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Service Manual s130 Skid Steer Loader PDF Free
Service Manual s130 Skid Steer Loader PDF Free
Publications.
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
WRONG
parts. Publications.
Have good ventilation when
welding or grinding painted
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ALPHABETICAL INDEX
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CONTROL PANEL (SJC)........................................ 50-01
CONTROL PANEL SETUP ..................................... 60-01
CONTROL PEDALS AND LINKAGE ...................... 50-01
HYDROSTATIC PUMP ............................................30-01
HYDROSTATIC PUMP (SJC) ..................................30-01
HYDROSTATIC SYSTEM INFORMATION..............30-01
CONTROL PEDALS (ACS) .................................... 50-01
CONTROL SYSTEM (ACS) .................................... 60-01 INSTRUMENT PANELS .........................................60-01
CONVERSIONS ................................................SPEC-01
CRANKSHAFT AND PISTONS .............................. 70-01 LIFT ARMS ..............................................................50-01
CYLINDER (BOB-TACH) ........................................ 20-01 LIFT ARM BYPASS CONTROL VALVE ..................20-01
CYLINDER (LIFT) ................................................... 20-01 LIFT ARM SUPPORT DEVICE................................10-01
CYLINDER (TILT) ................................................... 20-01 LIFTING AND BLOCKING THE LOADER...............10-01
CYLINDER HEAD ................................................... 70-01 LIGHTS....................................................................60-01
S130 LOADER SPECIFICATIONS.................... SPEC-01
DIAGNOSTICS SERVICE CODES......................... 60-01 LOADER STORAGE AND RETURN TO SERVICE 10-01
DRIVE BELT ........................................................... 30-01 LUBRICATING THE LOADER.................................10-01
DRIVE COMPONENETS ........................................ 40-01 LUBRICATION SYSTEM .........................................70-01
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WINDOW (REAR)....................................................50-01
WINDOW (SIDE) .....................................................50-01
WINDOW (TOP) ......................................................50-01
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS
SPECIFICATIONS
FW SSL-1008 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).
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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-1008 SM
FW SSL-1008 SM
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903
Use updated
IMPORTANT
files from Bobcat See your Bobcat dealer for more information on
translated versions.
Publications.
This notice identifies procedures which must be
followed to avoid damage to the machine.
• The AEM Safety Manual delivered with the machine
gives general safety information.
SI SSL-1008 SM
File
Call Before You Dig
has expired.
Dial 811 (USA Only)
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(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1008 SM
SI SSL-1008 SM
Fire Extinguishers
File has expired.
SI SSL-1008 SM
Figure 1
1
P-48387
File has expired. The engine serial number is in the location shown
[Figure 2].
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The loader serial number plate is located on the outside
of the loader frame [Figure 1].
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
Figure 3
B-16315
FRONT
LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDER FRONT AUXILIARY
QUICK COUPLERS
LIFT ARM
REAR
GRILL LIFT
CYLINDER
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT * TIRES B-23186B
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FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-100-1
10-100-2
ENGINE
SERVICE
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-3
SPECIFICATIONS
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . 10-120-1
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Case Drain Filters. . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter. . . . . . 10-120-5
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . 10-120-3
Procedure
Figure 10-10-1
P-31849
Figure 10-10-3
WARNING
P-3868
Always park the loader on a level surface.
Put the floor jack under the front of the loader [Figure 10-
10-3].
WARNING Lift the front of the loader and put jack stands under the
axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
NOTE: Make sure the jack stands do not touch the
Failure to use jackstands can allow the machine to
tires. Make sure tires clear floor or any
fall or move and cause injury or death.
obstacles.
W-2017-0286
Installing
WARNING 3
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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 P-54469
support. Replace if damaged.
D-1009-0409
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure
Remove attachment from the loader. (See Removal And 10-20-2] to the lift arm support device so the spring does
Installation on Page 50-40-1.) OR (See Removal And not interfere with the support device engagement.
Installation on Page 50-41-1.)
Sit in the operator’s seat, fasten the seat belt and lower
the seat bar. Start the engine.
Installing (Cont’d) Remove the pin from the lift arm support device.
1 2
Lower the lift arms slowly until the support device is held
Install pin (Item 2) [Figure 10-20-3] into the rear of the lift
Start the engine.
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arm support device below the cylinder rod. Figure 10-20-5
P-54468
Raise the lift arms a small amount. The spring will lift the
support device off the lift cylinder rod. Lower the lift arms.
Stop the engine.
Raise the seat bar, disconnect the seat belt, move pedals
until both pedals lock and exit the cab.
Description
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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
Figure 10-30-1
N-20520 N-20519
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Install jackstands under the rear of the loader frame
[Figure 10-30-1].
Raising (Cont’d)
Figure 10-30-3
slowly until the cab is all the way up and the latching Support the cab and release the latching mechanism
mechanism engages [Figure 10-30-3]. (Inset) [Figure 10-30-4]. Remove your hand from
latching mechanism when the cab is past the latch stop.
Publications. WARNING
NOTE: Always use the grab handles to lower the cab.
Figure 10-30-5
N-20120 N-20608A
N-20520 N-20519
NOTE: The weight of the cab increases when
equipped with options and accessories such
as cab door, heater, air conditioning, etc. In Install the plates and nuts (both sides) [Figure 10-30-5].
these cases, the cab may need to be raised
slightly from the latch to be able to release the Tighten the nuts to 40 - 45 ft.-lb. (54 - 61 N•m) torque.
latch.
Figure 10-30-6
B-15551J
B-25286A
P-68116
File has expired.
P-68115
See your Bobcat dealer for availability.
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The LIFT & TILT VALVE light (Item 2) [Figure 10-30-6]
will be ON when the door is closed and the PRESS TO
•
•
Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
Do not use abrasive or highly alkaline cleaners.
OPERATE LOADER BUTTON is pressed. • Do not clean with metal blades or scrapers.
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. N-19048A N-18530
W-2058-0807
Procedure
Figure 10-60-1
P16117
1
File has expired. to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
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The remote start tool (Item 1) [Figure 10-60-1] is
required when the service technician is checking the
Pressing the switch a third time will turn the flow OFF.
The switch is used when checking pressures and flow
rate.
hydraulic/hydrostatic system or adjusting the steering
linkage. The auxiliary pressure release (Item 3) [Figure 10-60-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.
Figure 10-60-3
2
1 1
P16114
P16120
N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the plug (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
Figure 10-60-7 2
2
1
1
P16119
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NOTE: To monitor, diagnose or load new software
the Service PC must be connected to the
Remote Start Tool Switch.
N-19150
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key switch on or start the engine. Example: adjusting the
steering linkage.
Open the rear door of the loader. Connect the remote start tool to the engine harness
connector [Figure 10-60-12].
Figure 10-60-10
NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
1
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
N-19151
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-13
2
3 1
P16118
File has expired. P16116 used to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
The remote start tool (Item 1) [Figure 10-60-13] has able to turn.
three rocker switches.
Use updated files from Bobcat 10-60-14] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
Publications. active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
Figure 10-60-15
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Push the couplers on the front auxiliary block toward the
block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-15].
Description
Kit Includes:
6689778 - Remote Start Tool (Service Tool) 1
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-61-16
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
Figure 10-61-18
P-76452
2
The loader service tool harness (Item 1) [Figure 10-61- When the remote start procedure is completed, replace
Figure 10-61-19
harness [Figure 10-61-20].
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1
P-76451
Figure 10-61-21
2 1
3 2
1 P-76450
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21] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
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
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
P-76451
Pressing the RUN button on the Remote Start Tool
disconnects the operator panel from the start circuit.
If the service technician will be working in the engine Loaders without an attachment control harness, remove
Figure 10-61-25
The tool listed will be needed to do the following
Figure 10-61-23
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1 1
P-76452
Figure 10-61-26
5 3
2
6 4
1
P-76439
3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
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26] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
The START button (Item 4) [Figure 10-61-27] is used to
start the loader engine.
damage or corrosion when not in use.
The traction lock button (Item 5) [Figure 10-61-27] is
Connect the Remote Start Tool (Service Tool) connector used to turn traction lock ON or OFF. Push the button and
(Item 1) to the loader harness connector (Item 2) and the the button will illuminate indicating the traction lock is
other Remote Start Tool (Service Tool) connector to the disabled in which the wheels or tracks are able to turn.
ACD harness connector (Item 3) [Figure 10-61-26].
Loader S/N: xxxx60000 & Below
NOTE: The right instrument panel (Key Switch or
Keyless) must be in the off position or the The auxiliary button (Item 6) [Figure 10-61-27] is used to
Remote Start Tool (Service Tool) will not activate the auxiliary hydraulics. The button will illuminate
operate. to indicate the auxiliary hydraulics are active. Pressing
the button once will activate maximum flow. Pressing the
button again will activate variable flow. Pressing the
button a third time will turn the flow OFF. The button is
WARNING used when checking pressures and flow rate.
Figure 10-61-28
1 2
P-34661
The gear icon with the left facing arrows (Item 1) [Figure
10-61-28] will illuminate and blink when the RUN key is
Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on the sidewall of the tire.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Operator Cab
Indicators and Lights
safety treads that are damaged or worn.
Check the fastening bolts, washers and nuts. Check the condition of the cab.
Check for correct operation of all indicators and lights.
(If Equipped)
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Heater and A/C Filters
Check fluid level and add as needed. Check for damage and leaks. Repair or
replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE ❏
MAINTENANCE in this manual.)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲
Drive Belts (Alternator, air Check condition and tension. Adjust or replace as needed.
conditioner, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ●
Charge Filter, Reservoir Breather breather.
Engine Oil and Filter Replace oil and filter. ▲ ✶
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ▲
Engine Valves Adjust the engine valves. ❍
Coolant Replace the coolant Every 2 years
■ Or every 12 months.
▲ Perform at first 50 hours, then as scheduled.
❏ Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
● Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when the transmission warning light
comes ON while operating or as scheduled.
✶ Change oil and filter every 250 hours when operating under severe conditions.
❍ Perform at first 500 hours, then as scheduled.
Figure 10-80-1
1
1
P-54385
B-15553G
Remove the wing nut and remove the dust cover (Item 1)
It is important to change the air filter element only when [Figure 10-80-3].
the Air Cleaner icon in the right panel is ON (Item 1)
[Figure 10-80-1] and you hear three beeps from the Figure 10-80-4
P-54386
1
Remove the wing nut and remove the outer filter element
(Item 1) [Figure 10-80-4].
Press and hold the LIGHT button (Item 1) [Figure 10-80- Install a new outer element.
2] for two seconds.
Install the dust cover and the wing nut [Figure 10-80-4].
If the filter element needs replacement, the CODE [01- (Be sure the evacuator is down.)
17] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2]. Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
Inner Filter
Figure 10-80-5
Install the dust cover and the wing nut [Figure 10-80-6]
Remove the wing nut and remove the inner filter element
(Item 1) [Figure 10-80-5].
Check the cooling system every day to prevent over- Open the rear door and raise the rear grill.
heating, loss of performance or engine damage. Figure 10-90-2
Cleaning
1
P-39967
2
File has expired. Remove the coolant fill cap (Item 1) [Figure 10-90-2].
Check the coolant level. The level markers are on the
tank. Coolant must be at the bottom marker when the
engine is cold; top marker when hot.
Publications.IMPORTANT
NOTE: Be careful when raising and lowering the oil
cooler so that the oil cooler does not fall on
the radiator and damage the fins. AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Raise the oil cooler and use low air pressure or water
pressure to clean the top of the radiator (Item 2) [Figure Too much antifreeze reduces cooling system
10-90-1]. efficiency and may cause serious premature engine
damage.
Lower the oil cooler. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Check the cooling system for leaks. boiling point and freeze protection of the system.
Lower the rear grill and close the rear door. Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
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
Open the rear door and raise the rear grill. Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank. (See Checking Level on Page
Figure 10-90-3 10-90-1)
2 Remove the coolant fill cap. Fill the tank until it is at the
lower marker on the tank.
P-54299
File has expired.
P-54298
NOTE: When installing the coolant fill cap, the cap
must be tightened until it clicks.
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
• Cold weather conditions can lead to plugged fuel
The following is one suggested blending guideline which system components and hard starting.
should prevent fuel gelling during cold temperatures:
• Biodiesel blend fuel is an excellent medium for
TEMPERATURE F° (C°) NO. 2 NO. 1 microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50% • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as plugged
Below -20° (-29°) 0% 100%
fuel filters and deteriorated fuel lines.
The following fuels may be used in this machine: • Shorter maintenance intervals may be required, such
as cleaning the fuel system and replacing fuel filters
• Low Sulfur (500 ppm sulfur) Diesel Fuel. and fuel lines.
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to prevent moisture from collecting in the fuel tank.
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
File has expired. 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].
1
Install and tighten the fuel fill cap (Item 1) [Figure 10-
Fuel Filter
Removing Water
Figure 10-100-3
1
P-54298
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Replacing Element
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
Remove the filter element (Item 2) [Figure 10-100-3].
Close the vent (Item 1) [Figure 10-100-4] on the fuel
Clean the area around the filter housing. Put clean oil on filter housing
the seal of the new filter element. Install the fuel filter, and
hand tighten. Open the vent (Item 3) [Figure 10-100-4] on the fuel
Remove air from the fuel system. (See Removing Air injection pump
From The Fuel System below.)
Squeeze the hand pump (priming bulb) (Item 2) [Figure
Removing Air From The Fuel System 10-100-4] until the pump feels solid.
After replacing the filter element or when the fuel tank Tighten the vent plug (Item 3) [Figure 10-100-4].
has run out of fuel, the air must be removed from the fuel
system before starting the engine. Start the engine.
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-110-1
1 3
File has expired. Use a good quality motor oil that meets API Service
Classification of CD or better See Oil Chart [Figure 10-
P-54298 110-2].
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P-24679
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Remove the drain hose from its storage position (Item 1)
and remove the drain plug (Item 2) [Figure 10-110-3].
Put clean oil on the new oil filter gasket, install the filter
and hand tighten.
2
1
P-64023A
File has expired. Use the correct hydraulic / hydrostatic fluid shown in
chart [Figure 10-120-2].
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Remove the dipstick (Item 1) [Figure 10-120-1].
1
File has expired.
Figure 10-120-4
P-54300
File has expired. (See Checking And Adding Fluid on Page 10-120-1.)
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Clean the surface of the filter housing where the filter
seal contacts the housing.
Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.
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
Install right side access cover and lower the cab. (See
Lowering on Page 10-30-3.)
1
Start the engine and operate the loader hydraulic
controls. Stop the engine and check for leaks.
2
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Remove the case drain filter (Item 2) [Figure 10-120-6].
1
2
P-54307
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Clean the surface of the filter housing where the filter
seal contacts the housing.
Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.
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
Breather Cap
Figure 10-120-9
P-1497
P-1497
Checking And Adding Oil Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
The chaincase contains the final drive sprockets and
chains. Use the same type of oil as the hydraulic / Figure 10-130-2
hydrostatic system. (See (S130) LOADER
SPECIFICATIONS on Page SPEC-10-1.)
Figure 10-130-1
Use updated files from Bobcat Recycle or dispose of the used oil in an environmentally
safe manner.
P-31287
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Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the wedge does not contact the lower edge of the hole
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
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WARNING Inspect the mounting frame on the attachment and Bob-
Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
Bob-Tach wedges must extend through the holes in
damaged, bent or missing. Keep all fasteners tight.
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
Look for cracked welds. Contact your Bobcat dealer for
come off and cause injury or death.
W-2102-0497
repair or replacement parts.
N-17023 B-15177
Figure 10-141-4
2
P-24488A B-15177
B-15891
attachment mounting frame (Item 2) [Figure 10-141-5].
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The levers and wedges must move freely. Figure 10-141-6
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
B-17460
Lubrication Locations
Figure 10-150-1
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-150-3].
1
File has expired. Figure 10-150-4
Figure 10-150-2
4. Base End Tilt Cylinder (Both Sides) [Figure 10-150-
4].
P-54474
Figure 10-150-5
P-54308
Figure 10-150-8
5. Rod End Tilt Cylinder (Both Sides) [Figure 10-150-5].
Publications. 9
P-43829 P-43830
Figure 10-150-9
7
P-1564
9
7. Bob-Tach Wedge (Both Sides) [Figure 10-150-6].
P-43831
Wheel Nuts Check the tires regularly for wear, damage and pressure.
Inflate tires to the maximum pressure shown on the
Figure 10-160-1 sidewall of the tire.
Figure 10-160-2
B-9976
See the SERVICE SCHEDULE for the service interval to
check the wheel nuts [Figure 10-160-1]. (See SERVICE
Publications.
When checking wheel nut torque, set the torque wrench
to 140 ft.-lb. (190 N•m) to prevent over-tightening.
the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Mounting
Publications.
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
Cleaning Procedure
WARNING
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrestor muffler. (See SERVICE
When the engine is running during service, the
SCHEDULE on Page 10-70-1.)
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Do not operate the loader with a defective exhaust
death.
system. W-2006-0284
requirements
Publications.
Consult local laws and regulations for spark arrestor
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
I-2022-0807 outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Stop the engine and open the rear door.
Figure 10-170-1
WARNING
Stop engine and allow the muffler to cool before
1 cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
P-54302
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-170-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285
Figure 10-180-1
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
Publications.
Publications.
fuel, add fuel stabilizer and run the engine for at least
30 minutes.
Fully lower the lift arms and put the attachment flat on the
ground.
Figure 10-200-1
P-66663
WARNING
Pull the engine speed control fully backward [Figure 10-
Figure 10-200-2
Publications.
200-1] to decrease the engine speed.
Before you leave the operator’s seat:
• Lower the lift arms, put the attachment flat on the
ground.
• Stop the engine.
• Engage the parking brake.
• Raise seat bar.
• (Foot Pedal Controls) Move pedals until both
lock.
• (Advanced Control System-ACS) Move the
hydraulic controls to the NEUTRAL POSITION to
make sure that both lift and tilt functions are
deactivated.
1 The seat bar system must deactivate the lift and
tilt control functions when the seat bar is up.
Service the system if hand controls do not
deactivate.
2 • (Selectable Joystick Controls-SJC) Move the
B-15552G B-15553G
joysticks to the NEUTRAL POSITION to make
sure that travel and hydraulic functions are
deactivated.
The seat bar system must deactivate these
Engage the parking brake. functions when the seat bar is up. Service the
system if controls do not deactivate.
Turn the key switch to the STOP position (Item 1) [Figure W-2463-0603
10-200-2] (Key Switch) or press the STOP button (Item
2) [Figure 10-200-2] (Keyless).
Lift the seat bar and make sure the lift and tilt functions
are deactivated.
Pull on the tag on the top of the rear window to remove Pull the plastic loop at the top of the window in the front
Publications.
the rubber cord [Figure 10-200-4].
Push the rear window out of the rear of the operator cab.
door to remove the rubber cord [Figure 10-200-6].
Figure 10-200-7
Figure 10-200-5
X X
X X
P-24472
6707852
P-45260A
Push the window out with your foot [Figure 10-200-7] at
any corner of the window.
Exit through the rear of the operator cab [Figure 10-200-
5]. Exit through the front door.
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 44 PILOT ACTIVATED DIRECTIONAL
Capacity . . . . . . . 14.0 Qts. (13,25 L) RESTRICT FLOW DURING BOOM CONTROL VALVE - HYDRAULIC
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) POWERED BOB-TACH
2 SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL
3 File has expired.
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar)
CONTROL VALVE - BICS CONTROL
46
RESTRICTION - 0.089 inch (2,26 mm)
4 37
P-OUT P-IN T
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
13
28
Publications. CHARGE
INLET Dealer Copy -- Not
13
12 for Resale
AUXILIARY
SPOOL
12
B
20
B A
31
2
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
3 8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
52 51 POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
LIFT ARM BY PASS VALVE
32
19
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 14.0 qt. (13,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 49 SOLENOID ACTIVATED DIRECTIONAL
3
File has expired.
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 bar)
Normally Closed
18 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
34 CHECK VALVE - BUCKET POSITION
VALVE
CONTROL VALVE (TWO COIL)
50 FIXED CAPACITY DISPLACEMENT
19 PULL BUTTON ACTIVATED HYDRAULIC MOTOR
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 51 ANTICAVITATION VALVE
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 52 PROPORTIONAL RELIEF VALVE –
Use updated files from Bobcat
6
PRESSURE: 5075 PSI (350 bar)
54
CHARGE PUMP -
12.8 GPM (48,5 L/min) at High Engine Idle
SPOOL CHECK VALVE - With 300 PSI (20,7 bar) Spring
38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL with 0.016 inch (0,40 mm) orifice
22 FLOW DIVIDER ADJUSTMENT VALVE BI-DIRECTIONAL HYDROSTATIC
PRESSURE BLEED-OFF VALVE MOTOR 55 SOLENOID ACTIVATED CONTROL
8 HYDRAULIC PUMP . . . . . . . Gear Type VALVE - FORWARD/REVERSE
23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 56 SERVO PISTON -Swash Plate
16.9 GPM (64 L/min.) at High Engine Idle
CONTROL VALVE - BASE
40 SOLENOID ACTIVATED DIRECTIONAL 57 POSITION SENSOR -Swash Plate
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
2650-2750 PSI (183-190 bar)
VALVE (ON/OFF)
at Front Quick Couplers
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE
10 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 26 SOLENOID ACTIVATED DIRECTIONAL
42 RESTRICTION - 0.343 inch (8,7 mm)
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
27 PILOT ACTIVATED DIRECTIONAL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 FILTER - Bob-Tach Valve
CONTROL VALVE - AUXILIARY
28 CHARGE PRESSURE SENSOR
13 PORT RELIEF/ANTICAVITATION VALVE: 44 PILOT ACTIVATED DIRECTIONAL
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) CONTROL VALVE - HYDRAULIC
3500 PSI (241,3 bar) POWERED BOB-TACH
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 45 RESTRICTION - 0.089 inch (2,26 mm)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 46 RESTRICTION - 0.025 inch (0,6 mm)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-0794legend (2-6-08)
Printed in U.S.A.
91 of 764
(REAR QUICK
HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE COUPLERS) MALE
4 37
P-OUT P-IN T
Publications.
6 36 13
20
12
Dealer Copy -- Not for Resale12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
28
31
57 14
2 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 56 5
55
3
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
50 LIFT CYLINDERS
52 51 53 10
FAN MOTOR OUTLET 18
HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P2 LIFT ARM BY PASS VALVE
P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-0794 (2-7-08)
92 of 764
HYDRAULIC SYSTEM INFORMATION
Publications.
Enclosure outline for several
components assembled in one unit. VENTED
RESERVOIR
atmosphere).
AND FILTERED
(reservoir open to
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.
Publications.
direction of flow.
VARIABLE CAPACITY
CONTROL VALVE WITH SPRING
RETURN (mechanical).
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).
NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for
allows free flow in one direction only. the opening (fully or restricted) or the closing of one or
more flow paths (represented by several squares).
P
(Variable Position) Joystick
Controlled, variable pressure to shift
the pilot activated directional control
SHUTTLE VALVE - The Inlet port
IN
OUT
Publications.
IN connected to the higher pressure is
automatically connected to the Outlet
port while the other Inlet port is
valve spool.
O
IS
D
FRON T
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
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
The transmission warning light comes ON when hydraulics are operating. 1, 3,
Slow hydraulic system action. 1, 3, 4, 6, 8, 10, 11
Hydraulic action is not smooth. 1, 4, 5, 6, 7, 11
Lift arms go up slowly at full engine RPM. 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
Bypass valve stuck.
File has expired.
Bypass valve stem bent or broke.
12
13
Testing
WARNING 2
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-45266
from a physician familiar with this injury.
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and
Figure 20-20-1
File has expired. tighten.
Engage the parking brake. Lower the seat bar. Start the
Publications. repair.
P-45265
WARNING
Lower the lift arms. Stop the engine. Pull up on the lift
arm bypass control to release the hydraulic pressure. AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Check only one cylinder at a time. Open the rear door. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Disconnect the negative ground cable from the battery. explosion or fire.
W-2103-0508
Disconnect the hose (Item 1) [Figure 20-20-1] from the
lift cylinder base end port.
Figure 20-20-3
P-45268
Figure 20-20-6
Stop the engine. Pull up on the lift arm bypass control to
release the hydraulic pressure.
Publications.
from the lift cylinder.
Figure 20-20-4
1
P-45258
2
Remove the retainer bolt (Item 1) [Figure 20-20-6] and
nut from the lift cylinder rod end pivot pin (both sides).
Use a drift pin and hammer, remove the cylinder pivot pin
P-45267 (Item 2) [Figure 20-20-6] (both sides).
Parts Identification
1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring
7 8
4
5
Publications. 14
1 13
2 12
3
11
10
B-13593
Wash the cylinder parts in solvent and air dry them. P-48036
cylinder.
Use updated files from Bobcat
the rod in and out slowly to remove the fluid from the
Figure 20-20-9
Figure 20-20-7
Publications.
Put the base end of the cylinder in a vise.
2
2 1
1
P-48038
Figure 20-20-10
1
P-48040
Figure 20-20-13
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-10]. Allow
Publications.
compress the seal into place.
Figure 20-20-11
1
P-48041A 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-
2 13].
P-48039
Figure 20-20-14
P7425
P-48043A P7427
Testing
Figure 20-21-1
File has expired.
Figure 20-21-3
1
N-20739
1 Remove the grease fitting from the rod end pivot pin
N-20734
Rod End Pivot Pin Bushing And Seal Removal And Figure 20-21-7
Installation
Figure 20-21-6
1
1
N-20737
File has expired. N-18556 Remove the retainer nut (Item 1) [Figure 20-21-7] and
bolt from the base end pivot pin.
Remove the old seal (both sides) from the end of the tilt Installation: Tighten the retainer nut and bolt to 25 - 28
Publications.
Install the new seals with the lip facing in [Figure 20-21-
6].
Install the rod end of the tilt cylinder into the Bob-Tach.
N-00845
Parts Identification
1
15
Publications.
6
16 17
4
3
19
7 12
13
8
5
10
14
20
11
MS1797
Lubricate all O-rings and seals with hydraulic oil during Remove the nut (Item 1), piston (Item 2) and head (Item
installation.
File has expired.
Hold the hydraulic cylinder over a drain pan and move
3) [Figure 20-21-10].
Publications.
1
2
Use a spanner wrench to loosen the head (Item 1) Assembly: Mark the end of the shaft and nut. Tighten
[Figure 20-21-9] from the cylinder case. the nut an additional 135 degrees or 2-1/4 flats [Figure
20-21-11].
Assembly: Tighten the head with a spanner wrench until
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-21-9].
2
2
P-48039
Figure 20-21-15
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-12] from the piston.
Publications.
P-48040
Figure 20-21-16
1
P-48043 P7427
Publications.
1
P7425
P-48042
Testing
1
WARNING 2
P-43211
Engage the parking brake. Lower the seat bar. Start the
Diesel fuel or hydraulic fluid under pressure can engine.
penetrate skin or eyes, causing serious injury or
Figure 20-22-1
P-31514
Figure 20-22-3
1 1
1 2 P-31513
Parts Identification
1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod
14
13 12
11
10
9
8 7 6
5
4
15
PE1064
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Hold the hydraulic cylinder over a drain pan and move and head (Item 4) [Figure 20-22-6] from the rod.
the rod in and out slowly to remove the fluid from the
Figure 20-22-5
nut (Item 1) [Figure 20-22-6].
3
2
1
4
1
P-43212
P16295
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-22-5].
Remove the O-ring (Item 1), and seal (Item 2) from the
Assembly: Tighten the head with a spanner wrench until piston (Item 3) [Figure 20-22-7].
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-22-5]. NOTE: The piston center hole (Item 4) [Figure 20-22-
7] has a bevel on one end. The bevel goes
toward the rod when assembling.
Figure 20-22-8
1
P-48040
Figure 20-22-11
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-22-8]. Allow the
Figure 20-22-9
Publications.
compress the seal into place.
1
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2 11].
P-48039
Figure 20-22-12
P7425
P-48043A P7427
IMPORTANT
File has expired.
P-48503
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284 Connect the IN port (Item 1) [Figure 20-30-1] of the
hydraulic tester to the bottom (female) quick coupler on
the loader.
Publications.
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Figure 20-30-2
death.
W-2006-0284
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 N-18409
The tools listed will be needed to do the following • Press the AUXILIARY HYDRAULICS Button (Item 1)
procedure: [Figure 20-30-2] Maximum Flow.
O-ring
1
1
Figure 20-30-4
B-6764
(SJC) RIGHT STEERING CONTROL
P-73289
Figure 20-30-6
P-54186
File has expired. P-54172 remove the main relief valve (Item 1) [Figure 20-30-7].
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
Figure 20-40-1
DANGER
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Publications.
The lift and tilt functions are operated using mechanical
linkages to connect the foot pedals to the lift and tilt
spools.
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
The auxiliary function is operated by pilot pressure. to fall and cause injury or death.
There is one solenoid located by each side of the spool. W-2059-0598
Only one solenoid at a time is activated by the switch on
the right side control handle/lever. The activated solenoid
sends pilot pressure oil to one side of the spool and
forces the spool to shift.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Removal and Installation (Cont’d) NOTE: Remember the hose routing for ease of
control valve installation.
Drain the hydraulic reservoir.(See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) Figure 20-40-4
Figure 20-40-2
1
File has expired. 1
P-54183
Figure 20-40-5
Publications.
Remove the right rear tire.
Figure 20-40-3
P-67082
1
Remove the tie-straps (Item 1) [Figure 20-40-5] from the
fixed end main valve hose.
P-68855
Figure 20-40-6
3 1
P-68862
Remove the connector pins (Item 1) [Figure 20-40-8].
Mark and disconnect the five electric solenoid connectors Figure 20-40-9
for correct installation (Item 1) [Figure 20-40-6].
40-6]. Publications.
Disconnect and cap the drain hose (Item 3) [Figure 20-
1
Figure 20-40-7 2
1 P-54161
2
P-68860
Figure 20-40-10
P-68864
1
Remove and cap both tubelines (Item 1) [Figure 20-40-
Figure 20-40-13
Publications. 1
P-68865
1
Disconnect and cap the tubeline (Item 3) [Figure 20-40-
13] from the lift section of the control valve.
P-54153
Figure 20-40-14 1
1
P-68871
Figure 20-40-17
Publications.
1
P-68868P-
P-68868
51713
1
Remove the two mounting bolts (Item 1) [Figure 20-40-
17] that secure the control valve to the side of the loader.
Identification Chart
Figure 20-40-18
J2
C2 J4 C3
D5 E3 B3
E3
G1 G2
F2 B2 A3 D3
D4 F4 E2
A2
C4
J1
J3
MS1937
ITEM
A1
Publications.
S130 LOADER
Lift Cylinder Base End
ITEM
E1
S130 LOADER
Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Lift Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Valve Solenoid
D1 Anti-Cavitation Valve
H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End)
J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
J4 Drain (Case)
Tilt (Rod End)
MR Main Relief Valve – 2700 PSI
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)
Figure 20-40-19
P-51440
Publications.
Installation: Lubricate the O-ring and tighten the valve to
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Figure 20-40-20
P-51439
Load Check Valve Removal And Installation (Tilt & Anti-Cavitation Valve Removal And Installation
Auxiliary) (Lift, Rod End)
At the front side of the control valve locate the tilt section
Publications.
IMPORTANT
NOTE: The tilt and auxiliary load check valves are
interchangeable.
1
3
2
P-51453
Figure 20-40-25
Figure 20-40-26
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4
1
3 1
2
P-51451
Figure 20-40-29
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1
P-51694
Replace the O-ring (Item 1) [Figure 20-40-30] before Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)
installation. torque.
P-51696
Remove the port relief plug (Item 1) [Figure 20-40-33] Figure 20-40-36
from the auxiliary circuit of the control valve.
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P-51640
1
Figure 20-40-37
1
P-51461
Figure 20-40-40
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-37].
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P-51462
1
Installation: Always use new O-rings (Item 1) [Figure
20-40-40]. Tighten to 40 ft.-lb. (54 N•m) torque.
P-51460
Figure 20-40-41
1 P-51697
File has expired. P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-43] from the
end cap/spool lock block.
Remove the three screws (Item 1) [Figure 20-40-41] on
the rubber boot retainer plate.
Figure 20-40-42
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1
2
1
1 P-68017
Figure 20-40-47
1 1
1
1
File has expired.
P-51699A
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Remove the rubber boots and retainer plate from the lift
and tilt spools.
Remove the O-ring (Item 1) [Figure 20-40-47].
1
P-51700A
P-51512A
1 1 2
P-51515
IMPORTANT
Publications. The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
1
2
P-51514
Figure 20-40-52
P-51518
Figure 20-40-55
Figure 20-40-53
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1
2 1 P-51519A
3
Remove the lift spool seal (Item 1) [Figure 20-40-55]
from the linkage end of the valve.
2 P-51517
Figure 20-40-56
1
2
N-18916
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Figure 20-40-57
2
1
1
3
N-19004
N-18915
Remove the detent adapter (Item 1) [Figure 20-40-59]
from the spring assembly.
Install the spring tool (Item 1) [Figure 20-40-57] over the
centering spring.
Figure 20-40-60
N-18918
Remove the stud from the end of the spool [Figure 20-
Figure 20-40-63
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3
2
1
4
N-18920
Figure 20-40-64
2 Plastic
Plug
1 0.60 in.
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
Figure 20-40-67
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this O-ring. Always replace the o-ring and
recheck the lift spool before the control valve
is replaced.
Figure 20-40-65
N-18967
N-18963
Install the plastic plug and O-ring in the spool [Figure 20-
40-65].
Figure 20-40-68
1
N-19004
1 3
Install the spring tool (Item 1) [Figure 20-40-70] over the
2
File has expired.
N-18958
washer, spring, collar and detent adapter.
Figure 20-40-71
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with the detent pliers (Item 1) [Figure 20-40-69].
Figure 20-40-69
1
N-18917
N-18968
Figure 20-40-72
N-19007
Figure 20-40-75
washer. Publications.
Check the alignment of the detent adapter and the
1
CD-15051
Figure 20-40-76
2
P-51513
1
Install the end cap (Item 1) [Figure 20-40-78].
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Install the mounting screws (Item 2) [Figure 20-40-76].
Figure 20-40-77
P-51520
P-51514
Figure 20-40-80
1 4
P-51701
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-82].
Install the O-ring (Item 1) and bushing (Item 2) [Figure
Figure 20-40-83
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1
1
P-51511A
P-68017
1 2
1
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Installation: Install the lift spool (Item 1) and tilt spool
(Item 2) [Figure 20-40-84] lock solenoids and tighten to
35 - 45 ft.-lb. (52 - 61 N•m) torque.
1
1
P-68019
N-18942
1 Put the linkage end of the spool in the vice [Figure 20-
Publications.
Figure 20-40-88
N-19014
Figure 20-40-91
2 1
3
1
1
P-68020
Inspect the adapter (Item 1), collar (Item 2), spring (Item Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3
3) and washer (Item 4) [Figure 20-40-91].
Figure 20-40-92
Use updated files from Bobcat Remove the spool centering block (Item 2) [Figure 20-
40-93] from the control valve.
2
1
2
1
P-51545 N-18943
Installation: Always use a new spool seal. Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-40-94] from the auxiliary spool.
Figure 20-40-95
1 2
2 P-51550A
1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
Figure 20-40-98
1
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2 1
P-51551A
P-51549A
Figure 20-40-99
1
1
1
P-68008
Remove the nut (Item 1) [Figure 20-40-99] from both Figure 20-40-102
solenoids.
Figure 20-40-100
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2
2
P-51555
Figure 20-40-103
2
P-68009
File has expired. P-68006 Installation: Lubricate the O-rings and tighten the stem
to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Remove the nut (Item 1) [Figure 20-40-103] from the Figure 20-40-106
solenoid stem.
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Figure 20-40-104
2
N-18694
Figure 20-40-107 1
1
1
1 2
1
2
2
2
P-51564
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-107] is for the lift
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P-51443
Figure 20-40-110
1
1
P-51706
2
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1
1
1
1 2
2
2
P-51564
P-51504
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-40-113] from the tilt lock valve, and replace
Remove the lift spool lock solenoid (Item 1) [Figure 20- with new.
40-111].
Figure 20-40-114
2
File has expired.
P-68010
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1
P-51437
Figure 20-40-116
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P-51463
Figure 20-40-118
P-68869
Figure 20-40-121
Remove the tubeline (Item 1) [Figure 20-40-118].
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P-68870
Description
Figure 20-41-1
WARNING
Never work on a machine with the lift arms up unless
File has expired. P-68027 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
The hydraulic control valve is located inside the main to fall and cause injury or death.
frame on the right hand side, below the operators cab. W-2059-0598
IMPORTANT
Publications.
The lift and tilt functions in the ACS or SJC hydraulic
control valve are operated using electronic control
handle/levers or foot pedals that send an electronic When repairing hydrostatic and hydraulic systems,
signal to the electronic actuators to move the lift and tilt clean the work area before disassembly and keep all
spools in the control valve. parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
The auxiliary function is operated by pilot pressure. damage the system.
There is one solenoid located by each side of the spool. I-2003-0888
Only one solenoid at a time is activated by the switch on
the right side control handle/lever. The activated solenoid Lift and block the loader. (See Procedure on Page 10-10-
sends pilot pressure oil to one side of the spool and 1.)
forces the spool to shift.
Raise the lift arms and install an approved lift arm support
The hydraulic control valve also contains a main relief device. (See Installing on Page 10-20-1.)
valve which is adjustable.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 20-41-2
1 1
P-54183
Figure 20-41-5
Remove the right rear tire.
Figure 20-41-3
Publications. 1
1 P-67082
P-68855
Figure 20-41-6 1
2
1
3 P-54142B
Figure 20-41-9
Mark and disconnect the three electric solenoid
connectors (Item 1) [Figure 20-41-6] for correct
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Disconnect and cap the drain hose (Item 3) [Figure 20-
41-6].
Figure 20-41-7
P-54093
1
P-54102
Figure 20-41-10
P-68865
1
Disconnect and cap the tubeline (Item 1) [Figure 20-41-
Figure 20-41-13
Figure 20-41-11
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2
P-68864
1
Disconnect and cap the tubelines (Item 1) and (Item 2)
[Figure 20-41-13] from the tilt section of the control
valve.
P-54097A
Figure 20-41-14
1 P-68868
Remove the fixed-end main valve hose (Item 1) [Figure Reverse procedure for installation.
20-41-14] from the main control valve fitting.
Publications. 1
P-68871
Figure 20-41-17
P-68030
1 File has expired. linkage pin (Item 1) [Figure 20-41-19] from the actuator
and the lift spool.
P-68028 Remove the actuator and linkage pin from the valve.
Figure 20-41-18
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(10,2 - 11,3 N•m) torque.
1
P-68031
1
Pull the actuator away from the control valve [Figure 20-
41-18].
Figure 20-41-21
P-68034
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Figure 20-41-22 1
P-68031
Pull the actuator away from the control valve [Figure 20-
41-22].
Figure 20-41-25
1
2
3
File has expired.
P-68035
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41-25] to the end cap.
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3
B2 D3
D4 A2 E2
C4
ITEM
A1
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S130 LOADER
Lift Cylinder Base End
ITEM
E1
S130 LOADER
Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Lift Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS Valve Solenoid
C3 Load Check Valve Auxiliary Function H2 BICS Lock Valve (Tilt)
C4 Check Valve
H3 BICS Lock Valve (Lift)
D1 Anti-Cavitation Valve
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm Bypass Orifice
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Base End) Main Relief Valve – 2700 PSI
MR
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)
Figure 20-41-27
1
P-68014
Figure 20-41-29
1
2
P-51439
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-31].
Remove and install new O-rings (Item 1) and back-up
1
3
2
P-51440
P-51453
Check for free movement of the load check valve (Item 1)
[Figure 20-41-30].
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-32].
Figure 20-41-33
1
3
2
1
P-68037
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-35].
At the back side of the control valve, remove the lift
Use updated files from Bobcat Installation: Install a new O-ring (Item 4) [Figure 20-41-
35] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
IMPORTANTPublications. torque.
Figure 20-41-34
P-51452
Figure 20-41-36
P-68037
Remove the tilt port relief/anti cavitation valve (Item 1)
[Figure 20-41-38] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item
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1
1
P-68039
P-68038
Replace the O-ring (Item 1) [Figure 20-41-39] before
installation.
Replace the O-ring (Item 1) [Figure 20-41-37] before
installation. Installation: Lightly lubricate with oil and tighten to 38 -
45 ft.-lb. (52 - 61 N•m) torque.
Installation: Lightly lubricate with oil and tighten to 38 -
45 ft.-lb. (52 - 61 N•m) torque.
Figure 20-41-40 1
P-68037
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-41-43
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P-51801
1
Figure 20-41-44
1
1
P-68016
Figure 20-41-45
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1
1
P-51460
At the bottom side of the control valve remove the plug Disconnect the tube line (Item 1) [Figure 20-41-50] from
(Item 1) [Figure 20-41-48]. the end cap block.
Figure 20-41-51
1
P-51462
P-68041
Figure 20-41-52
1
P-68043
1
Remove the two screws (Item 1) [Figure 20-41-54] from
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Remove the O-ring (Item 1) [Figure 20-41-52].
Figure 20-41-53 1
P-68044
P-68047
Figure 20-41-56
P-51772
1
Clamp the linkage end of the spool in a vise [Figure 20-
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-41-59
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1
P-51773
Figure 20-41-60
1
1
N-18920
Drill a hole all the way through the plug using a 7/64 in.
tap drill
Remove the bolt (Item 1) [Figure 20-41-60] holding the
Publications.
Remove spring tool from the spring assembly.
Figure 20-41-61
NOTE: DO NOT USE Loctite® ON THE STUD
THREADS.
Figure 20-41-63
3
2 2
1 1
4
P-51776
P-74183
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-61].
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-41-63].
Figure 20-41-64
2
3
3
P-68044
Publications. 1
2
P-51771 P-51775
Figure 20-41-67
P-68042
Figure 20-41-70
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1
P-68040
2 Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-41-70].
P-68049
Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
11,3 N•m) torque.
Install the O-ring (Item 1) and spacer (Item 2) [Figure 20-
41-68] on the lift spool. Connect the tube line (Item 3) [Figure 20-41-70] to the
end cap block.
Figure 20-41-71
2
P-68051
Figure 20-41-72
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1 1
2 1
P-68052
2
Remove the tilt spool, centering spring, back-up washer
P-68050
and spool seal (Item 1) [Figure 20-41-74].
Disconnect the tubeline (Item 1) [Figure 20-41-72]. Installation: Always use a new spool seal.
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
Figure 20-41-78
Put the linkage end of the spool in the vice [Figure 20-
41-75]. 2
Figure 20-41-76
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1
1
P-51545 N-18943
N-19014
Figure 20-41-79
1 1
2
P-68054
Figure 20-41-82
Disconnect the tubelines (Item 1) [Figure 20-41-79] from
the spool centering block.
Figure 20-41-80
P-68076
P-68053
Figure 20-41-83
1 1
2
P-68082
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P-68078
P-51553
Figure 20-41-87
1
2
P-68084
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N-18693A
P-51555
Remove the O-rings (Item 1) [Figure 20-41-88] from the Remove the O-rings (Item 1) [Figure 20-41-90] from
solenoid stem. both ends of the solenoid coil.
Check and clean the screen (Item 2) [Figure 20-41-88]. Use an Ohm meter to measure the solenoid coil
resistance.
Figure 20-41-91
3
2
1
1
N-18694
Publications. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Figure 20-41-93
1
1
1
2
1
1
2
2
2
P-51564
Locate the two BICS lock valves, (Item 1) is for the tilt Figure 20-41-96
circuit, and (Item 2) [Figure 20-41-93] is for the lift circuit.
Publications.
1
1
P-68080
Remove the lift lock valve (Item 1) [Figure 20-41-94] Installation: Lightly lubricate the lock valve O-rings and
from the back of the control valve. tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Figure 20-41-97
1
1
1
1
2
2
2
File has expired.P-51564
Figure 20-41-98
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1
P-51437
Figure 20-41-100
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1
P-51463
Figure 20-41-102
1
P-68869
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P-68870
P-68010
Inspect the screen (Item 1) [Figure 20-41-105].
Description
Testing WARNING
Figure 20-50-1 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
File has expired.
1
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Use updated files from Bobcat Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
10-20-1.)
Publications. P-68832
Raise the operator cab.(See Raising on Page 10-30-2.)
Figure 20-50-2
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1) 1
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms 3
slowly lower.
2
The knob should return to its original position.
P-54143
Figure 20-50-3
1
4
3
2
P-26065
Pump Test At Quick Couplers File has expired. should be approximately 16 - 17 GPM. Start turning the
restrictor clockwise, causing more restriction on the flow.
The GPM should drop off slightly until the pressure
The tools listed will be needed to do the following reaches approximately 2400 PSI. At approximately 2400
procedure: PSI the flow should start decreasing rapidly until the
Figure 20-60-1
the flow should be at 0 GPM. Turn the restrictor (Item 2)
[Figure 20-60-1] counterclockwise to free flow. Shut the
front auxiliary hydraulics off.
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If flow and pressure specs are not obtained, go to Direct
Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-60-2.)
P-16903 P-68872
WARNING
P-67082
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) [Figure 20-60-2]
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)
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WARNING 2 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.
P-54312
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Open the rear door of the loader. of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-3] from the tester to the tubeline (Item 2) [Figure
Connect the remote start tool. (See REMOTE START 20-60-2] on the control valve.
TOOL KIT-MEL1563 on Page 10-60-1.)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
Figure 20-60-4
MEL1563 or 6689779 - Remote Start Tool
EXAMPLE: TESTER
CONNECTION MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
6661247 - Filter Assembly
Reservoir
17 KB 1212 - Elbow Fitting
15 KB 1212 - Straight Fitting
15 KB 0812 - Reducer Fitting
WARNING
Hydraulic Pump
Out Put jackstands under the front axles and rear corners
In
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Publications.
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
WARNING
RPM*.
Never work on a machine with the lift arms up unless
Warm the fluid to 140° F (60° C) by turning the restrictor the lift arms are secured by an approved lift arm
control (Item 1) [Figure 20-60-4] on the tester to about support device. Failure to use an approved lift arm
1000 PSI (6895 bar). DO NOT exceed system relief support device can allow the lift arms or attachment
pressure. Open the restrictor control and record the free to fall and cause injury or death.
flow (GPM) at full RPM*. W-2059-0598
Push the maximum/variable flow switch (on the remote NOTE: The fluid from the charge pump must be
start tool) to engage the front auxiliary hydraulics, the filtered after it passes through the Hydraulic
light will come ON. Push the button (on the right control Tester, to prevent any contamination to the
lever) for fluid flow to the quick coupler (fluid pressure will Hydrostatic Pumps.
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least Raise the operator cab. (See Raising on Page 10-30-2.)
80% of free flow.
Open the rear door of the loader.
%= HIGH PRESSURE FLOW (GPM) X 100
FREE FLOW (GPM) Connect the remote start tool. (See REMOTE START
TOOL KIT-MEL1563 on Page 10-60-1.)
Figure 20-60-5
1
2
3 4
1 3
2
P-39248
Figure 20-60-6
Use updated files from Bobcat
Publications.
1
1
1
P-67077
P-39247
Remove the hydraulic reservoir strap (Item 1) [Figure
20-60-8] and lower the hydraulic reservoir.
Determine the proper direction of oil flow through the filter
housing (Item 1) [Figure 20-60-6] and [Figure 20-60-7]. Secure the hydraulic reservoir in a place that allow room
to reach the hydraulic fan motor.
Figure 20-60-9
1 3
1
P-68873
File has expired. P-67078 60-11] approximately 3 feet long to the outlet side of the
hydraulic filter assembly (Item 3) [Figure 20-60-11] and
the fitting on the hydraulic fan motor (Item 2) [Figure 20-
Disconnect the OUTLET hose (Item 1) [Figure 20-60-9] 60-9].
from the hydraulic fan motor.
P-54190A
Figure 20-60-12
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
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connected correctly, increase the engine speed to full
RPM*.
DANGER 1
P-68874
P-90328
Remove the nut from the speed control linkage (Item 1)
AVOID DEATH [Figure 20-60-13].
•
File has expired.
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Disconnect the rear light electrical connector (Item 2)
[Figure 20-60-13].
• Keep out of this area when lift arms are raised Remove the fuel fill and belt shield mounting screws
unless supported by an approved lift arm (Item 3) [Figure 20-60-13].
support. Replace if damaged.
Publications.
IMPORTANT 1
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
Figure 20-60-15
1 1
P-68857
Publications.
1
P-37339
P-68858
Installation: Tighten the engine mount bolt to 70 ft.-lb. NOTE: A shaft (Item 2) [Figure 20-60-18] with the
(95 N•m) torque. dimensions of 1.5” diameter by 2.125” long
will be needed to push the engine/hydrostatic
pump assembly.
Figure 20-60-19
P-43940 P-43938A
P-66898
Parts Identification
15
14
7 5
13
8
5 6
4
12 3
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5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
12. Pump Center Section
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)
B-21259A
Figure 20-60-22
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-60-
Publications.
to 54 ft.-lb. (73,2 N•m) torque.
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
Figure 20-60-24 1
P-64511
2
Figure 20-60-27
1
Figure 20-60-25
Publications.
1
P-64512
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-60-24] & [Figure 20-60-25] from the pump 60-27]. If excessive wear or damage is visible,
end section. the pump must be replaced.
Figure 20-60-28
P-64515
Figure 20-60-31
Figure 20-60-29
1
Publications.
P-64516
Figure 20-60-32
1
P-64519
1
2 Figure 20-60-35
2
Figure 20-60-33
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-60-35].
[Figure 20-60-32] & [Figure 20-60-33] from the pump
center section. Inspect for damage and replace as
needed.
Figure 20-60-36
2
1
1
P-64526
Figure 20-60-39
Publications.
Figure 20-60-37
2
1
P-64527
Figure 20-60-40
1
P-64530
1
Remove the drive gear (Item 1) [Figure 20-60-42] from
Figure 20-60-43
Figure 20-60-41
Publications.
1
P-64531
P-64529
Figure 20-60-44
2
P-64535
Figure 20-60-47
Publications. 1
2
P-64536
Figure 20-60-48
3
2
1
P-64540
Publications. 1
2
2
1 P-30188A
P-64538
Remove the pre-load seal (Item 2) [Figure 20-60-49]. Remove the shaft seal (Item 1) [Figure 20-60-51] from
the pump flange section.
Pump Test At Quick Couplers File has expired. Turn the restrictor control (Item 2) [Figure 20-70-52] on
the tester counterclockwise to obtain free flow, the flow
The tools listed will be needed to do the following should be approximately 16 - 17 GPM. Start turning the
procedure: restrictor clockwise, causing more restriction on the flow.
Figure 20-70-52
reaches approximately 2400 PSI. At approximately 2400
PSI the flow should start decreasing rapidly until the
pressure reaches 2650 - 2750 PSI. At 2650 - 2750 PSI
the flow should be at 0 GPM. Turn the restrictor (Item 2)
Publications. 1
[Figure 20-70-52] counterclockwise to free flow. Shut the
front auxiliary hydraulics off.
P-16903 P-66894
WARNING 1
P-68163
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) [Figure 20-70-53]
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-70-54
1.)
Publications.
WARNING 2
1
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-70-54] from
the tester to the OUTLET hose (Item 1) [Figure 20-70-
Open the rear door of the loader. 53] of the pump. Connect the OUTLET hose (Item 2)
[Figure 20-70-54] from the tester to the tubeline (Item 2)
Connect the remote start tool. (See REMOTE START [Figure 20-70-53] on the control valve.
TOOL KIT-MEL1563 on Page 10-60-1.)
Figure 20-70-55
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Publications.
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
P-69182
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 proportioning valve electrical connector
Publications.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
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-69184
NOTE: The fluid from the charge pump must be
filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1)[Figure 20-70-57].
Hydrostatic Pumps.
*Refer to (See Hydraulic System on Page SPEC-10-3.)
Raise the operator cab. (See Raising on Page 10-30-2.) for system relief pressure and full RPM.
Figure 20-70-58
4 3
P-48256A
2 1 Be sure all connections are tight and that the hoses are
File has expired. P-69185 not touching any moving parts before starting the loader
[Figure 20-70-59].
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*.
Parts Identification
15
14
7 5
13
8
5 6
4
12 3
Publications. 11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
12. Pump Center Section
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)
B-21259A
Publications.
I-2003-0888
Figure 20-80-1
2
P-68234
Figure 20-80-3 1
P-48258
Use updated files from Bobcat Reverse the removal procedure to install the filter
housing and filter.
1
3
P-68846
2
Remove the four mounting bolts (Item 1) [Figure 20-80-
Figure 20-80-6
Figure 20-80-8
Publications. 3
2
1
4
1
2
P-68847
P-67076
Charge filter assembly components:
Description
Lift and block the loader. (See Procedure on Page 10-10- Raise the operator cab. (See Raising on Page 10-30-2.)
1.) Figure 20-90-1
Start the engine. Raise the lift arms and install an
DANGER
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
support device can allow the lift arms or attachment
P-67073
to fall and cause injury or death.
W-2059-0598
Mark and disconnect the hoses (Item 1) [Figure 20-90-2]
from the hydraulic fluid reservoir.
Figure 20-90-3
2
2
P-54304
N-20565
Description
N-19346
Publications.
Figure 20-100-1
P-54319
1
2
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 20-100-2] & [Figure 20-
100-3].
N-19345
Figure 20-100-4
1 2
1
Disconnect the inlet and outlet hoses (Item 1) from the oil
cooler (Item 2) [Figure 20-100-4].
Publications.
Lift up the oil cooler and remove the cooler from the
loader.
Description
Figure 20-110-1
Remove the solenoid stem (Item 1) [Figure 20-110-2]
Figure 20-110-5
DANGERPublications. Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
10-20-1.)
Stop the engine.
Raise the operator cab. (See Raising on Page 10-30-2.)
Disconnect solenoid connector harness (Item 1) [Figure
20-110-5].
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 20-110-6
A
B D
C
P-68844
1
1
Disconnect tubeline (Item 1) [Figure 20-110-8] at tee
Publications.
1
1
P-68845
P-68842
Figure 20-110-10
1
N-19072
Figure 20-110-13
Publications.
2
N-19070
N-19041
Installation: Put oil on O-rings and back-up washers and Assembly: Tighten the plug to 56 - 64 ft.-lb. (75,9 - 86,8
tighten the solenoid stem to 30 - 40 ft.-lb. (40,7 - 50,2 N•m) torque.
N•m) torque.
Figure 20-110-14
1 N-19045
Check the flow control spool for wear, check the O-ring
Publications.
on the plug and replace as needed.
Figure 20-110-15
3
1
N-19046
1
Remove the plug (Item 1), spring (Item 2) and unloading
2 spool (Item 3) [Figure 20-110-17].
Description
The right side auxiliaries are located on the inside of the P-90328
right side lift arm at the front of the machine.
AVOID DEATH
The rear auxiliary valve is located on the right side of the • Disconnecting or loosening any hydraulic
machine below the fuel fill hose. The valve is accessed tubeline, hose, fitting, component or a part failure
by opening the rear door. can cause lift arms to drop.
P9137
WARNING
Use a test meter to measure coil resistance [Figure 20-
AVOID INJURY OR DEATH
120-1]. Coil wires do not have polarity. Correct resistance
Always clean up spilled fuel or oil. Keep heat, flames,
is 8.6 - 9.5 ohm @ 68 degrees fahrenheit.
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Replace the test meter with 12 volt power. You can see
explosion or fire.
and hear the spool shift. W-2103-0508
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 20-120-2
3 P-54280
Publications.
Remove the nut from the speed control linkage (Item 1)
and unplug the rear lights electrical connector (Item 2)
1
1
[Figure 20-120-2].
1
Remove the fuel fill bracket mounting screws (Item 3)
[Figure 20-120-2]
Figure 20-120-5
P-76751
P-76745
IMPORTANT
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. 1
I-2003-0888
P-76791
Figure 20-120-8
File has expired. 120-9] located on all sides of the diverter valve and can
be removed for clean out purposes.
1
P-76747
Figure 20-120-11
1
1
P-76789A
Publications. 2
1
1 1
2 P-48757
1 P-76794
Publications.
1
2
2
1
P-48754 P-76796
Inspect the O-rings (Item 1) and back-up washer (Item 2) Remove the metal shields (Item 1) and solenoid valve
[Figure 20-120-16] for damage. coils (Item 2) [Figure 20-120-18].
Figure 20-120-19
1
P-48761
Figure 20-120-20
Figure 20-120-22
Publications.
1
1
P-48762
2 P-48764
Figure 20-120-23
1 1
P-48752
2
Inspect the O-rings (Item 1) and back-up washer (Item 2) Figure 20-120-26
[Figure 20-120-23].
1
P-48766
Remove the #8 SAE hex head plug (Item 1) [Figure 20- Assembly: Tighten the orifice to 22 ft.-lb. (29,8 N•m)
120-24]. torque.
1
2
P-76798
File has expired. P-48765 SAE hex head plugs (Item 2) [Figure 20-120-29].
Figure 20-120-28
Figure 20-120-30
Publications.
1
P-48752
P-48786
The Power Bob-Tach block is an option that allows the Drain the hydraulic reservoir. (See Removing And
operator to hydraulically control the Bob-Tach levers for Replacing Hydraulic Fluid on Page 10-120-2.)
mounting and dismounting the attachments.
Figure 20-130-1
The power Bob-Tach is operated by a switch on the front
console.
3
The power Bob-Tach block is mounted on the right side
of the machine in front of the engine on the backside of 1
the hydraulic gear pump.
WARNING
File has expired. 2
3
Never work on a machine with the lift arms up unless
P-68848
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
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
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 20-130-2
P-48227
P-48226
Figure 20-130-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
Figure 20-130-8
1
1
P-48122
Publications.
1
2
1
P-48384
3
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-130-
(Item 2) [Figure 20-130-9]. 11] to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
Figure 20-130-12 2
1
2
P-48106A
Figure 20-130-13
Publications.
1
1
2
P-48386
Figure 20-130-16
1
P-48174
1
2 2
1 1
P-48138
P-48173
IMPORTANT P-34661
1 P-34760
3
1
2
P-34665
Figure 20-140-7
Publications. 1
P-34664
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC 01) UNLESS OTHERWISE SPECIFIED.
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
Description
Description
WARNING
P-68211
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
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Lift and block the loader. (See Procedure on Page 10-10-
1.)
1 P-68831
Remove the four motor cover mounting screws (Item 1) Remove the two hoses (Item 1) [Figure 30-20-3] from
[Figure 30-20-2]. the hydrostatic motor.
Publications.
IMPORTANT
on the hydrostatic motor must be tightened to
115 - 125 ft.-lb. (156 - 170 N•m) torque.
Figure 30-20-4
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
P-68831
Figure 30-20-5
Parts Identification
16
14
20 3
15
14
19 14
16 18
3 13
18
19
17 3 5
12
10
5
9
Publications. 6 3
3
5
4
2
1
PE2620T
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
P-68211
Figure 30-20-6
Remove the nine tie bolts (Item 1) [Figure 30-20-7] from
Figure 30-20-8
3
8
Publications. 2
P-64267 1
7
4
Drain the oil from the motor.
Seal all open ports and clean the motor with solvent. P-68211
Figure 30-20-9
3
1
2
1
P-63785
Figure 30-20-10
Figure 30-20-12
Publications. 1
2
1
P-68213
P-68212
P-64274
2 3
P-39898
P-64268
Publications.
NOTE: Care should be taken to keep the geroler
assembly together.
1
P-64272
Figure 30-20-19
Publications.
1
1
P-64273
1
The hydrostatic motor carrier is the mating connection MEL1420 - Carrier Seal Tool
from the hydrostatic drive motor to the transmission case.
Remove the hydrostatic motor. (See Removal And
The hydrostatic motor carrier contains a shaft that rotates Installation on Page 30-20-1.)
on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains. Damaged or
severely worn bearings can destroy a drive motor.
Publications.
side and another set for the right hand side of the loader.
P-68214
30-30-1
263 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-4
Figure 30-30-2
P-4454A
Figure 30-30-5
Drill a 0.125 in. (3 mm) hole in the motor carrier seal
[Figure 30-30-2].
P-39786A
Hit the tool with a hammer until the seal is fully seated on
Use a slide hammer to remove the seal from the motor the carrier shaft [Figure 30-30-5].
carrier shaft [Figure 30-30-3].
30-30-2
264 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Removal And Installation
2
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Publications.
check the plug (Item 2) [Figure 30-30-6]
located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
Remove the control panel. (See Removal and Installation
on Page 50-100-2.)
drain lubrication oil from the hydrostatic Remove the lift arm bypass control valve. (See Removal
motor can leak into the chaincase. and Installation on Page 20-50-1.)
30-30-3
265 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-9
Figure 30-30-7
P-54235A
Publications.
Installation: Tighten the motor carrier mounting bolts to
125 - 140 ft.-lb. (170 - 190 N•m) torque.
1
Figure 30-30-8
2
P-39813
P-54226 Fasten a chain hoist to the bolt on the motor carrier and
remove the carrier from the loader.
For ease of removal, fasten the front drive chain Reverse the removal procedure to install the motor
(previously removed) to the chaincase as shown (Item 1) carrier.
[Figure 30-30-8].
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-30-
8] from the sprocket.
30-30-4
266 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D)
Parts Identification
2
3 File has expired.
4
6
7
P-64693
1. SHAFT 5. HOUSING
3. BEARING 7. SEAL
4. RACE
30-30-5
267 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-13
Figure 30-30-11
7.000’’
Length
(177,8 mm) P-39816
Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-30-13].
procedure. Refer to [Figure 30-30-11] for the correct
Publications.
2
1
1
P-39815
P-4365
30-30-6
268 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-17
Figure 30-30-15
P-39820
Use 4-5/16 inch driver tool and press the new inner
Fasten the carrier motor housing to the work surface bearing race into the motor carrier housing [Figure 30-
securely with the inner bearing race (Item 1) [Figure 30- 30-17].
Figure 30-30-18
Publications.
Remove the bearing race from the carrier housing
[Figure 30-30-15].
Figure 30-30-16
P-39819
Use 4-5/16 inch driver tool and press the new outer
Put the motor carrier housing in the hydraulic press as bearing race into the motor carrier housing [Figure 30-
shown [Figure 30-30-16]. 30-18].
Use a 3-7/8 inch driver tool and press the outer bearing Press the bearing race in until it is fully seated in the
race from the housing. carrier housing.
30-30-7
269 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-20
Figure 30-30-19
Publications.
Use the fabricated press tool (Item 1) and 3.0 inch driver
tool, install the new inner bearing (Item 2) [Figure 30-30-
over the sprocket shaft as shown.
Put the outer bearing over the end of the sprocket shaft
19] on the sprocket shaft as shown. and press the bearing on with the press tool and driver
tool [Figure 30-30-20].
Remove the press and drive tools from the sprocket
shaft. Remove the press and driver tools from the sprocket
shaft.
30-30-8
270 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-23
Figure 30-30-21
1
1
Put the snap ring (Item 1) [Figure 30-30-21] over the end
P-4375
of the sprocket shaft.
Using the press and driver tools, press the snap ring
23] and install the shaft seal.
Hit the tool with a hammer until the seal is fully seated on
Publications.
(Item 1) [Figure 30-30-21] over the sprocket.
Figure 30-30-24
the shaft.
Figure 30-30-22
P-39821
30-30-9
271 of 764
HYDROSTATIC MOTOR CARRIER (CONT’D)
Figure 30-30-25
The carrier shaft must turn freely with end play not to
exceed 0.007 in. (0,17 mm).
30-30-10
272 of 764
HYDROSTATIC MOTOR CARRIER (SJC) Shaft Seal Removal And Installation
The hydrostatic motor carrier is the mating connection MEL1420 - Carrier Seal Tool
from the hydrostatic drive motor to the transmission case.
Remove the hydrostatic motor. (See Removal And
The hydrostatic motor carrier contains a shaft that rotates Installation on Page 30-20-1.)
on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains. Damaged or
severely worn bearings can destroy a drive motor.
Publications.
carrier. The brake disk is mounted to the shaft in the
motor carrier.
P-68214
Figure 30-31-2
P-4454A
Figure 30-31-5
Drill a 0.125 in. (3 mm) hole in the motor carrier seal
[Figure 30-31-2].
P-39786A
Hit the tool with a hammer until the seal is fully seated on
Use a slide hammer to remove the seal from the motor the carrier shaft [Figure 30-31-5].
carrier shaft [Figure 30-31-3].
2
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Publications.
check the plug (Item 2) [Figure 30-31-6]
located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
Remove the control panel. (See Removal and Installation
on Page 50-100-2.)
drain lubrication oil from the hydrostatic Remove the lift arm bypass control valve. (See Removal
motor can leak into the chaincase. and Installation on Page 20-50-1.)
Figure 30-31-7
P-54235A
Publications.
Installation: Tighten the motor carrier mounting bolts to
125 - 140 ft.-lb. (170 - 190 N•m) torque.
1
Figure 30-31-8
2
P-39813
P-54226 Fasten a chain hoist to the bolt on the motor carrier and
remove the carrier from the loader.
For ease of removal, fasten the front drive chain Reverse the removal procedure to install the motor
(previously removed) to the chaincase as shown (Item 1) carrier.
[Figure 30-31-8].
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-31-
8] from the sprocket.
Parts Identification
2
3 File has expired.
4
6
7
P-64693
1. SHAFT 5. HOUSING
3. BEARING 7. SEAL
4. RACE
Figure 30-31-11
7.000’’
Length
(177,8 mm) P-39816
Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-31-13].
procedure. Refer to [Figure 30-31-11] for the correct
Publications.
2
1
1
P-39815
P-4365
Figure 30-31-15
P-39820
Use 4-5/16 inch driver tool and press the new inner
Fasten the carrier motor housing to the work surface bearing race into the motor carrier housing [Figure 30-
securely with the inner bearing race (Item 1) [Figure 30- 31-17].
Figure 30-31-18
Publications.
Remove the bearing race from the carrier housing
[Figure 30-31-15].
Figure 30-31-16
P-39819
Use 4-5/16 inch driver tool and press the new outer
Put the motor carrier housing in the hydraulic press as bearing race into the motor carrier housing [Figure 30-
shown [Figure 30-31-16]. 31-18].
Use a 3-7/8 inch driver tool and press the outer bearing Press the bearing race in until it is fully seated in the
race from the housing. carrier housing.
Figure 30-31-19
Publications.
Use the fabricated press tool (Item 1) and 3.0 inch driver
tool, install the new inner bearing (Item 2) [Figure 30-31-
over the sprocket shaft as shown.
Put the outer bearing over the end of the sprocket shaft
19] on the sprocket shaft as shown. and press the bearing on with the press tool and driver
tool [Figure 30-31-20].
Remove the press and drive tools from the sprocket
shaft. Remove the press and driver tools from the sprocket
shaft.
Figure 30-31-21
1
1
Put the snap ring (Item 1) [Figure 30-31-21] over the end
P-4375
of the sprocket shaft.
Using the press and driver tools, press the snap ring
23] and install the shaft seal.
Hit the tool with a hammer until the seal is fully seated on
Publications.
(Item 1) [Figure 30-31-21] over the sprocket.
Figure 30-31-24
the shaft.
Figure 30-31-22
P-39821
Figure 30-31-25
The carrier shaft must turn freely with end play not to
exceed 0.007 in. (0,17 mm).
Description
1
Charge pressure is a supply of oil to the hydrostatic
pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
3
Charge pressure is obtained from the standard section 2
on the hydraulic gear pump.
The charge pressure sender is located on the charge Connect the gauge (Item 1), to the adapter fitting (P/N
3
1
P-43196A
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
Testing (Cont’d)
Figure 30-40-3
P-68838
Remove the hydraulic cap (Item 1) [Figure 30-40-3] from Tighten the hydraulic fittings.
the hydraulic control valve charge pressure inlet fitting.
Figure 30-40-5
2
1
Publications.
8.1 ft.-lb. (10 - 11 N•m) torque.
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.
I-2003-0888
N-17231
Figure 30-40-6
Remove the plug, spring and poppet [Figure 30-40-7].
Description
Figure 30-50-1
P-66670
NOTE: The two top valves are for the reverse drive
Check the O-ring (Item 2) [Figure 30-50-2] for damage
and replace as needed.
Publications.
loop and the two bottom valves are for the
forward drive loop.
If the replenishing/high pressure relief valve must be
replaced, it must be replaced as a complete unit.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 2
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
P-34567B
Publications.
1 P-34567A
P-34568
Figure 30-50-6
1
1
P-28850
2
Hold the nut (Item 1) [Figure 30-50-7] on the two
Installation: Install the key in the hydrostatic pump shaft Remove the two hydrostatic pump mounting bolts from
(Item 1) [Figure 30-50-6] before installing the pump drive the pump and drive belt housing.
Publications.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
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9
File has expired.
8 11
14.
15.
16.
Wear Plate
Piston Assembly
Piston Retainer
17. Retainer
14 18. Block
Publications. 2
17
12
17
15 24.
25.
Replenishing/High
Pressure Relief Valve
Coupler
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
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13.
14.
15.
Retainer
Piston Assembly
Wear Plate
File has expired.
7 4
3 9
16. Swash Plate
17. Housing 10
23.
Publications.
Piston Retainer
23
10
8
12
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
1
Figure 30-50-8
1 1
N-17193
N-19551
Disassembly (Cont'd)
1
Figure 30-50-11
2
1
N-17198
Figure 30-50-12
1
Publications.
1
N-17199
Disassembly (Cont'd)
Figure 30-50-15
1
3 3
2
3 3 2 1
3
N-17481
File has expired. N-17200 and the support washer (Item 3) from the drive shaft end
of the pump [Figure 30-50-17].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-50-18
2) for wear and replace as needed [Figure 30-50-15].
Publications.
Check pins (Item 3) [Figure 30-50-15] to see if they are
all the same length.
Figure 30-50-16
N-17239
N-17201
Disassembly (Cont'd)
Figure 30-50-19 1
1
N-17242
Figure 30-50-22
Remove the snap ring (Item 1) [Figure 30-50-19] from
the pump housing and remove the driveshaft and bearing
Publications.
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-50-22]
from the lower trunnion cover. Remove the cover.
N-17241
Disassembly (Cont'd)
Figure 30-50-23
2
2
1 1
1 N-17246
File has expired. N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-50-25].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-50-26
from the pump housing [Figure 30-50-23].
1
2
N-17247
Disassembly (Cont'd)
Figure 30-50-27
1 N-17249
Figure 30-50-30
Inspect the seal (Item 1) [Figure 30-50-27] in the upper
trunnion cover and replace if needed.
1 N-17251
2
Slide the swash plate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-50-30] from
the swash plate shaft.
Assembly
Figure 30-50-31
N-17252
Publications. 1
N-17253
Assembly (Cont'd)
Figure 30-50-34
1 1
2
N-17247
3
Install the upper trunnion seal (Item 1) [Figure 30-50-36]
Figure 30-50-37
Install the tapered bearing (Item 1) [Figure 30-50-34] on
the swash plate shaft.
2
N-17246
3
Install the linkage bracket (Item 1) [Figure 30-50-37] and
N-17248 the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 -
30 N•m) torque.
Assembly (Cont'd)
Figure 30-50-38
2
N-17243
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-50-38] and O-
ring (Item 2) [Figure 30-50-38] at the lower trunnion as
shown in [Figure 30-50-39]. Install the snap ring (Item 1) [Figure 30-50-41] on the
pump shaft.
Assembly (Cont'd) 1 1
Figure 30-50-42
3
2
1 1
1 N-17200
Publications.
1
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
50-43]. 30-50-45] onto the slipper holddown pins.
Assembly (Cont'd)
1
2
Figure 30-50-46
N-17194
File has expired. N-17198 locating pin (Item 2) [Figure 30-50-48] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-50-49
Lubricate the pistons and cylinder block bores and insert
N-17196
Assembly (Cont'd)
1 1
Figure 30-50-50
N-19550
Install the valve plate and end cap on the pump housing.
Coat the backside of the valve plate with petroleum jelly Figure 30-50-53
to hold it in position and install the valve plate onto the
Figure 30-50-51
Publications. 1
2
1
N-19571
Assembly (Cont'd)
Figure 30-50-54
Publications.
1
N-19569
Figure 30-51-1
P-64943
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
Raise the lift arms and install and approved lift arm P-64460
support device. (See Installing on Page 10-20-1.)
Place the loader on jack stands. (See Procedure on Page Disconnect all of the electrical harness connectors (Item
10-10-1.)
File has expired. 1) [Figure 30-51-3] from the loader harness.
Removal:
WARNING
Publications.
fall or move and cause injury or death.
W-2017-0286
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
Raise the operator cab. (See Raising on Page 10-30-2.)
damage the system.
I-2003-0888
Figure 30-51-2
1 Figure 30-51-4
P-64425
P-64426
Locate the two hydraulic controllers (Item 1) [Figure 30-
51-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.
Figure 30-51-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 7.7
Installation:
Figure 30-51-6
Publications.
1
P-64978
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 2
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
P-34567B
Figure 30-51-9
Publications.
P-34567A
1
P-34568
Install a puller on the hydrostatic pump drive pulley and
remove the pulley from the pump shaft [Figure 30-51-
Remove the hydrostatic pump mounting bolt (Item 1) 11].
[Figure 30-51-9] and washer(s).
Removal And Installation (Cont’d) Before putting a hydrostatic pump back into operation,
the hydrostatic pump should be filled with hydrostatic
Figure 30-51-12 fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Publications. 1
P-64458
1
Remove the air bleed plugs (Item 1) [Figure 30-51-14].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
P-28850 other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Hold the nut (Item 1) [Figure 30-51-13] on the two Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
hydrostatic pump mounting bolts (Item 2) [Figure 30-51-
12].
Parts Identification
3 1
1. O-ring 5 4
2. Bolt
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt
File has expired. 14
15
16
19 17
21
24 23 22 26
Publications.
18
27
32 19 29
28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
6 22. Plug
2
7 23. Screen
24. Plug
25. Orifice
30 26. Dowel Pin
27. Charge Pressure Relief
4 28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
B25010
Figure 30-51-15
1
1
P-64437
Publications.
Figure 30-51-16
Factory setting on the relief valve is 5075 PSI (350 bar).
4
3
2 1
P-64436
Figure 30-51-18 3 4
2 5
1
1 P-64435
The charge relief valve (Item 1) [Figure 30-51-18] is Inspect the sealing ring (Item 3) [Figure 30-51-20] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or
Figure 30-51-19 Publications. NOTE: 1.0 mm shim (Item 5) [Figure 30-51-20] = 43.5
PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
1
P-64435
Figure 30-51-21
1
1
1
P-64439
Publications.
Figure 30-51-22
2 2
1 1
1
P-64440
Figure 30-51-25
P-64442
P-64453
Figure 30-51-28
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
3
Use updated files from Bobcat
Figure 30-51-29
Publications.
2
P-64447
Figure 30-51-31
1 2
1
2
P-64463
P-64466
Figure 30-51-34
RIGHT SIDE
Figure 30-51-35
Publications.
2
P-64501
1 P-64456
2
Figure 30-51-39
Figure 30-51-40
1
P-64469
P-64471
Figure 30-51-47
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-44] in the
1
Publications.
1
P-64472
P-64479
Publications.
2
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-49] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-51].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-51-49] are not bent or damaged.
1 P-64483
Publications.
1
P-64482
1
2
1
P-64486
Figure 30-51-58
Figure 30-51-59
P-64485
P-64524
Figure 30-51-60
The drive shaft can be tapped out of the end housing with
B25013
a rubber mallet.
Figure 30-51-62
1 1
P-64489
Figure 30-51-63
P-64492
P-64491
Figure 30-51-66 1
2
1
P-64493
Figure 30-51-69
Figure 30-51-67
Publications. 1
3
P-64494
P-64466
Assembly: Align the servo piston so the guide slot Each servo has a pair of bushings (Item 1), O-rings (Item
(Item 1) [Figure 30-51-67] is parallel to the driveshaft 2) and square-cut seals (Item 3) [Figure 30-51-69].
centerline. Measure with a straight-edge [Figure 30-51-
66].
Figure 30-51-70
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-72] from the
Figure 30-51-73
Remove the lock nut (Item 1) [Figure 30-51-70] from the
servo piston.
1
1
Publications.
P-64498
Figure 30-51-74
1
1
2 1
3
P-64499
Remove the plug (Item 1) from the top center of the case Replace O-rings on plugs.
housing. Replace O-ring (Item 2) [Figure 30-51-74].
torque. Publications.
Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m)
1
Figure 30-51-75
P-64500
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-51-78 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.
Use updated files from Bobcat Raise the operator cab. (See Raising on Page 10-30-2.)
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
Figure 30-51-79
1
P-64438
1
Publications. 1
1 1
P-64977
Figure 30-51-83
1
P-64457
File has expired. P-64457 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-51-83]. Figure 30-51-86
P-64457
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-51-87 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
NOTE: The Hydraulic Controller Neutral Adjustment Raise the lift arms, and install an approved lift arm
must be performed whenever the Mechanical support device. (See Installing on Page 10-20-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Raise the operator cab. (See Raising on Page 10-30-2.)
28.)
Connect the remote start tool. (See REMOTE START
TOOL KIT-MEL1563 on Page 10-60-1.)
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
Figure 30-51-88
2
1
P-64975
1
File has expired. P-64460 pertaining to the side of the hydrostatic pump you are
adjusting.
Publications.
1 1
P-64459
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
Figure 30-51-92
P-64459
Publications. 1
P-64459
Turn the adjustment screw (Item 1) [Figure 30-51-93] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 18 ft.-lb. (25
N•m) torque.
Description To adjust the drive belt between the flywheel and the
hydrostatic pump pulley, use the following procedure:
The drive belt makes the mechanical connection from the
engine flywheel to the hydrostatic pump pulley. Stop the engine. Open the rear door.
The belt is a cord-reinforced rubber design. Disconnect the negative (-) battery cable.
Constant tension is applied to the drive belt by the use of Remove the belt shield. (See Shield Removal And
a spring-loaded belt tensioner. Installation on Page 30-50-1.)
The drive belt is protected by a plastic shield fastened to The pulley tensioner is located between the flywheel and
the flywheel housing by metal clips. The shield is also in pump pulley.
place to protect the operator.
Figure 30-60-3
Shield Removal And Installation
Figure 30-60-1
Publications. P-48478A
Remove the three drive belt shield mounting clips (Item NOTE: The pointer (Item 2) [Figure 30-60-3] will be at
1) [Figure 30-60-1]. the 1 o'clock position when the idler is not
under spring tension.
Figure 30-60-2
P-48000
Adjusting (Cont’d)
1
Figure 30-60-4
P-48478A
Publications.
NOTE: If the pointer does not move when prying on
the belt tensioner mounting bracket, manually
move the arrow towards the 3 o’clock position
Stop the engine and recheck the pointer position.
Readjust if necessary.
with a screwdriver while putting tension on
the bracket to help get it started. After the idler has been in service, readjust when the
pointer reaches the 1 o'clock position.
Figure 30-60-6
P-48481
Remove the drive belt from the pump pulley and flywheel.
File has expired. P-48000 Remove the drive belt from the loader [Figure 30-60-8].
Publications.
Remove the belt shield [Figure 30-60-6]. (See Shield
Removal And Installation on Page 30-50-1.)
Figure 30-60-7
P-48478A
Figure 30-60-9 1
P-48478A
Publications.
Removal And Installation on Page 30-50-1.)
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate
File has expired.
5
17. Locating Pin
18. Spring
Publications.
available individually. Consult
parts catalog for available
sub-assemblies. 7
15
8 16
17
9
18
10
19
20
E-2296
Figure 30-60-11
3
1
1
4
P-8861
Remove the grease cover (Item 1) [Figure 30-60-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-60-13] with a plastic hammer.
2 Publications.
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-60-14].
assembly (Item 5) [Figure 30-60-12].
Figure 30-60-15
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
File has expired. P-8871 (Item 1) [Figure 30-60-17] into the hub.
Figure 30-60-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-60-15] as shown.
2
3
P-8874
Figure 30-60-19
1
1
P-8877
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-60-19] over the roll pins. assembly, do not press down on the arrow
3
Publications.
2
1
P-8876
Fill the grease cap 1/4 full (approximately 1/2 - 3/4 oz.) of
grease.
Description
Figure 30-70-4
Publications.
1
3
P-76212
1
Remove the filter housing nut (Item 1) from the filter
housing (Item 2) [Figure 30-70-1].
2
Figure 30-70-2
P-76216
The larger taper spring (Item 1) slides over the end of the
2
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-70-4] slides into the filter element.
P-76214
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disk Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . . . . . 40-30-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-1
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-3
Description
Figure 40-10-1
Publications.
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the
discs.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
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 1
support device can allow the lift arms or attachment
N-19105
to fall and cause injury or death.
W-2059-0598
Disconnect and remove the engine speed control. (See Figure 40-10-4
Removal And Installation on Page 70-20-1.)
Publications.
Removal And Installation on Page 40-30-2.)
3
P-54222
Description
2
2
2 1
The tools listed are needed for the following procedure: Install the puller tool (Item 1) [Figure 40-20-2] on the
axle hub.
Publications.WARNING
20-1], use the following procedure:
Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for
Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair
Use updated files from Bobcat Place the new axle seal over the axle and into the axle
tube.
Publications. Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is
flush with the edge of the axle tube [Figure 40-20-5].
P-4181
File
WARNING
has expired. and the front cover (Item 2) from the chaincase [Figure
40-20-6]. (See Front Cover Removal And Installation on
Page 40-30-1.)
Figure 40-20-7
Never work on a machine with the lift arms up unless
Publications. W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 40-20-8
2
1
P-4162A
Publications.
until the axle is free from the sprocket and inner bearing.
Figure 40-20-10
P-4170
P-4169
Publications.
bearing mounting surface and until the bearing contacts
the spline on the shaft.
Put the tubing (Item 1) on the bearing puller (Item 2)
[Figure 40-20-12].
Press the splined end of the axle free from the bearing Put the bearing (Item 3) [Figure 40-20-12] on the tube as
[Figure 40-20-11]. shown.
Put the spline end of the axle shaft (Item 4) [Figure 40-
20-12] in the bearing and press the bearing onto the axle.
Figure 40-20-13
2
1
P-4179
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
When the bearing reaches the bearing mounting surface,
Figure 40-20-16
Publications.
P-4172
P-4180
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-14].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].
Figure 40-20-19
Figure 40-20-18
Publications.
P-4173
To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.
WARNING
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
P-54227
Raise the loader lift arms and install an approved lift arm
support device.(See Installing on Page 10-20-1.)
Remove the parking brake disc (Item 1) [Figure 40-20-
Raise the loader operator cab. (See Raising on Page 10- Remove the six carrier mounting bolts (Item 2) [Figure
30-2.) 40-20-20] from inside the chaincase.
Figure 40-20-21
Publications.
Installation on Page 70-20-1.)
Remove the front (or rear) axle and sprocket. (See Axle P-54226
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
Tip the end of the sprocket on the motor carrier toward
the rear of the loader and remove the rear drive chain
from the sprocket.
Figure 40-20-22
Publications.
Use MEL1037 Chain Link Tool and #80 chain adapter.
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22]. Tighten the
threaded rod of the chain link tool to 130 ft.-lb. (176 N•m)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307
Description
P-68818
DANGER
Remove the front chaincase cover mounting screws
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
DANGER 2 1
3
5
6
7 7
P-54161
P-90328
AVOID DEATH Disconnect the lift control cross bar from the lift pedal
•
File has expired.
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
linkage (Item 1) [Figure 40-30-2].
Publications.
WARNING Remove the chaincase cover mounting screws (Item 5)
[Figure 40-30-2].
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Remove the tie straps (Item 6) [Figure 40-30-2] and
support device. Failure to use an approved lift arm remove the center chaincase cover.
support device can allow the lift arms or attachment
to fall and cause injury or death. NOTE: There are machined recesses (Item 7) [Figure
W-2059-0598 40-30-2] on the bottom side of the cover to
help pry the cover off.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.) Installation: Apply polyurethane sealer to mating
surfaces. Polyurethane sealant should be applied to the
Raise the loader operator cab. (See Raising on Page 10- screw threads to stop oil leakage. Tighten the mounting
30-2.) screws to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
DANGER
3
3 P-54088
•
Use updated files from Bobcat
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Keep out of this area when lift arms are raised
help pry the covers off.
Publications.
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage. Tighten the mounting
screws to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
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
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50-90-1
50-80-1
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . 50-80-2
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . 50-80-2
50-123-1
Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . . . 50-123-2
Removal (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . 50-123-1
Description
Figure 50-10-1
P10564 P10563
Publications.
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2
1
P-54068
Figure 50-10-5
4 6
5
7
1
2 9 8
10
1
N-19383
10
3.)
Figure 50-10-6
Publications. 1
7
N-19219
1
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Reverse the above procedure to install the seat bar into Installation: Tighten the mounting bolt (Item 2) [Figure
the operator cab. 50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.
Figure 50-10-9
5
4 6
2 7
1
File has expired. N-19340
Figure 50-10-10
Publications.
1
7
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
10].
Figure 50-10-11
6 7
5
4 6
N-19222
3
2
1 Turn the bolt (Item 1) [Figure 50-10-12] & [Figure 50-10-
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
WARNING 1
P1518 P1528
WARNING Remove the cab nut and holddown plate (Item 1) [Figure
Publications.
1
P-54018
N-20617D
Figure 50-20-4
2 1
P-48587
Figure 50-20-5 Remove the front screw (Item 1) [Figure 50-20-6] from
the gas cylinder mounting bracket.
Publications.
1 2
P-43354
Figure 50-20-7
2
1
1
P1008
Figure 50-20-10
1
Publications.
2
P-68819
Reverse the above procedure to install the gas Apply a small amount of Loctite® #242 on the threads of
cylinder(s). the cylinder rod [Figure 50-20-10].
Figure 50-20-12
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and 1
could cause injury or death.
W-2245-0796
Figure 50-20-11
N-20617D
Remove the heater unit from the cab (if equipped). (See
Removal And Installation on Page 80-40-1.)
Publications.
Figure 50-20-14
N-20627A N-20628D
P-54021
Figure 50-30-1
1
1
1
2
N-20729A
Raise the operator cab. (See Raising on Page 10-30-2.) Locate the seat belt bolts under seat pan insulation
(Items 1 & 2) [Figure 50-30-3] and peel back or cut
N•m) torque.
Publications.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2 N-20655
Figure 50-31-1
1 2
N-20974
File has expired. N-20647 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising on Page 10-30-2.) Figure 50-31-4
Figure 50-31-2
Publications.
1
N-20973
P10564 P10563
Figure 50-31-5
1 1
2 1
2
1
1
N-20974
Publications.
Remove the slide rail (Item 2) [Figure 50-31-5] from the
bottom of the seat frame.
Figure 50-31-7
N-18579
Figure 50-31-8
1 1
N-18580
Publications.
N-18581
Figure 50-31-11
2
1
P-43118
Pull the seat back adjustment lever (Item 1) [Figure 50- Remove the operator seat. (See Removal And
31-11] and tilt the seat back all the way forward. Installation on Page 50-31-1.)
1 1
N-18578
Figure 50-31-14
1
2 3
P16284
File has expired. 1 Remove the seat belt retractor (Item 2) [Figure 50-31-
15]
3
Installation: Be sure tether strap (Item 3) [Figure 50-31-
Publications.
Remove the end release buckle (Item 2) [Figure 50-31-
14]
Figure 50-31-16
OUTSIDE OF CAB
1
Use updated files from Bobcat
2
Publications. P16126
INSIDE OF CAB
P16128
Description
Figure 50-40-1
N-20734
Publications. N-20733
N-20739
Figure 50-40-4
1
1
P-3908
Figure 50-40-6
Publications.
must be removed to prevent the pivot pin from
being locked in the Bob-Tach frame.
Figure 50-40-7
3
2
1
Publications.
Installation: Push the pivot pin (Item 2) into the Bob-
Tach frame. Position the end of the pin flush with the end
of the Bob-Tach bushing (Item 3) [Figure 50-40-7].
Figure 50-40-8
1
P-3924A
Publications.
P-3925
Remove the lever mounting bolt and nut (Item 1), washer
(Item 2) and spring (Item 3) [Figure 50-40-9].
Figure 50-40-12
2
1
P-3914
1
File has expired. P-3926 Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-14] (both sides) if worn or damaged.
Remove the spring, bolt and clevis assembly (Item 1) NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-14]
Publications.
Always replace bent or broken wedges.
Figure 50-40-13
4
3 P-3929
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
or clevis (Item 4) are damaged, put the assembly in the
vise. Loosen and remove the bolt (Item 1) [Figure 50-40-
13] with a 5/16 inch allen wrench.
Figure 50-40-15
Figure 50-40-16
Publications.
1
P-3909C
Description
Publications.
1
2
P-43823
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the Bob-Tach lever to
secure the clamp.
Figure 50-41-3
1
2 1
P-3909
3
Publications.
Tach pivot pin. (Both sides)
Use a punch to push the pivot pins all the way inside the Remove the Bob-Tach pivot pin (Item 1). (Both sides)
Bob-Tach frame. Thread the bolt (Item 2) [Figure 50-41-5] into the pivot
pins and pull.
Remove the Bob-Tach from the lift arms.
Check for wear and damage on the pins and the Bob-
Remove the dust cup (Item 3) [Figure 50-41-3] (Both Tach bushings (Item 3) [Figure 50-41-5]. Replace as
sides) when the Bob-Tach is free from the loader. needed.
Figure 50-41-6 1
1 N-18560
Use the following procedure to remove and install the Figure 50-41-9
Bob-Tach lever (Item 1) [Figure 50-41-6], spring and
Publications. 3
1 4
P-43824
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-9].
Figure 50-41-10
1 1
P-3914
3 2
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) NOTE: The Bob-Tach stop (Item 1) [Figure 50-41-12]
needed.
Use updated files from Bobcat
Remove the bolt and replace the damaged parts as
available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
N-18563
Figure 50-41-13
Publications.
Figure 50-41-14
P-3909C
Figure 50-50-1
1
2
P-48506
P-43215
Figure 50-50-4
1
P-54324
1
Remove the tubeline clamps (Item 1) [Figure 50-50-6]
Figure 50-50-7
Right Side
Publications.
P-54323
1
Remove the lift arm support device (Item 1) [Figure 50- Remove the retainer bolt (Item 2) [Figure 50-50-7] and
50-5]. nut from the lift cylinder rod end pivot pin.
Figure 50-50-8
1
1 2
P-4345
Wrap one of the 7 ft. lifting straps around the lift arm
Publications.
scratches.
Figure 50-50-11
50-8].
Figure 50-50-9
1
2
P-4348
N-20865 Put the middle of the second lifting strap (Item 1) [Figure
50-50-11] up into the lift arm as shown.
Remove the left side lift cylinder pivot pin (Item 1) [Figure Install the lift cylinder pivot pin (Item 2) [Figure 50-50-11]
50-50-9]. and secure the pin with the mounting bolt and nut.
Wrap both ends of the strap around the top of the lift arm
and down the back of the lift arm [Figure 50-50-11].
Figure 50-50-12
1
P-54025
Continue to wrap the lifting strap around the lift arm a Installation: Tighten the pivot pin mounting bolt and nut
second time [Figure 50-50-12]. to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Publications.
should be installed on the right side lift arm.
Use the chain hoist and lower the lift arms so they rest on
the blocking.
Figure 50-50-14
N-20774C
Pull the lift arms away from the loader [Figure 50-50-15].
File has expired. Lower the lift arms slowly and put on the floor.
Raise the lift arms with the chain hoist so the lift arms are
free from the loader [Figure 50-50-14].
Figure 50-60-1
1 2
P-48130
Open the rear door. Reverse the removal procedure to install the grill.
P-48252
2 2
P-43360
1
Remove the top and bottom door hinge mounting bolts
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the engine harness. hinge as shown.
Lift the door away from the loader frame and put the door
Figure 50-70-2
Publications. flat on the floor.
P-34588
Figure 50-70-6
1
1
Figure 50-70-5
Publications. Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 2
3 Align the striker assembly in the center of the mounting
holes.
Figure 50-70-7
1
P-31128
Figure 50-70-8
Publications.
3
P-31127
Figure 50-80-1
2
P-54376
Disconnect the fuel fill hose (Item 1) and the vent hose
File has expired. P1616 (Item 2) [Figure 50-80-3] from the fuel tank.
Figure 50-80-4
Remove the cover (Item 1) [Figure 50-80-1] which is
installed over the fuel drain near the rear of the
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
Figure 50-80-5
2 P-54376
File has expired. Disconnect the fuel fill hose (Item 1) [Figure 50-80-7]
from the fuel tank.
P-54041
Figure 50-80-8
Figure 50-80-6
Publications. 1
P-54375
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
WARNING P-28907
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
Publications.
DANGER 1
P-90328 P-28909
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the two mounting bolts (Item 1) [Figure 50-90-
tubeline, hose, fitting, component or a part failure 2] from the pedal mounting bracket.
can cause lift arms to drop.
• Keep out of this area when lift arms are raised Remove the pedal assembly from the loader.
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Figure 50-90-3
1 1
P-54158
P-54175
P-28941
Remove the crossbar from the pivot [Figure 50-90-6].
Remove the bolt, washer and nut (Item 1) [Figure 50-90- Installation: Check the nylon bushing (Item 1) [Figure
4] to disconnect the lift pedal linkage from crossbar. 50-90-6] for wear and replace as needed.
Figure 50-90-7 1 2
P-28907
File has expired. P-30150 pedal linkage (Item 2) [Figure 50-90-9] from the pedal.
Figure 50-90-8
Publications.
1
P-54158
Pedal (Adjusting)
2
After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve 1
spool must travel full stroke without the pedal hitting the
floor panel.
Figure 50-90-10
P-28907
Publications.
Loosen the two mounting bolts (Item 1) [Figure 50-90-
standard torque.
Description
WARNING P-28957
Publications.
Raise the operator cab.(See Raising on Page 10-30-2.)
DANGER
P-28958A
Tilt the foot pedal up and remove the two nuts (Item 1)
P-90328 [Figure 50-91-2].
AVOID DEATH Remove the foot pedal and sensor assembly from the
• Disconnecting or loosening any hydraulic 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 50-91-3
P-28957
Publications. 1
P-28958A
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
P-21924
Remove the foot pedal assembly.
Figure 50-91-7
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) [Figure 50-91-8] from the foot pedal.
Description
Figure 50-100-1
P-54658
The steering system [Figure 50-100-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the 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. The returning force of the torsion bushings.
bellcranks have grease fittings.
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
rubber torsion bushings pressed into the bellcranks. made. Do not fully tighten torsion bushing
Bellcranks mount to the control panel. bolts again until all steering adjustments have
been made first.
Steering linkage bars are a two-piece design. Steering
linkage bars are adjustable in length for “full travel Sequence of steering adjustments:
adjustment”.
1. Set neutral of pintle arms, “creep”
Steering linkage bars attach to the pintle arms where a
2. Set linkage travel at steering linkage bars
rubber torsion bushing is pressed into the pintle arms.
3. Set drift at drift adjustment bolts
P-54147
P-90328
AVOID DEATH Raise the lift arms and install an approved lift arm support
•
File has expired.
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
device. (See Installing on Page 10-20-1.)
Use updated files from Bobcat Loosen the jam nut (Item 1) from the bypass control knob
(Item 2) [Figure 50-100-2].
Publications.
WARNING Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-2].
Never work on a machine with the lift arms up unless Figure 50-100-3
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
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
P-54146
fall or move and cause injury or death.
W-2017-0286
Figure 50-100-4 2
1 1
2 2 3
P-26323
1 1
Publications.
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 35 -
40 ft.-lb. (47,5 - 54,2 N•m) torque.
P-26325
P-26329
1 P-54148 P-54136
Publications. 1
1
P-54134
Shock Removal And Installation NOTE: The steering shaft can be removed without
removing the control panel from the loader.
Figure 50-100-10 Photo [Figure 50-100-11] shows the control
panel removed for clarity purpose only.
Figure 50-100-11
3
Remove the mounting nut (Item 1) [Figure 50-100-10]
from the end of the shock connected to the steering
Publications.
P-48278
2
2 1
1
P-28845
2
Publications.
installing the right and left bellcranks.
WARNING
2 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 1 1
to fall and cause injury or death.
W-2059-0598
P-67067
WARNING Scribe a mark across the top of the steering linkage bars
of the frame before running the engine for service. Remove the four steering linkage mounting bolts (Item 2)
Failure to use jackstands can allow the machine to [Figure 50-100-14].
Raise the lift arms and install an approved lift arm support
bars. Tighten the steering linkage mounting bolts to 35 -
40 ft.-lb. (47,5 - 54,2 N•m) torque.
Publications.
device. (See Installing on Page 10-20-1.)
2
5
2
P-48630
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-15]. 1 Bolt
P-48632
Figure 50-100-18
2
1
3
2 3
6
5
1
1 4
2
1
P-48627
2
File has expired.P-48629 are worn, loosen the bolt (Item 2) and rotate the cams 1/4
turn [Figure 50-100-19].
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-18]. 19] from the pintle.
Publications.
Installation: Tighten the centering block bolts to 35 - 40
ft.-lb. (47,5 - 54,2 N•m) torque.
100-19].
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-19].
centering plate.
Figure 50-100-20
ROLLER CAMS 2
2
1
P-54615
3
Loosen the bolt (Item 1) and remove the pintle base (Item
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-20].
Figure 50-100-21
Publications.
1
4
3
1
P-48624
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering linkage bar (Item 4) for damage and replace as
needed [Figure 50-100-21].
Figure 50-100-23 2
1
3
1
P-54625
Publications.
pintle base should be level with the top of the pump shaft.
Tighten the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque. 3
2
1
P-54624
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-25].
Figure 50-100-26
4 1 3
2 2
3 P-48619
Figure 50-100-30
2 1
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 50-100-31
2
P16121
2 Using the remote start tool, turn the key (Item 1) [Figure
properly. Publications.
centering block will also become aligned NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-32 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
3 release the hydraulic brake.
Using the remote start tool, turn the key (Item 1) [Figure
50-100-33] and start the engine and run at low idle.
1
Tighten bolts (Item 3) [Figure 50-100-32] to 35 - 40 ft.-lb.
(47,5 - 54,2 N•m).
2
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-31] & [Figure 50-
100-32].
P-48451
Figure 50-100-34
2 1
1
P-54610
File has expired. NOTE: The neutral range (dead-band) will vary
between the hydrostatic pumps.
Figure 50-100-36
1
2 2 1
Publications.
Test both levers by moving them backward and forward
and letting them return to neutral by the return spring
force.
2
1
WARNING
P-48448
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 nut (Item 1) 3 to 4 turns, then loosen the bolt
Figure 50-100-38
Raise the lift arms and install an approved lift arm support
Publications.
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
Lift and block the loader. (See Procedure on Page 10-10- P-54613
1.)
Loosen the nut (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.)
from the torsion bushing (Item 2) [Figure 50-100-38].
Pre-load tension in the torsion bushings must be
The bolt must be loose enough to allow the torsion
removed before adjusting the steering linkage.
bushing (Item 2) [Figure 50-100-38] to turn freely
between the torsion bushing and the linkage bar.
1 3 4
P-51174
Figure 50-100-40
Remove the 3/8 in. (10 mm) thick spacer (Item 4) [Figure
50-100-41].
3 2
4
1
P-51173
1
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) Before adjusting the linkage, check that the base pintle
[Figure 50-100-40]. arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-42] are tighten to 35
- 40 ft.-lb. (48 - 54 N•m) torque. There should be no play
between the pintle arm and the square pump shaft.
Figure 50-100-43
1
1 1
P-51175
Publications.
1
P-54613
P-51134
Figure 50-100-47 1
1
P-37574
Tighten the two bolts and nuts (Items 1 & 2) [Figure 50- Repeat steps on the other control lever.
100-47] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque at the
Use updated files from Bobcat The traditional benchmark for drift is less than 10 ft. of
“drift” in 100 ft. of travel distance.
Description
WARNING
With the option of SJC you receive a control panel that
has two electronic handles that control the steering, lift
Never work on a machine with the lift arms up unless
and tilt functions. There is no mechanical linkages
the lift arms are secured by an approved lift arm
connecting to the hydrostatic pumps or the control valve.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
The control panel is connected to the lower main frame
to fall and cause injury or death.
and wraps around and underneath the operator seat. W-2059-0598
Figure 50-101-1
Publications. 1
P-73677
AVOID DEATH Remove the bolts from the speed control bracket (Item 2)
• Disconnecting or loosening any hydraulic [Figure 50-101-1].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27
• Keep out of this area when lift arms are raised N•m) torque.
unless supported by an approved lift arm
support. Replace if damaged. Remove the bolts from the speed control lever (Item 3)
D-1009-0409 [Figure 50-101-1].
Figure 50-101-2
1
2
1
1
4
P-73293
3 3
Disconnect the right and left joystick wire harness
Publications.
[Figure 50-101-2]. Remove the shield.
Figure 50-101-3
P-73678
Figure 50-110-1
P-28845
File has expired. To replace the rubber boot (Item 1) [Figure 50-110-2] on
the control panel, remove the control lever (See Lever
2 Removal And Installation on Page 50-110-1.)
1
Publications.
Disconnect the electrical connectors (Item 1) [Figure 50-
110-1].
Figure 50-111-1
1
N-17773
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Handle Sensor (Item 1) [Figure 50-111-1].
1
P-28963
Figure 50-111-4
1
P-21860
2
Remove the handle lock solenoid connector (Item1)
NOTE: Pry out with a small screw driver and push the
Disconnect the harness connector (Item 1) [Figure 50- connector down.
111-4] from the handle sensor connector.
Figure 50-111-5
1
Publications.
1
5
4
2
1
P-21862
P-21878
1
Figure 50-111-11
2
3
Remove one of the two mounting screws (Item 1) [Figure
50-111-8] from the handle sensor.
Publications. 7
4 1
3 8
P-21799
1
Figure 50-111-12
1
1 N-17384
Figure 50-111-15
Remove the handle sensor (Item 1) [Figure 50-111-12].
(See Handle Sensor Removal And Installation on Page
Publications. 1 2 2
N-17385
Figure 50-111-16
2 1
2
1 P-48736
Publications.
N-22796
Figure 50-111-19
2
1
2
P13734
B-16618
Remove the control lever from the cross shaft and control
panel.
Figure 50-111-22
Publications.
Install the new boot and reinstall the control lever. (See
Boot Removal And Installation on Page 50-110-1.)
Description
Figure 50-112-1
P-64298
Figure 50-112-3
Publications.
The tools listed will be needed to do the following
3
procedure:
2
MEL1608-Joystick Test Harness [Figure 50-112-1]
MEL1563 or 6689779-Remote Start Tool
Multimeter
P-28312
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) Disconnect the joystick harness connector (Item 1) from
the loader wiring harness (Item 2) [Figure 50-112-3].
Raise the operator cab. (See Raising on Page 10-30-2.)
Install the test harness (Item 3) [Figure 50-112-3]
Connect the remote start tool to the loader. (See between the two connectors.
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.) Turn the remote start key to ON position without starting
the loader.
Figure 50-112-4
1 1
P-73247
Figure 50-112-6
Repeat the procedure at the right joystick wiring harness
connector (Item 1) [Figure 50-112-4]. (If needed.)
1
Publications.
1
P-73248
Figure 50-112-7
1
1
P-73245
File has expired. P-73240 Disconnect both of the electrical harness connectors
from the loader harness (Item 1) [Figure 50-112-8].
P-73246
Pull on the tag (Item 1) [Figure 50-120-1] on the rear Install the rubber molding (Item 1) [Figure 50-120-2]
window to remove the rubber cord. around the edge of the rear opening in the operator cab.
Figure 50-120-3
Publications.
fragments from the rubber molding before
installing a new window.
P16015A
Installation (Cont’d)
Figure 50-120-4
1 1
P16013
Apply liquid soap in the rubber molding (Item 1) [Figure Tapping the window corners will help seat the window in
50-120-4] to make installation easier. the molding.
Publications.
Align the other lower corner of the window in the molding.
Figure 50-120-5
P-64998
Figure 50-121-1
1 1
Figure 50-121-2
Publications.
1
1
1
1
N-20950
Figure 50-122-1
2
N-20814
File has expired. P-66024 and knob removed to illustrate the direction of
movement.
Release the latch (Item 1) [Figure 50-122-1] and slide Move the window slide rail using the two thumb pads
the front window back towards the rear of the operator (Item 2) [Figure 50-122-2] and [Figure 50-122-3]
2 2
P-66019
Figure 50-122-4
2
1
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1
P-66020
3 1 1
2
1 P-24472
Publications.
Figure 50-123-2
N-20171
Figure 50-123-4
1
P-66059
Figure 50-123-5
Publications.
4] cut off the excess molding. seated in the lower portion of the molding.
Figure 50-123-7
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-123-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-123-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.
Figure 50-123-8
Publications.
Figure 50-123-9
P-66051
1
Replace the Lexan glazing under the following
conditions:
Publications.
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Publications.
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Actuator Connector Disassembly And Assembly. . . . . . . . . . . . . 60-130-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Foot Lock Solenoid Removal And Installation . . . . . . . . . . . . . . 60-130-12
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . 60-130-11
Handle Lock Solenoid Disassembly And Assembly. . . . . . . . . . 60-130-10
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . 60-130-10
Handle Sensor Connector Disassembly And Assembly . . . . . . . 60-130-3
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
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WIRING SCHEMATIC
STD CAB HARNESS
S130 (S/N 529211001 AND ABOVE)
(S/N 529611001 AND ABOVE)
(S/N A1Z711001 – A1Z759999)
(S/N A8KA11001 – A8KA59999)
(S/N A84W11001 AND ABOVE)
PROTECTED POWER
PROTECTED POWER
PROTECTED POWER
PROTECTED POWER
COMPUTER POWER
COMPUTER POWER
COMPUTER POWER
COMPUTER POWER
RUN/ENTER SW
RUN/ENTER SW
CLOCK/LATCH
CLOCK/LATCH
CLOCK/LATCH
CLOCK/LATCH
HEADLIGHTS
HEADLIGHTS
SYSTEM Rx
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
SYSTEM Rx
SYSTEM Tx
STSTEM Tx
STSTEM Tx
GROUND
GROUND
GROUND
GROUND
BUZZER
BUZZER
START
START
START
START
DATA
DATA
OPEN
OPEN
DATA
DATA
File has expired.
C G E F H K D A B J C J B A G D K H F E C G E F H K D A B J C J B A G D K H F E
C G E F H K D A B J C J B A G D K H F E C G E F H K D A B J C J B A G D K H F E
9330
9330
1920
1920
1220
1910
9310
1220
1910
9310
9110
9340
9300
9110
9340
9300
9320
9330
9310
1210
9320
9330
9310
1210
2910
9210
9300
9220
2910
9210
9300
9220
9120
9120
2920
2920
9350
9350
S1 S1
BUZZER (+) BUZZER (+)
S2 2910 S2 2910
BUZZER (-) 2930 2920 BUZZER (-) 2930 2920
39
31
40
35
8
1
Use updated files from Bobcat
39
31
40
35
8
1
9340
2900
9350
9200
9210
9200
9110
2900
9220
2770 39
31
40
35
8
1
39
31
40
35
8
1
9340
2900
9350
9200
9210
9200
9110
2900
9220
2770
7
37
41
48
42
7
37
41
48
42
Publications.
9100
1900
1200
9100
1910
1900
1220
1200
9120
1920
1210
7
37
41
48
42
7
37
41
48
42
9100
1200
9100
1910
1900
1220
1200
9120
1920
1210
4 4 4500 4 4 4500
C482 C482
45 45 3910 A A GND 45 45 3910 A A GND
SEATBAR SEATBAR
C408 CAB MNFR HARNESS CONN
1100
27 27 A A C209 27 27 A A C209
24 24 2790 B B DOME LIGHT 24 24 2790 B B DOME LIGHT
2710 2710
13 13 SWITCH 13 13 SWITCH
30 30 30 30
17 17 17 17
9 9 9 9
10 10 10 10
22 22 22 22
16 16 C434 16 16 C434
28 28 2765 2765 2750 B B LEFT 28 28 2765 2765 2750 B B LEFT
20 20 6110 A A HEADLIGHT 20 20 6110 A A HEADLIGHT
4500
4500
2770
2770
14 14 14 14
25 25 6100 6100 6120 A A C435 25 25 6100 6100 6120 A A C435
47 47 2760 B B RIGHT 47 47 2760 B B RIGHT
15 15 HEADLIGHT 15 15 HEADLIGHT
19 19 19 19
18 18 18 18
6 6 3 1 4 6 SW1 6 6 3 1 4 6 SW1
11 11 BRAKE 11 11 BRAKE
38 38 2 5 SWITCH 38 38 2 5 SWITCH
21 21 21 21
1770
1770
26 26 26 26
23 23 1100 23 23 1100
43 43 1770 43 43 1770
32 32 32 32 1700
3 3 3 3
5 5 5 5
1170
1700
2730
2 2 2 2
36 36 36 36
29 29 29 29 A B C
A B C
STANDARD CAB HARNESS 7116261
C129
ACCESSORY
CONNECTOR STANDARD CAB HARNESS 7143070
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WIRING SCHEMATIC TO MAINFRAME
SSL 7-PIN
C426 To Mainframe
OPTIONS 7100 C CAN CONNECTOR D F C E A B G
Harness
2650 F
S130 (S/N 529211001 AND ABOVE)
C103
G
(S/N 529611001 AND ABOVE)
9800
1160
9700
1710
9500
9600
2710
BACK-UP E
(S/N A1Z711001 – A1Z759999) ALARM 6310 A
(S/N A8KA11001 – A8KA59999) D KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
(S/N A84W11001 AND ABOVE) 6200 H UNSW POWER 2 1160 RED/WHT 2720 H GROUND
(PRINTED FEBRUARY 2008) Printable Version Click Here 2600 B CAN SHIELD
SW POWER
C
1
9710
1730
PUR
RNG
9710
1720
F
B
CAN SHIELD
SW POWER ACD
V-0797 Machine
CAN LOW B 9620 PUR 9610 E CAN LOW
Connector
2620
2610
6320
6330
2640
CAN HIGH A 9520 PUR 9510 D CAN HIGH
TO MAINFRAME
GROUND 3 2730 BLK C OPEN
7100 C 7-PIN A OPEN
2650 F 1 2 2 1 2630 6210
C666 ATTACHMENT
CONNECTOR G OPEN
C604 C605
C103
6600 G LEFT WORK RIGHT WORK J
1 2 2 1 BOOM-MOUNTED
BACK-UP
6400 E N ACD CONNECTORS
ALARM 6310 A SW POWER K 1740
6500 D GROUND B 2740 C703 J2 - 10-PIN BLACK
6200 H STANDARD TAILGATE E OUTPUT E 5100 5100 C E OUTPUT
2600 B F OUTPUT F 5350 5350 H F OUTPUT
LEFT TAILLIGHT RIGHT TAILLIGHT
HARNESS - 7109403 G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
6340
2620
Output
2610
6610
6320
6620
6330
2640
C OUTPUT C 5300 5300 G C OUTPUT
Connector
D OUTPUT D 5150 5150 D D OUTPUT
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
DELUXE TAILGATE TO ENGINE OR
CONNECTOR
5900 J ID #1
A B C D E F MAINFRAME 5500 A ID #2
HARNESS - 7109404 LEFT WORK
ACCESSORY STOP LIGHT
REGISTRATION RIGHT WORK A B C D E F
B ID #3
STOP TURN TAIL STOP C604 C103 C605 ACD
TAIL TURN
C ID #4 Input
LEFT TAILLIGHT RIGHT TAILLIGHT A B C D E F A B B A A B C A B C D E F G H A B C D E F
D ID #0 Connector
E OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
6410
6810
6640
2540
2540
2530
6240
1720
2720
1740
2730
1730
6600
2530
2520
7100
6370
6310
2500
7100
6500
6400
6200
6250
2520
2510
6240
6230
6510
6710
6610
2550
F OPEN
N
P
M TO OLDER
A MODEL ATTACHMENTS 46 C C 6430 A A 6520
C506
6800
2670
6700
2660
TO ATTACHMENT
6360
2650
1370
2640
B 2620
J
Publications.
2630
N 87A 87 86 87A 87 86
2640 87A 87 86 87A 87 86
P LEFT RIGHT 2610 2650
M TO OLDER FLASHER FLASHER
2660
D S 2730
6350
6340
A BRN LT
C623
1370
6210
6310
E BLK TM TO OPTIONS
1020
1320
1020
1320
1020
1320
2790
2795
(EXTERIOR CAB)
F DBL CENTER
G RED GD 6440 1
C669
H YEL RT 2785 2
A B A B A B
L 6540 3
To Starter "B" Terminal
K
4 WAY FLASHER 1010
Left Marker Fuse 10A Right Marker Fuse 10A Signal Fuse 10A
GRADER HARNESS - HARNESS - 6718873 HARNESS 6726430
6706391 ROAD LIGHTS
POWER BOB-TACH
SOLENOID M
FRONT WIPER
BOTTLE AND TANK SSL 7-PIN
C426 To Mainframe
TO OPTIONS CAN CONNECTOR Harness
D F C E A B G
FRONT WIPER
C606
9800
1160
1710
9500
9600
2710
9700
C M
C607
(DELUXE ACCESSORY) CAN HIGH A 9520 PUR 14 9510 D CAN HIGH Engine
7112290 3 7310 GROUND G 2730 BLK 13 C OPEN Compartment
PARK
HIGH
C666 ATTACHMENT
C667
1 OPEN
4440 1 F OUTPUT F 5350 5350 H F OUTPUT
4
5
4440
4450 4451
2450 2 7117322 7104465 G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
6
4455 1
4470 4471 Output
YELLOW TIE STRAP C OUTPUT C 5300 5300 G C OUTPUT
2470 2 Connector to
ADDITIONAL POWER CONNECTOR
D OUTPUT D 5150 5150 D D OUTPUT Engine
4475 1 A F
1740 A A OUTPUT 5250 5250 A OUTPUT Compartment
GREEN TIE STRAP
2740 B M OUTPUT M 5200 5200 E B OUTPUT
ID (K TO L) L 5910 5000 A J OUTPUT
REAR AUX JUMPER HARNESS - 7102338 ID (K TO P) P 5510
12
5450 K K OUTPUT
TO MAINFRAME 11
TO 1730
(ACCESSORY CONNECTOR)
1720 A
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
C402
B 2720
Boom 5500 A ID #2
7100 A
B ID #3
ACD
ALARM
BACK-UP ALARM HORN TO HANDLE CONNECT0R C ID #4 Input
C412
1720 1730 A
CONTROL HARNESS - G OPEN
2720 B FRONT HORN HARNESS - 6719151
BACK-UP ALARM 6732730 H
K
OPEN
OPEN
ADDITIONAL POWER Rev. none
SWITCHES HARNESS - CONNECTOR
C491
B
7107544 1740 A
STROBE OR
BEACON
2 1
1 1530 1530 1 SSL 7-PIN
2 3000 3000 2
C609 CAN CONNECTOR
T3
T4
2 1 TO
3 2570 2570 3 KEY "RUN" D 9800 D RED = RED
STROBE/BEACON WIRES CONNECT BY
4 3070 3070 4 RNG = ORANGE
TO WHEEL TO JOYSTICK TO OPTIONS
UNSW POWER 2 1160 F BLK = BLACK LETTER ACROSS
SPEED HARNESS CAN SHIELD C 9700 C LBL = LIGHT BLUE CONNECTORS
1 1540 1540 1 6700 E DOME LIGHT A B
C668 OR C670
2 3020 3020 2 TO OPTIONS A Harness LGN = LIGHT GREEN B A BATTERY FEED 1000-1999 RED, RED/WHT, RNG
T1
C608
CAN LOW B 9600 A A RED DGN = DARK GREEN GROUND 2000-2999 BLK
3 2580 2580 3 (4 WAY FLASHER) C YEL = YELLOW MONITORING 3000-3999 LBL
4 3080 3080 4 2 2785 2780 D
CAN HIGH A 9500 B B BLK
PNK = PINK
SOME CONNECTOR HYDRAULIC 4000-4999 LGN
C669
GROUND 3 2700 G WHT = WHITE BODIES NOT SHOWN ATTACHMENT CONTROLS 5000-5999 YEL
1 6440 F
JUMPER HARNESS - Connector
7-PIN
DOME LIGHT BRN = BROWN FOR DRAWING CLARITY LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
3 6540 B
on Loader C666
ATTACHMENT
CONNECTOR C426 TAN = TAN
PUR = PURPLE ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
482 of 764 6736808 EXTERIOR CAB HARNESS - Boom GRY = GRAY
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
- +
Publications.
BATTERY - Used for supplying and SWITCH - Single Pole - Double
storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch to
warn personnel.
4 5
positions.
File has expired. RESISTOR - Limits current flow.
6
Publications.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown
in the open position.)
to
B
File has expired.
TEMPERATURE SENDER - Provides
a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at
C 212
SW9
C670 SW8
SW7 C 483
S3
S4
C 611
C 630
C 635
T3
Publications. C 480
SW1
SW2
SW3
C 435 SW4
C 408 SW5
SW6
C 426
T4
T1
T6
T3
T8 C 405
C 113
C 112
C 108
C 423
C 105
C 107
C 407-1
C 101
C 419
C 418
C 420
C 421 C 409
C 422 C 492
MS2190
Description
Figure 60-10-1
1 1
P-28840
Figure 60-10-2 The fuse panel cover (Item 1) [Figure 60-10-3] has a
decal inside to show the location and amp ratings.
P-13848A
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
3 7 19
4 8 14 16 20
10 12
7117407
Publications. 10-5].
R - Relay
Solenoid Testing
Figure 60-10-6
Publications.
WARNING 1
1
Publications.
3
P-09589 P-09590
Servicing
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.
P-09589 P-09590
WARNING 3 1
Publications.
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
60-20-5] to the positive terminal on the loader starter.
Publications.
Loosen the adjustment bolt (Item 2) [Figure 60-30-1].
Move the alternator until the belt has 5/16 in. (8,0 mm)
movement at the middle of the belt span with 15 lbf. (66
N) of force.
2
WARNING
AVOID INJURY OR DEATH 1
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
If electrolyte is taken internally drink large quantities If the charging system malfunctions check the following:
W-2065-0807
Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 60-30-1.) If belt is worn or
deteriorated replace.
Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair/replace. If fuse is in
Publications.
AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
doubt, remove it and check for continuity.
1. If the test light does not light up, reattach the clamp
Damage to the alternator can occur if: and proceed to alternator voltage test. (See Below.)
• Engine is operated with battery cables
disconnected. 2. If the test light lights up, there is a short (drain) in the
• Battery cables are connected when using a fast electrical system of the loader. The short must be
repaired before the charging system can be checked.
charger or when welding on the loader. (Remove
both cables from the battery.) 3. Disconnect the alternator B+ terminal (Item 1) and L
• Extra battery cables (booster cables) are & S terminal connector (Item 2) [Figure 60-30-2] and
connected wrong. if the test light goes out, the alternator is faulty. If the
I-2023-1285 test light stays on, find the short in the system and
repair it.
Figure 60-30-3
P-66815
Publications.
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-3]. 1
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature).
Figure 60-30-6
P-34679
File has expired.
P-66817
Publications.
replace wire harness.
Figure 60-30-7
DANGER
P-90328
•
File has expired.
AVOID DEATH
Disconnecting or loosening any hydraulic
1
Publications.
WARNING
60-30-7] from the alternator.
Figure 60-30-8
IMPORTANT 3
P-24543
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected. Remove the adjustment bolt (Item 1) [Figure 60-30-8]
• Battery cables are connected when using a fast from the mounting bracket.
charger or when welding on the loader. (Remove
both cables from the battery.) Remove the alternator belt (Item 2) [Figure 60-30-8]
• Extra battery cables (booster cables) are from the alternator pulley.
connected wrong.
I-2023-1285 Remove the mounting bolt (Item 3) [Figure 60-30-8].
Parts Identification
Publications. 10
11
19
18
17
16
15
C-3529B
Testing
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
Publications.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-3
4
2
1
File has expired.
P-34385
Publications.
Disconnect the engine harness power wire and positive
(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-40-3].
Parts Identification
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
21
32
File has expired. 7*
15
37
14
5 8
Publications. 14
12
6
29
1 4
3
28
2
27
25. Holder
35 26. Bracket
27. Ring
28. Bolt
22 26
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
36. Bracket
24
37. Bearing
4 5 6 7
11
12
13
8
File has expired.
9 10
B-15551
1
Use updated files from Bobcat
DESCRIPTION
3
Publications.
HOURMETER / CODE DISPLAY /
ENGINE PREHEAT COUNTDOWN
FUEL GAUGE
HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES*
relating to the loader monitoring system. COUNTDOWN - Preheat time remaining
Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time
to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE CODES (Item 2).
(CODES* show only when there is an error found by loader monitoring system.)
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold 2 seconds to
view Shtdn (SHUTDOWN) feature & Operational Code Number in HOURMETER/CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXIMUM
FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast
movement of auxiliary functions (The farther you move the switch, the faster the movement of auxiliary
functions.) MAXIMUM FLOW allows for only fast movement.]
7 AUXILIARY PRESSURE RELEASE Rear Auxiliary Only - With key ON or engine running, press and hold button for 5 seconds.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
8 PRESS TO OPERATE LOADER Press to activate BICS System when the Seat Bar is down and operator is seated in operating position.
9 SEAT BAR The light comes ON when the seat bar is down.
10 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE button is pressed. The lift and tilt
functions can be operated when the light is ON.
11 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can
be moved forward or backward when the light is ON.
12 TRACTION LOCK OVERRIDE (Function Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to
use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader
service. Press a second time to lock the brakes.
13 ALARM The ALARM beeps when there is an Error, WARNING or SHUTDOWN condition.
* For further description of SERVICE CODES (See DIAGNOSTICS SERVICE CODES on Page 60-90-1.)
15 17 19 21 23 25 27
28
ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
LIGHT
15
(Opt.)
Device
Use updated files from Bobcat
14 System (ACS)
Attachment Control ON
(ACD) FLASHING
---
3 Beeps
-
*
---
Error
Electrical controlled attachment is present.
Error with Attachment Control Device (ACD)
(Opt.)
General
16 Warning
Publications.
ON
ON
3 Beeps
3 Beeps
FLASHING Continuous
**
*
Error
WARNING
Error with one or more engine or hydraulic functions.
Engine speed high or in shutdown.
SHUTDOWN Engine speed extremely high. Engine will stop in 10 seconds.
17 NOT USED
Fuel ON 3 Beeps * Error Fuel level sender system fault.
18 Level FLASHING 3 Beeps * WARNING Fuel level low.
* These functions are monitored and have associated SERVICE CODES. See SYSTEM SETUP AND ANALYSIS for description of SERVICE CODES.
Figure 60-50-3
5 6
ENTER PASSWORD
1 3
LANGUAGES
2
B-16165
The first screen you will see on your new loader will be as
Figure 60-50-5
Publications.
description of screens to setup the system for your use.
(See Right Panel Setup (Keyless) on Page 60-180-1.)
8 NOT USED
decrease. There are four positions;
OFF-1-2-3.
---
9 TEMPERATURE Turn clockwise to increase the
CONTROL temperature; counterclockwise to
decrease.
1 2 Publications.
3
FRONT PANEL
4 5 6 7 8
REF.
NO.
1
DESCRIPTION
ADVANCED
FUNCTION / OPERATION
Figure 60-50-8
1
N-20140
Figure 60-50-11
Remove the three mounting bolts (Item 1) [Figure 60-50-
8].
1
P-28360
N-20158
Figure 60-50-12
N-20163
File has expired. N-20141 wire harness connector (Item 1) [Figure 60-50-14] from
the panel.
Remove the ignition switch (Item 1) [Figure 60-50-12] Remove the panel from the loader cab.
from the control panel.
N-20142
N-20103
Figure 60-50-16
1
1
N-20144
Figure 60-50-17
Publications.
1
2
N-20165
Figure 60-50-19
N-20147
Publications.
N-20146
N-20141
P-28360
Figure 60-50-25
1
1
1
P-26255
Publications.
2
1
P-26251
Figure 60-60-1
1 1
N-19351
Figure 60-60-2Publications.
1
N-19349
Figure 60-60-4
1 2 1
1
3
P-66221
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
P-66222
Description
The main controller provides information to all other controllers. All loaders have a main controller.
The main controller is located behind the access panel near the operators left foot.
Connector Identification
41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1
9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
41 50 41 50
31
J1 40 31 J2 40
21 30 21 30
11 20 11 20
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V-171/V-172
41 50
J1
1400 8000 X 9800 X X 3420 7200 3520 X
1 2 3 4 5 6 7 8 9 10
V-172
WARNING 1
P-54201
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
Remove the three mounting bolts (Item 2) [Figure 60-70-
Publications.
P-67074
Description
2
The Bobcat Controller (ACS) is part of the Advanced
Control System (ACS) which is a selectable foot/hand
control system. Electrical actuators shift the spools on
the hydraulic control valve.
Publications.
1
P-16536 P-21879
Description (Cont'd)
Figure 60-71-4
Figure 60-71-5
Publications.
1
P-21769
Connector Identification
G H
J J1 J3
F K
E A
D J3
B
C G H
F J
K J2
F E
G D A
E H B
A C
B J2
D
J1
C
File has expired.
J1
J3
J2
2
WARNING
2
Never work on a machine with the lift arms up unless 1
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-28966
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
Lift the controller out from the mounting location.
Stop the engine. Raise the seat bar. Remove the two mounting bolts (Item 2) [Figure 60-71-
7] to remove the controller from the bracket.
P-28964
The drive controller is located behind the right side The hydrostatic drive pump is a Rexroth A22 unit. It has
access panel near the operators right foot. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller monitors the position of the left forward and reverse outputs of the pump to the drive
joystick, pump swash plate angles and the output of the motors. The Rexroth pump is equipped with position
wheel speed sensors. sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
The drive controller works along with the ACS controller uncommanded swash plate movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
P-66836
Connector Identification
P-64295
P-64296
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. 1
W-2059-0598
P-73288
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the controller (Item 1) [Figure 60-72-2].
Figure 60-72-1
File has expired.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 60-72-3
Publications. 1
1 1
P-73285
P-73287
Figure 60-80-1
1
P-28302
Publications.
The speed sensor is sealed with an O-ring (Item 1)
[Figure 60-80-1] to keep hydraulic oil inside the motor
carrier and dirt out.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Testing (Cont’d)
Figure 60-80-3
3
2
1
2
1
P-64976
Locate the speed sensor (Item 1) [Figure 60-80-3] on the Turn the remote start key to ON position without starting
top of the right or left hydrostatic motor carrier. the loader.
torque.
Publications.
Disconnect the speed sensor wire connector (Item 3)
The voltage should be approximately 5 volts.
Figure 60-80-5 1
1 P-64764
File has expired.P-64762 the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.
Raise the lift arms and install an approved lift arm support Figure 60-80-8
device. (See Installing on Page 10-20-1.)
Figure 60-80-6
2
P-64765
1
P-64762
Figure 60-80-9
1
1
P-26292
Figure 60-80-12
The electrical connector can be replaced.
Figure 60-80-10
Use updated files from Bobcat
Publications.
1
2
P-26295
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue
Description
Figure 60-90-1
1 4
Publications.
one SERVICE CODE is present, the codes will scroll on
the HOURMETER/CODE DISPLAY.
CODE CODE
01-16 Air filter not connected 11-05 Seat bar sensor short to battery
01-17 Air filter plugged 11-06 Seat bar sensor short to ground
02-16 Hydraulic/Hydrostatic filter not connected 12-21 Front auxiliary PWM switch out of range high
02-17 Hydraulic/Hydrostatic filter plugged 12-22 Front auxiliary PWM switch out of range low
12-23 Front auxiliary PWM switch not in neutral
03-09 Battery voltage low
03-10 Battery voltage high 13-05 Fuel shut-off hold solenoid short to battery
03-11 Battery voltage extremely high 13-06 Fuel shut-off hold solenoid short to ground
03-14 Battery voltage extremely low 13-07 Fuel shut-off solenoid open circuit
03-22 Battery voltage out of range low
14-02 Fuel shut-off pull solenoid error ON
04-09 Engine oil pressure low 14-03 Fuel shut-off pull solenoid error OFF
04-14
04-15
04-21
File has expired.
Engine oil pressure extremely low
Engine oil pressure shutdown level
Engine oil pressure out of range high
15-02
15-03
Traction lock pull solenoid error ON
Traction lock pull solenoid error OFF
04-22 Engine oil pressure out of range low
16-05 Traction lock hold solenoid short to battery
17-05
Traction lock hold solenoid open circuit
CODE CODE
26-02 Front base solenoid error ON 32-63 ACS Pedal lock short to ground
26-03 Front base solenoid error OFF 32-64 ACS Pedal lock short to battery
32-65 ACS Sensor supply voltage out of range
27-02 Front rod solenoid error ON 32-66 ACS Battery voltage out of range
27-03 Front rod solenoid error OFF 32-67 ACS Switch flipped while operating
32-68 ACS Lift handle information error
28-02 Diverter solenoid error ON 32-70 ACS Right hand drive short to ground
28-03 Diverter solenoid error OFF 32-71 ACS Right hand drive short to battery
32-74 ACS Left joystick X-axis out of range
29-02 High flow solenoid error ON 32-75 ACS Interrupted unswitched power
29-03 High flow solenoid error OFF 32-76 ACS CAN joystick information error
32-77 ACS Remote control information error
30-28 Controller memory failure
36-48
Hydraulic fan error OFF
CODE CODE
38-21 Left joystick Y axis out of range high 38-68 Wheel angles (alignment) not calibrated
38-22 Right joystick Y axis out of range high 38-69 Lift & tilt actuators calibration fault
38-23 Front right steering sensor out of range high 38-70 Recovery mode failure
38-24 Front left steering sensor out of range high 38-71 Battery out of range
38-25 Rear right steering sensor out of range high 38-72 Drive pump not calibrated
38-26 Rear left steering sensor out of range high 38-73 Steering mode switch flipped while operating
38-27 Lift actuator out of range high 38-74 Right wheel speed uncommanded motion
38-28 Tilt actuator out of range high 38-75 Left wheel speed uncommanded motion
38-29 Left joystick X axis out of range low 38-76 Undercurrent steer pressure solenoid
38-30 Right joystick X axis out of range low 38-77 Undercurrent front right extend steer solenoid
38-31 Left joystick Y axis out of range low 38-78 Undercurrent front right retract steer solenoid
38-32 Right joystick Y axis out of range low 38-79 Undercurrent front left extend steer solenoid
38-33 Front right steering sensor out of range low 38-80 Undercurrent front left retract steer solenoid
38-34
38-35
38-36
File has expired.
Front left steering sensor out of range low
Rear right steering sensor out of range low
Rear left steering sensor out of range low
38-81
38-82
38-83
Undercurrent rear right extend steer solenoid
Undercurrent rear right retract steer solenoid
Undercurrent rear left extend steer solenoid
38-37 5 volt sensor supply 1 out of range low 38-84 Undercurrent rear left retract steer solenoid
38-38 5 volt sensor supply 2 out of range low 38-85 5 Volt sensor supply 1 out of range high
CODE CODE
40-28 Right joystick internal failure 75-18 Right swash plate not in neutral
40-48 Right joystick multiple 75-19 Left joystick X-axis out of range high
75-21 Left joystick Y-axis out of range high
41-09 Alternator voltage low 75-22 Right joystick Y-axis out of range high
41-10 Alternator voltage high 75-23 Right front wheel angle sensor out of range high
41-11 Alternator voltage extremely high 75-24 Left front wheel angle sensor out of range high
75-25 Right rear wheel angle sensor out of range high
44-02 Horn error ON 75-26 Left rear wheel angle sensor out of range high
44-03 Horn error OFF 75-27 Left swash plate out of position
75-28 Right swash plate out of position
45-02 Right blinker error ON 75-29 Left joystick X-axis out of range low
45-03 Right blinker error OFF 75-31 Left joystick Y-axis out of range low
75-32 Right joystick Y-axis out of range low
46-02
46-03
Left blinker error ON
Left blinker error OFFFile has expired. 75-33
75-34
75-35
Right front wheel angle sensor out of range low
Left front wheel angle sensor out of range low
Right rear wheel angle sensor out of range low
47-21 8 volt sensor supply out of range high 75-36 Left rear wheel angle sensor out of range low
47-22 8 volt sensor supply out of range low 75-37 5 volt sensor supply 1 out of range low
49-02
Use updated files from Bobcat
Front light relay error OFF
60-21
Publications.
Rear light relay error OFF
CODE CODE
75-68 Angle sensors not calibrated 80-03 ACD output ‘A’ error OFF
75-69 Battery voltage out of range high
75-70 Interrupted power (Also occurs after software 81-02 ACD output ‘B’ error ON
updates)
75-71 Battery voltage out of range low 81-03 ACD output’ B’ error OFF
75-72 Drive pump not calibrated
75-73 ISO/H pattern switch flipped while operating 82-02 ACD output ‘C’ error ON
75-74 Right wheel speed uncommanded motion 82-03 ACD output ‘C’ error OFF
75-75 Left wheel speed uncommanded motion
75-76 No communication from ACS controller 83-02 ACD output ‘D’ error ON
75-77 Left speed sensor out of range high 83-03 ACD output ‘D’ error OFF
75-78 Right speed sensor out of range high
75-79 Left speed sensor out of range low 84-02 ACD output ‘E’ error ON
75-80
75-81
75-82
File has expired.
Right speed sensor out of range low
Right front steer retract short to battery
Left front steer retract short to battery
84-03
85-02
ACD output ‘E’ error OFF
78-74 Door/transport lock open/active 93-02 Service tool output ‘F’ error ON
93-03 Service tool output ‘F’ error OFF
80-02 ACD output ‘A’ error ON
Description
Figure 60-100-1
1 2 3 4
B-15551G
Publications.
The Press To Operate button activates the system and
allows the operator to function the loader.
2]. Publications.
left instrument panel should be ON [Figure 60-100-
bar, start engine and press the PRESS TO OPERATE
LOADER button.
10. Raise lift arms about 6 feet (2 meters) off the ground.
2. Raise seat bar fully. All four BICS lights (Items 1, 2, 3,
and 4) [PRESS TO OPERATE LOADER, SEAT BAR, 11. Turn key OFF (Key Switch Panel), press STOP button
LIFT & TILT VALVE AND TRACTION*] on left (Keyless Panel), and wait for the engine to come to a
instrument panel should be OFF [Figure 60-100-2]. complete stop.
NOTE: Record what lights are blinking (if any) and 12. Turn key ON (Key Switch Panel), press RUN/ENTER
the number of light flashes. (See button (Keyless Panel). Press the PRESS TO
Troubleshooting Chart on Page 60-100-4.) OPERATE LOADER button, move hand control or
joystick to lower the lift arms. Lift arms should not
Inspecting Deactivation Of The Auxiliary Hydraulics lower.
System (Engine STOPPED - Key ON)
13. Move the control (foot pedal, hand control or joystick)
3. Sit in operator’s seat, lower seat bar, and press the to tilt the bucket (or attachment) forward. The bucket
PRESS TO OPERATE LOADER button. Press the (or attachment) should not tilt forward.
auxiliary hydraulics FLOW button. The auxiliary
FLOW button light will come ON. Raise the seat bar.
The light should be OFF.
Troubleshooting WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
Publications.
Troubleshooting Chart
PROBLEM SOLUTION #
SOLUTION SUGGESTIONS
Publications.
5. Check 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 tester
adapter (MEL1567) for the following procedure:
[Figure 60-110-1].
Figure 60-110-2
Publications.
P-4699
1
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
N-19558 sensor.
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 60-110-5.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.
Figure 60-110-5
Publications. Remove the mounting bolt (Item 1) from the seat bar
mount (Item 2) [Figure 60-110-6].
Figure 60-110-7
2
1
3
Figure 60-110-8
3
1
1
P-4703
Publications.
[Figure 60-110-8]. the Present position.
Figure 60-110-10
Publications.
1
P-4699
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged.
File has expired.
Intermittent activation of traction lock.
1, 2, 3, 4, 5, 6, 7,11,12,13
8, 9, 10, 11
Publications.
Fuse And Relay Location / Identification on Page 60-10-8.)
5. To test the solenoid, the pull coil should be about 0.3 ohm and the hold coil should be about 10.9 ohm.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check flywheel RPM sensor and wiring.
12. Check the Display Panel for an error code. (See Electrical System Service Manual)
13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
WARNING 2
AVOID INJURY OR DEATH 1
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat P-54187
Company parts if repair is necessary.
W-2165-0100
Remove the two bolts (Item 1) and remove the bracket
Publications. P-4712
photo [Figure 60-120-1].
Figure 60-120-3
P-54174
2
NOTE: The loader control panel and linkage crossbar
have been removed for clarity purpose only.
The traction lock can be removed without
removing the control panel.
1
4 1
3 2
P-68144
Remove the shaft mounting bolt (Item 1), spring (Item 2),
File has expired. P-68143 washer (Item 3) and wedge (Item 4) from the assembly
shaft (Item 5) [Figure 60-120-5]. Inspect all parts for
damage or wear. Replace if necessary.
Remove and inspect the compression spring (Item 1) and
spring cap washer (Item 2) [Figure 60-120-4] for wear or Installation: Thoroughly clean and dry the shaft
Figure 60-120-6
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[Figure 60-120-4] on the collar located on the electric
solenoid.
P-54196
1
2
P-54200
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1
P11333
Figure 60-120-11
1
INCORRECT CORRECT
2
3
2
P11337
1
Install the traction wedge assembly (Item 1) into the
N-19106
File has expired. N-19105 solenoid and traction lock guides (Item 2) [Figure 60-
120-12].
Install the traction lock guides (Item 1) to the chaincase After the bolts have been tightened recheck to make sure
cover (Item 2) [Figure 60-120-11] using the four bolts the shaft assembly is moving freely in the guides.
Inspecting
Figure 60-120-13
1
P-68145
Use updated files from Bobcat See Adjusting on Page 60-170-1 for Flywheel RPM
sensor adjustment.
1
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2 3 4 B-15551G Fasten the seat belt, disengage the parking brake pedal,
press the green PRESS TO OPERATE Button and raise
the Seat Bar fully. Move the control levers slowly forward
Fasten the seat belt, disengage the parking brake button, and backward. The Traction lock should be engaged.
press the PRESS TO OPERATE LOADER Button (Item Lower the Seat Bar. Press the green PRESS TO
1) [Figure 60-120-13] and raise the Seat Bar fully. Move OPERATE Button.
the steering levers slowly forward and backward. The
TRACTION lock (Item 4) [Figure 60-120-13] should be Engage the parking brake pedal and move the control
engaged. Lower the Seat Bar. Press the PRESS TO levers slowly forward and backward. The Traction lock
OPERATE LOADER Button (Item 1) [Figure 60-120-13]. should be engaged.
Description
Troubleshooting Chart
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then illuminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is illuminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature
To see what error occurred. (See SPEED SENSORS (SJC) on Page 60-80-1.)
Figure 60-130-1
2
3
1
1 P13733
3-Terminal - Green
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1
1
P13725 P13732
Figure 60-130-4
1
3
2
P13735
1
2
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.
Figure 60-130-5
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130-4] from the handle lock solenoid connector.
1
P13725 P13732
P13725 P13732
Figure 60-130-8
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
File has expired.P13735 3 & 4) [Figure 60-130-10] from the loader wiring harness
connectors.
Using 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.
N-22783
2
P-54184 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Items 1 & Using a small screwdriver, lift the handle tabs (Item 2)
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
P-24233
P-21699
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and needs replacement. If the switch handle is
good and just needs to be removed for control
handle or lever replacement, then remove the
NOTE: Leave all the other heat shrink tube on the
wires for protection.
connectors on the end of the harness and pull Tape half of the wires back and half forward [Figure 60-
switch handle and harness up through the top 130-14] to keep the harness small enough to route
of the lever tube. through the control lever tube.
Figure 60-130-13
P-24234
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
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NOTE: Do not pull the wire harness tight. Allow a
small amount of slack or slight bend at the
handle pivot area. Verify the control handle
F-Terminal - Tan
G-Terminal - Pink
H-Terminal - Orange/Black
returns to neutral position. J-Terminal - Blank
K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
2 B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
1 A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695 E-Terminal - Blank
Figure 60-130-17
3 1
2
P13735
1
Install the wires into the connectors as listed below:
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3 1
N-17772
2
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
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1
N-17741
Figure 60-130-24
P-21878A
1
Figure 60-130-25
Figure 60-130-27
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1 P-21789
P-21832
Figure 60-130-28
1
File has expired.
P-24269
Figure 60-130-29
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3
2
1
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-130-29].
Figure 60-130-30
1 P-21790
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P-30078
Identification Chart
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
*3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
The ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab, must
be illuminated continuously.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down
Identification Chart
RIGHT HAND
17 18
2 1
8
10
1. Front Aux.
2. Front Aux.
14
15
P-24820
P-73297
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
T130 Solenoid
Number
Hydraulic
Coupler
Wiring
Number
Front
1 Female 4340
6 (Base)
4 2 Front
1
2 Male 4330
(Rod)
Diverter &
3 4450/4480
Bleed
5 4 Rear Aux Base 4440
3
5 Rear Aux Rod 4430
6 High Flow 4460
Figure 60-150-1
1 2
2
3
1
P-76450
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NOTE: Make all connections with the key in the OFF
position.
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
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performance codes are present or when replacing a
controller or actuator.
COMPUTER) on Page 60-150-1.)
•
Contamination in the spool.
Retest With Warm Hydraulic Oil • The controller may be defective, replace the
controller.
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
•
Use updated files from Bobcat
centering spring, replace if necessary.
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P-24826
or
Press RUN/ENTER
B-16628
Figure 60-160-5
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1
2
B-16627
1
Push the PRESS TO OPERATE button (Item 1) [Figure NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
60-160-5] to unlock the hand controls.
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.
Calibration is complete.
P-28063
Figure 60-160-10
2
1
P-26477A
1
P-26480
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. 1
W-2017-0286
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1
P-26480
Figure 60-160-16
P-26477A
The Control Pattern ISO Switch (Item 1) [Figure 60-160- Three audible beeps will sound.
16] will start flashing.
B-19873
P-26476
P-26476
Figure 60-160-20
2 75-98
P-26477A
Three audible beeps will sound and the error code (Item
Press the PRESS TO OPERATE LOADER Button (Item 2) (75-98) will be displayed if the operator presses the
1) [Figure 60-160-20] while holding the left joystick in HOLD FOR CODES (LIGHTS) switch (Item 3) [Figure
Figure 60-160-21
Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
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Figure 60-160-23
P-26474
Figure 60-160-24
B-19873
P-26482
Move the throttle (Item 1) [Figure 60-160-24] to high idle. Figure 60-160-26
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The calibration procedure will stop.
WARNING P-64321
Put jackstands under the front axles and rear corners The loader speed will “ramp up” quickly (Item 1)
of the frame before running the engine for service. [Figure 60-160-26] and slow down 3 times in a row.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death. The loader will then “stair step” the speed (Item 2)
W-2017-0286
[Figure 60-160-26] until it reaches full speed and then
come to a stop.
File has expired. P-26483 the left joystick to forward position [Figure 60-160-25]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-160-27] until the reverse calibration is 160-27] and check for normal reverse wheel or track
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1 2 After calibration is complete, use Steering Drift
Compensation for fine tuning or if an acceptable line of
drift can not be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
P-64321
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
NOTE: Software version 61 or higher is required to pressed to enable the BICS.
support this feature. The loader’s software
version can be displayed in the HOURMETER Perform pre-starting and starting procedures:
/ CODE display. (See Operation and
Maintenance Manual for correct procedure.) 1. Fasten seat belt.
See your Bobcat dealer to update your
machine’s software version if necessary. 2. Lower seat bar.
•
Use updated files from Bobcat
planers and silt fence installers.
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Figure 60-161-1
STEERING DRIFT COMPENSATION
B-23580B
3
5
B-15551
B-15551F2
1 2 B-15551F3 4
Right Joystick
1 2 B-15551
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P-24820B P-24802B
three seconds. [SEt] (Item 3) will appear in the display
(item 2) [Figure 60-161-3] and the machine will
disengage from steering drift compensation.
Description 2
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ft.-lb. (16 - 23 N•m) torque, while holding the sensor from
turning.
P-68136
SELECTION
EXAMPLE
BUTTONS
Press
LOADER FEATURES
B-16162
ICON DESCRIPTION
Right Panel Setup (Keyless) (Cont’d) The Keyless Right Panel allows the user to view
information concerning the operation of Bobcat
More Examples attachments.
Press . . .
TOOL/SETUP Press
LOADER FEATURES
DISPLAY OPTIONS TOOL/SETUP
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN/ENTER to set clock.
Press EXIT to return to previous level menu.
Press
RESET JOB CLOCK (Password required) LOADER FEATURES
(Job Clock keeps a running total for job hours)
Languages
LANGUAGES
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Select the language, press RUN/ENTER.
Press EXIT to return to previous level menu.
B-16163/B16164/B-16161/B-15753A/B-15754A/B-15755A
Password Description
Master Password:
Owner Password:
File has expired.
Allows for full use of the loader and to setup the
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User Password:
Figure 60-190-1
Changing the Password - Keyless Right Panel Display Screen
B-16163
B-24288
to Continue ENTER
B-24290
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B-24291
B-16171 B-16171
Figure 60-190-2
Press
LOCK/UNLOCK
Press
EXIT
Machine is now
UNLOCKED and
can be started
without using a
password.
B-16163/P-76075/P-76076/P-76076A/P-76077
Description
Figure 60-200-1
1
3
B-16163A
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when there are less than 10 hours until the next planned
maintenance. The hour interval (Item 1) and [SEr] (Item
2) will alternate in the display screen (Item 3) [Figure 60-
200-1] for 10 seconds. The display will then revert back
to the previous display and will appear for 10 seconds
every time the machine is started until the maintenance
clock is reset.
Figure 60-200-2
1
P-76122
Setup
Figure 60-200-4
P-64243
Figure 60-200-6
The easiest way to determine if a Bobcat controller is
recent enough to add the maintenance clock is to
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inches (not maintenance clock compatible) [Figure 60-
200-4].
Using the remote start tool and service PC, connect and
upgrade the Bobcat controller to version 37 or greater
software. (See SERVICE PC (LAPTOP COMPUTER) on 1
Page 60-150-1.)
Setup (Cont’d)
1
Figure 60-200-7
P-76118
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2
P-76115
Setup (Cont’d)
Figure 60-200-11
P-76112
1
4 2
1
P-76111
Setup (Cont’d)
Figure 60-200-15
1
2
P-76110
Figure 60-200-18
The current maintenance clock Length (Interval) and
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NOTE: If the interval is set to 10 hours or less, the
maintenance clock will reset and log a reset
time but the wrench icon, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.
P-64244
Figure 60-200-16
After the maintenance clock has been activated, the first
analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-18]. If past
the interval, the number will reflect negative hours.
1
P-76111
Reset
Figure 60-200-19
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Press and hold the HIGH FLOW and AUXILIARY
PRESSURE RELEASE buttons (Item 2) simultaneously,
until [rESEt] appears in the display screen (Item 3)
[Figure 60-200-19].
P-76108
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
Use updated files from Bobcat Move both steering levers or joystick(s) in the reverse
position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
Figure 60-210-2
P-69346
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-3
1
File has expired. 1
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Place the steering levers in the neutral position.
PROBLEM CAUSE
2, 6, 7
PROBLEM CAUSE
5, 6
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches and can not be
Stop the engine and open the tailgate. adjusted.
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-6
1
2 2
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-210-5]. Remove the alarm from the
mounting bracket.
Figure 60-210-7
1
3
2
3
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Disconnect the remaining White wires to the other switch
terminals (Item 3) [Figure 60-210-7].
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Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . 70-70-4
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . 70-70-11
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . 70-70-3
Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Description
Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Head
Cylinder Head Surface Distortion
Thickness of Gasket (Used)
(New)
File has expired.
0.002 (0,05) Max.
0.0453 - 0.0492 (1,15 - 1,25)
0.0512 - 0.0551 (1,3 - 1,4)
Top Clearance (Piston to Head) 0.0236 - 0.0276 (0,60 - 0,70)
Compression 427 - 469 PSI (29,4 - 32,4 bar)
Valves
Use updated files from Bobcat
Difference Between Cylinders 10%
Valve Springs
Free Length 1.642 - 1.661 (41,7 - 42,2)
Allowable Limit 1.622 (41,2)
Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.4 lb. (117,6 N)
Allowable Limit 22.5 lb. (100,0 N)
Valve Timing
Intake Valve (Open) 9 degrees B.T.D.C.
(Close) 45 degrees A.T.D.C.
Exhaust Valve (Open) 50 degrees B.T.D.C.
(Close) 12 degrees A.T.D.C.
Specifications (Cont’d)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Rocker Arms
O.D. of Rocker Arm Shaft 0.5501 - 0.5506 (13,973 - 13,984)
I.D. of Rocker Arm Bushings 0.5512 - 0.5519 (14,0 - 14,018)
Clearance Between Rocker Arm & Bushing 0.0006 - 0.0018 (0,016 - 0,045)
Allowable Limit 0.0039 (0,10)
Camshaft
Journal O.D. 1.5722 - 1.5728 (39,934 - 39,95)
Bearing I.D. 1.5748 - 1.5758 (40,0 - 40,025)
Oil Clearance 0.002 - 0.0036 (0,05 - 0,091)
Allowable Limit
Alignment Allowable Limit
Cam Lobe Height
File has expired. 0.006 (0,15)
0.0004 (0,01)
1.3346 (33,90)
Allowable Limit 1.3327 (33,85)
End Clearance 0.0028 - 0.0087 (0,07 - 0,22)
Cylinders
Cylinder Bore I.D. 3.4252 - 3.4261 (87,00 - 87,022)
Allowable Limit +0.0059 (+0,15)
Piston Rings
Ring Gap (Top Ring) 0.0079 - 0.0138 (0,20 - 0,35)
Limit Permitted 0.0492 (1,25)
Ring Gap (2nd Ring) 0.0138 - 0.0197 (0,35 - 0,50)
Limit Permitted 0.0492 (1,25)
Ring Gap (Oil Ring) 0.079 - 0.0157 (0,20 - 0,40)
Limit Permitted 0.0492 (1,25)
Side Clearance of Ring Groove:
Top Ring 0.0037 - 0.0047 (0,093 - 0,12)
Second Ring 0.0037 - 0.0047 (0,094 - 0,12)
Oil Ring 0.0008 - 0.002 (0,02 - 0,052)
Pistons
Piston Pin Bore 0.9843 - 0.9848 (25,0 - 25.013)
Limit Permitted 0.9862 (25,05)
Specifications (Cont’d)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Connecting Rod
Piston Pin O.D. 0.9843 - 0.9847 (25,002 - 25,011)
Small End Bushing I.D. 0.9852 - 0.9858 (25,025 - 25,04)
Clearance Between Piston Pin & Small End Bushing 0.0006 - 0.0015 (0,014 - 0,038)
Allowable Limit 0.0059 (0,15 mm)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)
Oil Pump
Oil Pressure Rated RPM 43 - 64 PSI (3 - 4,4 bar)
Limit Permitted 36 PSI (2,5 bar)
Idle Speed
Limit Permitted File has expired.
Clearance Between Inner Rotor & Outer Rotor
14 PSI (1 bar)
7 PSI (0,5 bar)
0.0012 - 0.0055 (0,03 - 0,14)
Outer Rotor & Pump Body 0.0043 - 0.0075 (0,11 - 0,19)
End Clearance Between Inner Rotor & Cover 0.0041 - 0.0059 (0,105 - 0,15)
Limit Permitted
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Oil Clearance Between Journal & Bearing #1 0.0016 - 0.0046 (0,04 - 0,118)
0.0079 (0,2)
Journal O.D. #1 2.3591 - 2.3598 (59,921 - 59,940)
Bearing I.D. #1 2.3614 - 2.3637 (59,98 - 60,039)
Oil Clearance Between Journal & Bearing #2 0.0016 - 0.0041 (0,04 - 0,104)
Limit Permitted 0.0079 (0,2)
Journal O.D. #2 2.3591 - 2.3598 (59,921 - 59,940)
Bearing I.D. #2 2.3614 - 2.3632 (59,98 - 60,025)
Oil Clearance Between Crank Pin & Bearing 0.0010 - 0.0034 (0,025 - 0,087)
Limit Permitted 0.0079 (0,2)
Crank Pin O.D. 1.8488 - 1.8494 (46,96 - 46,97)
Crank Pin Bearing I.D. 1.8504 - 1.8522 (47,0 - 47,046)
Crankshaft Side Clearance 0.0059 - 0.0138 (0,15 - 0,35)
Limit Permitted 0.0197 (0,5)
Specifications (Cont’d)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Timing Gear
Timing Gear Backlash:
Crank Gear-Idle Gear 0.0016 - 0.0044 (0,042 - 0,112)
Idle Gear-Cam Gear 0.0016 - 0.0045 (0,042 - 0,115)
Idle Gear-Injection Pump Gear 0.0016 - 0.0045 (0,042 - 0,115)
Crank Gear-Oil Pump Gear 0.0016 - 0.0043 (0,042 - 0,109)
Limit Permitted 0.006 (0,15)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.001 - 0.0026 (0,025 - 0,066)
Limit Permitted 0.004 (0,10)
Idle Gear Side Clearance Idle Gear 0.005 - 0.019 (0,12 - 0,48)
Thermostat
Valve Opening Temperature
File has expired. 176.9° - 182.3° F (80.5° - 83.5° C)
Valve Fully Open 203° F (95° C)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
Publications.
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)
Publications.
21. Cylinder head gasket leaking.
22. Overheating.
23. Cold running.
48. Faulty water pump.
49. Plugged breather pipe.
50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery
3
4
P-90328
2
3
AVOID DEATH
•
File has expired.
Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
P-68848
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Publications.
WARNING 70-10-2] so the belt shield (Item 4) can be removed.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
pump.
Remove the mounting screw (Item 1) to remove the oil
Remove the battery from the loader. (See Removal And filter drip shield (Item 2) [Figure 70-10-3].
Installation on Page 60-20-1.)
The drip shield is snapped into place on the filter
Drain the engine coolant from the cooling system. (See housing.
Removing And Replacing Coolant on Page 10-90-2.)
Figure 70-10-4
1
2
Use updated files from Bobcat for the differential pressure switch on the filter housing.
Publications. 10-4].
Figure 70-10-5
P-66872
P-48606
Figure 70-10-7
File has expired.
P-68851
Figure 70-10-8
1
2
P-66875
Figure 70-10-9Publications.
2
P-67069
1
Mark and disconnect the charge pump filter outlet hose
(Item 1) [Figure 70-10-11].
Figure 70-10-12
1
2 P-67078
10-12].
Publications.
Cap or plug all hoses and fittings.
2
Figure 70-10-13
1
2 1
1
2
P-68856
Figure 70-10-16
2
P-28231
1
P-68857
File has expired. P-68858 and nut from the left front engine mount.
Publications.
Figure 70-10-18
2.5”
2.5”
1/4” (4)
1-1/2” Square Tubing
1/4” Wall Thickness Thick Gusset
1”
16”
1
4”
1”
45° 9”
1”
Publications. .375”
Use Two 3/8”x 1-1/4” Bolts
for Drilled and Tapped Holes. MC-1799C
P-68852
Figure 70-10-21
Fasten securely one end of the chain to the lifting eye P-48661A
(Item 1) [Figure 70-10-21].
5 Snubbing Spacer
Washer
MC-1765A
6
Publications.
Replace all four engine mounts two front and two rear.
Compression - Checking
Figure 70-10-25
P-51938
Publications.
Disconnect the air cleaner inlet hose (Item 1) [Figure 70-
head.
P-51936
P-51937 P-51939
Install the correct compression adapter (Item 1) [Figure Push the button on the compression gauge to release
70-10-26] into the cylinder head. pressure [Figure 70-10-28].
Removal And Installation Remove the two mounting screws (Item 1) [Figure 70-
20-1] from the speed control mounting bracket.
Figure 70-20-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
•
File has expired.
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.
WARNING Pull the speed control away from the loader frame and
Publications.
Never work on a machine with the lift arms up unless
disconnect the speed control rod (Item 1) [Figure 70-20-
2] from the control.
the lift arms are secured by an approved lift arm Installation: Be sure to install the speed control rod in
support device. Failure to use an approved lift arm the bottom hole of the speed control lever.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 70-20-3
W-2059-0598
Figure 70-20-1
1 1
2
P-34156
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 70-21-1
2
P-73687
Publications.
Remove the foot rest, from the loader.
P-64313
70-21-1
635 of 764
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-6
1 3 5 3
P-34654A
The parts that go into the pivot arm (Item 1) are the bolt
Remove the bolt and nut (Item 1) [Figure 70-21-4] from Figure 70-21-7
the hand speed control pivot arm.
Publications.
1
P-73685
Remove the keeper and pin (Item 1) [Figure 70-21-5] Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
that attaches the pivot arm to the speed control cable. N•m) torque.
70-21-2
636 of 764
ENGINE SPEED CONTROL (SJC) (CONT'D) Disassembly And Assembly
Figure 70-21-8
1
1
P-64305
Figure 70-21-9
Publications.
1
P-64305A
2
1 Remove the bushing/nut (Item 1) [Figure 70-21-11] from
the pedal lever.
P-73688
70-21-3
637 of 764
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-14
Figure 70-21-12 1
P-34659
1
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
Figure 70-21-15
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing/nut.
Figure 70-21-13
Publications.
2
P-64307
1
70-21-4
638 of 764
MUFFLER Figure 70-30-2
P-54044
3
Remove the right side mounting bolt (Item 1) [Figure 70-
Publications.
Disconnect the exhaust pipe from the muffler.
1
2
P-54049
File has expired. P-54046 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Remove the two upper mounting bolts (Item 3) [Figure
70-40-1] from the air cleaner sensor on the air cleaner. 70-40-2] from the top mount of the air cleaner.
Publications. 1
Reverse the removal procedure to install the air cleaner.
P-54054
WARNING P-68848
AVOID BURNS
Do not remove radiator cap when the engine is hot. Open the drain valve (Item 1) [Figure 70-50-2] on the
You can be seriously burned.
File has expired.
W-2070-1203
engine block and drain the coolant into a container.
Figure 70-50-3
Figure 70-50-1
Publications.
1
P-48571
P-54001
Loosen the hose clamp (Item 1) [Figure 70-50-3] from
the left side radiator hose and disconnect the hose from
Loosen the radiator cap (Item 1) [Figure 70-50-1] from the radiator.
the pressurized expansion tank.
Remove the radiator mounting bolt (Item 2) [Figure 70-
50-3].
Figure 70-50-4 2
1
1
P-54062
Figure 70-50-7
Publications. 3
P-54311
Publications.
The hydraulic fan speed at cold engine startup will range
from 0 to 500 RPM’s until the engine coolant and the
hydraulic fluid reach basic operating temperatures.
DANGER 2 4
P-67080
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 3
Publications.
Never work on a machine with the lift arms up unless
Remove the sealant between the blower housing and the
loader frame (Item 4) [Figure 70-50-9].
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Figure 70-50-10
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
IMPORTANT 1
Raise the lift arms and install an approved lift arm support Remove the fan motor inlet hose (Item 1) and outlet hose
device. (See Installing on Page 10-20-1.) (Item 2) [Figure 70-50-10].
Raise the operator cab.(See Raising on Page 10-30-2.) Remove the fan motor case drain hose (Item 3) [Figure
70-50-10].
Remove the fan motor/charge pump filter housing. (See
Charge Filter Housing Removal And Installation on Page
Disconnect the electrical connector (Item 4) [Figure 70-
20-80-3.)
50-10].
P-76698
1
2
After the blower housing is installed, apply a bead of
Figure 70-50-12
Publications.
P-66649
Figure 70-50-14
1 1
P-54421A
Remove the lock nut and spacer (Item 1) [Figure 70-50- Reverse removal procedure for installation.
14].
2Publications.
1
P-54419
B-14424
Publications.
Installation: Always use a new gasket when installing
the water pump.
Install a new seal (Item 4) [Figure 70-50-18] when
assembling the water pump.
Figure 70-50-19
1 2 1
6 4
5 7
5
File has expired.
Publications. 9
10
7 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-19].
Remove bolts (Item 7), nut (Item 8), top and bottom
housing (Item 9), and gasket (Item 10) from the cylinder
head [Figure 70-50-19].
Oil Pan Removal And Installation Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Remove the engine and hydrostatic pump assembly from 100-1.)
the loader. (See Engine Removal And Installation on
Page 70-10-8.) Remove the crankshaft gear.
Figure 70-60-1 1
2
2
Use updated files from Bobcat P-66843 Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-60-3].
Publications.
Remove oil pan bolts securing oil pan (Item 1) [Figure
70-60-2]. Slightly tapping on the oil pan with a soft mallet
will break loose the oil pan from the engine block.
Remove the oil pump mounting bolts. Remove the oil
pump (Item 2) [Figure 70-60-3].
Figure 70-60-2
P-66844
Figure 70-60-4
A-2732
Outer Rotor
Use updated files from Bobcat
Between Inner & (0,03-0,14 mm)
If the clearance exceeds the allowable limit, replace the
oil pump.
Figure 70-60-6
Publications.
If the clearance exceeds the allowable limit, replace the
oil pump.
PI-10009
Figure 70-60-7
Publications.
If the oil pressure is less than the allowable limit, check
the following items:
Figure 70-70-1
2 P-47266
Publications.
Remove the three bolts (Item 1) [Figure 70-70-1].
The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the
engine according to changes in the engine load.
Figure 70-70-3
4. Fork Lever
5. Fork Lever
Publications.
3. Governor Spring
Figure 70-70-4
1
1
P-48586
Stop the engine and open the rear door [Figure 70-70-4]. Disconnect the connector (Item 1) [Figure 70-70-6].
Figure 70-70-5
Publications. 2
P-51943
The reading between electrical connector terminal C and Reverse the above procedure to install the fuel shutoff
terminal B must be between approximately 0.35-0.4 ohm. solenoid.
Figure 70-70-10
1 1
1
P-51945
Clean the area around the injection pump thoroughly.
Figure 70-70-9
3 P-51944
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) from the injection pump vent [Figure 70-
70-9].
Figure 70-70-11
P-51683
1
Remove the high-idling body (Item 1) [Figure 70-70-13]
Figure 70-70-14
Publications.
Remove the intake manifold from the engine.
damaged.
2
Figure 70-70-12
P-51951
P-51942
Figure 70-70-15
P-51952
1
P-4359
1
Remove the injection pump (Item 1) [Figure 70-70-17]
1 2
P-4357
Figure 70-70-18
1
P-64218
File has expired. P-4364 Ensure the control rack pin (Item 1) is to the left side of
the fork lever (Item 2) [Figure 70-70-20].
Figure 70-70-19
Publications.
1
P-48779
1
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Disconnect the number one (closest to water pump) Install a short plastic tube (Item 1) [Figure 70-70-22] in
Figure 70-70-21
File has expired.
cylinder high pressure line from the injection pump. the number one cylinder port of the injection pump. The
tube should fit securely in the port and point upward.
P-54133
Figure 70-70-23
1
Rotation
Direction
1 P-4364
File has expired. P-48823 needed to adjust the fuel delivery timing.
Publications.
The first mark to appear in the window with
the rotation is 9.25° which is used for loaders
with the Kubota V2003T engine. 1
Rotate slowly until fuel just starts to flow upward into the The size of shims are identified by a symbol on the
plastic tube. shims.
At this instant, the 9.25° BTDC timing mark on the (1) Two holes means 0.008 in (0.20 mm) shim.
flywheel should be aligned with the mark in the window
(Item 1) [Figure 70-70-23] for the V2003T engine. (2) One hole means 0.010 in (0.25 mm) shim.
The 8.2° BTDC on the flywheel should be aligned with (4) Three holes means 0.014 in (0.35 mm) shim.
the mark in the window (Item 1) [Figure 70-70-23] for the
V2203 engine.
Figure 70-70-26
File has expired.
2
1
Use updated files from Bobcat Remove the four retainer bolts from the top of the fuel
1
Publications. injectors (Item 1) [Figure 70-70-27].
P-51949
Fuel Injector Removal And Installation (Cont’d) The tool listed will be needed to do the following
procedure:
Figure 70-70-28
OEM1064 - Injector Nozzle Tester
Figure 70-70-30
1
Publications.
ft.-lb. (25,5 - 29,4 N•m) torque.
Figure 70-70-29
If the measurement is not within the factory
specifications, replace the injection nozzle assembly.
P-37583
Nozzle Spray Condition The tool listed will be needed to do the following
procedure:
The tool listed will be needed to do the following
procedure: OEM1064 - Injector Nozzle Tester
Figure 70-70-31
Correct Incorrect
nozzle assembly.
Publications.
If the spraying condition is defective, replace the injection If any fuel leak is found, replace the injection nozzle
assembly.
Figure 70-80-1
2 3
P-51933
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-80-2] from the top of
each glow plug.
Publications.
resistance is infinite, the coil of the glow plug is broken.
Figure 70-80-3
P-51935
Figure 70-80-4
2 1
3
B-5568
Photo [Figure 70-80-4] shows the glow plug removed Loosen the lock nut (Item 1) [Figure 70-80-5].
from the engine. Inspect the glow plugs and replace
Publications. 70-80-5].
Figure 70-80-6
4
3
1 2 3 4 5 6 7 8 1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
Valve
I=Intake I E I E I E I E
E=Exhaust
Figure 70-80-9
2 4 1
2
3
P-47243
Publications.
8 ft.-lb. (7 - 11 N•m). Tighten center bolts first, then work
your way to the front and back of the valve cover.
1
Figure 70-80-10
2
2
2
2
B-14332
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-80-12].
P-47242
Installation: Tighten the bolts to 17 - 20 ft.-lb. (23,5 -
27,5 N•m) torque.
Loosen the bolts on the clamps (Item 1) and remove the
injection tubes (Item 2) [Figure 70-80-10]. Remove the pushrods (Item 2) [Figure 70-80-12].
2
17 9 1 8 16
13 5 4 12
P-47247
Publications.
Figure 70-80-14
correct sequence after the engine has been
run for 30 minutes.
Figure 70-80-16
1
1
2
P-47246
P-47248
Remove the clamps (Item 1) and remove the hose (Item
2) [Figure 70-80-14] from the thermostat housing.
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-16].
Publications.
(See Cylinder Head Top Clearance on Page 70-80-8.)
Figure 70-80-18
checked, and reassembled.
P-47252
Cylinder Head Disassembly and Assembly Clean the surface of the cylinder head.
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-22] on the
spring [Figure 70-80-20]. cylinder head.
Publications. the straight edge and the surface of the cylinder head.
Figure 70-80-23
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-20] & [Figure 70-80-21]. and two diagonal as shown in figure [Figure 70-80-23].
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly and Assembly on Page
Figure 70-80-24 70-80-7.)
2 Figure 70-80-25
1 3
Figure 70-80-26
8.86” (225 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259”
(6,5-6,6 mm)
0.2” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-27]. recessing or protrusion with a depth gauge [Figure 70-
80-29].
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 & 2)
[Figure 70-80-27], press the new guide until the tool
contacts the cylinder head.
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
Intake 60°
Exhaust 45°
45° Exhaust
15° Exhaust 60° Intake
30° Intake
PI-9994
Valve Spring
Figure 70-80-33
A-2759
Publications.
Put the spring on a flat surface, place a square on the
side of the spring [Figure 70-80-33].
Figure 70-80-35
1
2
B-3697
Use updated files from Bobcat If the clearance exceeds the allowable limit, replace the
bushing.
Publications. If the clearance still exceeds the allowable limit after the
bushing is replace, replace the rocker arm shaft.
Remove the top edge from the cylinder bore with a ridge
reamer.
Figure 70-90-1
P-51633A
1
2
File has expired. Use a hammer handle and push the piston/connecting
rod assembly out of the cylinder bore [Figure 70-90-2].
P-47269
Publications.
Remove the oil pump strainer (Item 1) and O-ring (Item
2) [Figure 70-90-1] by tapping the edge of the strainer
with a soft faced hammer.
4
1 3
5
2 6 4
1
P-47271
Publications.
(Item 4) [Figure 70-90-4].
Figure 70-90-5
1
3
PI-10015
Figure 70-90-9
1.378”
6.38” (162 mm)
Measure the I.D. of the piston pin bore in both horizontal (35 mm)
and vertical directions [Figure 70-90-7].
Publications.
Allowable Limit
(25,0 - 25,013 mm)
0.9862 in.
(25,05 mm)
(25,0-25,01 mm)
MC-1366
Figure 70-90-10
1
P-47273
PI-10016
Measure the O.D. of the piston pin (Item 1) [Figure 70-
90-8].
Use a press and special driver tool to remove the small
Measure the I.D. of the connecting rod small end (Item 2) end bushing [Figure 70-90-10].
[Figure 70-90-8].
Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until
it is flush [Figure 70-90-10].
Figure 70-90-11
PI-10017
Install a piston ring into the lower part of the cylinder If the clearance exceeds the allowable limit, replace the
bore. Measure the ring gap with a feeler gauge [Figure ring. If the clearance still exceeds the allowable limit,
Figure 70-90-13
A-2717
Connecting Rod Alignment Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
NOTE: The small end bushing is the basis of this Page 70-90-1.)
check, check the bushing for wear before
doing this check. Figure 70-90-16
Put the gauge over the piston pin and move it against the 4
face plate.
Figure 70-90-15
1
P-47274
Publications. B-4067 Install two screws in the bearing case cover and remove
the cover (Item 3) [Figure 70-90-16].
If the gauge does not fit squarely against the face plate, Remove the two gaskets (Item 4) and oil seal (Item 5)
measure the space between the gauge and face plate [Figure 70-90-16] from the cover.
[Figure 70-90-15].
Figure 70-90-17
If the measurement exceeds the allowable limit, replace
the connecting rod.
P-47275
Figure 70-90-18
1
1
P-47278
Figure 70-90-19
Publications. 1
P-47279
Before removing the crankshaft/main bearings, check the NOTE: Turn the crankshaft as needed to allow the
end play. Install a dial indicator. Move the crankshaft crank pin journals to pass through the cut out
[Figure 70-90-19] to the flywheel side, zero the dial
indicator. Measure the end play by pulling the crankshaft (Item 1) [Figure 70-90-21] of the engine block.
toward the gear case side.
Mark the bearing case halves for correct installation.
If the measurement exceeds the allowable limit, replace
the thrust washers [Figure 70-90-19].
Figure 70-90-22
A-2763
Remove the two bearing case bolts [Figure 70-90-22]. Turn the crankshaft at a slow rate to obtain the
Figure 70-90-25
120
PI-10021
Figure 70-90-26
PI-10022
Publications.
Oil Clearance
(46,96-46,98 mm)
0.0010-0.0034 in.
Remove the sleeve.
(0,025-0,087 mm)
Allowable limit 0.0079 in. (0,2 mm)
Figure 70-90-28
2 2
1 3
B-3618
Publications.
NOTE: The sleeve is installed with the larger
chamfered surface to the front of the
crankshaft (Item 1) [Figure 70-90-27 on Page
Journal O.D.
Oil Clearance
2.3591-2.3598 in. (59,92-59,94 mm)
0.016-0.0046 in. (0,040-0,12 mm)
9]. Allowable Limit 0.0079 in. (0,2 mm)
Figure 70-90-29 NOTE: Make sure you use the correct size bearing
when installing. Oversize bearings are
generally marked.
B-3631
P-48778
0.8” (20 mm)
2.551-2.555
1.57” 0.4” (64,80-64,90 mm) Remove the front bearing with the special removal tool
(40 mm)
File has expired.
(10 mm) MC-1367 [Figure 70-90-31].
Publications. 0.16”
(4 mm)
0.8”
(20 mm) Bearing Number 1
Recession
0.1654 - 0.1772 in.
(4,2 - 4,5 mm)
2.551-2.555”
2.83” (64,80-64.90 mm) Clean the crankshaft journal and bearing. Put a strip of
(72 mm) press gauge on the center journal.
2.68”
(68 mm) Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
0.8” (20 mm)
1.57” 2.354-2.358” NOTE: DO NOT turn the crankshaft with the press
0.4” (59,80-59,90 mm) gauge installed. Incorrect measurements will
(40 mm) (9mm) MC-1365 be obtained.
Figure 70-90-34
Figure 70-100-1
P-47256
Figure 70-100-4
Bend a hook on the end of a 7.87 in. (200 mm) long,
0.050 in. (1.2 mm) diameter hard wire [Figure 70-100-1].
P-47257
Figure 70-100-5
P-47259
Publications.
1
1
2
B-14340
B-14339
Timing Gearcase Cover Removal And Installation When the gears are installed, check the backlash of the
(Cont'd) gears.
Installation: Install new O-rings and oil seal into the Install a dial indicator [Figure 70-100-10].
Figure 70-100-11
1
2
1
P-47262
File has expired. camshaft retainer plate bolts (Item 2) [Figure 70-100-13].
Remove the bolts.
Publications.
alignment when installing the timing gears [Figure 70-
100-11].
Figure 70-100-12
PI-10002B
Camshaft - Servicing
Figure 70-100-15
B-5001
Figure 70-100-18
1.3327 in. (33,85 mm)
Publications.
A-2761
1.650-1.652”
(41,9-41,95 mm)
1.494-1.495”
(37,95-37,97 mm)
MC-1366
Figure 70-100-21
Measure the O.D. of the idler gear shaft [Figure 70-100-
19].
Figure 70-110-1
1
P-48850
File has expired. The ring gear (Item 1) [Figure 70-110-2] on the flywheel
is an interference fit. Heat the ring gear enough to
1 expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.
Publications.
Remove the six mounting bolts (Item 1) from the engine
450° - 500° F (232° - 260° C).
Fit the ring on the flywheel and be sure the gear is seated
flywheel (Item 2) [Figure 70-110-1].
correctly.
Installation: Apply engine oil to the threads and seats
before tightening. Tighten to 72 - 80 ft.-lb. (98 - 108 N•m)
torque.
P-48651B
Figure 70-110-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
File has expired. P-48650 110-7] which fasten the housing on the engine.
Publications.
Figure 70-110-6
Remove the housing.
P-4231A
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Publications.
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Operators Normally, But Air Flow Is Insufficient .
80-30-1
80-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . 80-30-6
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . 80-30-7
HEATER
Description
Figure 80-10-1 1
2 3
N-20876
2
1
N-22092
Description (Cont'd)
Figure 80-10-4
Figure 80-20-1
P-28820
P-28819
Filter Elements Removal And Installation (Cont'd) Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-20-5
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 80-20-7
P-48008
1 1
Figure 80-20-6
1) [Figure 80-20-7]. The screws do not need to be
completely removed, they are secured on the back with
plastic retaining washers.
Figure 80-20-8
P-48007
POSSIBLE CAUSE
1. Air leak.
File has expired. INSPECTION
Check to make sure air hoses are properly hooked to
Louvers, and air ducts.
SOLUTION
Repair or adjust.
2. Plugged cab filters. Check cab filter condition. Clean or replace filters.
Electrical System
Figure 80-30-1
1 1
P-68444
Figure 80-30-2
connector (Item 2) [Figure 80-30-3].
P-68118
Figure 80-30-4 1
P-28918
1
P-28920
Figure 80-30-7
C
H
B
M
L P-28920
Publications.
resistance between C terminal and the B terminal,
between the C terminal and the L terminal and also
between the B terminal and the L terminal frame [Figure
80-30-7].
Figure 80-30-10
A C
1
N-22175
B
File has expired. N-22290 potentiometer control (Item 1) [Figure 80-30-12] to the
full A/C position.
Publications.
Figure 80-30-11
A C
N-22290
Figure 80-30-14
N-20876
Figure 80-30-17
Publications.
A C
N-22290
P-68119
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-30-15] should be
approximately 39 K Ohm's. Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-
Check the resistance between the wire terminal C and 1.)
wire terminal B frame [Figure 80-30-15] should be
approximately 49 K Ohm's. Start the loader and run at high idle, for ten minutes.
If the resistance is not found replace the potentiometer. Check the heater hose (Item 1) [Figure 80-30-17] for
temperature.
Figure 80-30-18
2
1 P-68117
Place the remote start tool on the left fender of the loader,
File has expired. N-20876 so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-19], as the key of the remote
start tool is turned to the ON position without starting the
Raise the lift arms and install an approved lift arm support loader. The heater valve should rotate. Place a mark on
device. (See Installing on Page 10-20-1.) the heater valve shaft.
Publications.
Raise the operator cab. (See Raising on Page 10-30-2.)
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-19], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-40-1
1 P-68840
Figure 80-40-4
P-68841
1
Remove the two mounting nuts (Item 1) [Figure 80-40-4]
at the left side.
P-68118
Figure 80-40-5
Publications.
Figure 80-50-1 1 1
2
P-69829
File has expired. P-66921 and remove the mount plate from the end of the unit.
Figure 80-50-3
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Publications.
Remove the heater valve (Item 1) [Figure 80-50-1]. (See
Removal and Installation on Page 80-70-1.)
1
Remove the two heater hoses from the heater coil. N-22094
Cap the hoses and the heater coil to prevent coolant loss
from the system. Remove the two mount bolts (Item 1) [Figure 80-50-3]
from the heater coil.
Remove the rear cover from the heater unit. (See
Cleaning The Heater Coil on Page 80-20-2.) Remove the heater coil from the unit.
Figure 80-60-1
N-22099
File has expired. N-22096 (Item 1) [Figure 80-60-2] from the unit.
Figure 80-60-3
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Publications.
NOTE: The heater fan assembly can be removed from
the heater unit without disconnecting the
heater plumbing. The unit is removed here for
photo clarity.
1 1 2
N-22108
Remove the eight mount bolts (Item 1) [Figure 80-60-4] Figure 80-60-7
from the blower wheel cover.
Publications.
Remove the fan motor mount.
Figure 80-60-5
N-22109
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-60-7].
1
2
N-22107
Figure 80-60-8
N-22111
Figure 80-60-11
Figure 80-60-9
Publications.
1
N-22116
N-22112
Connector Identification
Figure 80-60-12
The wiring code for the blower fan connector [Figure 80-
60-12] is:
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the Heater Unit from under the cab and place it
across the mainframe supported by blocks (See Removal
And Installation on Page 80-40-1.)
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.
Figure 80-70-3 1
P-66925
2
2
P-66926
P-66924
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalent Chart. . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . SPEC-50-1 SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 54 inch dirt bucket and may vary with other bucket
types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
55 in.
96° (1398 mm) 65.6 in.
(1666 mm)
139.5 in.
(3543 mm)
File has expired.
40°
84.9 in.
Publications.
(1964 mm) (2157 mm)
23°
25°
35.5 in.
7.4 in. (900 mm)
(188 mm) 42.9 in.
120.1 in. (1089 mm)
(3051 mm) 53.4 in.
(1355 mm)
B-24432
B-24433B
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
Performance
Rated Operating Capacity (ISO) 1300 lb. (590 kg)
Tipping Load (ISO) 2634 lb. (1195 kg)
Operating Weight 5235 lb. (2375 kg)
SAE Breakout Force - Lift 2800 lb. (1270 kg)
- Tilt 3000 lb. (1361 kg)
Push Force 3400 lb. (1542 kg)
Travel Speed 7.3 mph (11,8 km/hr.)
Controls
Vehicle Steering Direction and speed controlled by two hand levers or optional joysticks.
Loader Hydraulics
- Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System
(ACS) or Selectable Joystick Control (SJC)
- Front Auxiliary
Engine
Make/Model Kubota V2203-M-DI
Fuel/Cooling Diesel / Liquid
Horsepower (SAE Net) 46 HP (34,3 kW) @ 2800 RPM
Torque (SAE Net) 103.5 ft.-lb. (140,4 N•m) @ 1700 RPM
Number of Cylinders Four
Displacement 134 cu. in. (2,2 L)
Bore/Stroke 3.425 in. / 3.638 in. (87 mm / 92,4 mm)
Lubrication Gear Pump Pressure system with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel Compression
Low Idle 1075 - 1225 RPM
High Idle 2860 - 3000 RPM
Hydraulic System
Pump Engine driven gear type
Pump Capacity 16.9 GPM (64 L/min.) @ 3135 Pump RPM @ 91% efficiency
System Relief at Quick Couplers 2650 - 2750 PSI (182,7 - 189,6 bar)
Filters Full flow replaceable, 3 micron synthetic media element.
Hydraulic Cylinders Double acting; Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter: Lift Cylinder (2) 2.00 in. (50,8 mm)
Tilt Cylinder (1) 3.50 in. (88,9 mm)
Rod Diameter: Lift Cylinder (2) 1.25 in. (31,8 mm)
Tilt Cylinder (1) 1.50 in. (38,1 mm)
Stroke: Lift Cylinder (2) 26.57 in. (674,9 mm)
Tilt Cylinder (1) 14.50 in. (368,3 mm)
Control Valve 3 spool, open center type with float detent on lift
and electrically controlled auxiliary spool.
Fluid Lines SAE standard tubelines, hoses and fittings.
Fluid Type File has expired. BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (2.5 Gal.)
6903118 - (5 Gal.)
6903119 - (55 Gal.)
Electrical
Alternator
Publications. Belt driven, 90 amps ventilated
Battery 12 volts, 600 cold cranking amps @ 0° F (-18° C);
115 minute reserve capacity at 25 amps
Starter 12 volts; Gear Reduction Type; 4.02 HP (3 kW)
Instrumentation Standard Instrumentation:
Gauges:
Hourmeter, Fuel, Engine Temperature.
Warning Lights:
Engine Coolant Temperature, Engine Oil Pressure, Hydraulic Oil Temperature
& Charge Pressure, Hydraulic Filter, Engine Air Filter, Seat Belt, Fuel Level,
General Warning, System Voltage.
Indicators:
Attachment Control Device (ACD), Advanced Control System (ACS), BICS
Functions, Engine Preheat, Headlights, Bucket Positioning, Attachment
Auxiliary Hydraulics modes.
Optional Instrumentation:
Same gauges and warning lights as standard Instrumentation.
- Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
- Additional Features Include: Keyless Start with password capability, Digital
Clock, Attachment Information, Digital Tachometer, High-Flow & Two-Speed
Lockouts, Multi-Language Display, Help Screens, Diagnostic Capability &
Engine / Hydraulic Systems Shutdown Function.
Drive System
Main Drive Hydrostatic 4 wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors.
Final Drive #80 HS endless roller chain & sprockets in sealed chaincase with oil lubrication.
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 (50,3)
Wheel Bolts (8) 9/16 in.
Capacities
Cooling System
Without Heater 12 qt. (11,4 L)
With Heater 12.6 qt. (11,9 L)
Fuel 13.3 Gal. (50,4 L)
Engine Oil With Filter
Hydraulic Reservoir File has expired. 9.2 qt. (8,7 L)
14 qt.(13,3 L)
Hydraulic/Hydrostatic System 6 Gal. (22,7 L)
(Including Reservoir)
Tires
Standard Duty
Heavy Duty
Use updated files from Bobcat 10.00-16.5, 8 ply rating
10.00-16.5, 10 ply rating
Severe Duty
Flotation
Solid
Publications. 10.00-16.5, 10 ply rating
31.5x13-16.5
10.00-16.5 Poly Foam Filled, 10 ply rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
Thread
sae grade 5 sae grade 8
size
in.-lb. 0.250 80 - 90 110 - 120
(N•m) (9,0 - 10,2) (12,4 - 13,6)
0.3125 180 - 200 215 - 240
(20,3 - 22,6) (24,2 - 27)
ft.-lb. 0.375 25 - 28 35 - 40
(N•m) (34 - 38) (47 - 54)
0.4375 40 - 45 60 - 65
Publications.
0.875
(300 - 330)
330 - 360
(450 - 490)
(410 - 450)
475 - 525
(645 - 710)
1.000 475 - 525 725 - 800
(645 - 710) (985 - 1085)
1.125 650 - 720 1050 - 1175
(880 - 975) (1425 - 1600)
1.250 900 - 1000 1475 - 1625
(1200 - 1360) (2000 - 2200)
1.375 1200 - 1350 2000 - 2200
(1630 - 1830) (2720 - 2980)
1.500 1500 - 1650 2600 - 2850
(2040 - 2240) (3530 - 3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680 - 5150)
1.750 2500 - 2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150 - 3500 5500 - 6100
(4270 -4750) (7450 - 8300)
2.000 3800 - 4200 6500 - 7200
(5150 - 5700) (8800 - 9800)
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].
Washer
Washer
O-ring
O-ring
Flare Fitting
Figure SPEC-30-4
Publications.
Use the chart [Figure SPEC-30-5] to find the correct
tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-30-5
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (N•m)
1/4” 7/16” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)
Publications.
the connection [Figure SPEC-30-6].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Specifications
WARNING
Use Bobcat hydraulic/hydrostatic transmission fluid
(P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.),
During cold weather (32°F [0°C] and below), do not
(P/N 6903119 - 55 Gal.).
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
10-20
40-20
50-40
Publications.
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10-70
50-41
50-50
10-90 50-80
10-100 50-100
10-120
10-140 60-10
10-160 60-30
10-200 60-50
60-70
20-01 60-140
20-20
20-40 70-10
20-41 70-50
20-60 70-70
20-80 70-90
30-10 80-30
30-30 80-50
30-40
SPEC-40
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60-100
60-141
20-60 60-160
20-70
30-01
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50-101
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SECTION 30
60-01
ELECTRICAL SCHEMATICS
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60-20
60-30
60-40
60-50
60-80
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