOR GND
SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122
13
23
6
HYD LOCK
SOLENOID SIGNAL
TRACTION
SOLENOID OUTPUT
HYD CHARGE PRESS
SENDER SIGNAL
HYDRAULIC
FAN SIGNAL
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT15/F4 8 START ENGINE 24 2 2 2
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
SW12
DESOX INHIBIT SWITCH(OPT KIT)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
* DLX CAB HARN 7301237 ONLY
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT11/D1 5
4230 LGN 4
SHT12/F3
4240 LGN SW4 3
SHT12/D3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
MFR HARN CONN 3 (DK GRAY)
4220 LGN SP29 4235 LGN 4235 LGN
5 5 7 7
4275 LGN 4275 LGN
3 3 8 8
2 2
4550 LGN
9 9
4550 LGN *
2795 BLK GND
1850 RNG/WHT 1850 RNG/WHT 1
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT15/C2
1885 RNG/WHT
SHT15/B3
2885 BLK
SHT15/B3
2060 BLK
SHT11/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
(SEE ADDITIONAL
2690 BRN
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 SENSOR 3620 LBL
SHT10/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/H1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
6 6
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR
2 2 WIPER MOTOR GROUND
C
SP13 SP52
5100 YEL 5370 YEL 5370 YEL 5375 YEL 7310 WHT
5V CTRLR PWR 24 3 3 3 3 WASHER SIGNAL
C482
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
RIGHT HANDLE LEFT
SHT3/E3 A
ROCKER DOWN 4930 LGN
31 J
RIGHT HANDLE 4940 LGN
30 H LEFT POSITION SWITCH
LEFT ROCKER UP
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN RIGHT ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8 4230 LGN
T20 SHT11/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
4820 LGN
7
C410
TRIGGER
GATEWAY CTRLR
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - FC1
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
6630 PNK
6320 PNK
FC2 FC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR
SHT4/D8 2
5
RELAY SIGNAL C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK 31
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
SW11
1
3
C
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
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
(NOT IN STD FUEL HARN 7149219)
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
3500 LBL
T3
SHT10/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 SHT10/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT16/F6
2905 BLK
J1B
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIG 7
RIDE CONTROL
RELAY - L
FUSE RELAY CENTER
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL
COIL COIL FRC1 FRC1
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428
* SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MAN SIG 16 7 7 3
C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR 10 C PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 5V SUPPLY 24 B
J2B
SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8
2280/BLK
SEE MANUAL CONTROL
2240/BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170/RED/WHT C409 C466
C492 C493 J3-ACS K A
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2660/BRN 2 GND C428 TILT ACTUATOR
C
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
5750/YEL 3990/LBL 2 SIG
5650/YEL 5980/YEL
5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL
BUS BAR
1010 RED
SHT7/G1
FUSE 3 30 A
1310 RED 1360 RED/WHT
3A 3B SHT10/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8
BUS BAR
FUSE 2 20 A
SP26 1340 RED 1330 RED/WHT
2A 2B SHT14/D8
1350 RED/WHT
FUSE 20 5 A SHT14/F8
1325 RED
1335 RED 1345 RED/WHT
20A 20B SHT3/G8
FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8
1445 RED/WHT
SHT7/B3
FUSE 18 25 A
1190 RED 1165 RED/WHT
18A 18B SHT5/B8
1055 RED
FUSE 25 10A
1095 RED 1100 RED/WHT
25A 25B SHT9/H8
FUSE 26 15A
1220 RED 1230 RED/WHT
26A 26B SHT9/G8
FUSE 10 30A
1045 RED 1105 RED/WHT
10A 10B SHT7/E7
1460 RED/WHT
SHT16/B7
FUSE 22 25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
22A 22B SHT16/F7
SP24
FUSE 24 25 A
SP60 1290 RED 1370 RED/WHT
24A 24B SHT12/F8
FRC1 FRC1
1200 RED
SHT3/C8
1050 RED
SHT3/D8
1030 RED
SHT7/H8
86 85
G4
SP73
1508 RNG/WHT
3
POWER
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
J7A
SHT2/E1
1345 RED/WHT FUSE RELAY CENTER
FUSE 21 15 A
1535 RNG/WHT 1511 RNG/WHT
21A 21B SHT7/B7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
1790 RNG/WHT 1550 RNG/WHT
12A 12B SHT16/G7
1700 RNG/WHT
1520 RNG/WHT SHT11/C8
SHT13/D3 1705 RNG/WHT
SHT11/B8
1530 RNG/WHT 1620 RNG/WHT
SHT13/G3 SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
FUSE 14 5 A SHT11/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT11/D8
SP11 1960 RNG/WHT
J2B SHT11/F8
C428 1785 RNG/WHT
SHT12/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT11/F4
1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
FRC1 SWITCHED 2 2 SHT11/E4
POWER RELAY - A SP42 1565 RNG/WHT
SHT17/E4
FUSE 23 15 A
1815 RNG/WHT 1800 RNG/WHT
23A 23B SHT7/G8
3390 LBL
FRC1 FRC1
FRC1 SWITCHED
POWER RELAY - F 2055 BLK
SHT4/B8
1200 RED 30
SHT2/B1
+12V PWR
F1 87 F4 1585 RNG/WHT
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
SP37
1920 RNG/WHT 1920 RNG/WHT 1840 RNG/WHT
9 9 SHT5/D3
2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2320 BRN
2003 BLK SHT10/F7 GATEWAY CTRLR
6 2370 BRN
SHT12/D8
T32 J7A 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT10/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT17/F4 SHT10/D7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
C493
2150 BRN
2605 BLK ACS/SJC/AWS CONN 2 SHT7/G7
SHT5/E7 2235 BLK 2695 BRN
2080 BLK 3 3 SHT7/F7
SHT5/D3 2430 BRN
2240 BLK SHT7/C7
2070 BLK 4 4
SHT5/E3
C493 T6
2920 BLK 1 BATT GND
SHT11/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10
2960 BLK
SHT11/E4
2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT14/C4 B B
SP51
2610 BLK
SHT14/E4 2400 BLK
SHT7/E4 AUX CTRLR
2630 BLK
SHT14/B4 2405 BLK 2195 BRN
SHT7/D4 SHT13/G3 SP58 2995 BRN
2185 BRN 17 SENSOR GROUND
SHT17/D7
2455 BLK
SHT16/D6 J2B
2715 BLK
2065 BLK SHT6/D7
SHT3/C6
2505 BLK 2290 BLK
SHT17/G4 SHT15/B8
2045 BLK
SHT14/B8 2295 BLK
2035 BLK SHT7/D7
SHT10/G8
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8
C479
Z3 C408
GATEWAY CTRLR Z4 LEFT PANEL
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK)
SP79 SP19 SP18 SP39 SP35 120 OHM 0.5 W RESISTOR (BLACK)
9260 PUR 9230 PUR
SP31 9250 PUR 9270 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR
CAN LO 8 4 4 4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C503
9290 PUR RH DLX PANEL
7 7 CAN LO
9440 PUR
9190 PUR/WHT 4 CAN LO
8 8 CAN HI
9340 PUR/WHT
9240 PUR 2 CAN HI
1 1 CAN LO
AUX CTRLR
* C450
RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK
C450
RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
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
9420 PUR 9660 PUR CAN LO
J2B 4 4 4 4
TELEMATICS
1305 RED/WHT
PWR 10
2605 BLK
SHT2/H1
* C449 C459 C449
LEFT JOYSTICK
GND 11 SHT4/G8 LEFT JOYSTICK CONN LEFT JOYSTICK
C448 1840 RNG/WHT 1840 RNG/WHT +12V PWR
Z5 MFR HARN CONN 4 (BLACK) SHT3/B1 1 1 4 4
120 OHM 0.5 W RESISTOR SP104 9500 PUR/WHT 2080 BLK 2080 BLK GND
9515 PUR/WHT 9505 PUR/WHT 7 7 SHT4/G8 2 2 3 3
CAN HI 3 9510 PUR/WHT 9300 PUR/WHT 9540 PUR/WHT CAN HI
9 9 3 3 2 2
9610 PUR 9400 PUR 9640 PUR CAN LO
9615 PUR 9605 PUR 10 10 4 4 1 1
CAN LO 4 9600 PUR
8 8 SUSP SEAT JOYSTICK HARNESS
C481 SP103
C426
AUX CTRLR
Remote Run Tool, ACD
9500 PUR/WHT 9510 PUR/WHT
CAN HI 14 A A CAN HI
J2B
3615 LBL CAN SELECT
CAN SELECT 25 C C
3095 LBL
REMOTE KEY 24
J2A
GATEWAY CTRLR
J1B
1735 RNG/WHT SWITCHED POWER
SHT3/D1 E E
J7A C121
C163
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR
3
GATEWAY CTRLR 9195 PUR/WHT
4
2870 BLK 2875 BLK
9205 PUR SHT9/F8 5
20 ENG CAN LO SP78
C163
9105 PUR/WHT
14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
9285 PUR
3
9185 PUR/WHT
4
5
C164
1525 RNG
SHT3/H1 SP76
C162 C161
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR 9225 PUR
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER
9155 PUR/WHT
ENG CAN HI 3
9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT
9720 PUR/WHT
CAN HI DCU DIAGNOSTIC 5 82 CAN HI DCU DIAGNOSTIC
9820 PUR
CAN LO DCU DIAGNOSTIC 6 60 CAN LO DCU DIAGNOSTIC
C169
C121
1800 RNG/WHT
SHT2/F6
1800 RNG/WHT
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
STARTER RELAY SIGNAL 7 1
3560 LBL FOOT THROTTLE T11
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN GND FOOT THROTTLE 1
SHT4/G3 B HARNESS
AIR FILTER 7217683 T12
3150 LBL SWITCH (NC) C116 D 2015 BLK
AIR FILTER SENDER SIGNAL 16 A SIG
E SHT4/E3
FOOT THROTTLE INTDM F
C405 5695 YEL
5695 YEL +5V PWR
SHT12/C8 C C C
3695 LBL 3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A
2695 BRN 2695 BRN GND
SHT4/G3 B B B
3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25 C115
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12
J1A SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113
1 64 VREF 3 EGR
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
C148
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
C144 FUEL INJECTOR #3 HSDB 51 1
C154
J7B
J7B
SHT2/D1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN
86
87
85
2310 BRN
UNIT
RL010 RL010
8310 TAN
2985 BLK
4 92 94 86 85
2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGEN VALVE HIGH
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP57 8140 TAN
C156 2165 BLK 8260 TAN 1
59 RED AGENT SHIELD
49 HOSE 2 HEATER
HOSE 2 RELAY FB SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET C125
8250 TAN
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
C125
HOSE 3 HEATER
2050 BRN
2 9 ENV TEMP GND 8370 TAN 8360 TAN
ENVIRONMENTAL HOSE 3 RELAY FB 27 30
TEMPERATURE T SP61 87
8800 TAN
1 31 ENV TEMP SIG 8600 TAN C122
HOSE 3 HEATER 28 86 85 SUPPLY MODULE
C159
2075 BRN RL013 RL013
CATALYST 2 12 CAT TEMP DOC INLET
TEMPERATURE DOC 1690 RNG/WHT HEATER BATT+
T SM HEATER BATT 4 11
INLET 8530 TAN 8650 TAN
CAT TEMP DOC INLET HEATER SIGNAL
1 34 SM HEATER SIGNAL
3 12
1695 RNG/WHT PUMP MOTOR BATT +
C160 +5V POWER 55 3
SM PUMP MOTOR CONTROL 8700 TAN PUMP MOTOR CONTROL SIGNAL
76 2
SIGNAL
2095 BRN PUMP MOTOR GND
SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122
13
6
HYD LOCK
SOLENOID SIGNAL
TRACTION
SOLENOID OUTPUT
HYD CHARGE PRESS
SENDER SIGNAL
HYDRAULIC
FAN SIGNAL
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT16/F4 8 START ENGINE 24 2 2 2
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
SW12
DESOX INHIBIT SWITCH(OPT KIT)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
* DLX CAB HARN 7301237 ONLY
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT12/D1 5
4230 LGN 4
SHT13/F3
4240 LGN SW4 3
SHT13/D3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
MFR HARN CONN 3 (DK GRAY)
4220 LGN SP29 4235 LGN 4235 LGN
5 5 7 7
4275 LGN 4275 LGN
3 3 8 8
2 2
4550 LGN
9 9
4550 LGN *
2795 BLK GND
1850 RNG/WHT 1850 RNG/WHT 1
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT16/C2
1885 RNG/WHT
SHT16/B3
2885 BLK
SHT16/B3
2060 BLK
SHT12/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
(SEE ADDITIONAL
2690 BRN
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 SENSOR 3620 LBL
SHT11/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/H1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
6 6
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR
2 2 WIPER MOTOR GROUND
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V CTRLR PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5695 YEL
SHT7/F7
HARNESS WASHER PUMP
SHT10/D7
5190 YEL * C252
7253378
2845 BLK GND
5690 YEL B B 2
SHT7/D4 WASHER
MOTOR
7310 WHT PWR
A A 1
C253
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
RIGHT HANDLE LEFT
SHT3/E3 A
ROCKER DOWN 4930 LGN
31 J
RIGHT HANDLE 4940 LGN
30 H LEFT POSITION SWITCH
LEFT ROCKER UP
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN RIGHT ROCKER UP
4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8 4230 LGN
T20 SHT12/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
TRIGGER RETURN
GATEWAY CTRLR
4820 LGN
7
C410
TRIGGER
GATEWAY CTRLR
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - FC1
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
6630 PNK
6320 PNK
FC2 FC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR
SHT4/D8 2
5
RELAY SIGNAL C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK 31
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
SW11
1
3
C
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
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
(NOT IN STD FUEL HARN 7149219)
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
3500 LBL
T3
SHT11/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 SHT11/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK
J1B
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIG 7
FRC1 SWITCHED
POWER RELAY - L
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL
COIL COIL FRC1 FRC1
2040 BLK SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
C428
* SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MAN SIG 16 7 7 3
C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR 10 C PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 5V SUPPLY 24 B
J2B
SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8
2280/BLK
2240/BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170/RED/WHT C409 C466
C492 C493 J3-ACS K A
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
C471
2660/BRN 2 GND C428 TILT ACTUATOR
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
1 +5V PWR HALL SENSOR 7
5660/YEL
6
2980/BRN
2990/BRN
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 2
5750/YEL 3990/LBL SIG
B
C 5650/YEL 5980/YEL
D 5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL
9800
1160
9700
1710
9500
9600
2710
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
WIRE BREAK KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
on Loader 5900 J ID #1
Boom 5500 A ID #2
B ID #3
ACD
C ID #4 Input
D ID #0 Connector to
C667 SW7 DELUXE ATTACHMENT E OPEN
Engine
Compartment
DOOR HARN C250 SENSOR SHOWN REAR CONTROL HARNESS -
F OPEN
G OPEN
4 3630/LBL 1 SIG WITH DOOR OPEN C129 WIPER 6732730 H OPEN
TO CAB B
TO DLX CAB 6 1865/RNG/WHT 1 2
HARNESS
HARNESS 1 C 2820/BLK 3
3 4 5 7230/WHT T6 1
6 REAR
2 WIPER
MOTOR C667
7170531 SPECIAL APPS DOOR HARNESS DOOR HARN C250 SENSOR SHOWN
4 3630/LBL 1 SIG WITH DOOR OPEN
7180207 REAR WIPER HARNESS 5 1400/RED/WHT 2 PWR DOOR SENSOR
C251
6 7330/WHT C PARK
R2
CAB 1570/RNG/WHT
C667 750 OHM RESISTOR E
DOOR HARN C250 HARNESS
1W 5%
5 1400/RED/WHT 1 1400/RED/WHT 1 1850/RNG/WHT 3 7300/WHT A LOW
1 WIPER
1410/RED/WHT
2
3 7310/WHT 6 1860/RNG/WHT D SW PWR MOTOR
4 5
R1
300 OHM RESISTOR SW8
0.5W 5% C251 FRONT WIPER
SENSOR SHOWN SWITCH
4 3630/LBL 2 3630/LBL 3635/LBL 2 SIG WITH DOOR OPEN 2 2840/BLK B GND
1850/RNG/WHT
FRONT WIPER
SWITCH
E
(KIT AND OPTION HARNESS)
1 3 7300/WHT A LOW
3 7310/WHT
1
6
2
1860/RNG/WHT D SW PWR
WIPER
MOTOR ALL MODELS
4 5
2 2840/BLK 2850/BLK B GND Sheet 1 of 6
7171105 FORESTRY DOOR HARNESS
(PRINTED OCTOBER 2017)
C362 C414
A 4440/LGN 1 SIG
REAR BASE (M) C411 TO
B 2440/BLK 2 GND 7.5 OHM 12V MAINFRAME
CONNECTOR WHITE TIE STRAP A C E B D HARNESS
C413 (5 WAY LH)
C 4430/LGN 1 SIG
6000/PNK
REAR ROD (F)
D 2430/BLK 2 GND 7.5 OHM 12V
WIRE BREAK C497 6510/PNK
TO BROWN TIE STRAP
(TWO WIRE BREAKS
MAINFRAME
C416 B 6415/PNK 2780/BLK
JOIN ONE WIRE)
HARNESS E 4450/LGN 1 SIG REAR ROD LOCK 86 85
SHEET # 6410/PNK
F 2450/BLK 2 GND 7.5 OHM 30
87
12 V TO A 6515/PNK 2790/BLK
YELLOW TIE STRAP MAINFRAME
C417 86 85
HARNESS
G 4480/LGN 1 SIG 30 6010/PNK 6020/PNK
REAR BASE LOCK 87
H 2480/BLK 2 GND
9.8 OHM
GREEN TIE STRAP 12 V C 7200/WHT 2770/BLK
86 85
7173271 REAR AUX HARNESS C412 30
TO 87
B 2785/BLK
MAINFRAME
HARNESS A 1420/RED/WHT
(2 WAY LH)
TO C489-1 C489-2
ADDITIONAL
MAINFRAME B B
2720/BLK 2740/BLK ACCESSORY
HARNESS
C414 A 1720/RNG A POWER
(ACCESSORY
4440/LGN 1 SIG CONNECTOR
REAR BASE POWER)
AUX CTRLR J2B PIN 5
2440/BRN 2 GND 7.5 OHM 12V
AUX CTRLR J2A PIN 2 7151940 SJC/AWS/SCPA HRN/BLINKER HARNESS
WHITE TIE STRAP
C413
AUX CTRLR 4430/LGN 1 SIG
J2B PIN 7 REAR ROD
2430/BRN 2 GND 7.5 OHM 12V Printable Version Click Here
AUX CTRLR J2A PIN 10
BROWN TIE STRAP
TO C489-1
J2B PIN 4
4450/LGN
C416
1 SIG
WIRING SCHEMATIC
MAINFRAME REAR ROD LOCK
(KIT AND OPTION HARNESS)
B 2720/BLK 2450/BLK 2 GND
HARNESS 7.5 OHM
(ACCESSORY A 1780/RNG/WHT 2725/BLK YELLOW TIE STRAP 12 V
POWER) C417
ADDITIONAL
C489-2
A
4480/LGN 1 SIG
REAR BASE LOCK
ALL MODELS
ACCESSORY 2480/BLK 2 GND
POWER
CONNECTOR
B J2B PIN 6
GREEN TIE STRAP
9.8 OHM
12 V Sheet 2 of 6
7191339 or 7201414 REAR AUX HARNESS (PRINTED OCTOBER 2017)
C800
C667
6340/PNK A 6340/PNK REGISTRATION DOOR HARN C250 SENSOR SHOWN
2670/BLK B 2670/BLK (LICENSE PLATE) WITH DOOR OPEN
4 3620/LBL 1 SIG
LAMP
5 1400/RED/WHT 2 PWR DOOR SENSOR
7153090 HARNESS LICENSE LIGHT
6 C251
TO EURO 3 C PARK
7310/WHT
TAILGATE C603 HT
HARNESS Taillight Right CAB 3 30/W
E 1 1570 7
7104670 HARNESS 5
6 A LOW
C103 F 1850/RNG/WHT
D A 3 HT
6510/PNK 6510/PNK BLU
1 7 300/W E HIGH WIPER
C407-A C407-B 6610/PNK C RED 2814 MOTOR
2 2840/BLK 4
2 7305/WHT
H 6200/PNK 6320/PNK A A 6430/PNK B YEL
B 2600/BLK 2610/BLK D BLK 1860/RNG/WHT D SW PWR
BREAK CONNECTION INTERMITTENT WIPER
FOR ROADLIGHT KIT 2620/BLK SWITCH
-
2842/BLK B GND
6210/PNK +
Backup Alarm
7231771 INTERMITTENT WIPER DOOR HARNESS
6660294
NOTE: SPLICE ADDED BEFORE
WITH ROADLIGHT KIT: C 2650/BLK CONNECTOR INSTEAD OF AT PIN.
7100/WHT
TO ROADLIGHT KIT + -
C602
HARNESS G 6600/PNK Taillight Left
E Taillight Left Printable Version Click Here
F 7104671
7104671
WITHOUT ROADLIGHT
KIT: TO MAINFRAME
E 6410/PNK 6410/PNK
6620/PNK
A
C
BLU
RED
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
HARNESS 6330/PNK B YEL
6210/PNK
F D BLK
2640/BLK
2630/BLK
6210/PNK
-
-
ALL MODELS
+
6310/PNK 6250/PNK
Sheet 3 of 6
+
A 6310/PNK 6310/PNK
SP24
7217483 - HARNESS EUR TAILGATE
7175287 - HARNESS EUR TAILGATE (HARNESS SAME AS 7175287
EXCEPT AS SHOWN ABOVE) (PRINTED OCTOBER 2017)
C407-B
TO EURO
6430/PNK
TAILGATE F F
HARNESS Relay1
6420/PNK A 7210/WHT E
Right Side Lights
87 6410/PNK 6440/PNK D 7250/WHT 7260/WHT B
1020/RED 1410/RED/WHT
6510/PNK E C Brake Light
10.0 Amps 30 7200/WHT 7200/WHT
6400/PNK 6220/PNK C 7220/WHT 7240/WHT A
85 86 2020/BLK
2110/BLK B 2300/BLK 2320/BLK D Rear Turn Light
T01
Relay2
Left Side Lights
87 6310/PNK
1010/RED 1400/RED/WHT
10.0 Amps 30
T02
6300/PNK 85 86 2030/BLK
2120/BLK B 2300/BLK E
ADDITIONAL
1510/RNG A
ACCESSORY 6330/PNK A 7210/WHT F
2210/BLK B POWER
6120/PNK C 7220/WHT 7240/WHT A
CONNECTOR
6340/PNK D 7250/WHT 7260/WHT B Rear Position Light
1730/RNG A 1520/RNG 1500/RNG A 6520/PNK E 7200/WHT C
C 2200/BLK B HARNESS F D Brake Light
2730/BLK 2230/BLK 2320/BLK
87
6600/PNK B 6500/PNK
30
87A
85 86
TO
SJC/AWS/SCPA A 6330/WHT 2
4210/LGN 1 7210/WHT
CONTROLS HARNESS
(1 PIN CONN) 7270/WHT D 6340/RED 4 Position Light
H 6010/PNK 6320/PNK H
6530/PNK G
B 2000/BLK 2010/BLK B Printable Version Click Here
D
E
6210/PNK
6110/PNK
6230/PNK
6130/PNK
D
E HARNESS WIRING SCHEMATIC
HARNESS F
G
F
(KIT AND OPTION HARNESS)
A 6000/PNK 6000/PNK A ALL MODELS
C 7100/WHT 7100/WHT C
Sheet 4 of 6
(PRINTED OCTOBER 2017)
** HARNESS STVB 04
1
2
CONNECTOR
** HARNESS HEIGHT ADJUSTMENT
STVB A
STVB 02 STVB 92 L4/RD
WIRE BREAK
1 L1/BK
COMPRESSOR (TWO WIRE BREAKS
2 (SUSPENSION) JOIN ONE WIRE)
STVB B
3 SHEET #
S1
(MOMENTARY)
L2/RD 1 4
2
C277
HEATING MAT SEAT
1 L6/BK L3/RD YEL
2
** HARNESS STVB 03 STVB xx
3
L5/RD
1
HARNESS 4 L1/RD 2
5 L3/BK L4/BK
L12/BLK
60°C / 50°C
L13/BRN
6 L2/VT
BRN
L14/BRN
YEL HEATING MAT BACK
STVB H5 STVB xx
L11/BLK 1
2
60°C / 50°C
BRN
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 5 of 6
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7195572 (E)
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
C001
CALAMP TELEMATICS CONN
C678
1
MACHINE CONN
2
3 9502/PUR/WHT/18 4 CAN HI
4 9602/PUR/18 3
CAN LO
5
6
7
8
9
10 1167/RED/WHT/18 1
UNSWITCHED POWER 7335305 & 7335295 NON-TELEMATIC JUMPER
11 2712/BLK/18 2
CAN GROUND
12
CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Key - Multi position switch 0.5 ohm A the solenoid coils are listed next to
B
to activate various start functions at the component [if available]). The pull
ST different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch.
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
NA9085
NA9584
NA9586
NA9587
NA9665
Description
Figure 60-10-1
P100958A P121167
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Figure 60-10-2
1
P109659
1
Line up the clips on the back of the fuse panel cover with
P100414A
the slots (Item 1) [Figure 60-10-4] in the fuse panel and
push the cover into position when finished.
The fuse and relay panel is located behind an access Line up the clips on the access panel with the slots
panel near the left foot pedal or footrest. Pull the panel at provided and push the panel into position [Figure 60-10-
each end (Item 1) [Figure 60-10-2] to remove. 2]. A locating pin helps align the panel during installation.
1
P107513B
Figure 60-10-5
NA3313
The table below is for earlier models with decal part number 7251372. Fuse location and amperage ratings are shown
in the table below and on the decal [Figure 60-10-5]. Relays are identified by the letter “R” in the AMP column.
ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP
Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power
Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm
Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm
Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power
Accessories and
F9 Not Used -- F22 25 J Front Lights R
Front Horn
Cab Accessories
F11 Bobcat Controller 25 F24 25 L Not Used --
Power Port
Auxiliary
F13 25 F26 Dosing Controller 15
Controller
Figure 60-10-6
NA3314
The table below is for later models with decal part number 7280029. Fuse location and amperage ratings are shown
in the table below and on the decal [Figure 60-10-6]. Relays are identified by the letter “R” in the AMP column.
ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP
Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power
Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm
Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm
Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power
Accessories and
F9 Not Used -- F22 25 J Not Used --
Front Horn
Cab Accessories
F11 Bobcat Controller 25 F24 25 L Not Used --
Power Port
Auxiliary
F13 25 F26 Dosing Controller 15
Controller
Figure 60-10-7
NA3328
The table below is for later models with decal part number 7300261. Fuse location and amperage ratings are shown
in the table below and on the decal [Figure 60-10-7]. Relays are identified by the letter “R” in the AMP column.
ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP
Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power
Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm
Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm
Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power
Accessories and
F9 Not Used -- F22 25 J Not Used --
Front Horn
Auxiliary
F13 25 F26 Dosing Controller 15
Controller
Figure 60-10-8
NA3346
The table below is for models with decal part number 7323430. Fuse location and amperage ratings are shown in the
table below and on the decal [Figure 60-10-8]. Relays are identified by the letter “R” in the AMP column.
ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP
Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power
Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm
Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm
Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power
Accessories and
F9 Not Used -- F22 25 J Not Used --
Front Horn
Auxiliary
F13 25 F26 Dosing Controller 15
Controller
Figure 60-10-9
P121159
P121159A
P100958B P121621A
Solenoid Testing
Figure 60-10-13
P9175
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Stop the engine and open the rear door. Adjust battery wrap for proper fit.
When removing the battery from the loader, do not touch Connect the negative (-) cable last to prevent sparks.
any metal parts with the battery terminals.
Connect and tighten the battery cables.
Figure 60-20-1
Install and tighten the battery hold-down clamp.
1
WARNING
3
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
4
P121168 Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Disconnect the negative (-) cable (Item 1) [Figure 60-20-
1]. Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before
Remove the battery hold-down clamp (Item 3) [Figure connecting to a charger. Unplug charger before
60-20-1]. connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Disconnect the positive (+) cable (Item 2) [Figure 60-20- W-2066-0910
1] from the battery.
Servicing
Figure 60-20-3
P100959 P100960
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
3 1
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE P121189A
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery Connect the end of the first cable (Item 1) to the positive
make final connection (negative) at machine frame. (+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-4] to the
Do not jump start or charge a frozen or damaged positive (+) terminal on the engine starter.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before Connect the end of the second cable (Item 3) to the
connecting or disconnecting cables to battery. Never negative (-) terminal of the booster battery. Connect the
lean over battery while boosting, testing or charging. other end of the same cable (Item 4) [Figure 60-20-4] to
W-2066-0910 the engine.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Belt Replacement
Figure 60-30-1
1
1
2
2
P122535
Figure 60-30-2
P122385
WARNING 1 1
WARNING Inspect the fuse for the alternator in the fuse panel. If
fuse is burned, find the cause and repair / replace. If fuse
is in doubt, remove it and test for continuity.
BATTERY GAS CAN EXPLODE AND CAUSE
Check the electrolyte level in the battery. Add distilled
SERIOUS INJURY OR DEATH
water as needed. (Does not apply to maintenance free
Keep arcs, sparks, flames and lighted tobacco away
batteries.)
from batteries. When jumping from booster battery
make final connection (negative) at machine frame. Verify the charge of the battery. Make sure battery is fully
charged.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before Disconnect the battery cables (negative first, then
connecting to a charger. Unplug charger before positive). Inspect the cable clamps and battery posts for
connecting or disconnecting cables to battery. Never corrosion. Remove acid or corrosion from the battery and
lean over battery while boosting, testing or charging. cables with a sodium bicarbonate and water solution. Put
W-2066-0910 grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Figure 60-30-5
P122381
P122446
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Open rear door.
Turn the Remote Start Tool key to the ON position.
Connect the Remote Start Tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) or (See Figure 60-30-7
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)
Turn the engine on with the Remote Start Tool and run at
idle. With a voltmeter, test the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21,1°C (70° F) (Alternator Temperature).
Figure 60-30-8
1
2
P122448
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
P122382
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are Disconnect the red wire (Item 1) [Figure 60-30-10] from
connected wrong. the alternator which comes from the battery.
I-2023-1285
Figure 60-30-11
Figure 60-30-9
1
1 2
P122384
P122381
Figure 60-30-12
P122386
Figure 60-30-13
1
P122385
Parts Identification
1. Nut
2. Pulley
3. Spacer
4. Front Case
5. Bearing
6. Cover, Bearing
7. Bolt
8. Rotor
9. Stator
10. Seal 8
11. Rectifier
12. Stud 7
6
13. Holder, Brush
14. Guide, Slip Ring 5
15. Rear Case 4
12
3
2
1
15
14
12
11
9 10
7
6
5
16 7
13
NA6697S
The key switch must be in the OFF position. Disconnect the negative (-) cable from the battery.
Figure 60-40-1
1
2
Bat
S
M
Cranking
Motor P122383
Figure 60-40-2
Bat
S
M
Cranking
Motor
A-1991
Parts Identification
3
2 18
7
6
6 16
4 5
15
4
1
13
6
1
15
2
19
13 3
2 21
20
B-19824
Left Panel
Figure 60-50-1
2 3 12
13
1 7
4 14 18
6 8 9 10 11 16
17
5 15
19 22
20 21
23 24
25
P-90726K
The left panel [Figure 60-50-1] is the same for all machines regardless of options and accessories.
* This manual contains a table with Service Code descriptions. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
Display Screen
• Operating hours
• Engine rpm
• Battery voltage
• Drive response setting
• Steering drift compensation setting
• Maintenance clock countdown
• Service codes
• Engine preheat countdown
• Speed management setting
• Lift and tilt compensation setting
Figure 60-50-2
3 4 5 6 7
NA3071
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
5. Engine RPM
6. Battery / Charging Voltage
7. Service
Right Panel (Standard Key Panel) The switch location (Item 2) [Figure 60-50-3] can have
different functions depending on machine configuration.
Figure 60-50-3 See the following table for more information.
FUNCTION /
ITEM DESCRIPTION
OPERATION
P-85285
Figure 60-50-4
FUNCTION /
ITEM DESCRIPTION
OPERATION
2 3
Press the top to
SELECTABLE
select ‘ISO’ Control
JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
select ‘H’ Control
(Option)
Pattern.
4
P-90819H
ROTATING BEACON
(Option) Press the top to turn
This machine may be equipped with a Keyless Start
OR light ON; bottom to
Panel [Figure 60-50-4].
STROBE LIGHT turn OFF.
(Option)
1. Keypad (keys 1 through 0): Used to enter a number
code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.
Figure 60-50-5
FUNCTION /
ITEM DESCRIPTION
OPERATION
1
Press the top to
ADVANCED
2 select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
select Foot Controls.
3
P-90212J
ROTATING BEACON
(Option) Press the top to turn
This machine may be equipped with a Deluxe
OR light ON; bottom to
Instrumentation Panel [Figure 60-50-5].
STROBE LIGHT turn OFF.
(Option)
1. Keypad (keys 1 through 0): The keypad has two
functions:
Right Panel (Deluxe Instrumentation Panel) (Cont’d) Press the left or right scroll button to cycle through the
languages. The language that is stopped on becomes
Figure 60-50-6 the default language used for the Deluxe Instrumentation
Panel [Figure 60-50-6].
Figure 60-50-7
1 1
2 2
3 3
NA3323
This machine may be equipped with a left switch panel NOTE: Earlier models did not have switch locations
[Figure 60-50-7]. four and five on the left switch panel.
Figure 60-50-8 1
2
3
1 2 4
P-85267D
P-85282
1 1
1 1 2
2
P-85929
P-85928
1 P-85931
P-85930
Figure 60-50-14
3
3
1
1 1
1
2
2 P-90527
P-90819A
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-16].
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-14]. Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels. Tighten the panel screws to 3 - 4
panel mounting bolts to prevent stripping of the threaded N•m (25 - 35 in-lb) torque.
holes in the panels. Tighten the panel screws to 3 - 4
N•m (25 - 35 in-lb) torque. NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-16].
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-14]. Figure 60-50-17
Figure 60-50-15
P-90530
P-90818A
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-17].
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-15]. Remove the panel from the loader cab.
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Removal And Installation on Page 60-50-10.)
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.) Figure 60-50-19
Figure 60-50-18
2
P-85947
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel (Standard Key
Panel) Removal And Installation on Page 60-50-10.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-10.) Figure 60-50-22
Figure 60-50-20
1
1
P107695
1
P-85945
Remove the fastener (Item 1) and screw (item 2) [Figure
60-50-22].
Remove the two fasteners (Item 1) [Figure 60-50-20].
Figure 60-50-23
Figure 60-50-21
1 1
2
1 2
P-85944A
P-85946
Remove the two screws (Item 1) and the right side panel
Remove the fastener (Item 1) and the left side panel (Item 2) [Figure 60-50-23].
(Item 2) [Figure 60-50-21].
Figure 60-60-1
1
P-85436
1
Figure 60-60-4
P-85433
Figure 60-60-2
P-85435
1
Remove the two bulbs (Item 1) [Figure 60-60-3] and
[Figure 60-60-4] from the housing by turning bulb a 1/4
1 turn.
P-85434
Figure 60-60-5
1 2
P-85586C
P-85438
Pry the cab light (Items 1) free from the headliner (Item 2)
[Figure 60-60-7].
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light too far away from the
assembly a 1/4 turn. headliner to prevent damage to the wires.
P-85437 P115307
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].
Description
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2680 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL PULL RELAY SIGNAL
4 3380 LBL SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION PULL RELAY SIGNAL
9 OPEN NA NA
10 2670 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7021 WHITE AC SIGNAL MONITOR
12 OPEN NA NA
13 3430 LBL TRACTION PULL RELAY FEEDBACK
14 3420 LBL GLOW PLUG RELAY FEEDBACK
15 3160 LBL ENGINE SPEED SENSOR SIGNAL
16 3150 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 2380 BRN PTOL LED
20 3030 LBL PTOL SWITCH
21 3450 LBL SWITCHED POWER RELAY FEEDBACK
22 3560 LBL STARTER RELAY FEEDBACK
23 OPEN NA NA
24 8130 TAN START ENGINE
25 3140 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO SPEED GROUND
27 2360 BLACK TWO SPEED MAKEUP GROUND
28 3440 LBL REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 3410 LBL FUEL RELAY FEEDBACK
31 3460 LBL MRKR LIGHT PWR RELAY FEEDBACK
32 3220 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3220 LBL HYD FILTER DIFF PRESS
J1B
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 3190 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
3 1130 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4680 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4670 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9200 PUR/WHT CAN LO 0
9 9100 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3370 LBL SEATBAR SENSOR SIGNAL
12 3180 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 2230 BRN SENSOR GROUND
18 3170 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 3090 LBL REMOTE ATTACHMENT SIGNAL
22 3040 LBL RUN / ENTER
23 5190 YEL HYDRAULIC CHARGE PRESSURE
24 5100 YEL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL
Auxiliary Controller
1 1
34 26
J2A J2B
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645
J2A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BRN JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 3130 BRN JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT
12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA
J2B
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 1180 RED/WHT COMPUTER FUSE POWER OUT
3 1150 RED/WHT COMPUTER FUSE POWER OUT
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL
Figure 60-70-1
P101568
P122387
Figure 60-70-2
P122388
Description
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
P-21843
Figure 60-71-1
1 P-85902
P-85903
The drive controller is located underneath the operators The hydrostatic drive pump has two electromagnetic coils
cab attached to the control panel. on each of the two pumps to control the drive of the
loader. The coils will direct the forward and reverse
The drive controller monitors the position of the joysticks, outputs of the pump to the drive motors. The hydrostatic
pump swash plate angles and position of the ISO and H drive pump is equipped with position sensors mounted to
pattern switch. the bottom of the swash plates to provide feedback to the
controllers to sense uncommanded swash plate
The drive controller works along with the ACS controller movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
ACS
CONTROL
RIGHT DRIVE HYDRAULIC
HAND CONTROL MOTOR
PANEL
LIFT / TILT
ISO ACTUATORS
SWITCH
ENGINE
INTERNAL CAN BUS
RIGHT
JOYSTICK
FWD / REV
SWASH PLATE
LEFT SENSORS
JOYSTICK
AUXILIARY DRIVE
LEFT CONTROL PUMP
HAND
PANEL
HYDRAULIC
ACD
MOTOR
EXTERNAL CONTROL
GATEWAY CAN BUS
CONTROL NA5677
Connector Identification
P-64295
P-64296
Figure 60-72-1
1
1
P-64325
1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4
Figure 60-72-2
J S
P-64325
P-64324
Description
Description
1
The engine ECU controls the amount, timing, mixture
and pressure of fuel that is injected. The engine ECU
operates each kind of control based on the signals from
each type of sensor.
Cleaning
P114460
Figure 60-80-3 2
3
1
1
P114461
IMPORTANT 2 1
Figure 60-80-6
Figure 60-80-9
2
1 1
P122379
P114465
P114356
Figure 60-80-10 3
1
1
1
1 1
2 P114402
Figure 60-80-11
P114401
Remove the nut and the ground wire (Item 1) [Figure 60-
80-11] from the ECU.
Figure 60-90-1
WARNING
AVOID INJURY OR DEATH
1 2 3
The Bobcat Interlock Control System (BICS™) must
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-1111
NA3267
Figure 60-100-1
There are three display lights (Items 1, 2, and 3) [Figure
60-100-2] located on the left instrument panel that must
be OFF to fully operate the machine.
P-90674D WARNING
The Bobcat Interlock Control System (BICS™) has a AVOID INJURY OR DEATH
pivoting seat bar with armrests (Item 1) [Figure 60-100- Before you leave the operator’s seat:
1]. The operator controls the use of the seat bar. • Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
WARNING • Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
AVOID INJURY OR DEATH drive functions are deactivated.
When operating the machine:
• Keep the seat belt fastened snugly. The seat bar system must deactivate these functions
• The seat bar must be lowered. when the seat bar is up. See your Bobcat dealer for
• Keep your feet on the pedal controls or footrests service if controls do not deactivate.
and hands on the controls. W-2463-1110
W-2261-0909
Inspecting The BICS™ (Engine STOPPED - Key ON) 6. Fasten seat belt, disengage parking brake, press the
PRESS TO OPERATE LOADER button, and raise
See the SERVICE SCHEDULE for the correct service seat bar fully. Move steering levers or joystick(s)
interval. (See DIAGNOSTIC SERVICE CODES on Page slowly forward and backward. The TRACTION lock
60-90-1.) must be engaged. Lower the seat bar. Press the
PRESS TO OPERATE LOADER button.
Figure 60-100-3
7. Engage parking brake and move steering levers or
joystick(s) slowly forward and backward. The
1 2 3 TRACTION lock must be engaged.
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting chart.
2. Inspect wire connections on Bobcat controller to make sure connectors are locked into place.
3. Inspect pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Inspect sensor wire connection.
2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to test sensor and controller.
3. Inspect for loose hardware.
4. Inspect keyed bushing to make sure magnet collar rotates with seat bar.
5. Inspect magnet collar magnets for contamination such as metal particles.
Testing
Figure 60-110-1
1
P-4698
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure:
Figure 60-110-2
P-4699
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-110-6.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.
Figure 60-110-5
1
3
P100745
2
P100742 Remove the retaining pin (Item 1), clevis pin (Item 2), and
the seat bar mounting bolt and nut (Item 3) [Figure 60-
Remove the sensor mounting bolt and nut (Item 1) and 110-7].
disconnect the sensor wiring connector (Item 2) [Figure
60-110-5].
Figure 60-110-6
P100743
P100759
Figure 60-110-8
3
1
4
P100748
P100746
Install the new keyed bushing (Item 1), magnet bushing
(Item 2), seat bar sensor (Item 3) and the metal pivot
Pull the front of the seat bar down slightly from the top of bushing (Item 4) [Figure 60-110-10].
the cab, while raising the sensor end of the seat bar up,
away from the mount [Figure 60-110-8]. NOTE: The sensor must be centered on the metal
pivot bushing. When centered, the assembly
NOTE: The sensor end of the seat bar will raise easily will slide freely into the mount.
ONLY if the front of the seat bar is pulled
slightly down from the top of the cab.
Figure 60-110-11
Figure 60-110-9
4
3
3 1
6 1
2
P100749
2
P100747
Position the clevis (Item 1) over the mount (Item 2) and
Place a soft jaw locking pliers (Item 1) [Figure 60-110-9] lower the end of the seat bar until the mounting bolt (Item
on the cab side screen to hold the seat bar above the 3) [Figure 60-110-11] is resting on the top of the mount.
mount.
Remove the nut from the mounting bolt. Remove the
Remove the clevis pin bushing (Item 2) [Figure 60-110- mounting bolt and lower the seat bar until the seat bar
9]. Apply grease to the shoulder of the bushing to help and mount holes align and the clevis is over the clevis pin
retain it during assembly. Reinstall the clevis pin bushing.
bushing. Reinstall the seat bar mounting bolt. Apply
Remove and dispose of the keyed bushing (Item 3), Loctite® 243 to the nut threads. Install the nut and tighten
magnet bushing (item 4), and seat bar sensor (Item to 46 N•m (34 ft-lb) torque.
5)[Figure 60-110-9].
Installation (Cont’d)
Figure 60-110-12
1
2
P100751 3
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-110-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Figure 60-110-13
3
1
P-4703
Figure 60-110-15
P-85413F
Figure 60-110-16
P-4699
Description
Troubleshooting WARNING
The following troubleshooting chart is provided for quick
reference in locating and correcting traction lock Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnal only. See adjustments can cause injury or death.
BATS for detailed troubleshooting procedures if an error W-2004-1285
code is present.
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11
SOLUTION SUGGESTIONS
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 30 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses.
(See Electrical System, Information Page 60-01.)
5. To test the solenoid, the coil should be about 9.8 ohm.
6. Inspect brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Inspect the brake solenoid mounting nut for correct torque.
8. Inspect wire connections for loose connector body.
9. Inspect for loose or bent pins in connectors.
10. Inspect for loose spade connectors in fuse holder.
11. Inspect the left panel display for engine rpm, if no rpm inspect crankshaft sensor, camshaft sensor, wiring and
adjustment.
Inspecting
Figure 60-120-1
P-85413F
Description
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
Figure 60-130-1
1
3
2
1 P13733
1 1
1 1
P13725
P13725 P13732
Figure 60-130-4
3 1
2
P13735
2 1
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.
P13725 P13732
P13725 P13732
Figure 60-130-8
1
1
3 1
2
P-90994
1
Disconnect the left switch handle connectors (Item 1)
P13735 [Figure 60-130-10] from the loader wiring harness
connectors.
Use a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.
Figure 60-130-9
2 2
1
N-22783
P-90995 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Item 1) Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.
Figure 60-130-12
2
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 152 mm (6 in) piece of
heat shrink tube side on the end of the wires. Remove
Cut the wires (Item 2) [Figure 60-130-12] below the the heat shrink tube from the end of the wires before
switch handle and remove switch handle. routing through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle up out of lever tube. through the control lever tube.
Figure 60-130-13
P-90996
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700 C-Terminal - Purple/White
Figure 60-130-17
3 1
2
1 P13735
1 Figure 60-130-20
P-90994 1
3
2
Connect the handle harness connectors (Item 1) [Figure
60-130-17] and [Figure 60-130-18] to the loader harness
connectors.
P13735
1 - Terminal - Yellow/Red
2 - Terminal - Open
3 - Terminal - Orange/Black
Switch Handle Installation (Cont'd) NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
Figure 60-130-21
Figure 60-130-22
P-21804
P-66842
Figure 60-130-23
N-17741
Figure 60-130-24
1
2
1 P-21878A
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
Disconnect the harness connector (Item 1) [Figure 60-
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) torque.
Disconnect the harness connector (Item 2) [Figure 60-
130-24] from the handle lock solenoid connector. Figure 60-130-27
Figure 60-130-25
P-21789
1
P-21832
Replace the O-ring (Item 1) [Figure 60-130-27].
Figure 60-130-28
2
1 P-90980
Remove the two bolts (Item 1) and the foot sensor (Item
P-90979 2) [Figure 60-130-30].
Figure 60-130-29
P-90982
Figure 60-130-31
1 1
P-90992
1
P-24269
Disconnect the wire harness (Item 1) [Figure 60-130-33]
from the foot sensor shield lock solenoid.
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor. Remove foot lock solenoid (Item 2) [Figure 60-130-33].
Installation: Tighten the bolts to 10,2 N•m (90 in-lb) Installation: Apply a drop of oil on the solenoid threads
torque. Apply Loctite® 242 to the threads. and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 60-130-32
Figure 60-130-34
5
4
3
2
1
1 P-24270
P-21790
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), and O-ring (Item 4) [Figure 60-130- Replace the O-ring (Item 1) [Figure 60-130-34].
32].
Identification Chart
1 2 3 10 11 12
5
6
7 8
13
9
4
B-15781F / NA5717 / B-15781E
Description
Group 0 = No Jumpers
Group 1 = Pins K, L
Group 2 = Pins K, P
Group 3 = Pins C, D
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
Identification Chart
1 2 3 11 12 13
6
8 9
4
14
5 10
B-15781D / NA5718 / B-15781E
Description
Group 0 = No Jumpers
Group 1 = Pins K, L
Group 2 = Pins K, P
Group 3 = Pins C, D
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
3
14 9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-90898 12, 13, P-90899
P-90900 14 P-90900A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the 7- or
14-pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
3
14 9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-90898 12, 13, P-90899
P-90900 14 P-90900A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the 7- or
14-pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-90898 12, 13, P-90899
P-90900 14 P-90900A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the 7- or
14-pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
2 2 2 - - K from front 11
12 7 (pin side of 9
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-90898 12, 13, P-90899
P-90900 14 P-90900A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the 7- or
14-pin connector when connected.
Identification Chart
1 2 3 4 5 13 14 15 16 17
8
9
10
11
18
6 7 19
12
B-19873A / NA5719 / B-19874A
Description
Group 0 = No Jumpers
Group 1 = Pins K, L
Group 2 = Pins K, P
Group 3 = Pins C, D
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A
P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the 7- or
14-pin connector when connected.
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector Right Side Control
Handle Switches Activated Handle Switches
Connecting Remote Start Tool The tools listed will be needed to do the following
procedure:
The tools listed will be needed to do the following
procedure: Order from Bobcat Parts P/N: 7217666 - Remote Start
Tool (Service Tool) Kit
MEL1563 - Remote Start Tool Kit
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface)
7022042 - Remote Start Tool (Service Tool)
Figure 60-150-1 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
1 2 6689745 - BOSS® Service Tool Harness
Figure 60-150-2
P16119
3
The Service PC (Item 1) with the Remote Start Tool (Item 1
2) [Figure 60-150-1]. When connected to the loader, the
P-76450
Service PC is used to monitor, conduct diagnostics, and
upgrade software.
The Service PC (Item 1) with the Remote Start Tool
NOTE: Make all connections with the key in the OFF (Service Tool) (Item 2) [Figure 60-150-2]. When
position. connected to the loader, the Service PC is used to
monitor, conduct diagnostics, and upgrade software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 60-150-1] to the designated NOTE: Make all connections with the key in the OFF
serial port on the Service PC. position.
NOTE: The recommended serial cable length should Connect the Remote Start Tool (Service Tool) Computer
not exceed 4,6 m (15 ft). A serial cable longer Service Tool Harness (Item 3) [Figure 60-150-2] to the
than 4,6 m (15 ft) will create a degraded signal designated serial port on the Service PC.
causing communication errors.
NOTE: The recommended serial cable length should
Connect the other end to the connector on the Remote not exceed 4,6 m (15 ft). A serial cable longer
Start Tool. than 4,6 m (15 ft) will create a degraded signal
causing communication errors.
Connect the Remote Start Tool to the loader. (See
REMOTE START TOOL KIT - MEL1563 on Page 10-60- Connect the other end to the connector on the Remote
1.) Start Tool (Service Tool).
NOTE: Refer to BobcatDealerNET.com for PC Connect the Remote Start Tool (Service Tool) to the
requirements and the latest Service Analyzer loader. (See REMOTE START TOOL (SERVICE TOOL)
software. KIT - 7217666 on Page 10-61-1.)
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting
controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC. (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
controller or actuator.
NOTE: Password protected machines must have the
The Hydrostatic Pump Calibration (SJC) provides set password entered to perform the calibration
points to the Drive controller to actuate the hydrostatic procedure.
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a If a Service PC is not available, (See Lift And Tilt
desired travel path cannot be attained or replacing the Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
hydrostatic pump, hydrostatic motor, or controller. After Calibration (ACS) on Page 60-160-11.).
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the NOTE: Warm the hydraulic fluid to room temperature
hydrostatic pump control. 22°C (72°F), stop the engine and clear all
active service codes before running the test.
For more information on Steering Drift Compensation.
(See Description on Page 60-170-1.) Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the test
NOTE: The Actuator Test is the only test that uses a will be performed and the results can be viewed on the
Service PC. The Lift and Tilt Calibration (ACS Service PC (Laptop) monitor.
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
NOTE: This calibration procedure must be followed Move the right joystick to the forward-right corner position
when replacing the hydraulic control valve, lift [Figure 60-160-4] and hold in position.
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
Figure 60-160-3
SJC
P-85307
Figure 60-160-5
P-85413F
P-85493A
P-85307
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286 P-85493A
Figure 60-160-8
SJC 1
P-85307
P-85307
Figure 60-160-11
B-19873
P-85960
Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.
Figure 60-160-12
P-85413F
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413F 1) [Figure 60-160-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Audible beeps will sound, release handle.
1) [Figure 60-160-12] while holding the left joystick in
position.
Figure 60-160-15
P-85307
Figure 60-160-16
P107184
1
Press the PRESS TO OPERATE LOADER Button (Item NOTE: If at any time, during calibration, the operator
1) [Figure 60-160-16]. needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the
Audible beeps will sound. NEUTRAL position. The calibration procedure
will stop. To return to calibration mode, the
Start the engine from the RUN position. DO NOT TURN operator must start the complete procedure
TO OFF POSITION. This would cancel the calibration from the beginning.
mode and the procedure would have to be repeated.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 60-160-23
ACS
P-85413F
1
Push the PRESS TO OPERATE button (Item 1) [Figure
60-160-25] to unlock the hand controls.
P-85307B
Figure 60-160-26
P-85413F
Calibration is complete.
Figure 60-170-1
NA3232A
OR
P107005D P107006D
OR
Press the left scroll button on the left panel or the left
button on the left control to adjust the machine left.
[SFL01] (Item 4) through a maximum of [SFL10] will
appear in the data display (Item 1) [Figure 60-170-2].
The number will increase by one each time you press the
button. The higher the number, the greater the amount of
steering drift compensation to the left.
P122059
Steering drift compensation contains a total of 21 NOTE: The remote start remains OFF during the
settings. Steering drift compensation can be set to any procedure but must be connected to enable
point from NEUTRAL to [STL10] left, and from NEUTRAL service mode.
to [STR10] right. [ST---] is displayed when set for
NEUTRAL [Figure 60-171-1].
WARNING
AVOID INJURY OR DEATH
• Always keep bystanders away from the work area
and travel path.
• The operator must always look in the direction of
travel.
W-2813-1209
Operation (Cont’d)
1. Close door.
8. Press and hold the PRESS TO OPERATE LOADER Press the buttons on the left joystick (Item 5 & 6)[Figure
button for three seconds to enter drive response 60-171-3] to adjust. The number will change by one each
menu. time the button is pressed. Use the left button to increase
machine left or the right button to increase machine right.
9. Press the PRESS TO OPERATE LOADER button to
enter steering drift compensation adjustment. Forward adjustment is performed with left joystick in
NEUTRAL or during forward travel. Reverse adjustment
10. Current setting will appear. is performed during reverse travel. Adjustments are
effective immediately.
• Engine Speed
NA3189 • Engine Oil Pressure
• Engine Coolant Temperature
• Fuel Consumption
• System Voltage
ICON DESCRIPTION • Hydraulic Charge Pressure
• Hydraulic Fluid Temperature
DATE / TIME • Engine Oil Temperature
ENTER button
Select AM / PM / 24hr.
Press a scroll button (Item
Press [ENTER] to 1) repeatedly until the
continue. Security screen icon
(Inset) is highlighted.
1 1
Press left scroll button or NOTE: High-Flow and Two-Speed lockouts for the
[0] to exit without saving. owner are active even if the Password
Lockout feature is unlocked.
Password Description
Press a scroll button (Item
All new machines with a Deluxe Instrumentation Panel 1) repeatedly until the
arrive at Bobcat dealerships with the keypad in locked Security screen icon
mode. This means that a password must be used to start (Inset) is highlighted.
the engine.
1 1
For security purposes, your dealer may change the Select [1. PASSWORDS /
password and also set it in the locked mode. Your dealer LOCKOUTS].
will provide you with the password.
Master Password:
Owner Password:
User Password:
Select user.
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Turn the key switch to the RUN position to turn on the
factory which cannot be changed. This password is loaders electrical system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Allows for full use of the loader. It must be used to The left panel display screen will show [CODE].
change the owner password.
Enter the five digit owner password using the number
Changing The Owner Password keys (1 through 0). The unlock key green light will flash,
then become solid.
Turn the key switch to the RUN position to turn on the
loaders electrical system. The loader can now be started without using a password.
Enter the five digit owner password using the number NOTE: Use the following procedure to reset the
keys (1 through 0) if locked. machine lock so that the loader requires a
password to start the engine.
Figure 60-191-1
Turn the key switch to the RUN position to turn on the
loaders electrical system.
The lock key red light will flash and the left panel display
screen will show [CODE].
The lock key red light will flash and the left panel display
screen will show [ENTER].
Figure 60-200-1
2
1
3
NA3198
NA3086
Figure 60-200-2
NA3195
Setup
Figure 60-200-4
P-76110
P-64243A
Figure 60-200-5
1
1
P-76113
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.
Setup (Cont’d)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]
message will be displayed when the dealer information
has been transferred to the machine controller. 1
P-76111
Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
Figure 60-200-15
The current maintenance clock Length (Interval) and
Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-200-12].
P-76111
Reset
Figure 60-200-16
NA3273
Description
Inspection
Figure 60-210-17
P121187A
1
P-90644C
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-19
P-85723A
The back-up alarm switches (Item 1) [Figure 60-210-19] Inspect back-up alarm system for proper function. (See
are located alongside the steering bellcranks. Both Inspection on Page 60-210-1.)
switches must be adjusted properly for the back-up alarm
to operate correctly.
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in NEUTRAL / forward position. 2, 6, 7
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in NEUTRAL / forward position. 5, 6
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches.
Stop the engine and open the rear door.
Standard Controls and ACS (If Equipped)
Figure 60-210-21
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-22
2
2
1
P100048
1
Remove the alarm and bracket from the loader. Place the steering levers in the NEUTRAL position.
Figure 60-220-1
P-90901
Figure 60-220-2
1 3
P-90902
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6, 7
PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6
Figure 60-230-1
1
3
P121136
Figure 60-230-2
P114265
WARNING 1
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch.
• Allow to cool before servicing.
W-2533-1012 P121609
Figure 60-240-1
Rotate the SCR clamps (Item 1) [Figure 60-240-3] to
remove. Discard the clamps.
Figure 60-240-4
2
1
P121249
Figure 60-240-2
1
P115863B
1
1 Remove the V-Band clamp (Item 1) and the gasket (Item
2) [Figure 60-240-4]. Discard the V-Band clamp and
gasket.
P121610
Figure 60-240-5
1 2
P115928
Description 2
1
2 2
3 3
P127730
Procedure
GPS:
• Slow Blink - not observed, may be a very brief
moment.
• Fast Blink ~ 2 minutes.
• Solid LED achieved within 2 minutes.
Times may vary depending on systems ability to
pickup GPS satellites.
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3
Description
Figure 70-10-1
P121107
Specifications
Valve Springs
Free Length (Intake and Exhaust) 55,23 mm (2.17 in)
Tilt Allowable Limit (Intake and Exhaust) Below 1,8 mm (0.071 in)
Valve
Valve Clearance (Intake) 0,4 mm (0.016 in)
Valve Clearance (Exhaust) 0,45 mm (0.018 in)
Valve Stem OD (Intake) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Stem OD (Exhaust) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Face Width (Intake) 2,14 mm (0.084 in)
Valve Face Width (Exhaust) 1,63 mm (0.064 in)
Valve Face Angle 44,5° - 45.0°
Valve Guide Bore 7.0 - 7.015 mm (0.2756 - 0.2762 in)
Valve Guide Length 43,4 - 43,6 mm (1.7087 - 1.7165 in)
Valve Timing
Intake Valve (Open) 16 degrees B.T.D.C.
(Close) 54 degrees A.B.D.C.
Exhaust Valve (Open) 38 degrees B.B.D.C.
(Close) 24 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 16,15 mm (0.6358 in)
I.D. of Rocker Arm Bushings 16,03 mm (0.6311 in)
Camshaft
Journal O.D. 44,950 - 44,966 mm (1.7697 - 1.7703 in)
Bearing I.D. 45,0 - 45,025 mm (1.7717 - 1.7726 in)
Oil Clearance 0,065 - 0,106 mm (0.0026 - 0.0042 in)
Camshaft End Play 0,1 - 0,2 mm (0.0039 - 0.0079 in)
Cam Lobe Height (Intake) 39,78 mm (1.566 in)
Cam Lobe Height (Exhaust) 38,716 mm (1.524 in)
Side Clearance Allowable Limit 0,1 - 0,2 mm (0.0039 - 0.0079 in)
Cylinder Bore
Cylinder Bore I.D. 97,990 - 98,010 mm (3.8579 - 3.8587 in)
Piston Rings
Ring Gap (Top Ring) 0,25 - 0,40 mm (0.0098 - 0.0157 in)
Ring Gap (2nd Ring) 0,55 - 0,70 mm (0.0217 - 0.0276 in)
Ring Gap (Oil Ring) 0,20 - 0,40 mm (0.0079 - 0.0157 in)
Side Clearance of Ring Groove:
Top Ring 0,083 - 0,137 mm (0.0033 - 0.0054 in)
Second Ring 0,070 - 0,110 mm (0.0276 - 0.0043 in)
Oil Ring 0,030 - 0,070 mm (0.0012 - 0.0028 in)
Pistons
Piston Pin Bore 31,008 - 31,014 mm (1.2208 - 1.2210 in)
Specifications (Cont’d)
Connecting Rod
Piston Pin O.D. 35,995 - 36,000 mm (1,4171- 1.4173 in)
Small End Bushing I.D. 36,025 - 36,038 mm (1.4183 - 1.4188 in)
Oil Clearance Between Piston Pin and Small End Bushing 0,025 - 0,043 mm (0.0010 - 0.0017 in)
Oil Pump
Oil Pressure Rated rpm 294 - 539 kPa (2,94 - 5,39 bar) (43 - 78 psi)
Idle Speed Allowable Limit 147 - 294 kPa (1,47 - 2,94 bar) (21 - 43 psi)
Crankshaft
Connecting Rod Large End Bore 66,000 - 66,015 mm (2.5984 - 2.5990 in)
Connecting Rod Oil Clearance (Large End Bore) 0,026 - 0,064 mm (0.0001 - 0.0025 in)
Connecting Rod End Play 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Crankshaft Journal O.D. 74,955 - 74,970 mm (2.9510 - 2.9516in)
Oil Clearance Between Journal and Bearing 0,029 - 0,059 mm (0.0011 - 0.0023 in)
Crankshaft End Play 0,10 - 0,31 mm (0.0039 - 0.0122 in)
I.D. of Cylinder Block Main Bearing Bore
Class A 79,000 - 79,007 mm (3.1102 - 3.1105 in)
Class B 79,007 - 79,014 mm (3.1105 - 3.1108 in)
Class C 79,014 - 79,021 mm (3.1108 - 3.1111 in)
OD of Crankshaft Main Journal
Class A 74,955 - 74,960 mm (2.9510 - 2.9512 in)
Class B 74,960 - 74,965 mm (2.9512 - 2.9514 in)
Class C 74,965 - 74,970 mm (2.9514 - 2.9516 in)
Main Bearing Thickness
Blue 1,995 - 2,000 mm (0.0785 - 0.0787 in)
Yellow 2,000 - 2,005 mm (0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm (0.0789 - 0.0791 in)
Timing Gear
Timing Gear Backlash:
High Pressure Pump Gear To Idle Gear 0,081 - 0,196 mm (0.0032 - 0.0077 in)
Idle Gear To Crankshaft Gear 0,087 - 0,202 mm (0.0034 - 0.0080 in)
Idle Gear To Camshaft Gear 0,087 - 0,213 mm (0.0034 - 0.0084 in)
Crankshaft Gear To Oil Pump Gear 0,066 - 0,247 mm (0.0026 - 0.0097 in)
Thermostat
Valve Opening Temperature 82°C (180°F)
Valve Fully Open 97°C (207°F)
Sensor Location
Vehicle Side
Figure 70-10-2
2 6
4 5 3
P121122
Figure 70-10-3
2 2
5
3
P121123
P121135
Figure 70-10-5
1
1
P121136
2
Figure 70-10-6
1 P121131
P121128
Figure 70-10-9
P121134
Figure 70-10-12
EGR Valve Actuator (Item 1) [Figure 70-10-9].
Figure 70-10-10
P121127
Figure 70-10-13
1
P121133
Figure 70-10-16
Knock Sensor (Right Side) (Item 1) [Figure 70-10-13].
Figure 70-10-14
1
2
P121125
Figure 70-10-17
1
2 2
P115875
Figure 70-10-18
1 P115867
Water in Fuel Sensor (Item 1) [Figure 70-10-18]. Selective Catalytic Reduction (SCR) Downstream NOx
Sensor (Item 2) [Figure 70-10-20].
Figure 70-10-21
P120660
Torque Values
Thread Size
Strength Classification
(Dia. x Pitch)
8.8 10.9 12.9
M6 x 1,0 9,8 N•m 12,3 N•m 14,7 N•m
(7.2 ft-lb) (9 ft-lb) (10.8 ft-lb)
M8 x 1,25 21,6 N•m 30,4 N•m 37,3 N•m
(15.9 ft-lb) (22.4 ft-lb) (27.5 ft-lb)
M8 x 1,0 23,5 N•m 32,8 N•m 40,2 N•m
(17.4 ft-lb) (24.2 ft-lb) (29.7 ft-lb)
M10 x 1.5 43,1 N•m 60,8 N•m 72,6 N•m
(31.8 ft-lb) (44.8 ft-lb) (53.5 ft-lb)
M10 x 1,0 49 N•m 68,6 N•m 82,4 N•m
(36.2 ft-lb) (50.6 ft-lb) (60.8 ft-lb)
M12 x 1,75 73,5 N•m 103 N•m 122,6 N•m
(54.2 ft-lb) (76 ft-lb) (90.4 ft-lb)
M12 x 1,5 78,5 N•m 109,8 N•m 131,5 N•m
(57.9 ft-lb) (81 ft-lb) (97 ft-lb)
M14 x 1,5 127,5 N•m 181,4 N•m 215,7 N•m
(94 ft-lb) (134 ft-lb) (159 ft-lb)
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11
Troubleshooting (Cont’d)
Figure 70-10-22
P100332
P-76872
Figure 70-10-23
P115885
DANGER 2
P115920
P-90328
AVOID DEATH Remove the engine ground cable and chassis ground
• Disconnecting or loosening any hydraulic cable (Item 1) [Figure 70-10-25].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Remove the engine starter positive cable (Item 2)
• Keep out of this area when lift arms are raised [Figure 70-10-25] from the starter.
unless supported by an approved lift arm
support. Replace if damaged. Figure 70-10-26
D-1009-0409
WARNING
2
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.
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the tie strap (Item 1) and disconnect the
connector (Item 2) [Figure 70-10-26].
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the battery from the loader. (See Removal And
Installation on Page 60-20-1.)
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-5.)
Remove the SCR. (See SCR Removal And Installation
on Page 70-30-8.)
Figure 70-10-27
3
1
2
1
3
P115819
2
WARNING
AVOID INJURY OR DEATH 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
Figure 70-10-28
P121241
2
Remove the hose / clamp (Item 1) [Figure 70-10-30]
from the charge air cooler (left side).
P115923
Remove the fuel inlet line (Item 1) and the fuel return line
(Item 2) [Figure 70-10-28] from the high pressure pump.
Install caps and plugs.
Figure 70-10-31
1
1
2
P120680
Figure 70-10-34
Remove the hose / clamp (Item 1) [Figure 70-10-31]
from the charge air cooler (right side).
2
Figure 70-10-32
2 P115926
Figure 70-10-35
4
1
1
2
3
3 P115928
2 Remove the wire connector from the mass air flow sensor
P115857A (Item 1) and the engine compartment temperature
sensor (Item 2) [Figure 70-10-37].
Disconnect the wire harnesses (Item 1) [Figure 70-10- Remove the tie strap (Item 3) and the two bolts (Item 4)
35]. [Figure 70-10-37].
Remove the two bolts (Item 2) and reposition the NOx Remove the assembly from the machine.
bracket (Item 3) [Figure 70-10-35].
Figure 70-10-38
Figure 70-10-36
P115872
P115858A
P115820
Figure 70-10-40
1
2 1
1
P115828
Cut the tie straps (Item 1) and reposition the wire harness
(Item 2) [Figure 70-10-40].
Figure 70-10-43
1
1 2
P115927
IMPORTANT 3
Figure 70-10-46
P115934
1
Remove the case drain hose (Item 1) [Figure 70-10-48]
from the drain manifold.
P115932
Figure 70-10-49
Mark the location of the four hoses (Item 1) [Figure 70-
10-46] and disconnect.
Figure 70-10-47
P115935
1 1
Disconnect the hydrostatic pump connectors (Item 1)
[Figure 70-10-49].
P115933
Figure 70-10-50
P115939
P115940
P100806
Figure 70-10-54 1
2
2
P115938
Remove the engine mounting bolt (Item 1) [Figure 70- Figure 70-10-57
10-54] from the right side of the engine.
3
1
1
3
P115942
Figure 70-10-58
P115943
Figure 70-10-59
1 1
P106863
Raise the engine and pull the engine out of the loader far
enough to remove the Power Bob-Tach hoses (Item 1)
[Figure 70-10-59] (if equipped).
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-61].
Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
Use the following procedure to install new rear engine lb) torque.
mount:
Figure 70-10-62
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount 1
locations. 4
Replace all three engine mounts one rear and two sides.
5 2
Use the parts shown to install the new engine mounts
[Figure 70-10-60]: 6 3
Hex Nut - (Item 1) 7
Washer - (Item 2)
Tube Spacer - (Item 5) Use the parts shown to install the new side engine
mounts [Figure 70-10-62].
Engine Mount - (Item 6)
Mounting Bolt - (Item 1)
Cup Washer - (Item 7)
Cup Washer - (Item 2)
Mounting Bolt - (Item 8)
Engine Mount - (Item 3)
Figure 70-10-63
Washer
Engine
Mounting
Bracket
Engine
Mount
Snubbing
Washer
Spacer
Loader
Frame P-85987
Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
lb) torque.
Plug the fuel line and cap the fuel filter outlet to help
maintain fuel system cleanliness.
When removing the injectors leave the fuel lines Monitor the engine crank speed to ensure that a
connected to the fuel rail. Reroute the lines to allow any minimum of 180 rpm is achieved or reading will not be
small amount of fuel that may be present during the test valid.
to be collected [Figure 70-10-64].
Connect the Bobcat Engine Analyzer Diagnostic Tool and
Leaving the fuel lines connected to the fuel rail will also run the Compression test in Bobcat Engine Analyzer.
help prevent debris from entering the fuel rail. This test will cause the engine to crank while the test is
running. Observe the maximum compression reading on
Store each of the injectors in a new clean plastic bag. the compression gauge during cranking, not the test
results shown on the computer screen.
NOTE: Number the plastic bags to ensure that
injectors are installed in the same cylinders Repeat this procedure multiple times per cylinder until an
from which they were removed. average reading is recorded.
WARNING P115882
1 2
Open the rear door.
Figure 70-10-66
P127169
Figure 70-10-69
P-76439
Figure 70-10-70
P127170
WARNING P115882
P-76439
Figure 70-10-75
P127217
Figure 70-20-1 1
1
2
1 P107696
Figure 70-20-4
Remove the knob (Item 1) [Figure 70-20-1] from the
engine speed control.
Figure 70-20-2
1
P107697
Figure 70-20-5
P107706
Figure 70-20-6
P107475
2 P106591
Figure 70-21-2
1
P107707
2
1
Disconnect the electrical connector (Item 1) from the
engine speed control (Item 2) [Figure 70-21-4].
Figure 70-21-5
P107710
Figure 70-21-6
P107711
P107709
The engine speed control foot pedal pivot assembly
shown disassembled, [Figure 70-21-8] replace worn
Remove pivot bolt, nut (Item 1) and the spring (Item 2) parts as needed.
[Figure 70-21-6].
NOTE: No lubrication is necessary or recommended
on the engine speed control.
Figure 70-21-9
P107712
Figure 70-21-10
P107713
Align the tab (Item 1) with the slot (Item 2) [Figure 70-21-
10] during reassembly.
Figure 70-21-11
1
NA3283
The alarm will beep four times and [FOOT] will appear in
NA3281 the display screen [Figure 70-21-13].
Figure 70-21-14
Diagnostic service code [M2899] will appear in the
display screen if the foot operated engine speed control
pedal requires calibration [Figure 70-21-11].
1
NOTE: Do not press the foot operated engine speed
control pedal until instructed. The calibration
procedure will fail and must be repeated if the
pedal is pressed partially or out of sequence.
Figure 70-21-12
P107096
1 1
P-90687A P-85307Y
Press and hold the auto idle button (Item 1) [Figure 70-
21-11].
Figure 70-21-15
NA3267
Description
The engine exhaust system is equipped with a selective catalytic reduction (SCR) system. The SCR is an emissions
reduction device that removes nitrogen oxides from the exhaust gases.
The SCR system consists of the dosing module, DCU (Dosing Control Unit) and other components. The DEF (Diesel
Exhaust Fluid) / AdBlue® is stored in the DEF / AdBlue® tank. Once it is needed, it is pressurized by the supply module
and is delivered to the dosing module under a certain level of pressure.
The machine will periodically perform a process to clean sulfur oxides from the SCR. This process is called DeSOX.
The SCR requires Diesel Exhaust Fluid (DEF) / AdBlue® to perform the DeSOX process.
NOTE: Diesel exhaust fluid (DEF) and AdBlue® are different names for the same fluid.
Figure 70-30-1
P121002A
DEF /
ENGINE ENGINE
FLUID LEVEL ADBLUE® DISPLAY SERVICE
STAGE ALARM TORQUE RPM
LEVEL INDICATOR MALFUNCTION SCREEN CODES
DERATE DERATE
ICON
Four Green
Full
Lights
Three Green
75%
Lights
Two Green
50%
Lights
25% - One Green E00524617
Warning On DEF L [1] Three Beeps
10% Light U00176115
Three Beeps
E00524615
Less Than One Yellow (Additional
Level 1 On DEF L [1] E00524617 25%
10% Light beep every 20
U00176115
minutes)
Three Beeps
E00524615
for each code
Less Than One Red E00524616
Level 2 On DEF L [2] (Additional 50% 60%
5% Light E00524617
beep every 10
U00176115
minutes)
Three Beeps E00524600
for each code E00524616
Less Than One Red Low Idle
Final Flashing DEF L (Additional E00524617
2.5% Light Only
beep every 2 U00176101
minutes) U00176116
[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
NOTE: The level indicator, DEF / AdBlue® malfunction icon, and display screen are located on the left panel. (See
Left Panel on Page 60-50-1.)
DeSOX Process
—————————————————————————————————————————————————————
Figure 70-30-3
NA3288
If the machine is turned OFF during a passive DeSOX The forced DeSOX process will last 20 minutes.
process, the process will resume the next time the
machine is started after acceptable conditions are It is recommended to continue operating the machine
reached. under load until the DeSOX process is finished.
An optional kit is available to prevent the machine from performing a DeSOX process.
NA3289
Press and hold the bottom of the DeSOX Inhibit switch for
approximately 5 seconds to permanently prevent the
loader from performing a DeSOX process. The switch will
light while DeSOX is inhibited. Press and release the
bottom of the DeSOX Inhibit switch to reset and allow the
machine to perform a DeSOX process.
The following SCR system codes alert the operator of conditions that require attention. Continued operation of the machine
under these conditions will result in reduced machine performance.
NA3305
NA3303
NA3304 NA3306
[SCR] will appear in the data display [Figure 70-30-7] to [DOSE] will appear in the data display [Figure 70-30-9]
alert the operator that an SCR system component has to alert the operator that there has been an interruption in
been tampered with. (See SCR System Component DEF / AdBlue® dosing. (See Diesel Exhaust Fluid (DEF)
Tampering on Page 70-30-6.) / AdBlue® Dosing Interruption on Page 70-30-7.)
The machine can detect unsatisfactory quality DEF / AdBlue® and will alert the operator.
[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] Also code U00351600, U00351601, or U00351631 will be displayed.
NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)
The machine can detect tampering with SCR system components and will alert the operator.
[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] One or more ‘U’ codes could also be displayed.
NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)
EGR Impeded
The machine can detect an impeded exhaust gas recirculation (EGR) system and will alert the operator.
[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] Also code U06522621. Additional ‘E’ codes could also be displayed.
NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)
The machine can detect an interruption in DEF / AdBlue® dosing and will alert the operator.
[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] One or more ‘U’ codes could also be displayed.
NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)
WARNING
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch. 1
• Allow to cool before servicing.
W-2533-1012
P115863
Open the rear door.
Remove the rear grille and side panels. (See Removing Loosen the nut (Item 1) and remove the clamp (Item 2)
on Page 50-60-1.) [Figure 70-30-11].
Drain the engine coolant from the cooling system. (See Installation: Tighten the nut to 8 - 10 N•m (71 - 89 in-lb)
Removing And Replacing Coolant on Page 10-90-5.) torque.
NOTE: It is recommended that any clamps be
replaced with new if removed during service. Figure 70-30-12
Figure 70-30-10
1
1
2
1 1
P115864
Figure 70-30-13 1
1
1 P120664
2
Remove the four nuts and bolts (Item 1) from the SCR
mount bracket (Item 2) [Figure 70-30-13].
Figure 70-30-14
1
P115867
Figure 70-30-17
1 2
1
1
P121170
2
P115868 Remove the three bolts (Item 1) and the dosing module
(Item 2) [Figure 70-30-18].
Remove the two coolant lines (Item 1) and remove the Figure 70-30-19
DEF / AdBlue® line (Item 2) [Figure 70-30-17].
P121175A
DANGER
2
P121171
P-90328
Remove the four bolts (Item 1) and relocate the bracket
AVOID DEATH
(Item 2) [Figure 70-30-20].
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
Figure 70-30-21
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm 2
support. Replace if damaged. 1
D-1009-0409
WARNING 4
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the tie strap (Item 4) [Figure 70-30-21].
Figure 70-30-22
1
1
2 P121178
1 Remove the nuts and bolts (Item 1). Remove the DCU
from the bracket (Item 2) [Figure 70-30-24].
P121173
Figure 70-30-23
3
2
1
1
P121177
DANGER 2
P121186
P-90328
Push down on the retaining clip (Item 1) and remove the
AVOID DEATH
wire harness (Item 2) [Figure 70-30-25].
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
Figure 70-30-26
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
1
WARNING 1
Figure 70-30-27
2
2
1
P121225
P121176 Remove the filter cover (Item 1) from the supply module
(Item 2) [Figure 70-30-28].
Remove the inlet hose (Item 1), outlet hose (Item 2) and Installation: Tighten the filter cover (Item 1) [Figure 70-
the return hose (Item 3) [Figure 70-30-27] from the 30-28] to 20 N•m (15 ft-lb) torque.
supply module.
Figure 70-30-29
Remove the supply module from the loader.
P121226
Figure 70-30-30
P121228
Figure 70-30-31
1 P121230
1
DANGER 3
P121191
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. 2
W-2059-0598 P100007
Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-35].
Figure 70-30-36
1 1 2
1
2
P121198A
1 Remove the nut (Item 1) and loosen the nut and bolt
(Item 2) [Figure 70-30-38].
P121193 Installation: Torque the nut to 2,8 - 3,1 N•m (25 - 27 in-
lb) torque.
Remove the three nuts and bolts (Item 1) from the fill tube Figure 70-30-39
mount bracket (Item 2) [Figure 70-30-36].
Figure 70-30-37
2 1
1
3
2 P121196A
P121194
Figure 70-30-40
1
1
P121195A
Figure 70-30-41
1
1 2
1
1 2
P127576
Figure 70-30-44
P127571
Figure 70-30-42
1
P127574
P127573
Figure 70-30-45
NA12776B
Remove the four nuts and bolts (Item 1) from the sensor
mount (Item 2) [Figure 70-30-45].
1
DANGER 3
P121191
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. 2
W-2059-0598 P100007
Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-47].
Figure 70-30-48 1
2
3
3 2
1
4 P121232
P121223 Remove the clamp / hose (Item 3) and the coolant valve
(Item 4) [Figure 70-30-50].
Figure 70-30-49
1
1 1
P121233
WARNING
2
HOT SURFACES CAN CAUSE SERIOUS INJURY
1
• Do not touch.
• Allow to cool before servicing.
W-2533-1012
Figure 70-40-3
1
2
P115875
NOTE: When the downstream and upstream NOx Lift the DOC (Item 1) [Figure 70-40-3] up and out of the
sensors are both removed mark the sensors engine compartment.
for correct installation into the SCR or DOC.
P122084
1
Remove the four bolts (Item 1) [Figure 70-50-3] from the
air cleaner housing.
Figure 70-50-4
2
P122083
1
Remove the two bolts (Item 1) and set the dosing control
mount (Item 2) [Figure 70-50-1] to the side.
Figure 70-50-2
P122562
P122115
Remove the fuel cooler. (See Fuel Cooler Removal And P122120
Installation on Page 70-80-4.)
Remove the air cleaner housing. (See Housing Removal Remove the hose (Item 1) [Figure 70-60-2].
And Installation on Page 70-50-1.)
Figure 70-60-3
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203 1
Figure 70-60-1
P122124
1
Remove the hose (Item 1) [Figure 70-60-3].
P122119
Figure 70-60-4
1
1
P122111
Figure 70-60-5 1
1
P122107
Figure 70-60-8
1
1
P122123
2
Remove the nuts (Item 1) [Figure 70-60-10].
P122114
Figure 70-60-11
Figure 70-60-9 1
P122125
1
Attach the lifting device (Item 1) and remove the radiator /
oil cooler (Item 2) [Figure 70-60-11].
P122108
This machine may be equipped with a Reversing Fan. Unhook the rubber straps (Item 1) [Figure 70-60-12] and
remove the fan duct.
The function of the reversing fan is to clear dust and
debris from the rear grille. This is accomplished by
software control of a reversing valve in the reversing fan
motor assembly.
Standard Models 3
4
Figure 70-60-13
1
1
3
2
2
P128983
Figure 70-60-14
1 2 P128986
3
Figure 70-60-17
1
2
1
1
P115645A
P128987 Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-60-19].
Disconnect both electrical connectors (Item 1) [Figure Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)
70-60-17]. torque.
2
1 1 1
P115648 P115523
Remove the four nuts (Item 1) [Figure 70-60-18]. Remove the nut (Item 1) [Figure 70-60-20] from the
motor shaft.
Remove the hydraulic fan motor assembly (Item 2)
[Figure 70-60-18]. Installation: Tighten the nut to 61 - 75 N•m (45 - 55 ft-lb)
torque.
NOTE: The fan mounting nuts are a single use part
and should be replaced whenever they are
removed.
Figure 70-60-21 2
2
2
2
1
3
P115522
1
Remove and discard the two nuts and cotter pins (Item 1)
[Figure 70-60-22].
P115521
Figure 70-60-24
1
2
1
P115321A
Remove coil mounting nut (Item 1), the coil (Item 2), and
the proportional valve (Item 3) [Figure 70-60-26].
Remove the filter (Item 1) [Figure 70-60-24]. Installation: Tighten the coil mounting nut (Item 1)
[Figure 70-60-26] to 7-9 N•m (5-7 ft-lb) torque.
Installation: Lubricate threads and filter O-ring prior to
installation. Tighten the filter (Item 1) [Figure 70-60-24] Figure 70-60-27
to 37 - 45 N•m (27 - 33 ft-lb) torque.
Figure 70-60-25 1
EARLIER
MODELS
3 2
2 P128977
1
P115321 Replace the O-rings (Item 1) and back-up ring (Item 2)
[Figure 70-60-27].
Remove coil mounting nut (Item 1), the coil (Item 2), and
the proportional valve (Item 3) [Figure 70-60-25].
Figure 70-60-28
2
P115329
1
Remove the four bolts (Item 1) [Figure 70-60-30].
Figure 70-60-29
3
1 4
2
3
P115326
Remove and inspect the fitting (Item 1), the spring (Item
2), and the check valve (Item 3) [Figure 70-60-29] for
damage and replace as needed.
Figure 70-60-32
1
2 2
P128976
Figure 70-60-35
P128972
1
P128975
3
Remove coil mounting nut (Item 1), the coil (Item 2), and
the proportional valve (Item 3) [Figure 70-60-35].
2
Installation: Tighten the proportional valve (Item 3)
[Figure 70-60-35] to 28 - 34 N•m (21 - 25 ft-lb) torque.
1
Installation: Tighten the coil mounting nut (Item 1)
P128974 [Figure 70-60-35] to 7 N•m (5 ft-lb) torque.
Remove coil mounting nut (Item 1), the coil (Item 2), and
the reversing valve (Item 3) [Figure 70-60-33].
Figure 70-60-36
1
1
P-76726
P128977
1
Replace the two O-rings (Item 1) and back-up ring (Item 3 2
2) [Figure 70-60-36].
Figure 70-60-37
P128978
Figure 70-60-40
1
P128982
1
Replace the O-rings on the three plugs (Item 1) [Figure
70-60-42].
All Models
P128979
Figure 70-60-43
Figure 70-60-41
1 2
P115457
P128980
2
1
P115459
Remove the snap ring (Item 1), washer (Item 2), and the
seal (Item 3) [Figure 70-60-46].
3 Figure 70-60-47
4
P115460
Figure 70-60-45
P115459
Install a new seal (Item 1), washer (Item 2) and snap ring
(Item 3) [Figure 70-60-47].
P115458
Figure 70-60-48
2
1
1
P115475A
Figure 70-60-51
Install the gear assembly (Item 1) and the new seal (Item
2) [Figure 70-60-48] in the housing.
Figure 70-60-49
3 1
P115457
Figure 70-60-52
1
3
P115432
Figure 70-60-53
1
2
1
P115329
Assemble the fan motor and the filter adapter. Install the
P115430 four bolts (Item 1) [Figure 70-60-55].
Blower Housing Removal And Installation Drain the fluid from the radiator. (See Removing And
Replacing Coolant on Page 10-90-5.)
Figure 70-60-57
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 2
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 70-60-56