Professional Documents
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Service Manual: S/N 525011001 & Above S/N 525111001 & Above S/N 525211001 & Above S/N 525311001 & Above
Service Manual: S/N 525011001 & Above S/N 525111001 & Above S/N 525211001 & Above S/N 525311001 & Above
Manual
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6902732 (2-06) Printed in U.S.A. Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators 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-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR...............................................60-01
SERVICE PC (LAPTOP COMPUTER)....................60-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER............................. 10-01
SPEED SENSOR ................................................... 60-01
STARTER ................................................................60-01
SYSTEM CHARGING AND RECLAMATION ......... 80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE/PRESSURE................................ 80-01
THERMOSTAT ....................................................... 80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS ... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER ............10-01
TROUBLESHOOTING.............................................70-01
TURBOCHARGER ..................................................70-01
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
A general inspection of the following items must be made after the loader has had service or repair:
1. Check lift arm support device, 9. The parking brake must
replace if damaged. (Stored function correctly.
Position)
5. Check lift arm support device; 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. 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.
SI SSL-0206 SM
SI SSL-0206 SM
The machine and attachments have components that are Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Figure 2
P-48387
P-31846
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
Figure 4
B-16315
SEAT BAR
REAR AUXILIARY
GRAB HANDLES QUICK COUPLERS
STEERING
LEVER
TILT CYLINDER
STABILIZER ROD
BUCKET
FRONT AUXILIARY
QUICK COUPLERS
zOPERATOR CAB
REAR WINDOW (ROPS & FOPS)
REAR GRILL
LIFT ARM
REAR
LIGHT
REAR DOOR
* TIRES
B-16604
B-16605
OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)
* TIRES - The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section and your
Bobcat dealer for available tires.
BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective
Structure per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a
standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).
Figure 10-10-1
N-18877
B-7023A
Put the floor jack under the front of the loader [Figure 10-
10-2].
Lift the front of the loader and put jackstands under the
WARNING axle tubes [Figure 10-10-2].
Procedure
WARNING P-31849
1
WARNING P-34556
P-31857
WARNING The operator must be in the operator's seat, with the seat
belt fastened and seat bar lowered, until the lift arm
support device is installed.
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or Start the engine, and raise the lift arms all the way up.
with missing parts can cause lift arms to drop
causing injury or death. Have a second person install the lift arm support device
W-2271-1197 (Item 1) [Figure 10-20-2] over the rod of one of the lift
cylinders.
Figure 10-20-1
The lift arm support device must be tight against the
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].
P-31849
1
P-31842
Figure 10-20-3
P-31856
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-
20-3].
Start the engine, raise the lift arms all the way up.
Lower the lift arms all the way and stop the engine.
Level II - Protection from falling trees, rocks; for Always stop the engine before raising or lowering the
machines involved in site clearing, overhead demolition cab.
or forestry.
Stop the loader on a level surface. Lower the lift arms. If
the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)
Figure 10-30-2
P10564 P10563
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover N-20120
and falling objects, and result in injury or death.
W-2069-1299
Figure 10-30-3
P-31859
P10563
P10564 P10563
Emergency Exit
Figure 10-30-6
N-20171
x
N-18495
P-24472
Push the rear window out of the rear of the operator cab.
Push the window out with your foot [Figure 10-30-9] at
Exit through the rear of the operator cab [Figure 10-30- any corner of the window.
7].
Exit through the front door.
Procedure
WARNING
P-24480 P-24785
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.
W-2058-0494
Figure 10-40-1
P-31829
1
P-31912
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
Lower the bucket or attachment to the floor.
Be sure the transport and towing vehicles are of
adequate size and capacity (See LOADER Stop the engine.
SPECIFICATIONS on Page SPEC-10-1.), for weight of
loader.) Engage the parking brake.
The rear of the trailer must be blocked or supported (Item Install chains at the front and rear loader tie down
1)[Figure 10-40-1] when loading or unloading the loader positions (Inset) [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
Fasten each end of the chain to the transport vehicle.
Procedure
Procedure
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
1
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
P-24651
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-3
Figure 10-60-1
1
1
P-24653
P16115
Lift and block the loader. (See Procedure on Page 10-10-
1.)
The tool listed will be need to do the following procedure:
Raise the lift arms (if required by the procedure) and
MEL1563 - Remote Start Tool Kit install an approved lift arm support device. (See Installing
Lift Arm Support Device on Page 10-20-1.)
The remote start (Item 1) [Figure 10-60-1] is required
when the operator cab is in the raised position for service Raise the operator cab (if required by the procedure).
and the service technician needs to turn the key switch (See Raising The Operator Cab on Page 10-30-1.)
on or start the engine. Example: Control Handle: linkage
neutral adjustment. Open the rear door of the loader.
Procedure (Cont'd)
Figure 10-60-4
1 Figure 10-60-6
P-24652
Figure 10-60-5
P16118
Procedure (Cont'd)
Figure 10-60-7
P-34661
Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
Or every 12 months.
1
1
P-21769 P-31836
It is important to change the air filter element only when Remove the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated on Contents Page 70-01.
Figure 10-80-2
2 P-31837
1
Figure 10-80-5
P-31838
P-31837
Only replace the inner filter element under the following
conditions:
NOTE: Be sure all sealing surfaces are clean.
Replace the inner filter element every third time the
Install the new filter element and washer. Tighten the outer filter is replaced.
wing nut.
After the outer element has been replaced, start the
NOTE: Be sure sealing washer is in place on each engine and run at full RPM. If the HOURMETER /
wing nut [Figure 10-80-4]. CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
Install the dust cover and tighten the wing nut.
Remove the inner filter wing nut [Figure 10-80-6].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight. Remove the inner filter (Item 1) [Figure 10-80-6].
Figure 10-90-2
P-45101
Open the rear door and remove the rear grill. (See
Removal And Installation on Page 50-60-1.) Raise the air conditioning condenser (If equipped) and
the oil cooler and clean the top of the radiator [Figure 10-
Use air pressure or water pressure to clean the top of the 90-2].
oil cooler [Figure 10-90-1].
Lower the oil cooler on the loader frame.
WARNING
Check cooling system for leaks.
Figure 10-90-3
WARNING
MAX Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
P-45102
Close the rear door before operating the loader. Open the rear door and remove the rear grill.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Figure 10-90-5
P-48075
Remove the cover from the coolant recovery tank. Fill the
tank until it is at the lower marker (inside the tank).
Fuel Specifications
Contact your fuel supplier for local recommendations. Open the rear door.
Filling The Fuel Tank Remove the fuel fill cap (Item 1) [Figure 10-100-1]
Figure 10-100-2
WARNING WRONG
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. B-15650
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
Figure 10-100-3 system before starting the engine.
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
2 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
1
from a physician familiar with this injury.
W-2072-0496
Figure 10-100-4
P-48077
Removing Water
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-110-1
P-48079
1
3
1 P-1575
P-48078
Drain the oil into a container and dispose of used oil in an Start the engine and let it run for several minutes.
environmentally safe manner.
Stop the engine and check for leaks at the oil filter.
Remove the oil filter (Item 2) [Figure 10-110-2].
Remove the dipstick and check the oil level.
Clean the filter housing surface.
Add oil until it reaches the top mark (Item 1) [Figure 10-
Put clean oil on the new oil filter gasket. 110-3] on the dipstick. DO NOT OVERFILL.
Install the filter and hand tighten. Install the dipstick and the fill plug.
Install and tighten the drain plug. Close the rear door.
Checking And Adding Fluid (See SERVICE SCHEDULE on Page 10-70-1) for the
correct service intervals.
Figure 10-120-1
Open the rear door.
Lower the lift arms and tilt the Bob-Tach fully back. Use only recommended fluid in the hydraulic system.
(See HYDRAULIC/HYDROSTATIC FLUID
Stop the engine. SPECIFICATIONS on Page SPEC-50-1.)
Check fluid level in the sight gauge [Figure 10-120-1]. Stop the loader on a level surface.
Open the rear door and remove the rear grill. Lower the lift arms and tilt the Bob-Tach fully back.
Figure 10-120-2 Stop the engine.
Figure 10-120-3
2
1
P-45243
P-45243 P-48866
1
Remove the fill cap (Item 1) [Figure 10-120-2].
Install the fill cap. Replace the rear grill and close the rear
door. Remove the reservoir fill cap (Item 1) [Figure 10-120-3].
S175, S185 Bobcat Loader
10-120-1 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONTD) Figure 10-120-5
WARNING
1
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons 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 2
immediately.
W-2145-0290
P-45493
P-45499
Figure 10-120-6
P-34227
P-64317
(See SERVICE SCHEDULE on Page 10-70-1), for the
correct replacement interval.
On SJC equipped loaders, the hydrostatic charge
pressure filter (Item 1) [Figure 10-120-6] is located on a Raise the operator cab. (See Raising The Operator Cab
bracket mounted to the transmission. on Page 10-30-1.)
Remove and replace the hydrostatic charge pressure Remove the breather cap (Item 1) [Figure 10-120-7] and
filter. discard.
Add the correct fluid to the reservoir until the fluid level is Install new cap.
at the center of the sight gauge (Do not overfill).
Lower the operator cab. (See Lowering The Operator
Lower the operator cab. (See Raising The Operator Cab Cab on Page 10-30-2.)
on Page 10-30-1.)
Figure 10-130-1
P-64141
P-45496
Remove the chaincase cover (Item 1) [Figure 10-130-
2](See CHAINCASE on Page 40-30-1.)
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the hydraulic/ Use a vacuum pump to extract the fluid from the chain
hydrostatic system. (See LOADER SPECIFICATIONS on case.
Page SPEC-10-1.)
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole.
Figure 10-140-1
N-18460
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1
In The Attachment B-15177
Figure 10-150-4
N-17027
Figure 10-150-2
TS-1062
Figure 10-151-1
If the wedge does not contact the lower edge of the hole
B-15891 [Figure 10-151-3], the attachment will be loose and can
come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
B-17460
Procedure 3
Figure 10-160-1
2
1
N-18506
P-18506
N-18505
Access
Lubricate the loader as specified in the SERVICE Hole
SCHEDULE, Contents Page 10-01, for the best
performance of the loader.
Always use a good quality lithium based multi-purpose 2. Stabilizer Rod - Rear (Both Sides) [Figure 10-160-2]
grease when you lubricate the loader. Apply lubricant
until extra grease shows. 3. Lift Cylinder Rod End (Both Sides) [Figure 10-160-2].
Lubricate the following locations on the loader: 4. Lift Cylinder Base End (Both Sides) [Figure 10-160-
2].
1. Stabilizer Rod - Front (Both Sides) [Figure 10-160-1].
Figure 10-160-3
N-18510
Procedure (Contd)
Figure 10-160-4
10
6 7
N-18508
Figure 10-160-5
8 11
N-18511
P-31839
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-160-
9 7].
P16045
Procedure (Contd)
Figure 10-160-8
12
P1533
Mounting
Rotating IMPORTANT
Figure 10-170-2 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
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
B-9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].
Cleaning Procedure
WARNING
Figure 10-180-1
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
death.
W-2006-0284
Start the engine and run for about ten seconds while a
second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
(See SERVICE SCHEDULE on Page 10-70-1), for Lower the rear grill and close the rear door.
service interval for cleaning the spark arrestor muffler.
V-0444 25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20
12 12
13 B
CHARGE
INLET B A
BOB-TACH
CYLINDER
(OPTIONAL)
AUXILIARY
SPOOL
HYDRAULIC 14
36 POWERED
43 TILT CYLINDERS
BOB-TACH BICS CONTROL VALVE
(OPTIONAL)
5 5
D C
39
DR
8
INLET OUTLET
50
48 46 B A 17
47 TILT
42
CYLINDER
49 45 SPOOL
PP 11
DRIVE MOTOR 14
P1 P2
10 LIFT CYLINDERS
44
38
18
B A
LIFT
CYLINDER
SPOOL 35
15
14
4 37
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20
12 12
13 B
CHARGE
INLET B A
AUXILIARY
SPOOL
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
B A 17
42 TILT
53 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
BOB-TACH LIFT CYLINDERS
10
38 (OPTIONAL)
18
39
DR B A
LIFT
CYLINDER
54 SPOOL 35
48 46 15
47
14
37 49 45
4
PP
9 16 WORKING CIRCUITS
P1 P2 33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
44
COMPONENTS
V-0565 25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
13
20
12 12
CHARGE 13 B
INLET B A
BOB-TACH
CYLINDER
(OPTIONAL)
AUXILIARY
SPOOL
HYDRAULIC 14
36 POWERED
10 TILT CYLINDERS
BOB-TACH BICS CONTROL VALVE
(OPTIONAL)
5 5
D C
39
DR
10
INLET OUTLET
43
48 46 B A 17
47 TILT
13 CYLINDER
8 42 SPOOL
45
PP 11
DRIVE MOTOR 49 14
LIFT CYLINDERS
38 P2 10
P1
18
44
B A
13 LIFT
CYLINDER
SPOOL 35
15
4 37
14
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
13
20
12 12
CHARGE 13 B
INLET B A
AUXILIARY
SPOOL
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
38
18
39
DR B A
13 LIFT
CYLINDER
43 SPOOL 35
48 46 15
47
37 49 45
4
PP
14
9 16 WORKING CIRCUITS
53 41
33 33 PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
44
LIFT ARM BY PASS VALVE
32
19
4 37
P-OUT P-IN T
D
34
38 HYDRAULIC FILTER
31
53 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
52
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
51
52 14
2 31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 53 5
54
3
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
LIFT CYLINDERS
55 10
18
OUTLET HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
50
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-0715 (7-12-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
S175 (S/N 525215000 AND ABOVE)
(S/N 525315000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(S/N 525115000 AND ABOVE)
(PRINTED JULY 2005) Printable Version Click Here
V-0716legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 19.2 qt. (18,2 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 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE 50 RELIEF VALVE - 3300 PSI (228 bar)
4 37
P-OUT P-IN T
D
34
38 HYDRAULIC FILTER
31
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
57 14
2 31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 56 5
55 51
50
3 52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
LIFT CYLINDERS
59 10
18
HYDRAULIC
OUTLET
53 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-0716 (7-12-05)
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
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 come ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down with the pedal is in neutral position 4, 9, 10, 11
By-pass valve stuck 12
By-pass valve stem bent or broke 13
Checking
WARNING
2
Diesel fuel or hydraulic fluid under pressure can 1
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496 N-18786
Figure 20-20-1 Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.
Engage the parking brake. Lower the seat bar. Start the
engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
N-18785
Lower the lift arms. Stop the engine. Pull up on the lift WARNING
arm by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Check only one cylinder at a time. Open the rear door. Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
Disconnect the negative ground cable to the battery. W-2103-1285
N-18806
P-34048
Figure 20-20-6
1
1 2
N-18782
P-34047
Figure 20-20-9
P-34050
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
1 6
15
2
5
4
14
1 13
2 12
3
11
10
B-13593
Disassembly
2
Use the following tools to disassemble the cylinder:
Figure 20-20-13
P-48033
4
3 P-48039
2
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-11].
1 Figure 20-20-16
P-48040
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-16].
Assembly (Cont'd)
Figure 20-20-17
1
2
P7425
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-
P-48043A P7427 20].
Install the rod seal on the rod seal tool [Figure 20-20-18].
Assembly (Cont'd)
Figure 20-20-21
1
2 3
P-48036
Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-21].
Figure 20-20-22
P-48035
Checking
WARNING 1
Figure 20-21-1
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
N-18801 If there is leakage from the open port, remove the tilt
cylinder for repair.
WARNING 1
Use a drift pin and hammer, remove the rod end pivot pin
(Item 1) [Figure 20-21-4].
Figure 20-21-5
1
N-18544
3 2
Remove the attachment. Roll the Bob-Tach forward. Stop
the engine. Raise the seat bar.
Figure 20-21-6
2
P-24709
P-34228
Remove the tilt cylinder from the Bob-Tach. (See
Removal And Installation, Page 20-21-2.)
Disconnect the hose (Item 1) [Figure 20-21-6] from the
cylinder. Loosen the retainer bolt (Item 1) [Figure 20-21-7] from
the tilt cylinder rod base end pin.
Remove the cylinder (Item 2) [Figure 20-21-6] from the
rod end pivot pin. Installation: Tighten the retainer bolt to 175-190 ft.-lb.
(240-260 Nm) torque.
Remove the cylinder from the loader.
Strike the head of the bolt (Item 1) [Figure 20-21-7] to
push the pivot pin out.
Figure 20-21-8
1
1
N-18554
Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Rod End Pivot Pin Bushing And Seal
Replacement, Page 20-21-4.)
Figure 20-21-9
N-18555
Parts Identification
1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal MC-1688B
8. O-ring 16. Bushing
3
MC-01688A
4
10
7
12
6 13
5 11
MC-01688D
14
15
MC-01688C 16
15
PE-1056A
Disassembly
2
Use the following tools to disassemble the cylinder:
Figure 20-21-14
2
P-48034
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].
1 Figure 20-21-17
P-48040
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-17].
Assembly (Cont'd)
Figure 20-21-18
P7425
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
P-48043 P7427 21].
Install the rod seal on the rod seal tool [Figure 20-21-19].
Assembly (Cont'd)
Figure 20-21-22
1
1
2
P-48070
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-22].
Figure 20-21-23
P-48088 P-48089
Mark the end of the shaft and nut. Tighten the nut an
additional 135 degrees or 2-1/4 flats [Figure 20-21-23].
Checking
WARNING
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 which can result in injury or death.
W-2103-1285
1
P16330
2
Figure 20-22-1
1 P16332
Engage the parking brake. Lower the seat bar. Start the
engine.
N-21401
Push and hold the BOB-TACH "WEDGES UP" Switch
(Front Accessory Panel).
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1]. If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the Power Bob-Tach
cylinder for repair.
Figure 20-22-4
1 1
N-21401
Figure 20-22-5
N-21400
Identification
1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
2
3
4
5
6
7
8 9
10
11
12
13
B-16276
Disassembly
3
2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
Spanner Wrench
Figure 20-22-6
P16295
Figure 20-22-9
3 5
4
P16293
Figure 20-22-7
N-20611
3 2
1 Remove the wiper seal (Item 1) [Figure 20-22-9], and
rod seal (Item 2) [Figure 20-22-9], the back up washer
(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9]
from the head.
P16294
Assembly
3
Use the following tools to assembly the cylinder: 2 1
Lubricate all O-rings and seals with hydraulic oil during Piston: Install the O-ring (Item 1) [Figure 20-22-11] and
installation. seal (Item 2) [Figure 20-22-11] on the piston (Item 3)
[Figure 20-22-11].
Figure 20-22-10
NOTE: The piston center hole (Item 4) [Figure 20-22-
11] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
P7424
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10].
N-20612
Allow the seal to stretch for 30 seconds before installing it
on the piston.
Install the rod seal on the rod seal tool [Figure 20-22-12].
Assembly (Contd)
Figure 20-22-13
2
3
P7422
Figure 20-22-16
1 3
2 4
P7425
P16294
Install the rod seal in the head [Figure 20-22-14].
Install the wiper seal with the wiper toward the outside of Install the head (Item 1) [Figure 20-22-16], and spacer
the head. (Item 2) [Figure 20-22-16].
Assembly (Contd)
Figure 20-22-17
P16293
Checking
IMPORTANT
2
The hydraulic tester must be in the fully open
1
position before you start the engine.
I-2024-0284
WARNING P-34480
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
steering levers must be in neutral and the parking hydraulic tester to the bottom (female) quick coupler on
brake engaged. Failure to do so can cause injury or the loader.
death.
W-2006-0284
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
Turn the key switch to the OFF position. To release the N-18409
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds. Press the AUXILIARY HYDRAULICS Button (Item 1)
[Figure 20-30-2] Maximum Flow.
Lift and block the loader. (See Procedure on Page 10-
100-1.)
Figure 20-30-3
Right
Steering
Lever O-ring
Control
Back-up
B-6764
1
P-31833
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [Figure 20-30-4].
Push the front switch (Item 1) [Figure 20-30-3] to give
the front quick couplers a constant flow of fluid. Turn the adjusting screw in or out until the pressure is
correct.
To release from continuous operation, press the front
switch (Item 1) [Figure 20-30-3] a second time. NOTE: If the correct pressure can not be reached,
replace the main relief valve. Check the
Watch the flow meter on the hydraulic tester to make pressure setting of the new relief valve.
sure the flow is correct. Increase the engine speed to full
RPM.
Figure 20-30-5
1
1
P-48874
1
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
Identification IMPORTANT
Figure 20-40-1 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
The hydraulic control valve (2 piece casting) (foot control) Clean the area around the control valve.
has a removable BICS section (Item 1) [Figure 20-40-
1]. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-1.)
The BICS section and main control valve are in two
seperate castings. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (1 piece
casting) (foot control), (See Identification Chart on Page Remove the control pedal crossbar linkage and tilt
20-42-6.). linkage. (See Crossbar Linkage Removal and Installation
on Page 50-90-2.)
Removal And Installation
Figure 20-40-2
WARNING
Never work on a machine with the lift arms up unless P-34004
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
Remove the right rear tire.
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Locate and remove the access covers (Item 1)
[Figure 20-40-2] on the right side of the machine.
Figure 20-40-3
3
1
1
P-34387
Figure 20-40-4
2
1
1
P-34388
Figure 20-40-7
5 1
4 3
1
P-31997
2
Figure 20-40-8
P-34005
4
P-34390
Figure 20-40-11
P-34391
Figure 20-40-12
P-34006
Figure 20-40-14
1 1
1 1
2
1 1
N-18697
1
1
Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-40-16] from the top of the control
valve.
N-18679
Figure 20-40-15
6
3
1
2
5
4
N-18679
N-18695
The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS
valve assembly to the control valve. Thoroughly clean
Remove the BICS valve assembly from the top of the and dry bolts and threads in valve. Use liquid adhesive
control valve [Figure 20-40-15]. LOCTITE #242 or equivalent.
STEP TORQUE SEQUENCE
1 110-130 in.-lb.
(12,5-23,7Nm)
2 190-210 in.-lb.
1,2,3,4,5 & 6
(21,5-23,7Nm)
3 190-210 in.-lb.
(21,5-23,7 Nm)
*Torque must be 190-210 in.-lb. (21,5-23,7 Nm) for
every bolt or repeat step 3.
Figure 20-40-18
N-18687
1
Figure 20-40-20
N-18686
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-19] & [Figure 20-40-
20].
Figure 20-40-21 1
P-8956
1
Figure 20-40-22
2
1
N-18684
Figure 20-40-24
1
1
1
N-18689
Figure 20-40-27
1
1
N-18688 2
2
2 N-18690
N-18692
Figure 20-40-29
N-18693
Figure 20-40-31
3
2
P9175
1
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-18698
Figure 20-40-34
Mark each valve section, spool and related parts so that
they will be returned to its original valve section during
assembly.
1 1
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
1 1 Loosen the load check valve plugs (Item 1)
[Figure 20-40-35].
Figure 20-40-36
N-18697
3
2 N-18699
Figure 20-40-37
1
N-19031
2 3 4
The auxiliary section (Item 1) uses an orifice load check l l l 5
poppet (Item 2) [Figure 20-40-37]. l l
1
NOTE: For correct port locations and valve
B-06764
component values (See Identification Chart
on Page 20-40-11.)
1. Relief Valve
2. O-ring
Main Relief Valve
3. Sleeve
4. Glide Ring
Figure 20-40-38
5. O-ring
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-40].
N-18923
Figure 20-40-41
N-18977
Figure 20-40-42 4
3
1 1
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844
N-18923 Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-44].
Figure 20-40-45
1
N-18843
Figure 20-40-46
1
1
N-18923
Figure 20-40-49
1 N-18923
Remove the anti-cavitation valve (Item 2) Installation: Tighten the screws to 90-100 in.-lb. (10,2-
[Figure 20-40-48] & [Figure 20-40-49] from the control 11,3 Nm) torque.
valve for the lift section.
Figure 20-40-52
Figure 20-40-50
1 2 3 2
4
E-01509
1. Anti-Cavitation Valve
2. O-ring 2
1
3. Backup Washer
4. O-ring
N-18924
N-18839
Figure 20-40-53
N-18926
2
1
Remove the block [Figure 20-40-55].
N-18923 NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Figure 20-40-54
Lift Spool and Detent
Figure 20-40-56
2
2 1
N-18925
1
Remove the lock solenoids (Item 1) [Figure 20-40-53] &
[Figure 20-40-54] from the lock block.
N-18923
Figure 20-40-57
1 2 2
N-18971
Figure 20-40-58
2
1
1
N-18972
Remove the end cap (Item 1) [Figure 20-40-58]. Remove the detent bonnet (Item 2) [Figure 20-40-60].
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-61
N-18975
Figure 20-40-62
2
3 N-18930
1
N-18974
Figure 20-40-65
1
2
N-18916
1
1
N-18915
N-19004
Figure 20-40-69
N-18918
Figure 20-40-70
1
2
3 1
N-18920
N-18919A Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
Inspect the adapter (Item 1), collar (Item 2), spring tap drill.
(Item 3), and washer (Item 4) [Figure 20-40-70].
Turn a 6-32 tap (Item 1) [Figure 20-40-72] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Figure 20-40-73
2
Plastic
1 Plug
.60 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.60 inch (15,2 mm) from the spool
N-18961 [Figure 20-40-75].
Figure 20-40-76
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-73].
Figure 20-40-74
N-18967
Figure 20-40-77
1 N-19004
3
2
Install the spring tool (Item 1) [Figure 20-40-79] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-80
Figure 20-40-78
N-18917
N-18968
Figure 20-40-81
N-19007
Figure 20-40-82
N-19008
CD-15051
Figure 20-40-85
N-18976
1
Install the end cap (Item 1) [Figure 20-40-87].
2
N-18972 Figure 20-40-88
Figure 20-40-86
N-18930
N-18971
Figure 20-40-89
1 2
1
N-18923
2
1
N-18928
N-18923
N-18942
N-18942
Figure 20-40-94 1
N-19014
Figure 20-40-97
2 1
3
4
1
N-18976
Inspect the adapter (Item 1), collar (Item 2), spring Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
(Item 3), and washer (Item 4) [Figure 20-40-97]. Nm) torque.
2
1
N-18930 N-18943
N-18990
Remove the spool seal(s) (Item 1) and the back-up Remove the end cap, O-ring, springs and washer (both
washer (Item 2) [Figure 20-40-98]. sides).
Assembly: Always use a new spool seal. Assembly: Put grease on all the centering spring
component parts.
Figure 20-40-101
1
2
N-18823
Figure 20-40-102 3 2
1
N-18992
Figure 20-40-105
2
1
1
N-18800
Figure 20-40-108
Figure 20-40-106
N-18843
N-18993
Check that the load check valve seats are not worn.
Identification IMPORTANT
Figure 20-41-1 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
The BICS section and main control valve are in two Remove the control panel. ((See Removal and
seperate castings. Installation Page 50-100-1.)
P-48872
Figure 20-41-3
1
1
P-48881
Figure 20-41-6
Mark all tubelines and hoses for correct installation.
P-48878
1
1 3
P-48884
Figure 20-41-8
3
2
2 5
1 4
P-48883
P-48880
Remove the tilt tubeline (Item 1) [Figure 20-41-10] from
the bucket positioning valve (if so equipped) and the
Label and disconnect the actuator electrical connectors control valve.
(Item 1) [Figure 20-41-8].
Disconnect the lift tubeline (Item 2) [Figure 20-41-10].
Remove the bolt (Item 2) [Figure 20-41-8] from the wire
harness clamp. Disconnect the tilt tubeline (Item 3) [Figure 20-41-10].
Installation: Tighten the bolt to 25-28 ft.-lb. (34-38 Nm) Remove the tilt tubeline (Item 4) [Figure 20-41-10] from
torque. the bucket positioning valve and the control valve (if so
equipped).
Figure 20-41-11
1
1
2
P-48873
Figure 20-41-12
P-48884
Figure 20-41-14
1 1
1
1
2
1 1
N-18697
1
1 Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-41-16] from the top of the control
N-18679 valve.
Install the four large O-rings (Item 1) and the small O-ring
Remove the control valve. (See Removal and Installation (Item 2) [Figure 20-41-16] on the top of the control valve.
Page 20-41-1.)
Figure 20-41-15
N-18695
Figure 20-41-17
3 6
1 2
5 4
N-18679
Figure 20-41-18
N-18687
1
Figure 20-41-20
N-18686
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-41-19] & [Figure 20-41-
20].
Figure 20-41-21 1
1 P-8956
Figure 20-41-22
2
1
N-18684
Figure 20-41-24
1
1
1
N-18689
N-18688
Figure 20-41-27 1
N-18693
Figure 20-41-28
1 N-18692
N-18691
Figure 20-41-31
3
2
P9175
1
Use an Ohm meter to measure coil resistance [Figure
N-18694 20-41-32].
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
1 1 N-19114
Figure 20-41-34
N-18940
N-19113
N-21159
1
N-19099
Figure 20-41-41
1 1
N-19034
3
2 N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-43].
Figure 20-41-44
Remove the load check plugs (Item 1) [Figure 20-41-41].
Figure 20-41-42
1
1
N-19035
2 N-19102
Figure 20-41-45
1
2
3 4 5
B-06764
Figure 20-41-46
N-18981
N-19000
Figure 20-41-49
4 1
2
1
1. O-ring N-18980
2. Backup Washer
3. O-ring
Remove the anti-cavitation/port relief valve (Item 1) from
4. Relief Valve
the control valve for the tilt section [Figure 20-41-51].
N-18844
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lb. (47-54 Nm) torque.
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-41-49]. Figure 20-41-52
Figure 20-41-50
N-18843
Figure 20-41-53
E-1509A
1
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
N-18839
N-19036
N-19112
Remove the anti-cavitation valve (Item 1) [Figure 20-41- Remove the actuator (Item 1) [Figure 20-41-56] from the
53] & [Figure 20-41-54] from the control valve. control valve. (See Actuator Removal And Installation
Page 20-41-12.)
Figure 20-41-57
1 1
N-19112
Figure 20-41-58
1
1
1 N-19003
Figure 20-41-61 1
N-19014
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
N-18942 3), and washer (Item 4) [Figure 20-41-64].
Put the linkage end of the spool in the vice [Figure 20-
41-62].
2
1
2
1
N-18987
1
Remove the spool seal(s) (Item 1) and the back-up Figure 20-41-68
washer (Item 2) [Figure 20-41-65].
Figure 20-41-66
1 N-18988
Figure 20-41-69
3
2
1 N-18992
Remove the nut (Item 1) [Figure 20-41-69] from both Installation: Tighten valve to 96-144 in.-lb. (11-16 Nm)
solenoids. torque.
Installation: Tighten the nut to 96-144 in.-lb. (11-16 Nm) Figure 20-41-72
torque.4
Figure 20-41-70
2
1
1
N-18795
Remove the end plate (Item 1) and housing (Item 2) Installation: Always use new O-rings and apply oil to the
[Figure 20-41-70]. O-rings prior to installation.
Port-Auxiliary Section
Figure 20-41-73
2 1
N-18843
1
Identification IMPORTANT
Figure 20-42-1 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
1
Lift and block the loader. ((See Procedure on Page 10-
10-1.)
The hydraulic control valve (1 piece casting) (foot control) Clean the area around the control valve.
(Item 1) [Figure 20-42-1] does not have a removable
BICS section. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-1.)
The BICS section and main control valve are in one
casting. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (2 piece
casting) (foot control), (See Identification on Page 20-40- Figure 20-42-2
1.)
P-34004
Figure 20-42-3 2 1
3
1
1
P-51714
Figure 20-42-4
P-51715
1
Figure 20-42-7
1
1 1
P-48287
P-51723
1
Figure 20-42-11
2
1 1
P-51714
Figure 20-42-12
P-51729
Remove tubeline clamp bolt (Item 1) [Figure 20-42-12] Disconnect and cap the tubeline (Item 3) [Figure 20-42-
from the auxiliary tubelines in the left rear upright. 14] from the lift section of the control valve.
Figure 20-42-15 1
1
P-51726
1
Connect a hoist to the lifting brackets (Item 1) [Figure
20-42-17] on the control valve.
P-51728
Figure 20-42-18
Figure 20-42-16 1
1
P-34004P-
P-51713
51713
Identification Chart
Figure 20-42-19
C2 J2 C3
J4
D5 B3
E3
E3
G1 G2
F2 A3 D3
B2
D4 F4 E2
A2
D1
D2
A1
E1
F1 H2 B1
F3 H3
MR C1
H1 J3
J1
MS1926
Figure 20-42-20
1 P-51438
P-51690
Remove the lift load check valve (Item 1) [Figure 20-42-
22].
Remove the control valve and mount bracket (Item 1)
[Figure 20-42-20] from the loader. Installation: Lubricate the o-ring and tighten the valve to
55-65 ft.-lb. (75-88 Nm) torque.
Figure 20-42-21
Figure 20-42-23
2 1
2
2
P-51435
P-51439
1 1
3
2
P-51453
Check for free movement of the load check valve (Item 1) Installation: Install a new O-ring (Item 4) [Figure 20-42-
[Figure 20-42-24]. 26] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 Nm)
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)
Figure 20-42-25
P-51691
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-42-25].
1
3
2
1 P-51453
WARNING
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 20-42-28
P-51693
Figure 20-42-30
P-51692
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-42-33
1) [Figure 20-42-30].
Figure 20-42-31
P-51454
1
Replace the O-ring (Item 1) [Figure 20-42-33] before
P-51451
installation.
Replace the O-ring (Item 1) [Figure 20-42-31] before Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.
installation.
Figure 20-42-34
P-51692
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-42-37
[Figure 20-42-34] from the rod end of the tilt section.
Figure 20-42-35
1 P-51695
Figure 20-42-38
1 1
P-51459
P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-42-40].
Figure 20-42-39
1
P-51460
P-51506
1
P-51461 Remove the three screws (Item 1) [Figure 20-42-44] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 90-100 in.-lb. (10,
(Item 1) [Figure 20-42-42]. 11,3 Nm) torque.
1
2
1
P-51462
P-51701
Installation: Always use new O-rings (Item 1) [Figure Remove the rubber boots (Item 1) from the retainer plate
20-42-43]. Tighten to 40 ft.-lb. (54 Nm) torque. (Item 2) [Figure 20-42-45].
Figure 20-42-46
1 1
P-51699
1
1
P-51698
P-51700
Disconnect the tube line (Item 1) [Figure 20-42-47] from Remove the end cap/spool lock block (Item 1) [Figure
the end cap/spool lock block. 20-42-49] from the control valve.
Figure 20-42-50
P-51513
Figure 20-42-53
1
P-51511
1
Remove the O-ring (Item 1) [Figure 20-42-50]. 2
Figure 20-42-51
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-42-53].
P-51512
2 1
3
1
2 P-51517
IMPORTANT
The detent assembly has small springs and balls. Do 1
not lose these parts during disassembly and
assembly. P-51518
I-2012-0284
Figure 20-42-55 Remove the lift spool assembly and seal (Item 1) [Figure
20-42-57] from the control valve.
P-51516
Figure 20-42-58 1
3
N-18915
1
P-8988 2
N-18916
1 4
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-42-64].
Figure 20-42-63
N-18918
Remove the stud from the end of the spool [Figure 20-
42-65].
N-19009
Figure 20-42-66
N-18963
1
Install the plastic plug and O-ring in the spool [Figure 20-
42-68].
Drill a hole all the way through the plug using a 7/64 inch
tap drill
Figure 20-42-67
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-42-69].
2
1
N-18961
Figure 20-42-70
1
1
N-18968
1 3
2
N-18958
N-19004
Apply grease on all the detent component surfaces Install the spring tool (Item 1) [Figure 20-42-73] over the
before assembly [Figure 20-42-71]. washer, spring, collar and detent adapter.
Figure 20-42-74
CD-15051
1
Install the detent balls and spring [Figure 20-42-76].
Figure 20-42-77
N-18917
Figure 20-42-75
1
N-19007
N-19005
Figure 20-42-78
1
P-51514
Figure 20-42-79
2
P-51513
1
Install the end cap (Item 1) [Figure 20-42-81].
2
P-51515
Figure 20-42-82 1
P-51511
Figure 20-42-83
1 4
P-51701
P-51512 Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-42-85].
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-42-83] on the lift spool. Installation: Tighten the screws to 90-100 in.-lb. (10-
11,3 Nm) torque.
1 2
P-51698
P-51521
Connect the tubeline (Item 1) [Figure 20-42-86]. Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-42-88] from the tilt spool.
Figure 20-42-87
Figure 20-42-89
1
P-51697
P-51522
N-18942
1 Put the linkage end of the spool in the vice [Figure 20-
42-92].
P-51543
Install the spool tool (Item 1) [Figure 20-42-92] over the
centering spring.
Remove the spool centering block (Item 1) [Figure 20-
42-90] from the control valve. Figure 20-42-93
N-19014
Figure 20-42-94
2 1
3 1
P-51522
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 20-42-94]. Nm) torque.
Figure 20-42-95 Remove the spool centering block (Item 2) [Figure 20-
42-96] from the control valve.
2
1 Figure 20-42-97
1 2
1
P-51545 N-18943
Assembly: Always use a new spool seal. Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-42-97] from the auxiliary spool.
Figure 20-42-98
1 2
1
2 P-51550
Figure 20-42-99
2 1
P-51551
P-51549
Figure 20-42-102
1
P-51703
Remove the nut (Item 1) [Figure 20-42-102] from both Figure 20-42-105
solenoids.
Figure 20-42-103
1
2
2
P-51555
Figure 20-42-106
2
P-51445
Remove the nut (Item 1) [Figure 20-42-106] from the Figure 20-42-109
solenoid stem.
N-18694
Figure 20-42-110 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 20-42-110] is for the lift
circuit.
Figure 20-42-111
P-51443
Figure 20-42-113
1
P-51706
Locate the tilt circuit lock valve (Item 1) [Figure 20-42- Figure 20-42-116
113].
Figure 20-42-114
1
1
2 1
1
2
1
2
2
P-51564
P-51697P-
51504
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-42-116] from the tilt lock valve, and replace
with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-
42-114].
Figure 20-42-117
1
4
P-51447
Figure 20-42-118
P-51446
Figure 20-42-120
1 P-51707
Figure 20-42-123
Remove the fitting (Item 1) [Figure 20-42-120] from the
valve.
Figure 20-42-121
1
1
P-51463
Identification IMPORTANT
Figure 20-43-1 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
The hydraulic control valve (1 piece casting) (ACS) (Item Clean the area around the control valve.
1) [Figure 20-43-1] does not have a removable BICS
section. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-1.)
The BICS section and main control valve are in one
casting. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (2 piece
casting) (ACS), (See Identification on Page 20-41-1.) Figure 20-43-2
P-34004
Figure 20-43-3 1
2
1 3
1
P-51975
The fixed end main valve hose (Item 1) [Figure 20-43-3] Disconnect and cap the supply hose (Item 3) and the
is connected to a fixed end fitting on the control valve. supply hose clamp (Item 4) [Figure 20-43-5].
The hose is routed to the back upright where the hose is
connected to a tee fitting that feeds the base end of both Figure 20-43-6
lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.
1
NOTE: Remember the hose routing for ease of
control valve installation.
Figure 20-43-4
3
P-51976
1
Disconnect and cap the tubeline (Item 1) [Figure 20-43-
6] from the lift arm by-pass valve to the control valve.
Remove the tie-strap (Item 1) [Figure 20-43-4] from the Remove the lift arm by-pass tubeline (Item 3) [Figure
fixed end main valve hose. 20-43-6] from the control valve drain.
Figure 20-43-7
P-51983
Figure 20-43-8
P-51977
Figure 20-43-10
2 1
1
P-51980
Figure 20-43-11
2
1
1
P-51982
Remove tubeline clamp bolt (Item 1) [Figure 20-43-11] Disconnect and cap the tubeline (Item 3) [Figure 20-43-
from the auxiliary tubelines in the left rear upright. 13] from the lift section of the control valve.
Figure 20-43-14 1
1
P-51726
1
Connect a hoist to the lifting brackets (Item 1) [Figure
20-43-16] on the control valve.
P-51728
Figure 20-43-17
Figure 20-43-15
1
1 P-31999
P-34004P-
51713
Figure 20-43-18
1
1
P-51734
1
Using a drift pin and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-43-20] from the actuator
and the tilt spool.
P-51732 Remove the actuator and linkage pin from the valve.
Figure 20-43-21
Remove the two mount bolts (Item 1) [Figure 20-43-18]
from the tilt actuator.
Figure 20-43-19 1
1 P-51736
Pull the actuator away from the control valve [Figure 20-
43-19].
Figure 20-43-22
P-51800
Remove the two mount bolts (Item 1) [Figure 20-43-22] Figure 20-43-25
from the lift actuator.
Figure 20-43-23
1
1
2
P-51736
Pull the actuator away from the control valve [Figure 20-
43-23].
Figure 20-43-26
1 2
3
P-51738
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3 D3
B2
D4 E2
A2
D1
D2
A1
E1
F1 H2 B1
H3
MR C1
H1 J3
J1
MS1929
Figure 20-43-28
1 P-51740
P-51730
Remove the lift load check valve (Item 1) [Figure 20-43-
30].
Remove the control valve and mount bracket (Item 1)
[Figure 20-43-28] from the loader. Installation: Lubricate the O-ring and tighten the valve to
55-65 ft.-lb. (75-88 Nm) torque.
Figure 20-43-29
Figure 20-43-31
P-51731
P-51439
1 1
3
2
P-51453
Check for free movement of the load check valve (Item 1) Installation: Install a new O-ring (Item 4) [Figure 20-43-
[Figure 20-43-32]. 34] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 Nm)
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)
Figure 20-43-33
P-51741
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-43-33].
1
3
2
P-51453
1
WARNING
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 20-43-36
P-51452
Figure 20-43-38
1
P-51742
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-43-41
1) [Figure 20-43-38].
Figure 20-43-39
1 P-51454
Replace the O-ring (Item 1) [Figure 20-43-39] before Installation: Lightly lubricate with oil and tighten to 38-45
installation. ft.-lb. (52-61 Nm) torque.
Figure 20-43-42
P-51742
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-43-45
[Figure 20-43-42] from the rod end of the tilt section.
Figure 20-43-43
1 P-51801
Figure 20-43-46
1
1
P-51459
P-51743 At the top side of the control valve, remove the plug (Item
1) [Figure 20-43-48].
Figure 20-43-47
1
P-51460
1
P-51461 2
P-51744
Figure 20-43-53
1
P-51462 1
P-51745
Figure 20-43-54
1
P-51748
Figure 20-43-57
P-51746
Figure 20-43-55 1
P-51749
P-51747
Figure 20-43-58
P-51772
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-43-61
20-43-58] from the control valve.
Figure 20-43-59
1
P-51773
P-51771 Install the spring tool (Item 1) [Figure 20-43-61] over the
centering spring.
P-51771 P-51775
Remove the bolt (Item 1) [Figure 20-43-62] holding the Figure 20-43-65
centering spring to the spool.
Figure 20-43-63
2
3
3 3
4 1 P-51749
Figure 20-43-66
P-51746
Figure 20-43-67
3
2
1 1
2
P-51744
2
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-43-69].
P-51747
Installation: Tighten the screws to 90-100 in.-lb. (10-
11,3 Nm) torque.
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-43-67] on the lift spool. Connect the tube line (Item 3) [Figure 20-43-69] to the
end cap block.
Figure 20-43-70 2
P-51780
Figure 20-43-71
2
P-51781
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-43-76].
N-18942
Figure 20-43-77
Put the linkage end of the spool in the vice [Figure 20-
43-74]. 2
1
Install the spring tool (Item 1) [Figure 20-43-74] over the
centering spring.
Figure 20-43-75
1
1
P-51545 N-18943
N-19014
Figure 20-43-78
1 1
2
P-51783
Figure 20-43-79 2
P-51784
1
P-51782
Figure 20-43-82
1
2
P-51552
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Installation: Tighten the nut to 48-72 in.-lb. (5-8 Nm)
20-43-82] from the auxiliary spool. torque.
P-51786
P-51553
Remove the auxiliary spool (Item 1) [Figure 20-43-83]. Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-43-85].
Figure 20-43-86
1
1
2
P-51788
Figure 20-43-87
1
2
N-18693A
P-51555
Remove the O-rings (Item 1) [Figure 20-43-89] from
both ends of the solenoid coil.
Remove the O-rings (Item 1) [Figure 20-43-87] from the
solenoid stem. Use an Ohm meter to measure the solenoid coil
resistance.
Check and clean the screen (Item 2) [Figure 20-43-87].
The correct resistance for the coil is 9.79 .29 Ohms.
BICS Valve Solenoid Disassembly And Assembly Install new O-rings (Item 1) [Figure 20-43-89] & [Figure
(Contd) 20-43-91] and new back-up rings (Item 2) [Figure 20-43-
91] on the solenoid stem.
Figure 20-43-90
BICS Valve, Lock Valve Removal And Installation
Figure 20-43-92
1
2
1
P-51789
3
2
1
1
N-18694
P-51791
1 1
1 2
1 2
2
P-51564
1
2
Remove the O-rings (Item 1) and back-up rings (Item 2)
2 [Figure 20-43-96] from the tilt lock valve, and replace
2 with new.
P-51564
Figure 20-43-95
P-51792
Figure 20-43-97
4
P-51447
1
Figure 20-43-98
P-51446
Figure 20-43-100
1
P-51794
Figure 20-43-103
Remove the fitting (Item 1) [Figure 20-43-100] from the
valve.
Figure 20-43-101
1
1
P-51463
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull the Lift Arm By-Pass 1
Control Knob until the lift arms slowly lower.
1
P-31990A
WARNING Hold the Lift Arm By-Pass Control knob (Item 2) and
loosen the jam nut (Item 3) on the Lift Arm By-Pass valve
Never work on a machine with the lift arms up unless shaft [Figure 20-50-1].
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Remove the Lift Arm By-Pass Control knob (Item 2) and
support device can allow the lift arms or attachment the jam nut (Item 3) from the Lift Arm By-Pass valve shaft
to fall and cause injury or death. [Figure 20-50-1].
W-2059-0598
Remove the rubber washer (Item 4) [Figure 20-50-1].
Install jack stands under the rear corners of the loader.
Figure 20-50-2
1
1
4
2
3
P-26065
P-48431
Remove the by-pass valve (Item 1) [Figure 20-50-3]
from the valve block. Inspect the by-pass valve for
Disconnect the base end lift tubeline (Item 1) [Figure 20- damage and replace if necessary.
50-2] from the Lift Arm By-Pass valve.
Installation: Tighten the valve to 33-37 ft.-lb. (45-50
Disconnect the drain hose (Item 2) [Figure 20-50-2] from Nm) torque.
the Lift Arm By-Pass valve.
Inspect the hydraulic fittings on the valve block for
Disconnect the motor case drain hose (Item 3) [Figure damage and replace if necessary.
20-50-2].
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
1
P-26071
Figure 20-60-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
1 2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-26682
Figure 20-60-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
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
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
P-26068
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Disconnect and cap the inlet hose (Item 1)
[Figure 20-60-8] from the front of the hydraulic pump.
Figure 20-60-7
Figure 20-60-9
2
1
P-26071
P-26069
Raise the operator cab. (See Raising The Operator Cab Remove the hydraulic pump (Item 2) [Figure 20-60-9]
on Page 10-30-1.) from the hydrostatic pump.
Figure 20-60-10
P-26347
1 2
P-26347
Identification
15
8
7
6
14
13
12
11
7 9
1 5 10
4
3
B-16050A
P-26352
2
2
P-26353
1
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 20-60-13 1
P-26358
2
Figure 20-60-16
P-26354
1
Figure 20-60-14
4
3
1
P-26359
Remove the wear plate (Item 1) [Figure 20-60-13] & NOTE: Inspect the pump center section (Item 1)
[Figure 20-60-14] and section seal (Item 2) [Figure 20-60-16]. If excessive wear or
[Figure 20-60-13] & [Figure 20-60-14] from the pump damage is visible, the pump must be
end section. replaced.
Figure 20-60-17
1
P-26391
Figure 20-60-20
P-26389
Figure 20-60-18
P-26362
1
1
P-26362
Figure 20-60-21
P-26394
Remove the drive gear (Item 1) [Figure 20-60-21] from Figure 20-60-24
the pump end section.
P-26395
1
Remove the load seal (Item 1) [Figure 20-60-24].
P-26393
2
P-26398
P-26374
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
1
P-26753
Figure 20-61-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
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
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-26754
Figure 20-61-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
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
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm P-26739
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Disconnect and cap the inlet hoses (Item 1)
[Figure 20-61-8] from the front of the hydraulic pump.
Figure 20-61-7
Figure 20-61-9
1
2
1
P-26741
P-26740
Stop the engine. Raise the seat bar. Installation: Tighten the mounting bolts to 27-37 ft.-lb.
Lift and block the rear of the loader. (See Procedure on (37-50 Nm) torque.
Page 10-10-1.)
Remove the hydraulic pump (Item 2) [Figure 20-61-9]
Raise the operator cab. (See Raising The Operator Cab from the hydrostatic pump.
on Page 10-30-1.)
Figure 20-61-10
P-26684
1 2
P-26684
Identification
26
22 23
19
27
24 25
23
20
21
17 18
15 16 7 8
14
2
13
12
1 11
10
6 7 9
3 4 5
B-16051a
Figure 20-61-12
2
1
2
1 P-26622
Figure 20-61-13
1 1
P-26627
2 Figure 20-61-16
P-26625
Figure 20-61-14
1
3
1 P-26628
Figure 20-61-17
P-26631
Figure 20-61-20
P-26629
Figure 20-61-18
P-26632
1
Remove the drive gear (Item 1) [Figure 20-61-19] &
[Figure 20-61-20].
P-26636A
1
1
P-26635
2
Remove the load seal (Item 1) [Figure 20-61-23].
P-26633
Figure 20-61-24
Figure 20-61-22
1
P-26638A
P-26637
P-26634
Remove the pre-load seal (Item 1) [Figure 20-61-24].
Figure 20-61-25
2
P-26657
Remove the pump center section (Item 1) NOTE: Inspect the pump center section (Item 3) and
[Figure 20-61-25] from the pump sections. bushings (Item 4) [Figure 20-61-27]. If
excessive wear or damage is visible, the
Figure 20-61-26 pump must be replaced.
Figure 20-61-28
1
2
P-26655
P-26659
Remove the wear plate (Item 1) [Figure 20-61-26] &
[Figure 20-61-27] and section seal (Item 2)
[Figure 20-61-26] & [Figure 20-61-27] from the pump Remove the pump section (Item 1) [Figure 20-61-28]
section. from the pump end section.
Figure 20-61-29
P-26662
Figure 20-61-30
P-26661
Figure 20-61-32
P-26666
Figure 20-61-35
1
P-26665
1
1
P-26664
P-26670A
P-26669
2
Remove the load seal (Item 1) [Figure 20-61-38].
P-26667
Figure 20-61-39
Figure 20-61-37
1
P-26672A
1
1
P-26671
P-26668
Remove the pre-load seal (Item 1) [Figure 20-61-39].
Figure 20-61-40
P-26673
WARNING
2 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
IMPORTANT
P-64570 The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
The tools listed will be needed to do the following
procedure:
Figure 20-62-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 20-62-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
2
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
P-64315
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-62-3] on the tester to about procedure:
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm
and flow (GPM). The high pressure flow must be at least support device. (See Installing Lift Arm Support Device
80% of free flow. on Page 10-20-1.)
HIGH PRESSURE FLOW (GPM) Raise the operator cab. (See Raising The Operator Cab
%= X100 on Page 10-30-1.)
FREE FLOW (GPM)
2 1
P-48256
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Figure 20-62-7
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.
I-2003-0888
1
Figure 20-62-6
P-64547
1 Figure 20-62-8
2
P-64546 1
Figure 20-62-9 1
3
1
P-64446
2
Replace the O-ring (Item 1) [Figure 20-62-10] in the
P-64343 hydrostatic pump.
Identification
15
14
7 5
13
8
5 6
4
12 3
9
8
7
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
Figure 20-62-11
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-62-
P-64508 12].
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 20-62-13 1
P-64511
2
Figure 20-62-16
P-64509
1
Figure 20-62-14
3
4
1
P-64512
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-62-13] & [Figure 20-62-14] from the pump 62-16]. If excessive wear or damage is visible,
end section. the pump must be replaced.
Figure 20-62-17
P-64515
Figure 20-62-20
P-64513
Figure 20-62-18
P-64516
Figure 20-62-21
1
P-64519
1
2 Figure 20-62-24
P-64517
2
Figure 20-62-22
2 1
P-64520
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-62-24].
[Figure 20-62-21] & [Figure 20-62-22] from the pump
center section. Inspect for damage and replace as
needed.
Figure 20-62-25
2
1
1
P-64526
Figure 20-62-28
P-64521
3
Figure 20-62-26
2
1
P-64527
Figure 20-62-29
1
P-64530
1
Remove the drive gear (Item 1) [Figure 20-62-31] from
P-64528 the pump flange section.
Figure 20-62-32
Figure 20-62-30
P-64531
P-64529
Figure 20-62-33
2
P-64535
Figure 20-62-36
P-64532
Figure 20-62-34
2
P-64536
Figure 20-62-37
3
2
1
P-64540
Figure 20-62-40
1
2
2
1 P-30188A
P-64538
Remove the pre-load seal (Item 2) [Figure 20-62-38]. Remove the shaft seal (Item 1) [Figure 20-62-40] from
the pump flange section.
WARNING
2 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
IMPORTANT
P-64570 The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
The tools listed will be needed to do the following
procedure:
Figure 20-63-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 20-63-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
2
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
P-64315
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-63-3] on the tester to about procedure:
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm
and flow (GPM). The high pressure flow must be at least support device. (See Installing Lift Arm Support Device
80% of free flow. on Page 10-20-1.)
%= HIGH PRESSURE FLOW (GPM) X100 Raise the operator cab. (See Raising The Operator Cab
FREE FLOW (GPM) on Page 10-30-1.)
2 1
P-48256
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-48463
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Test The Output Of The Hydraulic Pump (High Flow) EXAMPLE: TESTER
(Cont'd) CONNECTION
Reservoir
Figure 20-63-7
Hydraulic Pump
Out In
High Flow Valve
1
1 B-16277
P-48256 Record the highest pressure (PSI) and flow (GPM). The
high pressure flow must be at least 80% of free flow.
Connect the INLET hose (Item 1) [Figure 20-63-8] from
the tester, to the high flow pump OUTLET hose (Item 1) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-63-7]. Connect the OUTLET hose (Item 2) FREE FLOW (GPM)
[Figure 20-63-8] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-63-7] on the High Flow A low percentage may indicate a failed pump.
valve.
*Refer to Hydraulic Schematics Legend for system relief
Lower the cab. pressure and full RPM.
2
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
P-64546
on Page 10-20-1.)
Lift and block the rear of the loader. (See Procedure on Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Page 10-10-1.) 63-10] and [Figure 20-63-11] from the back of the
hydraulic pump.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Remove the Power Bob-Tach block (Item 2) [Figure 20-
63-11] if equipped. (See Removal And Installation on
Drain the hydraulic fluid from the reservoir. (See Page 20-120-1.)
Replacing Hydraulic Fluid on Page 10-120-1.)
Figure 20-63-12
Open the rear door of the loader.
WARNING
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. 1
W-2059-0598
Figure 20-63-10
P-64544
P-64545
Figure 20-63-13
3
1
1
2
P-64343
Figure 20-62-15
P-64446
Identification
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7
12
7
8
7
9 6
5
3 4
6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Auxiliary Center Section
12. Splined Shaft
13. Charge Pump Section
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248
Figure 20-63-16
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 63-17].
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 20-63-18 1
P-64556
2
Figure 20-63-21
P-64554
1
Figure 20-63-19
3
4
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 63-20] & [Figure 20-63-21] from the charge center
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-63-18] & [Figure 20-63-19] from the high flow [Figure 20-63-21]. If excessive wear or
end section. damage is visible, the pump must be
replaced.
NOTE: Position wear plate (Item 1) [Figure 20-63-19]
inlets and traps as shown with bronze side
toward gears.
Figure 20-63-22
P-64560
Figure 20-63-25
P-64558
Figure 20-63-23
P-64561
Figure 20-63-26
P-64564
2
Figure 20-63-29
P-64562
2
Figure 20-63-27
2
1
P-64565
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-29].
[Figure 20-63-26] & [Figure 20-63-27] from the charge
center section. Inspect for damage and replace as
needed.
Figure 20-63-30 2
3
1
1
P-64569
Figure 20-63-33
P-64567
3
2
1 P-64571
Figure 20-63-34
1 1
P-64574
Figure 20-63-37
Figure 20-63-35
P-64575
P-64573
Figure 20-63-38
1 2
2
P-64578
Figure 20-63-41
P-64576
Figure 20-63-39 2
P-64579
1
Remove the wear plate (Item 1) and O-ring (Item 2)
[Figure 20-63-40] & [Figure 20-63-41] from the auxiliary
center section. Inspect for damage and replace as
needed.
Figure 20-63-42
1
1
P-64521
1
P-64520
Remove the pre-load seal (Item 2) [Figure 20-63-43]. Remove the auxiliary center section (Item 1) [Figure 20-
63-45].
Figure 20-63-46
P-64528
1
Figure 20-63-49
P-64526
Figure 20-63-47
4
1
1
P-64529
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-63-46] & [Figure 20-63-47] from the auxiliary [Figure 20-63-49]. If excessive wear or
center section. Inspect for damage and replace as damage is visible, the pump must be
needed. replaced.
Figure 20-63-50
1
1
P-64532
Figure 20-63-51
1
1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-63-53] from
the pump flange section.
NOTE: Inspect the drive gear (Item 1) [Figure 20-63-
51]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-63-
pump must be replaced. 53]. If excessive wear or damage is visible, the
pump must be replaced.
Figure 20-63-54
P-64537
Figure 20-63-57
P-64535
Figure 20-63-55
1 P-64538
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-57].
[Figure 20-63-54] & [Figure 20-63-55] from the pump
flange section. Inspect for damage and replace as
needed.
Figure 20-63-58
1
2
P-30188A
3
2
P-64541
IMPORTANT 1
P-48260
Implement Filter Housing
Figure 20-70-1 Disconnect the wires from the charge pressure sender
(Item 1) [Figure 20-70-2] from the filter housing.
P-48259
1
Figure 20-70-5
1
P-48258
P-64317
Remove the two mounting screws (Item 1) [Figure 20-
70-4] from the filter housing mounting bracket.
Disconnect the hoses (Item 1) [Figure 20-70-5] from the
Installation: Tighten the mounting screws to 15-20 ft.-lb. filter housing.
(20-27 Nm) torque.
Disconnect the hose (Item 2) [Figure 20-70-5] from the
Remove the hydraulic filter housing and filter. filter housing.
1
2
P-64317
Fluid Removal
IMPORTANT
Figure 20-80-1
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
1 damage the system.
I-2003-0888
1
P-34113
Figure 20-80-3
1
1
2
3
2
P-34040
2
1
1
2
P-34038N-
19059
P-34039
Figure 20-80-7
2
P-34044
Figure 20-80-8
1
2
P-34053
Remove the bolt and nut (Item 1) [Figure 20-80-8]. NOTE: Standard loaders without rear auxiliaries and
all high flow loaders will have a one-piece
Loosen the bolt and nut (Item 2) [Figure 20-80-8] to auxiliary tubeline from the control valve to the
allow the hydraulic reservoir mount to drop down. rear upright hoses. Disconnect the tubeline
(Item 1) [Figure 20-80-10] from the control
valve and loosen the fitting in the left rear
upright to allow movement of the tubeline for
the hydraulic reservoir removal.
Figure 20-80-11
P-34052
Figure 20-90-1
1 2
1
P-26312A
Figure 20-90-2
1
2
N-18191
Solenoid Testing
Figure 20-90-5
P9175
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
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
Figure 20-90-6
P-26310A
Figure 20-90-7
1
P-26313A
1
Disconnect the two tubelines (Item 1) [Figure 20-90-9]
P-26311A from the tee fitting.
Figure 20-90-10
Figure 20-90-8
4
1 2
3
P-26314
P-26312A
Installation: Tighten the nut to 4-6 ft.-lb. max. (5-8 Nm Disconnect the tubeline (Item 2) [Figure 20-90-10] from
max.) torque. Overtightening may cause valve failure. the C port (tilt rod end) on the BPV.
Remove the solenoid (Item 2) [Figure 20-90-7] and the Disconnect the tubeline (Item 3) [Figure 20-90-10] from
solenoid stem (Item 1) [Figure 20-90-8]. the D port (tilt base end) on the BPV.
Installation: Put oil on the O-rings and back-up washers Remove the mounting screws (Item 4) [Figure 20-90-
and tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 10].
Nm) torque.
Installation: Tighten the mounting screws to 15 ft.-lb. (20
Nm) torque.
Figure 20-90-11
1
N-19072
Figure 20-90-12
1 1
N-19041
N-19070
Remove the plug (Item 1) [Figure 20-90-14].
Figure 20-90-15
1
N-19045
Remove the plug (Item 1), and flow control spool (Item 2)
[Figure 20-90-15].
Check the flow control spool for wear, check the O-ring
on the plug and replace as needed.
Figure 20-90-16 3
N-19046
1
Remove the plug (Item 1), spring (Item 2) and unloading
2 spool (Item 3) [Figure 20-90-18].
Figure 20-100-2
3
1
P-34480
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Figure 20-100-3
Right
Steering
Lever
Control
1
P-31833
If the specs from above are reached, the high flow relief
valve is OK.
Figure 20-100-4
1 P-45469
To increase the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-100-5] clockwise a 1/4 turn and
recheck the high flow relief valve. (1/4 turn equals
approximately 200 PSI.)
P-48231
To decrease the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-100-5] counterclockwise a 1/4 turn
If the relief pressure is not correct, stop the engine and and recheck the high flow relief valve. (1/4 turn equals
raise the operator cab.(See Raising The Operator Cab approximately 200 PSI.)
on Page 10-30-1.)
NOTE: If the relief screw (Item 1) [Figure 20-100-5]
Remove the high flow relief valve adjustment plug (Item has been turned in 1/4 turn and the pressure
1) [Figure 20-100-4]. remains the same, remove and inspect the
high flow relief valve, replace as needed.
Figure 20-100-6
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
P-48235 100-7] from the solenoid.
Figure 20-100-8
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 20-100-6] which are connected to the
steering shaft on the control panel.
P-48238
When repairing hydrostatic and hydraulic systems, Disconnect and cap the hose (Item 1) [Figure 20-100-8]
clean the work area before disassembly and keep all from the pump outlet to the high flow valve.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Disconnect and cap the hose (Item 2) [Figure 20-100-8]
damage the system. from the high flow valve to the pump inlet.
I-2003-0888
Figure 20-100-9
1
2
P-48232
Figure 20-100-10
2 1
1
P-48110
Figure 20-100-11
1
P-48111
Figure 20-100-14
1
P-48113
2
Remove the check valve (Item 1) [Figure 20-100-16]
P-48112 from the high flow valve.
Figure 20-100-17
Inspect the relief valve and replace the two o-rings (Item
1) and washer (Item 2) [Figure 20-100-14].
Figure 20-100-15
1
P-48114
Solenoid Testing
Figure 20-100-18
P9175
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
P-48301
WARNING
The rear auxiliary valve (Item 1) [Figure 20-110-1] is
Never work on a machine with the lift arms up unless located between the control valve and the gear pump on
the lift arms are secured by an approved lift arm the right side of the loader.
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
IMPORTANT
When repairing hydrostatic and hydraulic systems,
WARNING 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
Always clean up spilled fuel or oil. Keep heat, flames, damage the system.
sparks or lighted tobacco away from fuel and oil. I-2003-0888
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death. Figure 20-110-2
W-2103-1285
Figure 20-110-3
1 1
P-48304
Figure 20-110-6
Remove the three access covers (Item 1) [Figure 20-
110-3] on the right side of the machine.
Figure 20-110-4
1
P-48303
Figure 20-110-7
2
P-48870
1
Remove the rear auxiliary valve (Item 1) [Figure 20-110-
P-48305 9] by moving the valve to the rear access hole which
allows enough room for the valve to be removed from the
loader.
Disconnect the pump outlet hose (Item 1) [Figure 20-
110-7] from the rear auxiliary valve. The valve needs to be tilted as shown in [Figure 20-110-
9] for it to be removed through the hole.
Disconnect the tubeline (Item 2) [Figure 20-110-7] from
the bottom of the control valve and the rear auxiliary
vavle.
Figure 20-110-8
P-48869
Figure 20-110-12
1
1
1
P-48751
Figure 20-110-11
1 P-48755
Figure 20-110-13
2 2 2
P-48752
1
Installation: Put oil on O-rings and back-up Remove the shuttle valve (Item 1) [Figure 20-110-12] &
washers.Tighten to 10 ft.-lb. (13,6 Nm) torque. [Figure 20-110-13] from diverter valve and inspect the
O-rings and back-up washers (Item 2) [Figure 20-110-
13] for damage.
Figure 20-110-14
P-48753
1
Figure 20-110-17
P-48755
Figure 20-110-15 1
2
2
2
1
P-48754
Figure 20-110-18
1
P-48761
1
2
P-48760
Figure 20-110-21 1
P-48763A
Figure 20-110-24
P-48762
Figure 20-110-22
1 2
2 2
1 1 P-48764
Figure 20-110-25
P-48765
Figure 20-110-26
P-48786
Figure 20-110-29
P9137
P-48758
Use a test meter to measure coil resistance [Figure 20-
110-30]. Coil wires do not have polarity. Correct
Remove the plugs (Item 1) [Figure 20-110-29]. resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.
Installation: Tighten the plug to 14 ft.-lb. (19 Nm) Replace the test meter with 12 volt power. You can see
torque. and hear the spool shift.
Inspection
WARNING
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm
2
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 3
P-48229
Figure 20-120-2
P-48227
Disconnect the power Bob-Tach harness from the NOTE: There is an O-ring in-between the power Bob-
solenoid connectors (Item 1) [Figure 20-120-2] by the Tach block and the hydraulic pump. Inspect
hydraulic pump. and replace as needed.
Figure 20-120-3
P-48226
Figure 20-120-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-6].
IMPORTANT 1
Figure 20-120-8
1
1
P-48122
Installation: Oil the check valve and O-rings and tighten Figure 20-120-11
the check valve to to 20-25 ft.-lb. (27,1-34 Nm) torque.
Figure 20-120-9
1
2
1
P-48384
3
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-
(Item 2) [Figure 20-120-9]. 11] to 12-14 ft.-lb. (16,3-19 Nm) torque.
Figure 20-120-12 3
2
1
P-48106
Remove the orifice screw (Item 2) located behind the NOTE: Remember the solenoid coil orientation for
plug (Item 1) [Figure 20-120-11]. ease of installation.
Figure 20-120-13
1 1
P-48386
NOTE: This plug is a zero leak plug and should not be Installation: Tighten the solenoid stem to to 20-25 ft.-lb.
removed. If removed damage may occur and (27,1-34 Nm) torque.
the plug and O-ring must be replaced.
Figure 20-120-16
1
P-48174
1
2 2
1 1
P-48138
P-48173
IMPORTANT 1
Figure 20-130-1
P-34661
Figure 20-130-3
2
1 1
3
6 2
4
5 3
P-48464
1
2
P-34665
P-34664
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9
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 30-10-1
CHARGE OIL
B-2804
Description
Figure 30-20-1
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
support device can allow the lift arms or attachment
1
to fall and cause injury or death.
W-2059-0598
N-00621
P-39894 Lift and block the loader. (See Procedure on Page 10-10-
1.)
The later design has the tie bolts (Item 1) [Figure 30-20-
2] mounting from the outside of the hydrostatic drive
motor. The tie bolt heads are not immersed in hydraulic
oil and are visible when the hydrostatic drive motor is
installed on the loader. This type is called the dry bolt
design.
Figure 30-20-3
1
1
1
1 N-19240
1 1
2 P-4141
N-19238
3
10
11
9
8
13
16
3
5
11 14
6
15 3
21 7
6
22
20
17
19
18
19
17
20 1
26
24
12 25 2
23
D-3431B
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-00623
Figure 30-20-7
Figure 30-20-10
1
2
N-00621
Seal all open ports and clean the motor with solvent.
Figure 30-20-8
N-00624
N-00622
N-00627
Figure 30-20-14
Turn the mounting flange backover and remove the seal
(Item 1) [Figure 30-20-11] from the mounting flange.
Figure 30-20-12
N-00628
Figure 30-20-15
N-00631
Figure 30-20-18
Remove the square cut seal (Item 1) [Figure 30-20-15]
from the gerolor.
1
Figure 30-20-16
N-00632
N-00635
Figure 30-20-22
Remove the square cut seal (Item 1) and small O-ring
(Item 2) [Figure 30-20-19] from the end cap.
Figure 30-20-20
N-00636
Turn the end cover over and remove the shuttle valve
N-00634 plug from the end cover [Figure 30-20-22].
2
1
1
2
3
N-00640
Figure 30-20-26
2
1
N-00639
N-00641
Remove the low pressure relief valve plug from the side
of the end cover [Figure 30-20-24].
The low pressure relief valve is made up of the poppet
(Item 1), the spring (Item 2) and the plug assembly
(Item 3) [Figure 30-20-26].
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-00643
Prior to assembly:
Clean all parts with solvent and dry with compressed air. Install the new O-ring on the plug and tighten to 300 in.-
lb. (34 Nm) torque [Figure 30-20-28].
Put grease on O-rings.
Figure 30-20-29
Lubricate parts with oil.
Figure 30-20-27
3 2
1
1
N-00644
Install the poppet (Item 1), the spring (Item 2) and the
N-00642
spring seat (Item 3) [Figure 30-20-29] in the end cover.
Install the poppet (Item 1) and spring (Item 2) [Figure 30- NOTE: The tapered end of the poppet must face
20-27] in the low pressure relief port in the end cover. towards the shuttle valve.
Figure 30-20-30 1
N-00648
Install the square cut seal (Item 1) and small O-ring (Item
N-00646 2) [Figure 30-20-32] in the end cover.
Figure 30-20-33
Install a new O-ring on the plug [Figure 30-20-30] and
tighten to 260 in.-lb. (41 Nm) torque.
Figure 30-20-31
4
2
3 1 N-00649
N-00647
Install the shuttle valve (Item 1), poppet (Item 2), spring
(Item 3) and spring seat (Item 4) [Figure 30-20-31] in the
port hole in the end cap.
Figure 30-20-34
N-00652
Figure 30-20-37
Align the case drain ports in the valve plate with the case
drain port in the end cover [Figure 30-20-34].
1
Figure 30-20-35
N-00653
Figure 30-20-38
N-00656
N-00655 N-00657
Install the two check balls (Item 1) [Figure 30-20-39] in Mark the case drain hole on the outer ring of the gerolor
their bores in the gerolor. (as shown) [Figure 30-20-41].
3
4
5
N-00660
1 Install the square cut seal (Item 1), seal (Item 2), back-up
N-00658 seal (Item 3), seal (Item 4) and back-up ring (Item 5)
[Figure 30-20-44] in the mounting flange.
Align the case drain holes and install the balance plate Figure 30-20-45
(Item 1) [Figure 30-20-42] on the gerolor assembly.
Figure 30-20-43
N-00661
N-00659 Mark the case drain holes on the side of the balance
plate [Figure 30-20-45].
Figure 30-20-46
N-00664
Install the nine bolts into the motor. Make sure all the
N-00662 parts are in correct alignment [Figure 30-20-48].
Figure 30-20-49
Align the case drain port (Item 1) [Figure 30-20-46] in
the mounting flange with the case drain port in the
balance plate (as shown).
Figure 30-20-47
MC-2230
16
14
20 3
15
14
19 14
16 18
3 13
18
19
17 3 5
12
11
10
5
9
8
7 10
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-39894
Figure 30-20-50
Figure 30-20-52
9 1
6
4
3
7
P-64267
Figure 30-20-53
3
1
2
1
P-63785
2
1
P-39896
P-39895
NOTE: Do not scratch or damage the surfaces of the Installation: Lubricate shuttle valve assembly with
motor sections. Always put them on a soft hydraulic oil and tighten plug to 260 in.-lb. (41 Nm)
surface. torque.
P-64274
2 3
P-39898
P-64268
1
P-64272
Figure 30-20-63
1
1
P-64273
1
WARNING
P-4456
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure. Drill a .125 inch (3 mm) hole in the motor carrier seal
Flying debris or loose material is present. [Figure 30-21-2].
Engine is running.
Tools are being used. Figure 30-21-3
W-2019-1285
Figure 30-21-1
1
P-4455
P-4153
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-21-3].
Figure 30-21-4
P-4149
P-4150
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-21-5].
WARNING
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-4152
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-21-
7]. (See Disk Removal And Installation on Page 40-10-
Lift and block the loader. (See Procedure on Page 10-10- 1.)
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising The [Figure 30-21-7] from the inside of the chaincase.
Operator Cab on Page 10-30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing The 125-140 ft.-lb. (170-190 Nm) torque.
Oil on Page 40-30-1.)
Figure 30-21-8
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
Figure 30-21-9
P-4165
Figure 30-21-10
P-4168
Parts Identification
2 8
3 4
5
4
3
6 7
MC-1937A
3. BEARING 7. SEAL
4. RACE 8. PLUG
Figure 30-21-11
7.000
Length
(177,8 mm) P-4176
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 30-21-13].
procedure. Refer to photo [Figure 30-21-11] for the
correct dimensions of the tool needed. NOTE: The outer bearing will now be free from the
sprocket shaft.
Figure 30-21-12
Figure 30-21-14
2
1
1
P-4372
P-4365
Figure 30-21-15
P-4369
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- 21-17].
21-15] facing up.
Press the bearing race in until it is fully seated in the
Install the slide hammer with puller end (Item 2) [Figure carrier housing.
30-21-15] on the bottom side of the bearing race.
Figure 30-21-18
Remove the bearing race from the carrier housing
[Figure 30-21-15].
Figure 30-21-16
P-4368
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 30-21-16]. 21-18].
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 30-21-19
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-21-20]
over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 inch driver
tool, install the new inner bearing (Item 2) [Figure 30-21- 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 30-21-20].
Remove the press and drive tools from the sprocket
shaft. Remove the press and driver tools from the sprocket
shaft.
Figure 30-21-21
1
1
P-4374
Put the snap ring (Item 1) [Figure 30-21-21] over the end
P-4375
of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-21-
ring so it will fit over the sprocket shaft. 23] and install the shaft seal.
Using the press and driver tools, press the snap ring Hit the tool with a hammer until the seal is fully seated on
(Item 1) [Figure 30-21-21] over the sprocket. the carrier shaft [Figure 30-21-23].
Press the snap ring on until it snaps into the groove on Figure 30-21-24
the shaft.
Figure 30-21-22
N-15088
Figure 30-21-25
N-15087
The carrier shaft must turn freely with end play not to
exceed 0.007 inch (0,17 mm).
WARNING
P-39783
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure. Drill a .125 inch (3 mm) hole in the motor carrier seal
Flying debris or loose material is present. [Figure 30-22-2].
Engine is running.
Tools are being used. Figure 30-22-3
W-2019-1285
Figure 30-22-1
1
P-39784
P-39780
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-22-3].
Figure 30-22-4
P-39780
P-39786
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-22-5].
WARNING
2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. 1
W-2059-0598
P-39781
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-22-
7]. (See Disk Removal And Installation on Page 40-10-
Lift and block the loader. (See Procedure on Page 10-10- 1.)
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising The [Figure 30-22-7] from the inside of the chaincase.
Operator Cab on Page 10-30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing The 125-140 ft.-lb. (170-190 Nm) torque.
Oil on Page 40-30-1.)
Figure 30-22-8
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.) 1
Figure 30-22-9
P-39812
Figure 30-22-10
P-39813
Parts Identification
2
3
4
5
4
3
6
7
P-64693
1. SHAFT 5. HOUSING
3. BEARING 7. SEAL
4. RACE
Figure 30-22-11
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 30-22-13].
procedure. Refer to photo [Figure 30-22-11] for the
correct dimensions of the tool needed. NOTE: The outer bearing will now be free from the
sprocket shaft.
Figure 30-22-12
Figure 30-22-14
2
1
1
P-39815
P-4365
Figure 30-22-15
P-39820
Use a 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- 22-17].
22-15] facing up.
Press the bearing race in until it is fully seated in the
Install the slide hammer with puller end (Item 2) [Figure carrier housing.
30-22-15] on the bottom side of the bearing race.
Figure 30-22-18
Remove the bearing race from the carrier housing
[Figure 30-22-15].
Figure 30-22-16
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 30-22-16]. 22-18].
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 30-22-19
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-22-20]
over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 inch driver
tool, install the new inner bearing (Item 2) [Figure 30-22- 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 30-22-20].
Remove the press and drive tools from the sprocket
shaft. Remove the press and driver tools from the sprocket
shaft.
Figure 30-22-21
1
1
P-39814
Put the snap ring (Item 1) [Figure 30-22-21] over the end
P-4375
of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-22-
ring so it will fit over the sprocket shaft. 23] and install the shaft seal.
Using the press and driver tools, press the snap ring Hit the tool with a hammer until the seal is fully seated on
(Item 1) [Figure 30-22-21] over the sprocket. the carrier shaft [Figure 30-22-23].
Press the snap ring on until it snaps into the groove on Figure 30-22-24
the shaft.
Figure 30-22-22
P-39821
Figure 30-22-25
N-15087
The carrier shaft must turn freely with end play not to
exceed 0.007 inch (0,17 mm).
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
P-28590
Figure 30-30-1
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 30-30-3
N-19567
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-3].
Sender Removal And Installation (SJC Machines) Lift and block the loader. (See Procedure on Page 10-10-
1.)
Figure 30-30-6 Remove the charge pressure sender (Item 2) [Figure 30-
30-6] from the fitting.
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, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-64435
Figure 30-30-7
P-64431
Figure 30-40-1 1
2
1
3
N-19566
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-34567
Remove the engine/hydrostatic pump assembly from the
loader. (See Removal And Installation on Page 70-80-1.)
Loosen the drive belt tensioner (Item 1) [Figure 30-40-4]
Remove the control handle linkage from the hydrostatic and remove the drive belt.
pump. (See Control Lever Removal And Installation on
Page 50-110-1.) Remove the hydrostatic pump drive pulley mounting nut
(Item 2) [Figure 30-40-4] and washer.
Remove the hydraulic pump from the hydrostatic pump.
(See Removal And Installation on Page 20-60-5.) Installation: Tighten the pump pulley mounting nut to
175-200 ft.-lb. (237-271 Nm) torque.
Figure 30-40-3
Figure 30-40-5
1
P-34568
P-4235
P-48650
Figure 30-40-7
P-28850
5
4
8
3
7
6
2
9 1
13 14
10 15
11 12
17
19
16
21
18
23 20
25
27
22
24
29
26
28
30 38
33
36
34 32
31
37
35
49 46
47 48
40 45
42
39 44
49
41
43
D-2427
17 6
16 1
8 2
11 3
14 13 10 5
12 7
15 9
22
23
18 19 21
20
24
26
28
30 25
32 27
29
34 31
36
38
33
35
37 47
39 46
45
44
48 43
49 40
42
50
51
41 58
52
53
57
53 52
59
55
54 56
D-2428
Figure 30-40-8
1
2
1 1
N-19569
N-21967
Remove the four mounting bolts (Item 1) [Figure 30-40-
10].
Remove the pump mounting bolts (Item 1) [Figure 30-
40-8] (both sides). Figure 30-40-11
Figure 30-40-9
1
2 N-19570
N-21969
Figure 30-40-12
1
3
1
N-19551
2 3
Remove the pump housing end cap (Item 1) [Figure 30-
N-19571 40-14].
Disassembly
Figure 30-40-13
1 1
N-17193
N-19550
Disassembly (Cont'd)
1
Figure 30-40-16
2
1
N-17198
Figure 30-40-17
N-17199
Disassembly (Cont'd)
Figure 30-40-20
1
3 3
2
3 3 2 1
3
N-17481
Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-23
2) for wear and replace as needed [Figure 30-40-20].
Figure 30-40-21
N-17239
N-17201
Disassembly (Cont'd)
Figure 30-40-24 1
1
N-17242
Figure 30-40-27
Remove the snap ring (Item 1) [Figure 30-40-24] from
the pump housing and remove the driveshaft and bearing
from the housing.
Figure 30-40-25
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-40-27]
from the lower trunnion cover. Remove the cover.
N-17241
Disassembly (Cont'd)
Figure 30-40-28
2
2
1 1
1 N-17246
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-31
from the pump housing [Figure 30-40-28].
Figure 30-40-29
1
2
N-17247
Disassembly (Cont'd)
Figure 30-40-32
1 N-17249
Figure 30-40-35
Inspect the seal (Item 1) [Figure 30-40-32] in the upper
trunnion cover and replace if needed.
Figure 30-40-33
1 N-17251
2
Slide the swashplate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-40-35] from
the swashplate shaft.
Assembly
Figure 30-40-36
N-17252
Figure 30-40-39
Tilt the swashplate (Item 1) [Figure 30-40-36] and
remove the swashplate and lower bearing from the pump
housing.
Figure 30-40-37
1
1
N-17249
Assembly (Cont'd)
Figure 30-40-40
2
N-17246
1
Install the linkage bracket (Item 1) [Figure 30-40-42] and
N-17248 the four mounting bolts and tighten to 18-22 ft.-lb. (24-30
Nm) torque.
Figure 30-40-41
N-17247
Assembly (Cont'd)
Figure 30-40-43
2
N-17243
Figure 30-40-46
N-17244
N-17242
Install the bearing race (Item 1) and O-ring (Item 2) at
the lower trunnion as shown in [Figure 30-40-44].
Install the snap ring (Item 1) [Figure 30-40-46] on the
pump shaft.
Assembly (Cont'd) 1 1
Figure 30-40-47
3
2
1 1
1 N-17200
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
40-48]. 30-40-50] onto the slipper holddown pins.
Assembly (Cont'd)
1
2
Figure 30-40-51
N-17194
Assemble the piston assemblies into the slipper guide. Figure 30-40-54
Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
40-51].
Figure 30-40-52
2 1
N-17196
Assembly (Cont'd)
1 1
Figure 30-40-55
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-57] to 35-45 ft.-
lb. (47-61 Nm) torque.
Coat the backside of the valve plate with petroleum jelly Figure 30-40-58
to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-55].
Figure 30-40-56 1
2
1
N-19571
Assembly (Cont'd)
Figure 30-40-59
N-19570
Figure 30-40-60
1
N-19569
Figure 30-41-1
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 Lift Arm Support Device
on Page 10-20-1.)
Disconnect all of the electrical harness connectors (Item
Place the loader on jack stands. ((See Procedure on 1) [Figure 30-41-3] from the loader harness.
Page 10-10-1.)
Removal:
WARNING
IMPORTANT
Put jackstands under the front axles and rear corners
of the frame before running the engine for service. When repairing hydrostatic and hydraulic systems,
Failure to use jackstands can allow the machine to clean the work area before disassembly and keep all
fall or move and cause injury or death. parts clean. Always use caps and plugs on hoses,
W-2017-0286
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Raise the operator cab. ((See Raising The Operator Cab
on Page 10-30-1.) Figure 30-41-4
Figure 30-41-2
1
P-64426
P-64425
Remove the four mount bolts (Item 1) [Figure 30-41-4]
from the hydraulic controller.
Locate the two hydraulic controllers (Item 1) [Figure 30-
41-2] on the hydrostatic pumps.
Figure 30-41-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-41-7] to 7.7
ft.-lb. (10,4 Nm) torque. Ensure bolts are tight to
P-64427 specifications.
Installation:
Figure 30-41-6
P-64978
IMPORTANT 1
1 Figure 30-41-11
P-64344
1
Remove the nut and washer from the pump drive shaft.
Figure 30-41-12
1 1 1 P-64343
1 1 Figure 30-41-15
P-64337 P-64338 1
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 14
15
16
19 17
21
24 23 22 26
20
25
18
26
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 30-41-16
1
1
P-64437
4
3
2 1
P-64436
Figure 30-41-19 3 4
2 5
1
1 P-64435
The charge relief valve (Item 1) [Figure 30-41-19] is Inspect the sealing ring (Item 3) [Figure 30-41-21] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or
foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 52 ft.-lb. (70 shims (Item 5) [Figure 30-41-21].
Nm) torque.
NOTE: 1.0 mm shim (Item 5) [Figure 30-41-21] = 43.5
Figure 30-41-20 PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
1
P-64435
Figure 30-41-22
1
1
1
P-64439
Figure 30-41-23
2 2
1 1
1
P-64440
Figure 30-41-26
P-64442
Figure 30-41-27
P-64453
Figure 30-41-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
41-31].
1
P-64445
Figure 30-41-30
3 1
P-64447
Figure 30-41-32
1 2
1
2
P-64463
Figure 30-41-33
P-64466
Figure 30-41-35
RIGHT SIDE
P-64454
Figure 30-41-36
LEFT SIDE
P-64501
1 P-64456
2
Figure 30-41-40
P-64455
LEFT SIDE
Figure 30-41-38 1
2
LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64502 37] and [Figure 30-41-38] in the case housing with the
notch (Item 1) [Figure 30-41-39] and [Figure 30-41-40]
that does not go through the valve plate.
Figure 30-41-41
1
P-64469
Figure 30-41-42
1
P-64475
P-64471
Figure 30-41-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-41-45] in the
1
slippers, are not plugged.
Figure 30-41-46
1
P-64472
P-64479
Figure 30-41-52
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-50] 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 30-41-52].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-41-50] are not bent or damaged.
1 P-64483
P-64482
1
2
1
P-64486
Figure 30-41-59
P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-41-56].
Figure 30-41-57
2 1
P-64523
Figure 30-41-60
P-64485
P-64524
Figure 30-41-61
P-64488
The drive shaft can be tapped out of the end housing with
B25013
a rubber mallet.
1 1
P-64489
Figure 30-41-64
P-64492
Figure 30-41-65
P-64491
Figure 30-41-67 1
2
1
P-64493
Figure 30-41-70
Figure 30-41-68
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 30-41-68] is parallel to the driveshaft 2) and square-cut seals (Item 3) [Figure 30-41-70].
centerline. Measure with a straight-edge [Figure 30-41-
67].
Figure 30-41-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-41-73] from the
P-64495 servo piston.
Figure 30-41-74
Remove the lock nut (Item 1) [Figure 30-41-71] from the
servo piston.
1
Assembly: Tighten lock nut to 22 ft.-lb. (30 Nm) torque. 2
Figure 30-41-72
P-64498
Figure 30-41-75
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 30-41-75].
Assembly: Tighten plugs to 18 ft.-lb. (25 Nm) torque.
Assembly: Tighten plug to 45 ft.-lb. (10 Nm) torque.
Figure 30-41-78
Remove internal screen (Item 3) [Figure 30-41-75].
Figure 30-41-76
P-64500
P-64462
Disassembly and Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swashplate relative
Figure 30-41-79 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.
W-2017-0286
Bearings (Item 1) [Figure 30-41-79] in case housing are
replaced by using a press and bearing driver.
Raise the lift arms, and install an approved lift arm
Inspect center coupler (Item 2) [Figure 30-41-79]. support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 30-41-80
1
P-64438
Figure 30-41-81
1
1
1 1
P-64977
Figure 30-41-84
1
P-64457
Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-41-85
P-64457
P-64457
Mechanical Neutral Adjustment (Contd) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-41-88 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.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 30-41-89
2
1
P-64975
1
Figure 30-41-90
1 1
P-64459
W-2276-1297
Figure 30-41-93
P-64459
P-64459
Turn the adjustment screw (Item 1) [Figure 30-41-94] 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
Nm) torque.
Shield Removal And Installation To adjust the drive belt between the flywheel and the
hydrostatic pump pulley, use the following procedure:
Figure 30-50-1
Stop the engine. Open the rear door.
Figure 30-50-3
P-48001 1
2
Remove the three drive belt shield mounting clips
(Item 1) [Figure 30-50-1] .
Figure 30-50-2
1 P-48478
P-48000
Adjusting (Contd)
Figure 30-50-4
P-48480
Note: If the pointer does not move when prying on Stop the engine and recheck the pointer position.
the tensioner mounting bracket, manually
move the arrow towards the 3 oclock 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.
P-48478
Stop the engine. Open the rear door. The belt tensioner is located between the flywheel and
pump pulley. Loosen and remove the bolt (Item 2)
Raise the operator cab. (See Raising The Operator Cab [Figure 30-50-7] from the belt tensioner.
on Page 10-30-1.)
Remove the belt tensioner assembly.
Remove the negative (-) cable from the battery. The
battery may be removed for additional working clearance. Figure 30-50-8
(See Removal And Installation on Page 60-20-1.)
P-48481
Remove the drive belt from the pump pulley and flywheel.
Remove the drive belt from the loader [Figure 30-50-8].
Figure 30-50-9
1
P-48478
Remove the negative (-) cable from the battery. the Remove the belt tensioner pulley from the housing.
battery may be removed for additional working clearance.
(See Removal And Installation on Page 60-20-1.) Reverse the removal procedure to install the drive belt
tensioner.
Remove the belt shield [Figure 30-50-9]. (See Shield
Removal And Installation, 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 5
17. Locating Pin
18. Spring
19. Shaft 6 13
20. Bracket
8 16
17
9
18
10
19
20
E-2296
Figure 30-50-11
3
1
1
4
P-8861
Remove the grease cover (Item 1) [Figure 30-50-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-50-13] with a plastic hammer.
Figure 30-50-12
Figure 30-50-14
2
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 30-50-14].
assembly (Item 5) [Figure 30-50-12].
Figure 30-50-15
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-50-17] into the hub.
Figure 30-50-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-50-15] as shown.
Figure 30-50-16
2
3
P-8874
Figure 30-50-19
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 30-50-19] over the roll pins. assembly, do not press down on the arrow
indicator plate. Support the hub assembly so
Figure 30-50-20 that it contacts only the hub and not the arrow
indicator plate.
2
1
P-8876
WARNING
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-19346
Remove the rear grill from the loader. (See Removal And
Installation on Page 50-60-1.)
Figure 30-60-3
Figure 30-60-1
1
2
P-45242
N-19345
Figure 30-60-4
1
2
1
P-45101
Lift up the oil cooler and remove the cooler from the
loader.
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disk Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Switch Operated Parking Brake. . . . . . . . . . . . . . . . . . . . . 40-10-2 SAFETY &
MAINTENANCE
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . 40-30-3
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-4
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 DRIVE
SYSTEM
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1
Axle Sprocket And Bearings Removal And Installation . . . 40-20-3
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . 40-20-8
ENGINE
SERVICE
SPECIFICATIONS
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
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 1
support device. Failure to use an approved lift arm
N-19105
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Inspect the traction lock guides (Item 1) [Figure 40-10-2]
and the brake disc for damage or wear and replace as
Raise the loader operator cab. (See Raising The necessary.
Operator Cab on Page 10-30-1.)
(See Inspecting on Page 60-110-3.)
Disconnect and remove the engine speed control. (See
Removal And Installation on Page 70-20-1.)
Figure 40-10-1
N-19081
Figure 40-10-3
2 1
P-21944
N-19082
The parking brake switch in the front panel (Item 1)
[Figure 40-10-5] replaced the pedal parking brake. (See
Figure 40-10-4 INSTRUMENT PANEL on Page 60-50-1.)
N-19083
2
2
2 1
P-4157 P-4159
The tools listed are needed for the following procedure: Install the puller tool (Item 1) [Figure 40-20-2] on the
axle hub.
Axle Hub Puller Tool
MEL1399 - Seal Driver Tool A driver tool (Item 2) [Figure 40-20-2] can be used for
MEL1242 - Power Ram (may be used if desired) centering the threaded rod of the puller.
Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for
P-4161 the following procedure:
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
Figure 40-20-4 sleeve kit is available from Bobcat Parts.
Place the new axle seal over the axle and into the axle
tube.
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
P-4147
Raise the lift arms and install an approved lift arm Remove the axle hub. (See Axle Seal Removal And
support device. (See Installing Lift Arm Support Device Installation on Page 40-20-1.)
on Page 10-20-1.)
Remove the sprocket mounting bolt (Item 1) [Figure 40-
Raise the operator cab. (See Raising The Operator Cab 20-7].
on Page 10-30-1.)
Installation: Tighten the sprocket mounting bolt to 300-
Remove the control panel. (See Removal and Installation 330 ft.-lb. (407-447 Nm) torque.
on Page 50-100-1.)
Figure 40-20-6
P-34255
Figure 40-20-8
P-4170
1
P-4158
A bearing puller (Item 1) [Figure 40-20-10] is needed for
the following procedure:
Install the MEL1242 power ram (Item 1) [Figure 40-20-8]
between the two sprockets. Put the axle/outer bearing assembly in the bearing puller
as shown and put in the hydraulic press [Figure 40-20-
Put a spacer between the power ram and axle. Push the 10].
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure Figure 40-20-11
until the axle is free from the sprocket and inner bearing.
Figure 40-20-9
2 P-4171
1
P-4162 Be sure the bearing puller makes good contact with the
inner race of the bearing and press the bearing off the
mounting surface of the axle.
Remove the drive chain from the sprocket (Item 1)
[Figure 40-20-9] and remove the sprocket from the Be sure to hold onto the axle during removal as it will
chaincase. slide freely along the axle shaft after removal from the
bearing mounting surface and until the bearing contacts
Remove the inner bearing (Item 2) [Figure 40-20-9] and the spline on the shaft.
remove the axle from the axle tube. (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20- Press the splined end of the axle free from the bearing
3.) [Figure 40-20-11].
Figure 40-20-12
4
3
P-4175
Put the spline end of the axle shaft (Item 4) [Figure 40-
20-12] in the bearing and press the bearing onto the axle.
P-4180
P-4172
Use the slide hammer and remove the bearing cup from
Use the tools provided in the MEL1202B Axle Bearing the axle tube [Figure 40-20-16].
Service Set for bearing cup removal and installation. A
slide hammer is also necessary for this procedure.
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 40-20-15
2
1
P-4179
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
Figure 40-20-19
P-4174
Figure 40-20-18
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-4152
Raise the loader lift arms and install an approved lift arm
support device.(See Installing Lift Arm Support Device on
Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 40-20-
20]. (See Disk Removal And Installation on Page 40-10-
Lift and block the loader. (See Procedure on Page 10-10- 1.)
1.)
Remove the six carrier mounting bolts (Item 2) [Figure
Raise the loader operator cab. (See Raising The 40-20-20] from inside the chaincase.
Operator Cab on Page 10-30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing The 125-140 ft.-lb. (170-190 Nm) torque.
Oil on Page 40-30-1.)
Figure 40-20-21
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
Figure 40-20-22
B-13504
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 Nm)
torque.
WARNING
DO NOT exceed the recommended torque of 130 ft.-
lb. (176 Nm). The tool may fail under too much
torque. Put cloth around the tool to protect yourself
from flying debris.
W-2233-0296
Figure 40-30-1
P-64141
P-34453
Remove the chaincase cover (Item 1) [Figure 40-30-
2](See Front Cover Removal And Installation on Page
The chaincase contains the final drive sprockets and 40-30-2.)
chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See HYDRAULIC/HYDROSTATIC Use a vacuum pump to extract the fluid from the chain
FLUID SPECIFICATIONS on Page SPEC-50-1.) case.
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
General Information
3 3
Early chaincase designs were assembled with gaskets
and polyurethane sealant between the chaincase covers
and chaincase housing. This was due to a weld that ran
down the middle of the top of the chaincase.The gasket 1
helps seal around the welded area. The polyurethane
sealant should be used with the gasket to ensure a good 2
seal.
Note: Both the later flat top and early chaincase Remove the front chaincase cover mounting screws
designs should use polyurethane sealer on (Item 1) [Figure 40-30-3].
the screw threads, to ensure a good seal.
Remove the front chaincase cover (Item 2) [Figure 40-
Front Cover Removal And Installation 30-3] from the loader.
Raise the loader lift arms and install an approved lift arm Note: On later flat top chaincases there are
support device. (See Installing Lift Arm Support Device machined recesses (Item 3) [Figure 40-30-3]
on Page 10-20-1.) on the bottom side of the cover to help pry the
covers off.
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.) Installation: Install a new gasket (if equipped). When
installing a cover on flat top chaincases, apply
polyurethane sealer to mating surfaces. Polyurethane
sealant should be applied to the screw threads and
gasket (if equipped) to stop oil leakage. Tighten the
mounting screws to 15-20 ft.-lb. (20-27 Nm) 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
Figure 40-30-5
3 3
1
1
Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
Figure 40-30-4 1
3 3
4
P-34446
3
Remove the chaincase cover mounting screws (Item 1)
[Figure 40-30-5].
2 1
Remove the center chaincase cover (Item 2) [Figure 40-
30-5] from the loader.
Disconnect the lift control cross bar (Item 1) [Figure 40- Installation: Install a new gasket (if equipped). When
30-4] from the lift pedal linkage. installing a cover on flat top chaincases, apply
polyurethane sealer to mating surfaces. Polyurethane
Disconnect the lift control cross bar (Item 2) [Figure 40- sealant should be applied to the screw threads and
30-4] from the lift spool on the main control valve. gasket (if equipped) to stop oil leakage. Tighten the
mounting screws to 15-20 ft.-lb. (20-27 Nm) torque.
Disconnect the electrical connector (Item 3) [Figure 40-
30-4] from the traction lock solenoid.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device 3
3
on Page 10-20-1.)
1
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
2
3
3
P-34259
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 SAFETY &
MAINTENANCE
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS). . . 50-111-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . . . . . 50-111-5
Control Handle Removal and Installation. . . . . . . . . . . . . . . . . . . 50-111-4
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-7
Control Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . 50-111-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . 50-111-2
DRIVE
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 SYSTEM
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . 50-110-1
Figure 50-10-1
P10564 P10563
Figure 50-10-2 Installation: Tighten the nuts to 40-50 ft.-lb. (54-68 Nm)
torque.
Figure 50-10-4
N-18463
Lower the seat bar. Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].
Figure 50-10-5
4 6
5
7
1
2 9 8
10
1
N-19383
N-18572
Figure 50-10-8
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 Nm)
torque.
Figure 50-10-9
5
4 6
2 7
1
N-19340
Figure 50-10-10
4
5
3 6
2
7
1
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-
N-19384 11] out of the clevis.
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
WARNING 1
Figure 50-20-1
P1518 P1528
Figure 50-20-3
N-19165
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-31965
Raise the lift arms. (See Installing Lift Arm Support
Device on Page 10-20-1.)
Install a strap (Item 1) [Figure 50-20-3] to the cab
Install an approved lift arm support device. handles to prevent the cab from falling forward.
Stop the engine. Raise the operator cab (See Raising The Operator Cab
on Page 10-30-1), to release the tension on the gas
cylinder.
Figure 50-20-4
1
2
P-48262A
Figure 50-20-6
P-31966
1 2
P-43354A
Loosen the front bolt (Item 1) and remove the rear bolt
(Item 2) [Figure 50-20-5] and [Figure 50-20-6] from the
gas cylinder mounting bracket.
1
N-20618
Figure 50-20-9
P-39601
Figure 50-20-10
2
1
P1008
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
could cause injury or death.
P1006 W-2245-0796
Apply a small amount of LOCTITE on the threads of the Use the hoist connected to the operator cab grab handles
cylinder rod [Figure 50-20-11]. to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-12].
Reinstall the washer and clevis on the cylinder rod.
Figure 50-20-13
1
N-19231
Figure 50-20-16
Remove bolt (Item 1) [Figure 50-20-13] from the cab
ground.
Figure 50-20-14
P-31966
N-19185
Figure 50-20-17
2 1
1
N-19202
N-19165
Figure 50-20-19
1
P-31967
Figure 50-30-1
1 1
1 2
N-20729
N-20729
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Item
1 & 2) [Figure 50-30-3] and peel back or cut insulation to
Remove the four seat mounting nuts (Item 1) [Figure 50- gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Figure 50-30-2
2
N-20655
Figure 50-31-1
1 2
N-20974
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)
Figure 50-31-2
N-20973
P10564 P10563
Figure 50-31-5
1 1
2 2
1
1
N-18579
N-18587
Press the two buttons (Item 1) [Figure 50-31-6] &
[Figure 50-31-7] and lift the seat cushion.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-31-7
1 1
N-18580
N-18581
Figure 50-31-10
2
1
P-43118
N-18583
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-10] and tilt the seat back all the way forward. Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)
Figure 50-31-11
Remove the seat shock mounting bolts (Item 1) [Figure
50-31-12] (Both ends.)
1 1
N-18578
Figure 50-31-13 1
3
2
P16284
Figure 50-31-15
OUTSIDE OF CAB
P16131
Figure 50-31-16
1 2
P16126
INSIDE OF CAB
P16128
Figure 50-40-1
P-48132
Figure 50-40-2
1
N-18547
1
2
Strike the head of the bolt (Item 1) [Figure 50-40-4] to
push the pivot pin into the Bob-Tach frame.
Use a long punch to push the pivot pin all the way into the
N-18545 Bob-Tach.
Figure 50-40-5
1
N-18560
1
Remove the Wedge (Item 1) [Figure 50-40-7].
N-18558
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-40-8
Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.
Figure 50-40-6
1
3
2
1
N-18561
Remove the lever mounting nut (Item 1), washer (Item 2),
N-18559 spring (Item 3) and lever (Item 4) [Figure 50-40-8].
Figure 50-40-9
2 4
3
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-9] are damaged, put the
assembly in a vise.
Figure 50-40-10
N-18563
Figure 50-41-1 1
2 3
P-48185
1
Remove the pivot pin (Item 1) [Figure 50-41-2] from the
P-48131
tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-41-1]. Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob-
Tach pivot pin.
Lower the Bob-Tach onto the blocks.
Installation: Tighten the bolt to 175-190 ft.-lb. (240-260
Remove the hoses to the cylinder fittings Nm) torque.
[Figure 50-41-1].
Figure 50-41-3
NOTE: The hose with the 45 end (Item 1)
[Figure 50-41-1] is connected to the base end
fitting on the cylinder.
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.
1
Remove the retainer bolt (Item 3) [Figure 50-41-1] and
nut from the tilt cylinder rod end pin (both sides).
P-48132
Figure 50-41-4
1
1
N-18559
Strike the head of the bolt (Item 1) [Figure 50-41-4] to Figure 50-41-7
push the pivot pin into the Bob-Tach frame.
Use a long punch to push the pivot pins all the way into
the Bob-Tach frame.
Figure 50-41-5
N-18560
P-48135
Figure 50-41-8
4
1
2
3 2
N-20625
3
5 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
4
P-48135 or clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise.
Remove the washers and bolts (Item 1) [Figure 50-41- Remove the bolt and replace the damaged parts as
8]. needed.
Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm) Figure 50-41-10
torque.
Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8]. 1
N-18563
Figure 50-50-1
N-18850
Roll the Bob-Tach fully forward. Stop the engine. Install plugs into the hose and tubeline ends.
Remove the Bob-Tach frame from the lift arms. (See Figure 50-50-4
Removal And Installation on Page 50-40-1.)
Figure 50-50-2
1
P-31832
1
Remove the front auxiliary mount mounting bolts (Item 1)
[Figure 50-50-4].
N-18805 Remove the front auxiliary tubelines from the lift arms.
Figure 50-50-5
1
P-34136
Figure 50-50-8
N-18793
N-18851
Remove the tilt port block mounting bolt (Item 1) [Figure
50-50-6] under the step.
Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-8].
Figure 50-50-9
1 1
P-31973
Use a slide hammer remove the lift cylinder rod end pivot
N-18806 pin (Item 1) [Figure 50-50-11] (both sides).
Use a drift pin and hammer remove the lift arm pivot pin
(Item 2) [Figure 50-50-9] (both sides).
Figure 50-50-10
P-31972
Figure 50-50-12
1
1
P-31970
2
Connect a nylon lift strap, chain and chain hoist to the lift
P-31971 arms (Item 1) [Figure 50-50-12] & [Figure 50-50-13].
Figure 50-50-14
1
2
P-31974
Remove the retainer bolt (Item 1) [Figure 50-50-14] and Installation: Tighten to 18-20 ft.-lb. (24-27 Nm) torque.
nut from the lift arm pivot pin.
Figure 50-50-16
Installation: Tighten to 18-20 ft.-lb. (24-27 Nm) torque.
Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 50-50-14] (both sides).
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist: 1
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
P-31975
Tools are being used.
W-2019-1285
Use a drift pin and hammer, remove the lift arm pivot pin
(Item 1) [Figure 50-50-16] (both sides).
Raise the lift arm link with the chain hoist and remove it
from the loader frame.
P-31969
N-18851
Raise the operator cab. (See Raising The Operator Cab Installation: Tighten to 18-20 ft.-lb. ( 24-27 Nm) torque.
on Page 10-30-1.)
Figure 50-50-20
Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-17].
Figure 50-50-18 1
P-31968
1
Figure 50-60-1
2
P-48130
Open the rear door. Reverse the removal procedure to install the grill.
Figure 50-60-2
P-48252
2
2
P-34606
P-48519
Lift the door away from the loader frame and put the door
flat on the floor.
2
P-34588
Figure 50-70-4
WARNING
AVOID INJURY OR DEATH
1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-31126
Figure 50-70-5
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
1
P-31127
P-28143
Installation: Tighten the cover mounting bolts to 190-240 Installation: Tighten the battery holder mounting bolts to
in.-lb. (21,5-27 Nm) torque. 190-240 in.-lb. (21,5-27 Nm) torque.
Figure 50-80-4
1 1
P1619
Drain the fuel from the tank through the fuel drain (Item 1)
P-28144
[Figure 50-80-2].
2
1
P13876
P13874
Lift the fuel tank up and remove the tank from the loader
[Figure 50-80-5].
1 P13875
P13870
Turn the fuel level sender out and remove it from the fuel
tank. Check the fuel level sender for damage and replace
if necessary.
Figure 50-80-9
P13873
Figure 50-80-10
1
P13872
Figure 50-90-1 1
P-34375
Installation: Tighten the bolt and nut to 21-25 ft.-lb. (28- Pedal Adjustment
34 Nm) torque.
After installing the pedal, adjust the pedal so that there is
Check the rubber bushing in the pedal for wear and clearance under the rear of the pedal. The valve spool
replace as needed. must travel full stroke without the pedal hitting the floor
panel.
WARNING P-34260
Never work on a machine with the lift arms up unless Remove the hairpin clip and cross-pin (Item 1) [Figure
the lift arms are secured by an approved lift arm 50-90-4] from the control valve lift spool.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Disconnect the crossbar from the control valve.
to fall and cause injury or death.
W-2059-0598 Figure 50-90-5
Figure 50-90-3
2
1
1
P-34376
P-34257
Figure 50-90-6
1 1
P-34258
P-34257
Remove the hairpin clip and cross-pin (Item 1) [Figure
50-90-8] from the control valve tilt spool.
Remove the bolt and nut (Item 1) [Figure 50-90-6] to
disconnect the lift foot pedal linkage from the crossbar Figure 50-90-9
linkage.
Figure 50-90-7
P-26008
Remove the bolt and nut (Item 1) [Figure 50-90-7] to Installation: Tighten the bolt and nut to 21-25 ft.-lb. (28-
disconnect the lift foot pedal. 34 Nm) torque.
Figure 50-91-1
2 1
P-21936
P-21927
Figure 50-91-2
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Figure 50-91-4
1
P-21940
P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6
Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35-40 ft.-lb. (47-54 Nm)
lubed torque. 1
Remove the two bolts (Item 2) [Figure 50-91-4] from the
bracket and sensor assembly. P-21935A
Figure 50-91-7
P-21931
Figure 50-91-8
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) from the foot pedal [Figure 50-91-8].
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
Remove the engine speed control. (See Removal And Disconnect the control harness connectors (Item 1)
Installation on Page 70-20-1.) [Figure 50-100-2] from left control levers.
Figure 50-100-1
2
1
3
P-48462
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-1].
2
2 2
1 1 P-26323
Scribe a mark across the top of the steering linkage bars Remove the fuse/relay cover (Item 3) [Figure 50-100-4].
(Item 1) [Figure 50-100-3] which are connected to the
steering shaft on the control panel. Figure 50-100-5
P-26325
Figure 50-100-6
1
1
1
1
1
P-26327
P-26329
Figure 50-100-9
1 3
2
3
1
P-4146
P-4154
Figure 50-100-12
2 1
P-3729
1
P-26331 Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-13].
To remove the steering shaft mounting bracket (Item 3) Remove the shoulder bolt/spring assembly.
[Figure 50-100-10], remove the three mounting bolts
(Item 1) [Figure 50-100-12] from the front of the control Installation: Tighten the centering spring shoulder bolt
panel. and a NEW lock nut to 25-28 ft.-lb. (34-38 Nm) torque.
Remove the steering shaft mounting bracket from each Figure 50-100-14
side of the control panel.
3 2
P-3736
Slide the plate (Item 1) to the right and remove it from the
two guide pins (Item 2) [Figure 50-100-14].
Figure 50-100-15
1
2
5
6
4 2
1
N-15312
2
1
P-3733
Figure 50-100-18
1
3
2 1
P-34365
Remove the nut (Item 1) [Figure 50-100-18] from the Installation: Tighten the nuts to 25-28 ft.-lb. (34-38 Nm)
torsion bushing/linkage bar. The bolt is threaded into the torque.
linkage bar, remove the bolt from underneath the pintle
lever. Remove the nuts (Item 2) from the linkage bar mounting
bolt. The bolts (Item 3) are threaded into the linkage bars,
Installation: Tighten the bolt to 11-13 ft.-lb. (21-25 Nm) remove the bolts (Item 3) [Figure 50-100-20].
torque, then tighten the nut to 21-25 ft.-lb. (28-33 Nm)
torque. The torsion bushings can now be removed from the
steering bell cranks.
Figure 50-100-19
Installation: Tighten the bolts to 11-13 ft.-lb. (21-25 Nm)
torque, then tighten the nuts to 21-25 ft.-lb. (28-33 Nm)
torque.
P-3734
Linkage Adjustment
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. 2
Failure to use an approved lift arm support device can allow
1
the lift arms or attachment to fall and cause injury or death.
W-2059-0598 3
P-34365
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-10-
1.)
Put jackstands under the front axles and rear corners Connect the remote start tool (MEL1429). (See
of the frame before running the engine for service. Procedure on Page 10-60-1.)
Failure to use jackstands can allow the machine to
fall or move and cause injury or death. Pre-load tension in the torsion bushings must be
W-2017-0286 removed before adjusting the steering linkage.
Figure 50-100-22
2
3
3
P-3726
Figure 50-100-23
1
1 3
P-3723
Remove access plug from the top of the control valve. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-23] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 inch (10 mm) thick spacer (Item 1)
[Figure 50-100-25].
Figure 50-100-24
Figure 50-100-26
4
2
1
3
3 1 2
4
P-3724
P-3730
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the pintle arm
arm cam (Item 2) and the centering block (Item 3) mounting bolt (Item 1) is tight, 25-28 ft.-lb. (34-38 Nm)
[Figure 50-100-24]. torque and that there is no play between the pintle arm
(Item 2) and the square pump shaft (Item 3). Also check
that the cam mounting bolts (Item 4) [Figure 50-100-26]
are tight, 45-50 ft.-lb. (62-68 Nm) torque.
Figure 50-100-27
P-3728
1
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
P-3727 pintle arm is rotated to the front as far as possible
[Figure 50-100-28]. Use a locking plier and clamp the
two linkage bars together.
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
27] on each steering linkage bar. Installation: Tighten the nuts and bolts to 25-28 ft.-lb.
(34-38 Nm) torque.
Figure 50-100-29
P-3723
Figure 50-100-30
P-37574
WARNING P-3731
2
3
4
P-3726
P-3725
Figure 50-100-34
P-3732
P16121 Move the right control lever until the tires do not turn
(neutral position).
Start the engine and run at high RPM. Move the right centering block to the left until it contacts
both pintle cams and the control lever is still in the neutral
Move the traction lock override switch (Item 1) [Figure position [Figure 50-100-35].
50-100-34] to the OFF position so the traction function is
unlocked. The wheels are now able to turn. Tighten the bolts to 25-28 ft.-lb. (34-38 Nm) torque.
Move the left control lever until the tires do not turn Test both levers by moving them backward and forward
(neutral position). and letting them return to neutral by the return spring
force.
Move the left centering block to the left until it contacts
both pintle cams and the control lever is still in the neutral If the levers do not return to neutral and the tires do not
position [Figure 50-100-33]. come to a complete stop, repeat the adjustment
procedure again.
Tighten the bolts to 25-28 ft.-lb. (34-38 Nm) torque.
Stop the engine.
NOTE: If the centering blocks are worn, they can be
removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.
Figure 50-100-36
1
1
P-34365
2
Tighten the two bolts to 11-13 ft.-lb. (15-17 Nm) torque,
then tighten the two nuts to 21-25 ft.-lb. (28-33 Nm)
P-3726 torque at the steering cross shaft (Items 1 & 2) [Figure
50-100-37].
Description
Figure 50-100-1
P-54658
The steering system [Figure 50-101-1] 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. Earlier designs use
steering input to the loader. a spring return adjustment, later designs use a thread
return adjustment.
The steering levers are attached to pivoting bellcranks
that pivot on a steering shaft and plastic bushings. The The steering system returns the levers to their starting
bellcranks have grease fittings. position by means of the centering spring and the
returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts.
NOTE: Torsion bushings need to be replaced if torn
The bellcranks are attached to steering linkage bars with or rotating in the housing. Loosen torsion
rubber torsion bushings pressed into the bellcranks. bushing bolts slightly before adjustments are
Bellcranks mount to the control panel. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
Steering linkage bars are a two-piece design. Steering been made first.
linkage bars are adjustable in length for full travel
adjustment. Sequence of steering adjustments:
1. Set neutral of pintle arms, creep
Steering linkage bars attach to the pintle arms where a
2. Set full travel at steering linkage bars
rubber torsion bushing is pressed into the pintle arms.
3. Set drift at drift adjustment bolts
S175, S185 Bobcat Loader
50-101-1 Service Manual
CONTROL PANEL (ADJUSTABLE PINTLES) Figure 50-101-2
(CONT'D)
2 1
P-48462
WARNING Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
Never work on a machine with the lift arms up unless on Page 10-20-1.)
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising The Operator Cab
support device can allow the lift arms or attachment on Page 10-30-1.)
to fall and cause injury or death.
W-2059-0598 Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.)
Remove the control knob (Item 2), jam nut (Item 1) and
Put jackstands under the front axles and rear corners rubber washer (Item 3) [Figure 50-101-2].
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Figure 50-101-3
fall or move and cause injury or death.
W-2017-0286
P-48277
1 1
2 2 3
P-26323
1 1
Remove the fuse/relay mounting bolts (Item 1) [Figure
50-101-5].
P-54609
Remove the fuse/relay cover (Item 2) and fuse/relay
block retaining bracket (Item 3) [Figure 50-101-5].
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-101-4] which are connected to the Figure 50-101-6
steering shaft on the control panel.
P-26325
Figure 50-101-7
11
P-26329
P-26328 P-26329
1
Remove the control panel mounting bolts (Item 1)
[Figure 50-101-7], [Figure 50-101-8] & [Figure 50-101-
P-26326 9] from both sides of the control panel.
1
P-26327
P-48275
Installation: Tighten the mounting bolts to 25-28 ft.-lb. Remove Control Handle Lever (Item 1) [Figure 50-101-
(34-38 Nm) torque. 11]. (See Control Lever Removal And Installation on
Page 50-110-1.)
Figure 50-101-12
2
2
1
1 P-26331
2
To remove the steering shaft mounting bracket (Item 3)
[Figure 50-101-11], remove the three mounting bolts
P-4154 (Item 1) [Figure 50-101-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks Remove the steering shaft mounting bracket.
(Item 1) from the cross shaft assembly [Figure 50-101-
12]. Installation: Tighten the mounting bolts to 15-20 ft.-lb.
(20-27 Nm) torque.
Assembly: Install new nylon bushings (Item 2) [Figure
50-101-12] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
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
1 1
the lift arms or attachment to fall and cause injury or death.
W-2059-0598
P-54609
WARNING Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-101-14] which are connected to the
Put jackstands under the front axles and rear corners steering shaft on the control panel.
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Remove the four steering linkage mounting bolts (Item 2)
fall or move and cause injury or death. [Figure 50-101-14].
W-2017-0286
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 35-
Raise the lift arms and install an approved lift arm 40 ft.-lb. (47,5-54,2 Nm) torque.
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) NOTE: After removal and installation of the linkage,
the linkage neutral adjustment procedure
Lift and block the loader. (See Procedure on Page 10-10- must be performed. See Page 50-101-13 for
1.) Linkage Neutral Adjustment procedure.
2
5
2
P-48630
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering 1 Bolt
spring shoulder bolt (Item 2) [Figure 50-101-15].
2 Bushings
Remove the bolt/spring assembly. 3 Washer
4 Bushing Spacer
Installation: Tighten the centering spring bolt and a
NEW lock nut to 25-28 ft.-lb. (34-38 Nm) torque. 5 Spring
6 Lock Nut
Figure 50-101-16
7 Centering Plate
8 Guide Bushings
1
P-48632
Figure 50-101-18 2
1
6 3
3
2
5
1
2 4
1
1 P-48627
2
If the surface of any of the four solid pintle cams (Item 1)
are worn, loosen the bolt (Item 2) and rotate the cams 1/4
P-48629 turn [Figure 50-101-19].
3 4
P-48625
2
2
P-48621
3
Remove and inspect the spring (Item 1) [Figure 50-101-
23]. Spring return style only.
P-54617
Figure 50-101-24
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-101-21].
Figure 50-101-22
1 2
P-54615
2
Loosen the bolt (Item 2) and remove the pintle base (Item
3) [Figure 50-101-23] and [Figure 50-101-24].
4
3
1
P-48624
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering control link (Item 4) for damage and replace as
needed [Figure 50-101-22].
2
1
3
P-54625
1
P-48659 Remove the bolt (Item 1) from the pintle solid cams (Item
2)_[Figure 50-101-26] and inspect the pintle solid cams
for damage or excessive wear.
NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2
will not line up with the bolt (Item 3) [Figure Nm) torque.
50-101-25].
Figure 50-101-27
Installation: Install the pintle base (Item 1) onto the
pump shaft (Item 2) [Figure 50-101-25]. The top of the
2
pintle base should be level with the top of the pump shaft.
3
Tighten the bolt to 35-40 ft.-lb. (47,5-54,2 Nm) torque.
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 50-101-27].
Figure 50-101-28
1 3
4 2
2
P-48619
3
Remove the base pintle (Item 1) [Figure 50-101-28] from Installation: Install the torsion bushing (Item 2) [Figure
the pump shaft. 50-101-29] into the pintle arm using the same procedure
as the removal.
Remove the retaining bolt (Item 2), adjusting screw (Item
3) and neoprene dampener (Item 4) [Figure 50-101-28] NOTE: When the torsion bushing is installed, the
from the base pintle. amount of bushing on each side of the pintle
arm should be the same.
Inspect parts for wear and damage, replace as needed
[Figure 50-101-28].
Figure 50-101-32
2
1
P-48450
2
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 50-101-33
2
P16121
Using the remote start tool, turn the key (Item 1) [Figure
2 50-101-35] to the run position.
P-54614
Move the traction lock override switch (Item 2) [Figure
50-101-35] so the traction function is unlocked. (The
Loosen the two bolts (Item 1) holding the right centering traction lock override switch light will be ON.) On a
block. Move the right hand centering block (Item 2) standard loader the wedge brake will unlock.
[Figure 50-101-33] until both pintle cams contact the
centering block. NOTE: When the engine is started, the wheels/tracks
may begin to move.
NOTE: The left centering block is not adjustable. By
adjusting the right centering block the left NOTE: In loaders equipped with manual steering and
centering block will also become aligned hydraulic brake, the steering levers may have
properly. to be moved during engine start-up to reduce
the amount of creep. This reduction in creep
Figure 50-101-34 will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key (Item 1) [Figure
50-101-35] and start the engine and run at low idle.
P-48451
Figure 50-101-36
1 1
2
P-54610
Figure 50-101-38
2 1
2 1
P-48632
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.
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
Failure to use an approved lift arm support device can allow
(Item 2). The bolt (Item 2) [Figure 50-101-39] must be
the lift arms or attachment to fall and cause injury or death.
W-2059-0598
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm Figure 50-101-40
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
WARNING
2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10- P-54613
1.)
Raise the operator cab. (See Raising The Operator Cab Loosen the nut (Item 1) only until the tension is released
on Page 10-30-1.) from the torsion bushing (Item 2) [Figure 50-101-40].
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 50-101-40] to turn freely
between the torsion bushing and the linkage bar.
Figure 50-101-41
1 3 4
P-51174
Remove access plug from the top of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-101-41] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 inch (10 mm) thick spacer (Item 4)
[Figure 50-101-43].
Figure 50-101-42
Figure 50-101-44
3 2
2
4
1
P-51173 1
P-51133
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the base pintle
arm cam (Item 2) and the centering block (Item 3) arm mounting bolt (Item 1) and both of the upper pintle
[Figure 50-101-42]. mount bolts (Item 2) [Figure 50-101-44] and tighten to
35-40 ft.-lb. (48-54 Nm) torque. There should be no play
between the pintle arm and the square pump shaft.
Figure 50-101-45
1
1 1
P-51175
P-54609
Disconnect the remote start tool. (See Procedure on
Page 10-60-1.)
Loosen the two bolts and nuts (Item 1) [Figure 50-101-
45] on each steering linkage bar. Figure 50-101-48
Figure 50-101-46 2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35-40
ft.-lb. (47,5-54,2 Nm) [Figure 50-101-48].
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
pintle arm is rotated to the front as far as possible
[Figure 50-101-46]. Use a locking plier, clamp the two
linkage bars together.
1 P-37574
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
P-64311
Figure 50-102-2
2
1
WARNING 1
Raise the lift arms and install an approved lift arm P-64319
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Remove the fuse cover mount screws (Item 1) [Figure
Raise the operator cab. (See Raising The Operator Cab 50-102-2].
on Page 10-30-1.)
Installation: Tighten screws to 8-11 ft.-lb. (11-15 Nm)
Remove the engine speed control. (See Removal And torque.
Installation on Page 70-20-1.)
Remove the fuse/relay cover (Item 2) [Figure 50-102-2].
Figure 50-102-3
1
1 1
P-64298
1
Disconnect the left joystick wire harness connector (Item
P-64309 1) [Figure 50-102-5].
Figure 50-102-4
P-64328
Figure 50-110-1
N-18884
1
P-48462
To replace the rubber boot (Item 1) [Figure 50-110-3] on
the control panel, remove the control lever (See above
Disconnect the electrical connectors from the control procedure).
lever [Figure 50-110-1].
Drill out the four rivets (Item 2) [Figure 50-110-3] located
Figure 50-110-2 on the flange of the rubber boot and remove the old boot.
1 1
2
N-22658
Components Identification
Figure 50-111-1
P-21879
P16572
1 P-21836
Figure 50-111-4
P-21861
1
Remove the handle sensor connector (Item 1) [Figure
50-111-6] from the clip.
P-21837 NOTE: Pry out with a small screw driver and push the
connector down.
Figure 50-111-7
P-21880
NOTE: Pry out with a small screw driver and push the
connector down.
4
Figure 50-111-8 3 8
1
1
5 4
2 3
4
5 6
2
P-21882
3
Figure 50-111-11
3
2
1 P-21879
1
P-21799
P16534
Figure 50-111-15
2
1
N-17394
Remove the rubber handle cover (Item 1) [Figure 50- Check all parts for wear and replace as needed.
111-15] from the handle.
Figure 50-111-18
Figure 50-111-16
2 2
N-22796
N-17385
1
1
1
1
N-22658
Figure 50-111-21
N-22667
B-16618
Remove the control lever from the cross shaft and control
panel.
Figure 50-111-22
2
2
1
1
N-22659
Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-110-
1.)
P-28312
Figure 50-112-2
P-64328
1
P-64298
Figure 50-112-5
Remove the two outside joystick mount screws (Item 1)
[Figure 50-112-7].
Figure 50-112-8
P-26220A
Figure 50-112-6
Remove the joystick from the rubber boot [Figure 50-
112-8].
1
P-26221
Joystick Removal (Right & Left) (Cont'd) Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
Figure 50-112-9 on Page 10-20-1.)
Figure 50-112-10
P-26224
Figure 50-112-11
P-64303
Figure 50-112-12
P-64308
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Calibration Procedure (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5
Lift and Tilt Calibration Procedure (SJC) . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER C
BUZZER
C422
START
START
OPEN
DATA
4380 1 1
DATA
7.7 ohm
PWM
WIRING SCHEMATIC 2
REAR BASE 2380 2
C414
HIGH FLOW BICS HYDRAULIC LOCK
1 1 4440
G
C
D
E
B
A
K
E
F
F
J
J
7.5 ohm
C415
12V
C420
7.5 ohm A A 4460 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 BLUE TIE STRAP 2410 B B 12V
(Without Options)
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B
S175 (S/N 525211001 - 525218874) ACROSS CONNECTORS
2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B YELLOW TIE YELLOW TIE
(S/N 525311001 - 525316211) B A
YELLOW TIE
STRAP
STRAP STRAP
LOCK VALVE
2340 2 2 PWM
C416A
C416
2450 2 2 2450 2450 2
S185 (S/N 525011001 - 525022472) 4450 1 1 4450 4451 4455 1
2
1
3600 A A SPEED
SOME CONNECTOR SENSOR MAIN
3610 B B
(S/N 525111001 - 525115404)
WORKLIGHTS
BODIES NOT SHOWN FRAME
GREEN TIE GREEN TIE GREEN TIE
FRONT
FOR DRAWING CLARITY STRAP LOCK VALVE HYDRAULIC
C108
C417A
Printable Version Click 3300 A A TEMPERATURE
C417
4480 1 1 4480 4481 4485 1 1
SWITCH
SENDER
BRAKE
3310 B B
V-0440
1930
RED = RED 2 2 2 500-3000 ohm
2000
2480 2480 2480 2
RNG = ORANGE
BLK = BLACK REAR AUXILIARY
C435
RIGHT
LBL = LIGHT BLUE 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
ARE CONNECTED IN SERIES FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE
LGN = LIGHT GREEN
HARNESS 7101973 A SEE C113 6120 A A
SWITCHED POWER 1000-1999 RNG FRONT AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C424
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4490 AIR FILTER BAR 6110 A A
LEFT
11 ohm
4330
4360
4340
PNK = PINK
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2490 B B
2110
3700
3200
2750 B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE B
4470
4460
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER -
2450 3100 A A +8 2910
ENGINE 8000-8999 TAN PUR = PURPLE 30-270 ohm
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT PWM +8V ENG SPEED 28
LOCK ANALOG 1 ROD TEMP SIGNAL SUPPLY SIGNAL
GROUND Tx RIGHT SERIAL IN
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15 11 9110 D
C105
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND REAR SPARE SYSTEM LH AUX SPARE AIR FILTER RH FRONT
3010 23
SERIAL IN BASE ANALOG 2 POWER Rx LEFT DIGITAL 1 SIGNAL
PWM -
DETENT
9400 F See C492
B B 3410 23
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 42 9410 G
B 9110 4440 1200 9200 4820 3700 4310 4920
2410 FRONT REAR STATUS SEAT BAR LH SKI FUEL PWM RH SKI
3910
SEE J2 COMPUTER
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL DOWN
BASE ROD IN +8v DOWN SENDER
2380 2390
POWER
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN OPEN SPARE
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER RELAY PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2
2 3 4 5 66 7 8 9 10
5 9100
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B
30 4930
2720 0.5-7.5 V B B 3510 TRAVEL F&R AUX RESERVED
SPARE
DIGITAL 2
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF
UNSWITCHED
(SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V HYD CHARGE ENG OIL RESERVED
SPARE
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
B B 3210 26
500-3000 ohm 41 42 43 44 45 46 47 48 49 50
180 A 1800 16 4820
SUPPLY 0
A 1400 8000 9800 3420 7200 3520
1020
J1 6 4810
C110
G A A J2
E3
D3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
ALTERNATOR 2010 6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
C
C101
2800
1490
2520
4240
1010 A A 8800 A A 8800
STARTER 0.3 ohm B B 8100 B B 8100
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
8250 B B 8250
Traction Lock C410 C409
B S
8200 A A
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
RGN
YEL
DBL
LGN
RGN
GLOW PLUGS 4100 B B PULL 0.3 ohm
1.0 ohm each
F
+ -
B 2600
HR HR HR HR
PWM
FLOAT
6200
SHIFT
H
SKI CTRL
SIDE
8590
8580
8570
8560
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1700 1055 4220 M M
7200 J J
C489
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 7101181 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 5
FUSE 3 FUSE 6 G 9410 S S 9420
25A 15A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12
1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A
F
A
D 9110 F
1080
1040
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
G
D
C
- F
E
A
B
+ 1300
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR V-0440 (7-12-05)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
PROTECTED POWER E
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx
12V
GROUND
2 2 2430 2370 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER C
BUZZER
C422
START
START
OPEN
DATA
4380 1
DATA
WIRING SCHEMATIC 2
REAR BASE 2380
C414
HIGH FLOW BICS HYDRAULIC LOCK
1 1 4440
G
C
D
K
A
B
B
A
K
E
F
F
J
J
7.5 ohm
12V
C420
C415
7.5 ohm A A 4460 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B
S175 (S/N 525211001 - 525218874) ACROSS CONNECTORS
2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
YELLOW TIE YELLOW TIE
A B YELLOW TIE
(S/N 525311001 - 525316211) B A
STRAP
STRAP STRAP
LOCK VALVE 2340 2 2 PWM
C416A
C416
2450 2 2 2450 2450 2 2
S185 (S/N 525011001 - 525022472) 4450 1 1 4450 4451 4455 1 1
3600 A A SPEED
SOME CONNECTOR SENSOR MAIN
3610 B B
(S/N 525111001 - 525115404)
WORKLIGHTS
BODIES NOT SHOWN FRAME
GREEN TIE GREEN TIE GREEN TIE
FRONT
FOR DRAWING CLARITY STRAP STRAP STRAP LOCK VALVE HYDRAULIC
(PRINTED JULY 2005)
C417A
C108
3300 A A TEMPERATURE
C417
Printable Version Click Here 4480 1 1 4480 4481 4485 1 1
SWITCH
SENDER
BRAKE
3310 B B
V-0441
1930
RED = RED 2480 2 2 2480 2480 2 2 500-3000 ohm
2000
RNG = ORANGE
BLK = BLACK REAR AUXILIARY
C435
RIGHT
LBL = LIGHT BLUE 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
ARE CONNECTED IN SERIES FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE
LGN = LIGHT GREEN
HARNESS 7101973 A SEE C113 6120 A A
SWITCHED POWER 1000-1999 RNG FRONT AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C424
CAB
2530 YEL = YELLOW 4490 A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 11 ohm AIR FILTER BAR 6110 A A
LEFT
4330
4360
4340
PNK = PINK
4410
4440
4430
12V
4420
2470 HYDRAULIC 4000-4999 LGN B B B B SWITCH
2770
2490 SEE J1 B 3710
3300
2110
3700
3200
2750 B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE B
4470
4450
4460
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER -
2450 3100 A A +8 2910
ENGINE 8000-8999 TAN PUR = PURPLE 30-270 ohm
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT PWM +8V ENG SPEED 28
LOCK ANALOG 1 ROD TEMP SIGNAL SUPPLY SIGNAL
GROUND Tx RIGHT SERIAL IN
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A 15
C105
HYDRAULIC CHARGE A 3400 3400 11 9110 D
C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
See C492
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 42 9410 G
B 9110 4440 1200 9200 4820 3700 4310 4920
2410 FRONT REAR STATUS SEAT BAR LH SKI FUEL PWM RH SKI
3910
SEE J2 COMPUTER
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL DOWN
BASE ROD IN +8v DOWN SENDER
2380 2390
POWER
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN OPEN SPARE
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER RELAY PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2
2 3 4 5 66 7 8 9 10
5 9100
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B
30 4930
2720 0.5-7.5 V B B 3510 TRAVEL F&R AUX RESERVED
SPARE
DIGITAL 2
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF
UNSWITCHED
(SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V HYD CHARGE ENG OIL RESERVED
SPARE
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
B B 3210 26
500-3000 ohm 41 42 43 44 45 46 47 48 49 50
180 A 1800 16 4820
SUPPLY 0
A 1400 8000 9800 3420 7200 3520
1020
J1 6 4810
C110
G A A J2
E3
D3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION J1
SHUTOFF
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010 A A 8800 A A 8800
STARTER 0.3 ohm B B 8100 B B 8100
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
8250 B B 8250
Traction Lock C410 C409
B S
8200 A A
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C C
WHT
2200
WHT
PUR
DGN
RGN
YEL
DBL
LGN
RGN
TO OPTIONS C465 C466
GLOW PLUGS 4100 B B PULL 0.3 ohm
A
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8580
8570
8560
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
AHC LIFT RIGHT
E 6400 HALL SENSOR TURN SIGNAL
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
7100 A TO OPTIONS C450
DGN
C
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
C
A
B
SWITCH) C407 C449
C
B
E
C
A
D
B
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
TO OPTIONS TO OPTIONS
C
B
A
L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
F 4730 CONNECTOR) CONNECTOR)
1510
4650
2650
D 4235
C488
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
6
(ALTERNATOR
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2260
2270
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
FUSE 1 FUSE 3 FUSE 6
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 B 1740 2280
1740 B H
MAINFRAME HARNESS 7101181 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4670
4750
4650
4770
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
D
C
- F
E
A
B
+ 1300 B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0441 (7-12-05)
BATTERY
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
WIRING SCHEMATIC
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
WIRES CONNECT BY LETTER 12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS)
(Without Options)
PWM
BUZZER
BUZZER
ACROSS CONNECTORS
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
A B PWM
REAR BASE 2380 2 2
B A
C414
HIGH FLOW BICS HYDRAULIC LOCK
1 1 4440
S175 (S/N 525218875 AND ABOVE)
G
C
D
E
B
A
K
E
F
J
7.5 ohm
C415
12V
C420
7.5 ohm A A 4460 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
SOME CONNECTOR
(S/N 525316212 AND ABOVE) BODIES NOT SHOWN
12V B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
FOR DRAWING CLARITY BUCKET POSITIONING FRONT ROD
S185 (S/N 525022473 AND ABOVE)
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
12V
PWM
(S/N 525115405 AND ABOVE) B B 2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1
Printable Version Click Here 3.3 ohm
CAB 6727178
UNSWITCHED POWER 1000-1999 RED RED = RED
(PRINTED JULY 2005) FUSED, UNSWITCHED POWER 1000-1999 RED/WHT RNG = ORANGE 2340 2 2 PWM
C416
MONITORING 3000-3999 LBL DBL = DARK BLUE SPEED
ARE CONNECTED IN SERIES 4450 A A 7.5 ohm MAIN
HYDRAULIC 4000-4999 LGN LGN = LIGHT GREEN 3610 B B SENSOR
WORKLIGHTS
ATTACHMENT CONTROLS 5000-5999 YEL YELLOW TIE STRAP 2450 B B 12V FRAME
2530 DGN = DARK GREEN
GROUNDS LIGHTS 6000-6999 PNK
FRONT
YEL = YELLOW
2470 ACCESSORIES 7000-7999 WHT PNK = PINK
ENGINE 8000-8999 TAN WHT = WHITE
SWITCH
BRAKE
2460 COMMUNICATION 9000-9999 PUR FRONT AUX RELIEF
2800 BRN = BROWN
1930
2000
C424
2450 TAN = TAN 4490 A A H SEE C110
3610 11 ohm
2440 2400 2300 PUR = PURPLE GREEN TIE 12V
C435
2490 B B J SEE C110
RIGHT
3510 GRY = GRAY STRAP 2760 B B
2430
2600 A SEE C113 6120 A A
2340 REAR AUX RELIEF
C405 C406
2110 SEAT
C417
CAB
2330 3700 A A
A A
C434
4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
2520
4360
4340
4410
4440
4430
4420
12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
3700
2740
3200
B B
3600
2750
4470
4460
4450
2100 3110 FUEL
2730 B B
2120 SENDER - +8
2720 3100 A A 30-270 ohm 2910
2420 J1 J2 2920 2900
C
2710 2930
A
2410 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2350 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2380 2390 3100 2760
SPOOL SPARE COOLANT ENG SPEED 28
2370
HARNESS 7112802 LOCK ANALOG 1
FRONT
ROD
COMPUTER
GROUND
SYSTEM
Tx
LH AUX
RIGHT
L HAND
SERIAL IN
TEMP SIGNAL
PWM +8V
SUPPLY SIGNAL
HYDRAULIC 1 2 3 4 5 6 7 8 9 10
C105 C108
2200 TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 4360 4330 2900 9100 4810 9210 3200 4300 3600
11 9110 D N K G L B R P S F E D C M A J H
2000 SENDER
B B 3310 2 2 3310 J 7 9210 E
500-3000 ohm
R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F See C492 C408
2240
N K G L B R P S F E D C M A J H
+
A 11 12 13 14 15 16 17 18 19 20
G
C110
A A 3400 3 3 3400 15 1200 9200 4820 3700 4310 4920 42 9410
HYDRAULIC CHARGE C 9110 4440
PRESSURE SENDER - C C 3420 5 5 3420 47 FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
0.5 - 7.5 V B BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
B B 3410 4 4 3410 3010 23
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
4430 9400 1900 3900
P05 4830 3100 4320 4930
B 4340
BUCKET 35 3910 SEE FUSE/RELAY
OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND
LH SKI
UP OPEN GROUND OPEN
RH SKI
UP
A CENTER
SWITCH
45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3440 34 9350
6 6 3430 3 HYD LOCK STATUS
HEADLIGHT BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH
SEATBAR
IN
OPEN TEMP OPEN OPEN
SWITCH B B SIGNAL
14 1200
41 42 43 44 45 46 47 48 49 50
4410 9410 4640 9340 3920 4500 3300 24 1900
RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) OPEN BLINKER RELAY PULL / 963
SWITCH MAKE-UP OUTPUT 1
5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
ALTERNATOR 2010 6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
C
4300
4320
4310
4910
4920
4930
4940
4230
2530
2800
C101
1490
2520
4240
1010 A A 8800 A A 8800
STARTER 0.3 ohm B B 8100 B B 8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
G
H
C
D
G
E
D
C
H
F
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200 2200 B
WHT
PUR
DGN
B
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B OPEN
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 7112824 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040
G
-
D
C
E
A
B
1300
F
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR V-0717 (7-12-05)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
2 2 2430 2370 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
WIRING SCHEMATIC 2
REAR BASE 2380
C414
HIGH FLOW BICS HYDRAULIC LOCK
1 1 4440
G
C
D
E
A
K
E
F
7.5 ohm
12V
C415
C420
7.5 ohm A A 4460 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B 2 2
S175 (S/N 525218875 AND ABOVE) ACROSS CONNECTORS
2420 2330 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
(S/N 525316212 AND ABOVE) B A
2340 2 2 PWM
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
(S/N 525115405 AND ABOVE)
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY
SWITCH
BRAKE
FRONT AUX RELIEF
V-0718
1930
RED = RED
2000
C424
RNG = ORANGE 4490 A A 11 ohm H SEE C110
BLK = BLACK GREEN TIE 12V
C435
2490 B B J SEE C110
RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN
SWITCHED POWER 1000-1999 RNG REAR AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4460
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330
1 2 3 4 5 6 7 8 9 10
2520 HARNESS 7112802 4360 4330 2900 9100 4810 9210 3200 4300 3600
11 9110 D N K G L B R P S F E D C M A J H
2100 HYDRAULIC 9210 E
7
C105 C108
TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F
See C492 C408
SENDER B
B 3310 2 2 3310 J 11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 500-3000 ohm 42 9410 G
+ 9110 4440 1200 9200 4820 3700 4310 4920
2410 A
C110
A A 3400 3 3 3400 15 FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE C BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
2380 2390 PRESSURE SENDER C 5 5 47
POWER +8v
J2
-
B C 3420 3420 21 22 23 24 25 26 27 28 29 30
2370 0.5 - 7.5 V
9400 1900 3900
P05 4830 3100 4320 4930
B B 3410 4 4 3410 3010 23 4340 4430
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
B OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
2800 HYDRAULIC OIL A A 3440 1200
6 6 3430 3 41 42 43 44 45 46 47 48 49 50
FILTER (DIFFERENTIAL)
3610 B B 4410 9410 4640 9340 3920 4500 3300 24 1900
SWITCH
2300
3510 RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) OPEN BLINKER RELAY PULL / 963
SWITCH MAKE-UP OUTPUT 1
2600 5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
2110
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
2730 SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION J1
SHUTOFF
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010 A A 8800 A A 8800
STARTER 0.3 ohm B B 8100 B B 8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
G
H
C
D
G
E
D
C
H
6732781
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C
WHT
2200 C
WHT
PUR
DGN
YEL
2200
RGN
B
DBL
LGN
RGN
B C465 C466
TO OPTIONS GLOW PLUGS 4100 B B OPEN
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
C 7100 A TO OPTIONS C450
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
TO OPTIONS TO OPTIONS
C
B
A
L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
F 4730 CONNECTOR) CONNECTOR)
1510
4650
2650
D 4235
C488
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
(ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
FUSE 1 FUSE 3 FUSE 6
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
MAINFRAME HARNESS 7112824 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0718 (7-12-05)
BATTERY
WIRING SCHEMATIC
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
HIGH FLOW REAR ROD (NOT Used For This Model)
CLOCK/LATCH
CLOCK/LATCH A
C413
C421
HEADLIGHTS
1 1 1
C415
A 4430 4370
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
7.5 ohm LIFT SPOOL LOCK
SYSTEM Tx
12V
GROUND
12V 2 2 2430 2370 2
GROUND
B B 2460 BLUE TIE STRAP BROWN TIE STRAP (Not Use For This Model )
BUZZER
BUZZER
C422
START
START
OPEN
1
DATA
4380
DATA B
2
S175 (S/N 525218875 AND ABOVE) REAR BASE 2380
C414
1 1 4440 BICS HYDRAULIC LOCK
G
C
D
E
K
A
B
E
F
F
J
J
7.5 ohm
(S/N 525316212 AND ABOVE) 12V
C420
WIRES CONNECT BY LETTER 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
ACROSS CONNECTORS 2410 B B 12V
S185 (S/N 525022473 AND ABOVE)
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
A B BUCKET POSITIONING FRONT ROD
C423
C418
(S/N 525115405 AND ABOVE) B A 9.8 ohm
12V
A
B
A
B
4420 4330 1 1 3.3 ohm
PWM
2420 2330 2 2 FRONT BASE
C419 C106
SOME CONNECTOR 4340 1 1 3.3 ohm
CAB 6727178
BODIES NOT SHOWN 2340 2 2 PWM
C416
RED = RED SPEED
UNSWITCHED POWER 1000-1999 RED
4450 A A 7.5 ohm SENSOR MAIN
RNG = ORANGE 3610 B B
WORKLIGHTS
2530 GROUNDS 12V FRAME
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT BLK = BLACK YELLOW TIE STRAP 2450 B B
FRONT
2470 SWITCHED POWER 1000-1999 RNG LBL = LIGHT BLUE
GROUND 2000-2999 BLK DBL = DARK BLUE
2460 MONITORING 3000-3999 LBL LGN = LIGHT GREEN
SWITCH
BRAKE
2450 HYDRAULIC 4000-4999 LGN FRONT AUX RELIEF
DGN = DARK GREEN
1930
2000
C424
ATTACHMENT CONTROLS 5000-5999 YEL
2440 2400 2800 LIGHTS 6000-6999 PNK
YEL = YELLOW 4490 A A 11 ohm H SEE C110
PNK = PINK GREEN TIE 12V
C435
3610 ACCESSORIES 7000-7999 WHT 2490 B B 3310 J SEE C110
RIGHT
2430 WHT = WHITE STRAP 2760 B B
2300 ENGINE 8000-8999 TAN
2340 3510 COMMUNICATION 9000-9999 PUR BRN = BROWN A SEE C113 6120 A A
TAN = TAN
2330 2600 REAR AUX RELIEF
PUR = PURPLE
C405 C406
SEAT
C417
CAB
2520 GRY = GRAY A A 3700 A A
C434
4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
2110
4330
4360
4340
4410
4440
4430
4420
12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
2100
3700
3200
B B
3600
2750
4470
4460
4450
2740 3110 B B FUEL
SENDER - +8
2420 2730 3100 A A 30-270 ohm 2910
2120 J1 J2 2920 2900
C
2720 2930
A
2410
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2380 2390 2710 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
3100 2760
2370 2350 SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2200 1 2 3 4 5 6 7 8 9 10
2000 HARNESS 7112800 4360 4330 2900 9100 4810 9210 3200 4300 3600
11 9110 D N K G L B R P S F E D C M A J H
HYDRAULIC 7 9210 E
C408
C105 C108
C110
FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE A A 3400 3 3 3400 15 BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
C POWER +8v
J2
PRESSURE SENDER C C 3420 5 5 3420 47 21 22 23 24 25 26 27 28 29 30
0.5 - 7.5 V
-
B
4430 9400 1900 3900
P05 4830 3100 4320 4930
23 4340
B B 3410 4 4 3410 3010
BUCKET
LH SKI RH SKI 35 3910
A
OPEN POSITION OPEN
KEY/ENTER
SWITCH
SEATBAR
GROUND UP OPEN GROUND OPEN UP
SEE FUSE/RELAY
B 45 3920 CENTER
31 32 33 34 35 36 37 38
38 39 40
C407
C112
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
4 2900
11 12 13 14 15 16 17 18 19 20
40 4940 2530 H
ENGINE OIL A A 3500 3500 37 8250 1110 9500 3400 6510 4200 4460 6210 8800
C107
C409
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300 4300 B
NOT USED FOR
THIS MODEL
31
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640 2530 K
ENGINE t 8150 1130 9700 8550 2100
C104
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
B B 3210
OUTPUT 2
26 4830 4230 G
500-3000 ohm 41 42 43 44 45 46 47 48 49 50
180 16 4820 1490 A
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2 4640 D
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800 4840 C
FUEL
EXCITATION J1 4830 B
SHUTOFF
ALTERNATOR 2010 4910 4820 G
6736515
HOLD PULL
4730
4110
7200
6510
6410
4200
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
1400 K
C410
10.9 ohm 2800 C C 2800
C101
C425
2200 C C 2200 B B J
M R
C109
TO OPTIONS 6736808
GLOW PLUGS
BATTERY CABLE
C454
CONNECTOR) 1
C454
5 1540 1 1 1540 1 1 PWR LEFT SIDE
F 1
3
3020 2 2 3020 2 2 SIG WHEEL SPEED
B 2600 3 4 4
HR HR HR HR DRIVE 0
3080 4 3080 4 SIG
H 6200
8590
8570
8560
8580
3 3
A 6310
C453
1
C453
7 1530 1 1 1530 1 1 PWR RIGHT SIDE
E 6400 1
3000 2 2 3000 2 SIG WHEEL SPEED
4 2
D 6500 2 4 4
9
2510 3070 4 3070 4 SIG
G 6600 3
8500
3020
C404
SEE CAB
FUSE 10
FUSE 11
FUSE 12
3
UNSWITCHED
FUSE 9
ATTCHMNT
25A
25A
25A
3080 1810 2 2
ACS
C350
SWITCH) 1640 STRAPS
LEFT RIGHT 0 2810 4 4 2810 1 1 GRD
C356
SAFETY STEERING STEER SWASHPLATE SWASHPLATE 4 RIGHT SWASH PLATE
A IN OPEN OPEN MODE OPEN MODE 1 ANGLE ANGLE OPEN OPEN
9 4720 3 3 4720 3 3 SIG
POSITION SENSOR
J 2730 1 2 3 4 5 6 7 8 9 10 2
3000 1 1
STARTER
3
POWER
FORWARD STEER
4
C360
DRIVE OPEN OPEN OPEN OPEN JOYSTICK X JOYSTICK Y
M 6500 GND MODE 2 OPEN
4 4
1 4720 2860 2860 1 1 GRD
C355
11 12 13 15 16 17 18 19 20 8
4 LEFT SWASH PLATE
L 6400 9530 4275 4530 4540 3 3 4950
2670
LEFT BRAKE
7 4950 3 3 SIG
POSITION SENSOR
R QUAD
F 4730 FORWARD CAN LOW R QUAD TWO LIGHT DRIVE DRIVE MAIN SENSER
1770 1 1 1770
DRIVE DRIVE A DRIVE B DRIVE SPEED 1 OUTPUT GRND GRND GRND OPEN 3 2 2 PWR
D 4235 21 22 23
2
4
25 J5 26 27 28 29 30 4
TO OPTIONS N 6300
REAR
4
PULL
C500
E 4550 4280 9730 3020 3080 9410 7100 1640 4 RIGHT REVERSE DRIVE SOLENOID
LEFT RIGHT RIGHT RIGHT RIGHT
5
2650 4 4 2650 2 2
REVERSE FORWARD FORWARD REVERSE REVERSE TWO UNSWITCHED UNSWITCHED SWITCHED
S 1700 3
GND GND DRIVE DRIVE GND SPEED 2 BATTERY BATTERY OPEN BATTERY
1
4280 5 5 4280 1 1
1740 41 42 43 44 45 46 47 48 49 50 LEFT REVERSE DRIVE SOLENOID
A 1140 4
2680 6 6 2680 2 2
FRONT &
MARKER
PULL
1150
FUEL
H 2
1
4270 7 7 4270 1 1
R J5 DRIVE 1 LEFT FORWARD DRIVE SOLENOID
1
2670 8 8 2670 2 2
B 2 2 4 4 3 1 3 2 1 5 1 2 2 3 3 4 3 3 1 1 2
1 4 6 2 5 4210
7 8 7 8 5 6 2 2 2 0 0 5 0 7 8 6 9 6 9 8 6
G
TO OPTIONS
A 6 6 6 6
2490
1250
1260
4275
4390
4540
4530
2470
9400
9410
4550
4220
9730
9630
9530
4350
7100
K
1750
(ALTERNATOR (BRAKE LIGHT)
& KITS) C474 4 4 4 4
GLOW
C449
FUSE 11
C459
25A 4530 2 2 4750 2 2 X
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
LEFT
1700 1055 4220 M A 1170 4540 3 3 4650 3 3 Y
JOYSTICK
7200 J G 9210 2080 5 5 2070 5 5 GRD
C489
FUSE 3
1 1 1 1
FR & MK LT
FUSE 1
FUSE 4
236
COMPUTER
PLUG STARTER
235
(ACCESSORY POWER LIGHT PULL TRACTION 4275 L R 9400 1520 1510 PWR
REAR LT
LIGHT
HEATER
0
0
25A
15A
25A
15A
6410 P S 9410
(ATTACHMENT)
(COMPUTER)
6510 N K 4550 B A B A B A
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 6 6 6 6
FUSE 5
M 4220
FUSE 7
FUSE 8
4550 K
FUEL PULL
TRACTION
1730 4 4 4 4
30A
30A
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
C450
9720 E L 4275 TO OPTIONS
C460
NOT USED NOT USED
(HEATER FOR THIS FOR THIS (BACKUP 4750 2 2 4750 2 2 X
9620 D P 6410 B
C497
) MODEL MODEL ALARM) RIGHT
3 3 3 3
C492
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5 4650 4650 Y
15A
G 9410 S N 6510 A TO OPTIONS JOYSTICK
15A 30A 30A 2070 5 5 2070 5 5 GRD
120
LIFT ACTUATOR
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 1610
C429
(UNSWITCHED 1170 A H 2240 4
4
POWER) (ACS) F 9110 4680
D 9110 F 5 5 RED
6 6
M
1080
1040
7 7
4690 8 8 BLK
2770 1 1 GND
4770 2 2 SIG
TILT ACTUATOR
1160
1730
9800
9510
9610
9710
2710
1630 3 3 PWR
4790
1190
1180
2260
2270
4680
4780
4690
1760
4750
4650
4670
2280
9540
9640
9740
2250
4770
1500
C428
4 4
1050 4780 5 5 RED
G
-
D
C
E
A
B
1300
F
+ B C G E J H F D A K H J C B D E F A G K A B D C G F H E J K
6 6
1060 TO OPTIONS M
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
J3 (Gray) J1 J2 (Black)
4790
7
8
7
8 BLK
1310
ACD & REMOTE ACS Controller
Printed in U.S.A. START CONNECTOR
1040
C630
2650 F
(S/N 525311001 AND ABOVE)
C612
OFF A 7010 B B
C103
6600 G
S185 (S/N 525011001 AND ABOVE) LOW
2100
B 2310 2205 C C
6400 E MEDIUM
(S/N 525111001 AND ABOVE) BACK-UP
ALARM 6310 A
TO OPTIONS (AC)
HIGH
(PRINTED JULY 2005) 6500 D
C433
C433
C410
C431
6200 H HERE OR TO OPTIONS
(HVAC JUMPER) HEATER VALVE C LGN C 4640
2600 B
DBL A A 3200 1300 A A RED 10 B BLK B
- +
C613
Printable Version Click Here WHT B B 7200 D D WHT 8 M
6340
C614
2620
7000
2610
6610
6320
6620
6330
2640
C BLK C C 2110 2130 C C BLK 7
1110
POTENTIOMETER B B
C611
H 1010 1 1 RNG M
2200 4 4 BLK
DELUXE EUROPEAN BLOWER SWITCH
5 5
POWER RELAY
TO OPTIONS
(DELUXE ACCESSORY)
C617
30 SSL 7-PIN
87A 1190 B CAN CONNECTOR Harness
D F C E A B G
HVAC HARNESS - 6725933 2740 C
9800
1160
9700
1710
9500
9600
2710
SSL 7-PIN
C426 To Mainframe TO HORN
C705
Harness CONNECTOR KEY "RUN" D 9800 PUR J1 - 8-PIN
CAN CONNECTOR D F C E A B G
UNSW POWER F 1160 RED/WHT 2720 H GROUND
C412
2750 B
HORN RELAY 1730 A CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
SW POWER E 1730 RNG 9 1720 B SW POWER ACD
9800
1160
9700
1710
9500
9600
2710
85 86 9 Machine
2770 7200 CAN LOW B 9620 PUR 9610 E CAN LOW
87 14 Connector to
2750 CAN HIGH A 9520 PUR 9510 D CAN HIGH
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A
30
2760 ADDITIONAL POWER
GROUND G 2730 BLK 13 C OPEN
Engine
Compartment
CONNECTOR
UNSW POWER 2 1160 RED/WHT 2720 H GROUND
Connector 7-PIN A OPEN
C666 ATTACHMENT
C490
E 85 86 2740 B
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD 2780 6415 on Loader
87 CONNECTOR G OPEN
SW POWER 1 1730 RNG 1720 B SW POWER ACD D 6410 6410 30 1740 A Boom
C411
87A 6020 J
Machine C
CAN LOW B 9620 PUR 9610 E CAN LOW BOOM-MOUNTED
Connector N
CAN HIGH A 9520 PUR 9510 D CAN HIGH B 6000 ACD CONNECTORS
TO AWS TO MAINFRAME SW POWER K 1740
C401or
3 C A 6510 B C A
C402
GROUND 2730 BLK OPEN
RIGHT BLINKER CONTROLS GROUND B 2740 C703 J2 - 10-PIN BLACK
C489
7-PIN 2720 B
A OPEN RELAY C497
C666 ATTACHMENT
CONNECTOR G OPEN 85 86
1720 A E OUTPUT E 5100 5100 C E OUTPUT
2790 6515 F OUTPUT F 5350 5350 H F OUTPUT
J 6510
87
BOOM-MOUNTED 30 G OUTPUT G 5400 5400 J G OUTPUT
N 87A 6010
ACD CONNECTORS H OUTPUT H 5050 5050 B H OUTPUT ACD
SW POWER K 1740 Output
C OUTPUT C 5300 5300 G C OUTPUT
GROUND B 2740 C703 J2 - 10-PIN BLACK AWS HORN/BLINKER HARNESS - 6726662 D OUTPUT D 5150 5150 D D OUTPUT
Connector to
Engine
E OUTPUT E 5100 5100 C E OUTPUT
A OUTPUT A 5250 5250 F A OUTPUT Compartment
F OUTPUT F 5350 5350 H F OUTPUT
M OUTPUT M 5200 5200 E B OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT
ID (K TO L) L 5910 5000 A J OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD TO OPTIONS TO OPTIONS 12
Output (HVAC)
ID (K TO P) P 5510 5450 K K OUTPUT
C OUTPUT C 5300 5300 G C OUTPUT (DELUXE ACCESSORY)
Connector 11
D OUTPUT D 5150 5150 D D OUTPUT C 2740 C C506 14-PIN
C704
C636
C642
ATTACHMENT J3 - 10-PIN GRAY
Connector
C417
A OUTPUT A 5250 5250 F A OUTPUT B 1140 B 1 4480 4481 4485 1 CONNECTOR
TO REAR AUX.
on Loader 5900 J ID #1
M OUTPUT M 5200 5200 E B OUTPUT A 1740 A TO MAIN 2 2480 2480 2 RELIEF SOLENOID
FRAME Boom 5500 A ID #2
ID (K TO L) L 5910 5000 A J OUTPUT
HARNESS B ID #3 ACD
C418
ID (K TO P) P 5510 5450 K K OUTPUT
HVAC/ACCESSORY 1 4450 4451 4455 1 TO REAR AUX.
DIVERTER SOLENOID
C ID #4 Input
2 2450 2
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY HARNESS - 6725390
2450
D ID #0 Connector to
Engine
CONNECTOR
5900 J ID #1
DELUXE ATTACHMENT E OPEN
Compartment
F OPEN
5500 A ID #2 CONTROL HARNESS - G OPEN
B
C
ID #3
ID #4
ACD REAR AUX. JUMPER HARNESS - 6732730 H OPEN
Input K OPEN
D ID #0 Connector
M
FRONT WIPER
BOTTLE AND TANK
7101973 Rev. none
E OPEN
F OPEN FRONT WIPER
MOTOR
G OPEN
H OPEN
V
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K OPEN
M
C622
7200 or YEL
7150 or DGN
2765 or BRN
LEFT TAILLIGHT
L X RIGHT TAILLIGHT
BACK-UP
ALARM
TO OPTIONS
2745
TO (DELUXE ACCESSORY)
POWER BOB-TACH MAINFRAME C 7310
TO ENGINE OR
C404
SOLENOID B
PARK
HIGH
TO OPTIONS B 2735 2755 B B A B C D E F REGISTRATION MAINFRAME RIGHT WORK A B C D E F
C610
LEFT WORK
C667
7100 A
C606
BACK-UP ALARM 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
C F 7190 7180
SWITCHES 2 2 2 2
D 4710
C607
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
SOLENOID MAINFRAME
E 2770 A A
WIPER HARNESS - 6730885
C402
1720 1730 A
9.8 ohms 2720 B
BACK-UP ALARM
POWER BOB-TACH HARNESS - SWITCHES HARNESS -
ADDITIONAL POWER
CONNECTOR TO ENGINE OR MAINFRAME
C491
41 B B 6730 B B 6720
BACK-UP E 40 A A 2660 OPEN C C 6620
ALARM A HARNESS 6713993 2630 D D 2620
REAR LIGHT HARNESS 6716419 M
FRONT WIPER
BOTTLE AND TANK BACK-UP ALARM D 40 A A 2640 OPEN E E OPEN
F H 42 B B 6330 F F 6320
RIGHT
WORKLIGHT
2620 6200 2600 B HARNESS - 6715659 B HARNESS 6713994 HARNESS 6731239
6210 6200 H 46 C C 6430 A A 6430
LEFT
WORKLIGHT
2630 6210 6310 A 41 B B 6730 B B 6830
E 40 A A 2660 OPEN C C 6630
RIGHT
TAILLIGHT
2610 6320 D HARNESS 6713993 2630 D D 2630
C622 FRONT WIPER
2650 G MOTOR
TO ATTACHMENT 40 A A 2640 OPEN E E OPEN
LEFT L X
2640 6330 7100 C B 42 B B 6330 F F 6330
TAILLIGHT V
J HARNESS 6713994 HARNESS 6731239
TO MAINFRAME M
BACKUP N
ALARM TO OPTIONS
2745
6800
2670
6700
2660
(DELUXE ACCESSORY) P
6360
2650
1370
2640
C 7310 M TO OLDER 2620
B 2735 2755 B B MODEL ATTACHMENTS 2630
A
C610
C506
C667
87A 87 86 87A 87 86
DOME LIGHT E 7160 C C D WHT S LEFT RIGHT 2640 87A 87 86 87A 87 86
TO OPTIONS SWITCH FLASHER FLASHER
A 7210 A A C BRN LT 2610 2650
C623
C608
6350
6340
TO OPTIONS
H YEL RT
1370
6210
6310
2790
2795
(EXTERIOR CAB)
L RNG
1020
1320
1020
1320
1020
1320
K RNG
6440 1
C669
2785 2
TO OPTIONS (HVAC)
GRADER HARNESS - 6540 3 A B A B A B
C631
C612
B B 2310 2300 B
A A 7030 A 6707303 4 WAY FLASHER To Starter "B" Terminal
Left Marker Fuse 10A
STROBE OR
BEACON
HARNESS - 6718873 1010
Right Marker Fuse 10A Signal Fuse 10A
1740 A
2 1 2740 B
C609
7020
7010
B A RNG = ORANGE
A C BLK = BLACK LETTER ACROSS
TO OPTIONS CAN SHIELD 9700 C
C632 (4 WAY FLASHER) C LBL = LIGHT BLUE CONNECTORS
ALARM SW POWER 1 1710 E To Mainframe
DBL = DARK BLUE A B
B A 2 2785 2780 D HORN TO HANDLE CONNECT0R Harness
CAN LOW B 9600 A LGN = LIGHT GREEN BATTERY FEED 1000-1999 RED, RED/WHT, RNG
C669
B A
C412
C601
(S/N 525111001 AND ABOVE) 1
7000 A
BEACON SWITCH 2
(PRINTED JULY 2005) C
6
V-0443 5 HAZARD SWITCH 3
7010 B
4
Printable Version Click Here 1130 6010
2 1
6430 5
4
3 X L
1180 3
RED = RED TO OPTIONS 1 2
WIRES CONNECT BY 4
6530
6
RNG = ORANGE (EXTERIOR CAB)
BLK = BLACK LETTER ACROSS 5
6 2750
E 6700 TO MAINFRAME
LBL = LIGHT BLUE CONNECTORS ACS SWITCH
2755
DBL = DARK BLUE A B D 2780 1
C670
LGN = LIGHT GREEN 4550 E
B A B 6540 2
DGN = DARK GREEN 3 R
YEL = YELLOW F 6440 2745
SOME CONNECTOR 4
PNK = PINK A
2755 4235 D
BODIES NOT SHOWN 5
WHT = WHITE 4275 C
6
BRN = BROWN FOR DRAWING CLARITY C
K
C488
TAN = TAN
PUR = PURPLE G
GRY = GRAY B
2730 J
1700 S
6400 L
6500 M
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1150 H
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL N
HYDRAULIC 4000-4999 LGN P
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK F
ACCESSORIES 7000-7999 WHT A
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR STANDARD ACCESSORY HARNESS - 6727468
TO OPTIONS
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH E
BEACON SWITCH
SWITCH
2770 V
1 2760 D M
2745 6420
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
2 3 4 7220
5 SWITCH
4 1
4 5 2
6530 3
TO OPTIONS 5 6 1730
6 2750 2 1
(EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
D 2780 6 5
4
C670
7310
B 6540 5
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A
C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411
(FRONT WIPER)
PLUG
6000 B C
C F
E
C667
7210 A
ACS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2
3 R 2735 B
4
2755 4235 D
5 4275
6 C
K
G
B
C488
2730 J
6400 L
6500 M
1150 H
6300 N
6600 P
TO EUR0. LIGHTS 4730 F
CONNECTOR 1140 A
1700 S
V-0443 (7-12-05)
Printed in U.S.A.
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. 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-2003-0199
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Description
Figure 60-10-1
P-26323
Figure 60-10-2 The fuse panel cover (Item 1) [Figure 60-10-3] & [Figure
60-10-5] has a decal inside to show the location and amp
ratings.
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
P-13848A
P-28903
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body. 1
If electrolyte is taken internally drink large quantities Disconnect the positive (+) battery cable (Item 1) [Figure
of water or milk! DO NOT induce vomiting. Get 60-20-2].
prompt medical attention.
W-2065-1296
Figure 60-20-3
Figure 60-20-1
P-48529
P-48527
Remove the battery from the loader [Figure 60-20-3].
Installation
WARNING
Figure 60-20-4
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Figure 60-20-5
P9588
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
3 1
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
P-31860
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Connect the end of the first cable (Item 1) to the positive
W-2065-1296 (+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-7] to the
positive terminal on the loader starter.
IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Figure 60-30-1
2 2
P-24416
1
4
1
3 P-24417
1
P-24543
Figure 60-30-3
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lb. (66 1 1
Nm) of force. 1
2 P-24542
Tighten the adjustment bolt and mounting bolt.
Lower the operator cab. (See Lowering The Operator The black cover has been removed to show alternator
Cab on Page 10-30-2.) rectifier/regulator assembly. The alternator contains field
coil diodes (low current) (Item 1) [Figure 60-30-2],
grounded heat sink (Item 2) [Figure 60-30-2] & [Figure
60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] &
[Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] &
[Figure 60-30-3], and four pair of large power diodes
(Item 1) [Figure 60-30-3] on the underside of the
rectifier.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
P-24547
Check the fuse for the alternator in the fuse panel. If fuse Connect the remote start tool to the loader. (See
is burned, find the cause and repair/replace. If fuse is in Procedure on Page 10-60-1.)
doubt, remove it and check for continuity.
Turn the engine on with the remote start tool and run at
Check the electrolyte level in the battery. Add distilled idle. With a voltmeter, check the voltage between the B+
water as needed. (Does not apply to maintenance free terminal and ground at the starter [Figure 60-30-5].
batteries.)
The voltage must be higher than 13.5 volts but lower than
Verify the charge of the battery. Make sure battery is fully 14.7 volts at 70F (Alternator Temperature).
charged.
If the voltage is higher that 14.7 volts, proceed to the
Disconnect the battery cables (negative first, then following high voltage test.
positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery If the voltage is lower than 13.5 volts, run the engine at
and cables with a sodium bicarbonate and water high idle and recheck voltage. If voltage is still below 13.5
solution. Put grease on the cable ends and battery volts, proceed with the following low voltage test.
terminals to prevent corrosion. Reconnect the cable to
the positive terminal.
1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test. (See Below.)
Figure 60-30-6 1
P-24568
1
P-34679 P-34678
P-24547
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] off the alternator. Check the continuity between the "S" terminal (Item
1) [Figure 60-30-8] and the positive (+) terminal on
Turn the remote start tool key to the ON position. the battery or starter terminal (Item 2) [Figure 60-30-
8]. There should be continuity. If no continuity,
Figure 60-30-7 replace wire harness.
P-34677
IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables
2
disconnected.
Battery cables are connected when using a fast
charger or when welding on the loader. (Remove 3
both cables from the battery.)
Extra battery cables (booster cables) are
P-24543
connected wrong.
I-2023-1285
Remove the adjustment bolt (Item 1) [Figure 60-30-10]
Figure 60-30-9 from the mounting bracket.
Figure 60-30-11
1
3
P-24547 2
Disconnect the red wire (Item 1) [Figure 60-30-9] from Remove the two screws (Item 1), nut/washer (Item 2)
the alternator which comes from the battery. and the plastic cover (Item 3) [Figure 60-30-11] from the
alternator.
Disconnect the wiring harness connector (Item 2) [Figure
60-30-9] from the alternator. NOTE: In the diode tests there should be continuity
in one direction only. Meter readings should
be different when probes are reversed. If the
diode being tested shows no continuity or
continuity in both directions, replace the
rectifier assembly.
Figure 60-30-12
1
1
P-24558
NOTE: Use the diode function (Item 1) [Figure 60-30- Reverse the probes to check the diode in the other
12] on the multimeter. direction.
1
2
P-24527
Figure 60-30-18
P-24524
P-24537
Touch the probes to the slip rings [Figure 60-30-20].
Use an ohmmeter to test the stator. The ohmmeter should read between 3.0-4.0 ohms.
Touch the probes to two of the bare stator wires [Figure If there is no continuity, replace the rotor.
60-30-18].
Move one of the probes to the third wire. Rotor Ground Test
Figure 60-30-19
P-24525
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-21].
Assembly
Figure 60-30-22
P-24557
Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-30-22]. Tighten to 72 + 14.5 ft.-lb. (98
+ 20 Nm) torque.
Checking
Figure 60-40-1
2
1
Bat
S
M
Cranking
Motor
P-34673
The battery must be at full charge. Hold-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the mounting bolt
The cable connections on the battery must be clean and (Item 2) [Figure 60-40-3] on the magnetic switch
tight. (solenoid). If there is no continuity replace the magnetic
switch (solenoid).
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1]. Figure 60-40-4
If the starter turns but does not turn the engine, the
starter drive has a defect. 2
Figure 60-40-2 1
P-34675
1
Bat
S
M
Cranking
P-34674
Motor
Figure 60-40-5
4
2
1
P-34385
Remove the negative (-) and positive (+) cables from the
battery.
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 7*
15
37
14
16 20
17
19 18
5 8
12
14
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
Figure 60-40-6
1
1
1
2
P-34596
Figure 60-40-7
1
1 2
4
3
3
N-00980
2 P-34600
Figure 60-40-11
3 2
1
P-34601
P-34599
Figure 60-40-14
1
3
2
2 2 4
P-34604
Figure 60-40-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Figure 60-40-17
N-00997
Figure 60-40-18
B-14458
Figure 60-40-21
N-00999
Check the commutator surface for burned spots which Replace the frame.
usually indicates an open-circuit, and correct it using
#400 sand paper. Figure 60-40-23
N-15005
S
M.T.
Starter B-14440
N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Clamp the starter in a vise. Using a 12 volt battery and
Replace the brush holder and yoke if the brushes need ammeter, connect the positive wire of the battery, and the
replacement. ammeter to the terminal [Figure 60-40-25]. Connect the
negative wire to the starter body. Using a jumper wire,
Check brush spring, for damage or rust. Replace as connect the S terminal to the main terminal.
needed.
The starter should show smooth and steady rotation
Brush Holder Insulation Test: Use a circuit tester, touch immediately after the pinion is engaged, it should draw
one probe to the positive brush holder plate and the other less than the specified current.
probe to the holder plate [Figure 60-40-24]. There
should be no continuity. If there is continuity, replace or Service Limit - 1150 Amp. Maximum @ Stall Condition
repair.
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
11 12
13 9 10
14
B-15551
REF.
DESCRIPTION FUNCTION / OPERATION
NO
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY / HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES*
GLOW PLUG COUNTDOWN relating to the loader monitoring system. COUTNTDOWN - Glow Plug time remaning
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time
to turn all lights off. HOLD FOR CODES - Press and hold two seonds 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 BASE or SHTDN ( SHUTDOWN) feature in HOURMETER/CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW (Option) Press to engage the HIGH FLOW auxiliary hydraulics. Press again to disengage.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXIMUM
FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast
movement of auxiliary functions (The farther you move the switch, the faster the movement of auxiliary
functions.) MAXIMUM FLOW allows for only fast movement.]
8 AUXILIARY PRESSURE RELEASE Press and hold for two seconds. The engine wil stop. Hydraulic pressure will be released in the rear auxiliary (If
so equipped) or right side front auxiliary circuit (If so equipped).
BOBCAT INTERBLOCK CONTROL SYSTEM (BICS)
16 18 20 22 24 26 28
29
B-15552B
ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
LIGHT
Advanced ON 3 Beeps * Error Error with Advanced Control System (ACS)
Control System
15
(ACS)
Attachment FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
16 Control
Device (ACD)
General ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
17 Warning ON 3 Beeps * WARNING Engine speed high or in shutdown.
FLASHING Continuous * SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
18 NOT USED
Fuel ON 3 Beeps * Error Fuel level sender system fault.
19 Level FLASHING 3 Beeps * WARNING Fuel level low.
Figure 60-50-3
1 3 ENTER PASSWARD
LANGUAGES
B-16165
4
6 The first screen you will see on your new loader will be as
5 B-15553B shown in [Figure 60-50-4].
1. Display Panel: The Display Panel is where all system NOTE: Your new loader (with Deluxe Instrument
setup, monitoring, troubleshooting, and error Panel) will have a Owner Password. Your
conditions are displayed. dealer will provide you with this password.
Change the password to one that you will
2. Function Icons: The lower left area of the Deluxe easily remember to prevent unauthorized use
Panel has the same Icons as the Standard Panel of your loader. (See ELECTRICAL SYSTEM
(See Right Panel (Standard) (With Key Switch) on SERVICE MANUAL.) Keep your password in a
Page 60-50-2.) These Icons are only visible when the safe place for future needs.
monitoring system has detected an error.
Start Engine: Use the Keypad to enter the numbers
3. Selection Buttons: The four Selection Buttons allow (letters) of your password and press the RUN / ENTER
you to select items from the Display Panel and scroll key (Item 5) [Figure 60-50-3].
through screens.
Press and hold the START Button (Item 6) [Figure 60-
4. Keypad: The numeric keypad (Item 4) [Figure 60-50- 50-3] until the engine starts.
3] has two functions:
Change Language: Press the Selection Button at the end
(a) To enter a number code (password) to allow of the arrow [Figure 60-50-4] to go to the next screen.
starting the engine (Keyless Start).
Figure 60-50-5
ENGLISH / INGLES
Use keypad to select languages
1. English
2. Espanol
3. Francaia
4. Deutsch
5. Italiano
6. Nederlands
EXIT
B-16160
Press
DISPLAY OPTIONS
Press
ADJUST CONTRAST
Press
UP OR DOWN
Arrow to
change contrast.
Press EXIT to
return to
previous level
menu.
B-16163/B16164/B-16161/B-16166/B-16167
Languages
TOOL/SETUP
LOADER FEATURES.
VITALS
Press SELECTION ARROW to select METRIC or
Enter Password on ENGLISH (M/E) readouts
Keypad
You can monitor real-tim readouts of:
Press Enter to Continue Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Re-enter new password. Hydraulic Ouil Temperature
Press Enter to Continue System Voltage
(See left.) Engine Speed
B-16163/B16164/B-16171/B-16172/B-16173/B-16174
17 OR
B-15993C
B-15993
Figure 60-50-12 1
1
N-20140
Figure 60-50-13
2
1
1
P-28360
Figure 60-50-16
N-20163
Figure 60-50-17
1
1 N-20142
N-20103
Figure 60-50-20
1
1
N-20144
Figure 60-50-21
1
2 N-20145
Figure 60-50-24
1
1
P-26255
With a flat blade screw driver, turn the light bulb Installation: Be careful to not overtighten the front
counterclockwise [Figure 60-50-24] and remove from accessory panel mounting bolts to prevent damage to the
the panel. plastic panel.
2
1
N-20147 P-26251
To install the bulbs, place them in the sockets and turn Pull the front accessory panel down and disconnect the
clockwise [Figure 60-50-25]. wire harness connector(s) (Items 1 & 2) [Figure 60-50-
27] from the switches.
Figure 60-60-1
1 1
N-19351
Figure 60-60-2
N-19349
Figure 60-60-4
P-48519
Figure 60-60-5
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
Identification Chart
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
Controller
41 50
41
31
J1 50
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
J1 50
1400 8000 X 9800 X X 3420 7200 3520 X
1 2 3 4 5 6 7 8 9 10
Harness Connector View
41 50
J2
4410 9410 4640 9340 3920 4500 X 3300 X X
1 2 3 4 5 6 7 8 9 10
V-172
WARNING 1
1
P-34842
Figure 60-70-1
1
1
N-19390
Remove the left front side panel (Item 1) [Figure 60-70- Loosen the two mounting bolts (Item 2) [Figure 60-70-3]
1]. of the system controller.
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-64327
Raise the operator cab. (See Raising The Operator Cab Figure 60-71-3
on Page 10-30-1.)
Figure 60-71-1
1
P-64297
P-64300 Remove the top controller mounting bolt (Item 1). Loosen
the two bottom controller mounting bolts (Item 2) [Figure
60-71-3] from the right side fender.
Remove the foot portion of the engine speed control
(Item 1) [Figure 60-71-1]. (See Removal And Installation Lift and remove the controller from the fender.
on Page 70-20-1.)
Installation: Tighten the mounting bolts to 12-14 ft.-lbs
(16-19 Nm) torque.
Figure 60-71-4
P-64325
Pull the controller out from the fender and loosen the
connector screw (Item 1) [Figure 60-71-4] to release the
connector.
Figure 60-71-5
P-64324
1
The wire location (Item 1) [Figure 60-71-7] is printed on
the connector, in the locations shown.
P-64325
Identification Chart
P-64295
P-64296
Display
Figure 60-80-1
B-15551B
CODE CODE
01-16 Air filter not connected 10-16 Hydraulic Charge filter not connected
01-17 Air filter plugged 10-17 Hydraulic Charge filter plugged
02-16 Hydraulic implement filter not connected 11-05 Seat bar sensor short to battery
02-17 Hydraulic implement filter plugged 11-06 Seat bar sensor short to ground
03-09 Battery voltage low 12-21 Front auxiliary PWM switch out of range high
03-10 Battery voltage high 12-22 Front auxiliary PWM switch out of range low
03-11 Battery voltage extremely high 12-23 Front auxiliary PWM switch not in neutral
03-14 Battery voltage extremely low
03-22 Battery voltage out of range low 13-05 Fuel shut-off hold solenoid short to battery
13-06 Fuel shot-off hold solenoid short to ground
04-09 Engine oil pressure low 13-07 Fuel shut-off solenoid open circuit
04-14 Engine oil pressure extremely low
04-15 Engine oil pressure shutdown level 14-02 Fuel shut-off pull solenoid error ON
04-21 Engine oil pressure out of range high 14-03 Fuel shut-off pull solenoid error OFF
04-22 Engine oil pressure out of range low
15-02 Traction lock pull solenoid error ON
05-09 Hydraulic charge pressure low 15-03 Traction lock pull solenoid error OFF
05-10 Hydraulic charge pressure high
05-11 Hydraulic charge pressure extremely high 16-05 Traction lock hold solenoid short to battery
05-14 Hydraulic charge pressure extremely low 16-06 Traction lock hold solenoid short to ground
05-15 Hydraulic charge pressure shutdown level 16-07 Traction lock hold solenoid open circuit
05-21 Hydraulic charge pressure out of range high
05-22 Hydraulic charge pressure of range low 17-05 Hydraulic lock valve solenoid short to battery
06-10 Engine speed high 17-06 Hydraulic lock valve solenoid short to ground
06-11 Engine speed extremely high 17-07 Hydraulic lock valve solenoid open circuit
06-13 Engine speed no signal
06-15 Engine speed shutdown level 18-05 Spool Lock Solenoid short to battery
06-18 Engine speed out of range 18-06 Spool Lock Solenoid short to ground
07-10 Hydraulic oil temperature high 18-07 Spool Lock Solenoid open circuit
07-11 Hydraulic oil temperature extremely high
07-15 Hydraulic oil temperature shutdown level 19-02 Bucket position solenoid error ON
07-21 Hydraulic oil temperature out of range high 19-03 Bucket position solenoid error OFF
08-10 Engine coolant temperature high 20-03 Two-speed solenoid error OFF
08-15 Engine coolant temperature shutdown level 21-02 Glow plug error ON
08-21 Engine coolant temperature out of range high 21-03 Glow plug error OFF
08-22 Engine coolant temperature out of range low
22-02 Starter error ON
09-09 Fuel level low 22-03 Starter error OFF
09-21 Fuel level out of range high
09-22 Fuel level out of range low 23-02 Rear base solenoid error ON
23-03 Rear base solenoid error OFF
CODE CODE
32-57 Lift actuator reduced performance
24-02 Rear rod solenoid error ON 32-58 Tilt actuator reduced performance
24-03 Rear rod solenoid error OFF 32-59 Lift actuator wrong direction
32-60 Tilt actuator wrong direction
25-02 Rear auxiliary relief solenoid error ON 32-61 Handle lock short to ground
25-03 Rear auxiliary relief solenoid error Off 32-62 Handle lock short to battery
32-63 Pedal lock short to ground
26-02 Front base solenoid error ON 32-64 Pedal lock short to battery
26-03 Front base solenoid error OFF 32-65 Sensor supply voltage out of range
32-66 Battery voltage out of range
27-02 Front rod solenoid error ON 32-67 Switch flipped while operating
27-03 Front rod solenoid error OFF 32-68 Lift handle information error
32-69 Control pattern switch flipped while operating
28-02 Diverter solenoid error ON 32-70 Right drive handle short to ground
28-03 Diverter solenoid error OFF 32-71 Right drive handle short to battery
32-75 Interrupted unswitched power
29-02 High flow solenoid error ON
29-03 High flow solenoid error OFF 33-23 Main Controller (Bobcat Controller) not
programmed
CODE CODE
38-04 No communication from joystick controller 38-53 Left forward drive solenoid error OFF
38-05 Left joystick X axis not in neutral 38-54 Left reverse drive solenoid error OFF
38-06 Right joystick X axis not in neutral 38-55 Right forward drive solenoid error OFF
38-07 Left joystick Y as not in neutral 38-56 Right reverse drive solenoid error OFF
38-08 Right joystick Y axis not in neutral 38-57 Front right extend steering solenoid error OFF
38-09 Control pattern switch - Short to Battery or Ground 38-58 Front right retract steering solenoid error OFF
38-11 Lift actuator not in neutral 38-59 Front left extend steering solenoid error OFF
38-12 Tilt actuator not in neutral 38-60 Front left retract steering solenoid error OFF
38-13 Lift actuator fault 38-61 Rear right extend steering solenoid error OFF
38-14 Tilt actuator fault 38-62 Rear right retract steering solenoid error OFF
38-15 Right wheel speed fault 38-63 Rear left extend steering solenoid error OFF
38-16 Left wheel speed fault 38-64 Rear left retract steering solenoid error OFF
38-17 Tilt actuator reduced performance 38-65 Steering pressure solenoid error OFF
38-18 Lift actuator reduced performance 38-66 Back-up alarm error OFF
38-19 Left joystick X axis out of range high 38-67 No communication from Bobcat controller
38-20 Right joystick X axis out of range low 38-68 Wheel angles (alignment) not calibrated
38-21 Left joystick Y axis out of range high 38-69 Lift & tilt actuators not calibrated
38-22 Right joystick Y axis out of range high 38-70 Interrupted power
38-23 Front right steering sensor out of range high 38-71 Battery out of range
38-24 Front left steering sensor out of range high 38-72 Drive pump not calibrated
38-25 Rear right steering sensor out of range high 38-73 Steering mode / drive mode switch flipped while
operating
38-26 Rear left steering sensor out of range high 38-74 Uncommanded right wheel speed error ON
38-27 Lift actuator out of range high 38-75 Uncommanded left wheel speed error ON
38-28 Tilt actuator out of range high 38-76 Undercurrent steer pressure solenoid
38-29 Left joystick X axis out of range low 38-77 Undercurrent front right extend steer solenoid
38-30 Right joystick X axis out of range low 38-78 Undercurrent front right retract steer solenoid
38-31 Left joystick Y axis out of range low 38-79 Undercurrent front left extend steer solenoid
38-32 Right joystick Y axis out of range low 38-80 Undercurrent front left retract steer solenoid
38-33 Front right steering sensor out of range low 38-81 Undercurrent rear right extend steer solenoid
38-34 Front left steering sensor out of range low 38-82 Undercurrent rear right retract steer solenoid
38-35 Rear right steering sensor out of range low 38-83 Undercurrent rear left extend steer solenoid
38-36 Rear left steering sensor out of range low 38-84 Undercurrent rear left retract steer solenoid
38-37 5 volt sensor supply 1 out of range low 38-85 5 Volt sensor supply 1 out of range high
38-38 5 volt sensor supply 2 out of range low 38-86 5 Volt sensor supply 2 out of range high
38-39 Lift actuator short to ground / out of range low 38-87 Front right wheel blocked (steering mechanical failure)
38-40 Tilt actuator short to ground / out of range low 38-88 Front left wheel blocked (steering mechanical failure)
38-41 Tilt actuator wrong direction 38-89 Rear right wheel blocked (steering mechanical failure)
38-42 Lift actuator wrong direction 38-90 Rear left steering error
38-43 Left forward drive solenoid error ON 38-91 Right speed sensor missing pulses
38-44 Left reverse drive solenoid error ON 38-92 Left speed sensor missing pulses
38-45 Right forward drive solenoid error ON 38-93 Unresponsive right speed sensor
38-46 Right reverse drive solenoid error ON 38-94 Unresponsive left speed sensor
38-47 Front right steering solenoid error ON 38-95 Left speed sensor reverse direction
38-48 Front left steering solenoid error ON 38-96 Right speed sensor reverse direction
38-49 Rear right steering solenoid error ON 38-98 Controller in drive calibration mode
38-50 Rear left steering solenoid error ON 38-99 Controller in wheel position calibration mode.
38-51 Steering pressure solenoid error ON
38-52 Back-up alarm error ON
CODE CODE
39-04 Left joystick no communication to Bobcat 50-38 Front reverse error OFF
controller
50-39 Rear PWM error on
40-04 Right joystick no communication to Bobcat 50-41 Rear PWM no signal
controller
50-42 Rear PWM not calibrate
44-02 Horn error ON 50-43 Rear forward error ON
44-03 Horn error OFF 50-44 Rear forward error OFF
50-45 Rear reverse error ON
45-02 Right blinker error ON 50-46 Rear reverse error OFF
45-03 Right blinker error OFF 50-47 Two speed error OFF
50-48 Two speed error ON
46-02 Left blinker error ON 50-49 Brake solenoid error ON
46-03 Left blinker error OFF 50-50 Brake solenoid error OFF
50-51 Brake solenoid no signal
47-21 8 volt sensor supply out of range high 50-52 Brake light relay error ON
47-22 8 volt sensor supply out of range low 50-53 Brake light relay error OFF
50-54 Differential lock error ON
48-02 Front light relay error ON 50-55 Differential lock error OFF
48-03 Front light relay error OFF 50-56 CAN communications fault
50-57 Drive controller not calibrated
49-02 Rear light relay error ON
49-03 Rear light relay error OFF 50-59 Front speed sensor missing pulses
50-60 Rear speed sensor missing pulses
50-01 Travel pedal out of range high
50-02 Travel pedal out of range low
50-03 Travel pedal not calibrated 50-63 Front angle sensor not calibrated
50-04 Brake Pedal out of range high
50-05 Brake Pedal out of range low
50-06 Brake Pedal not calibrated 50-66 Rear angle sensor not calibrated
50-07 Drive selector switch no signal 50-67 Front forward no signal
50-08 Drive selector switch multiple inputs 50-68 Front reverse no signal
50-09 Front wheel speed sensor out of range high 50-69 Rear forward no signal
50-10 Front wheel speed sensor out of range low 50-70 Rear reverse no signal
50-11 Rear wheel speed sensor out of range high 50-99 In calibration mode
50-12 Rear wheel speed sensor out of range low
50-13 Front wheel speed sensor no signal 60-21 Rear auxiliary control out of range high
50-14 Rear wheel speed sensor no signal 60-22 Rear auxiliary control out of range low
50-15 Dual wheel speed sensor fault 60-23 Rear auxiliary control not returning to neutral
50-24 Battery voltage over voltage
50-27 5V sensor #1 over voltage 62-04 Load moment monitoring in error
50-28 5V sensor #1 under voltage
50-29 5V sensor #2 over voltage 63-05 Short to battery
50-30 5V sensor #2 under voltage 63-06 Short to ground
50-31 Front PWM error on
50-33 Front PWM no signal 64-02 Switched power relay error ON
50-34 Front PWM not calibrate 64-03 Switched power relay error OFF
50-35 Front forward error ON
50-36 Front forward error OFF
50-37 Front reverse error ON
CODE CODE
65-02 Workgroup lockout error on 75-74 Left wheel speed uncommanded motion
65-03 Workgroup lockout error off 75-75 Right wheel speed uncommanded motion
65-05 Workgroup lockout short to battery 75-76 No communication from ACS Controller
65-06 Workgroup lockout short to ground 75-77 Left speed sensor out of range high
65-07 Workgroup lockout open circuit 75-78 Right speed sensor out of range high
75-79 Left speed sensor out of range low
66-05 Pilot pressure short to battery 75-80 Right speed sensor out of range low
66-06 Pilot pressure short to ground 75-85 5 volt sensor supply 1 out of range high
75-91 Left swash plate sensor reversed
74-72 Bobcat controller in boot code 75-92 Right swash plate sensor reversed
74-73 Left hand panel system RX error 75-93 Unresponsive right speed sensor
75-94 Unresponsive left speed sensor
75-04 No communication from Drive Controller 75-95 Left speed sensor reversed direction
75-05 Left joystick X-Axis not in neutral 75-96 Left speed sensor reversed direction
75-07 Left joystick Y-Axis not in neutral 75-98 Controller in Calibration Mode
75-08 Right joystick Y-Axis not in neutral
75-09 ISO/H pattern switch short to ground or battery 76-73 Left display panel RX error
75-17 Left swash plate not in neutral
75-18 Right swash plate not in neutral 77-48 Key Switch - Multiple
75-19 Left joystick X-Axis out of range high
75-21 Left joystick Y-Axis out of range high 78-74 Door/Transport Lock - Open/Active
75-22 Right joystick Y-Axis out of range high
75-27 Left swash plate out of position
75-28 Right swash plate out of position
75-29 Left joystick X-Axis out of range low
75-31 Left joystick Y-Axis out of range low
75-32 Right joystick Y-Axis out of range low
75-37 5 volt sensor supply 1 out of range low
75-39 Left swash plate sensor out of range high
75-40 Left swash plate sensor out of range low
75-41 Right swash plate sensor out of range high
75-42 Right swash plate sensor out of range low
75-43 Left forward drive solenoid error ON
75-44 Left reverse drive solenoid error ON
75-45 Right forward drive solenoid error ON
75-46 Right reverse drive solenoid error ON
75-52 Backup alarm error ON
75-53 Left forward drive solenoid error OFF
75-54 Left reverse drive solenoid error OFF
75-55 Right forward drive solenoid error OFF
75-56 Right reverse drive solenoid error OFF
75-66 Backup alarm error OFF
75-67 No communication from Bobcat Controller
75-69 Battery voltage out of range high
75-70 Interrupted power (also occurs after software
update)
75-71 Battery voltage out of range low
75-72 Drive pump not calibrated
75-73 ISO/H pattern switch flipped while operating
CODE CODE
80-02 ACD output A error ON
80-03 ACD output A error OFF
WARNING
lock should be engaged.
2. Raise the Seat Bar fully. All four BICS lights (Items
1, 2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE
LOADER, SEAT BAR, LIFT & TILT VALVE and
TRACTION*] on left instrument panel should be OFF
[Figure 60-90-1]
S175, S185 Bobcat Loader
60-90-1 Service Manual
BICS SYSTEM (CONT'D)
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
13. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.
Troubleshooting Chart
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
SOLUTION SUGGESTIONS
1. Refer to BICS troubleshooting guide.(See Troubleshooting Guide on Page 60-90-4.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
Troubleshooting Guide
2 Seat Bar is Seat Bar is up. Lift and tilt 2 11-05 Seat Bar sensor circuit shorted to battery
down. functions will voltage*.
not operate. 3 11-06 Seat Bar sensor circuit shorted to ground.
3 Control valve Control valve Lift, tilt and 1 17-07 Valve output circuit is open.
can be used. cannot be used. traction 2 17-05 Valve output circuit shorted to battery voltage*.
functions will 3 17-06 Valve output circuit shorted to ground.
not operate.
3 17-06 Controller not grounded or intermittent ground.
4 Loader can be Loader cannot Loader cannot 1 16-07 Traction lock hold solenoid circuit is open.
moved forward & be moved be moved 2 16-05 Traction lock hold solenoid circuit shorted to
backward forward and forward and battery voltage*.
backward. backward. 3 16-06 Traction lock hold solenoid circuit shorted to
ground.
5 15-02 Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be OFF).
6 15-03 Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
SEAT BAR LIFT & TILT VALVE TRACTION 03-09
Continuous System voltage low
Flashing 03-10 System voltage high
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and
both battery connections.
ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay.
*Normal BICS operating voltage is less than the electrical system voltage.
Troubleshooting Chart
WARNING
The following troubleshooting chart 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 #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS sensor tester MEL 1428 with seat bar adapter MEL1567 to check
sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
Test
Figure 60-100-1
1
P-4698
Figure 60-100-4
Use Sensor Tester (MEL1428) and seat bar sensor
tester adatper (MEL1567) for the following procedure:
Figure 60-100-2
P-4699
1
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 BICS Circuit Test on Page 60-100-5.)
Figure 60-100-5
2
N-19224
N-19219
Figure 60-100-7
2
1
3
N-19383
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Figure 60-100-8
3
1
1
P-4703
Figure 60-100-10
N-18409
Figure 60-100-11
P-4699
Troubleshooting Chart
WARNING
The following troubleshooting chart 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 CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock. 8, 9, 10, 11
Description Of The Control System Fasten the seat belt, disengage the parking brake button,
press the PRESS TO OPERATE LOADER Button (Item
Figure 60-110-1 1) [Figure 60-110-1] and raise the Seat Bar fully. Move
the steering levers slowly forward and backward. The
TRACTION lock (Item 4) [Figure 60-110-1] should be
engaged. Lower the Seat Bar. Press the PRESS TO
OPERATE LOADER Button (Item 1) [Figure 60-110-1].
Figure 60-110-2
1 2 3 4
B-15551G
P-48521
Inspecting
Figure 60-110-3
P-4712
P-34256
Figure 60-110-4
N-19079
Figure 60-110-7
Remove the bracket (Item 1) [Figure 60-110-4] from the
chaincase cover.
1
Installation: Tighten the mounting bolts to 25-28 ft.-lb. 2
(34-38 Nm) torque.
Figure 60-110-5
P7926
1
Remove and inspect the compression spring (Item 1)
and spring cap washer (Item 2) [Figure 60-110-7] for
wear or damage. Replace if necessary. The spring may
also stay with the shaft when the electric solenoid and
bracket are removed from the chaincase.
Solenoid Removal And Installation (Cont'd) The part number listed below will be needed to do the
following procedure:
Figure 60-110-8
P/N 6633583 - Polyurethane
2 Raise the loader lift arms and install an approved lift arm
3 support device.(See Installing Lift Arm Support Device on
Page 10-20-1.)
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
P-7964
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Remove the shaft mounting bolt (Item 1), spring from the
assembly shaft (Item 2). Remove the wedge (Item 3) Raise the operator cab. (See Raising The Operator Cab
[Figure 60-110-8] and inspect all parts for damage or on Page 10-30-1.)
wear. Replace if necessary.
Remove the engine speed control. (See Removal And
Installation: Thoroughly clean and dry the shaft Installation on Page 70-20-1.)
mounting bolt (Item 1), the shaft (Item 2) and wedge
(Item 3) [Figure 60-110-8]. Use LOCTITE #242 when Remove the control panel from the loader. (See Removal
assembling these parts to the traction lock assembly. and Installation on Page 50-100-1.)
Guide Removal
Figure 60-110-9
1
1
P11330
Figure 60-110-12
Remove the center chaincase cover [Figure 60-110-9]
(See Center Cover Removal And Installation on Page 40-
30-3.) 1
3
Figure 60-110-10
1
2
2
P11332
3
2
N-19106 N-19105
Apply a bead of polyurethane (P/N 6633583) on the Do not tighten at this time.
traction lock guides and bolts [Figure 60-110-13].
Figure 60-110-16
Figure 60-110-14
1
2
3
2
4 4
1
P11337
P11334
NOTE: Bolt (Item 3) [Figure 60-110-14] & [Figure 60- After the bolts have been tightened recheck to make sure
110-15] represents the rear of the chaincase the shaft assembly is moving freely in the guides.
cover.
Remove the wedge assembly (Item 1) [Figure 60-110-
Install and tighten the two bolts (Item 4) [Figure 60-110- 16].
14].
NOTE: The wedge assembly must slide freely in the
grooves of the guides. Tighten the four guide
bolts to 90-100 ft.-lb. (123-135 Nm) torque.
Figure 60-110-17
1
2
1
2
N-19109
Remove the two bolts (Item 1) and remove the electric Install the gasket (Item 2) [Figure 60-110-19].
solenoid (Item 2) [Figure 60-110-17] from the center
chaincase cover.
Figure 60-110-18
1
2
N-19079
Components Identification
2
Figure 60-120-1
1
11
2
P-21938 P-21939
The Advanced Control System (ACS) is a selectable foot/ NOTE: The calibration procedure must be followed
hand control system. when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
The ACS system allows the operator to quickly switch Calibration Procedure on Page 60-120-16.)
between foot and hand control modes.
Figure 60-120-3
Control Handle (Item 1) [Figure 60-120-1].
1
P-24203
Figure 60-120-4
P-21769
1
ACS error indicator (Item 1) [Figure 60-120-5].
P-21767
NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
ACS Controller (Item 1) [Figure 60-120-4]. (See DIAGNOSTICS SERVICE CODES on
Page 60-80-1.)
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Procedure on Page 60-120-16.)
Troubleshooting Guide
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 luminate 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 luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature
Attachment Two Speed Glow Plugs Seat Belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure
To see what error occurred. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.)
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
J3
J1 J2
P-21843
Figure 60-120-6
P-21840
Figure 60-120-7
P-21843
Figure 60-120-9
2
3
1
1
P13733
3-Terminal - Green
1
1
P13725 P13732
Figure 60-120-12
1
3
2
P13735
1
2
Figure 60-120-15
NOTE: Switch handle can be removed and installed
while in loader.
Figure 60-120-13 1
P13725 P13732
P13725 P13732
Figure 60-120-16
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
P13735 3 & 4) [Figure 60-120-18] from the loader wiring harness
connectors.
Using a pointed tool, press down on the tab (Item 1) Figure 60-120-19
[Figure 60-120-16] and pull the wire from the connector.
Figure 60-120-17
2 2
N-22783
2
N-17779 Roll the pistol grip handle cover (Item 1) [Figure 60-120-
19] down.
Disconnect the right switch handle connectors (Items 1 & Using a small screwdriver, lift the handle tabs (Item 2)
2) [Figure 60-120-17] from the loader wiring harness [Figure 60-120-19] and slightly rotate the switch handle.
connectors.
Figure 60-120-20
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-120-20] from the control lever. The switch handle comes with a 6 inch piece of heat
shrink tube slid over the end of the wires. Remove the
Cut the wires (Item 2) [Figure 60-120-20] below the heat shrink tube from the end of the wires before routing
switch handle and remove switch handle. the harness through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 120-22] to keep the harness small enough to route
switch handle and harness up through the top through the control lever tube.
of the lever tube.
Figure 60-120-21
P-24234
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700A 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 60-120-25
3 1
2
P13735
3 1
N-17772
2
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
N-18940
Figure 60-120-30
N-18912
Figure 60-120-32
1
N-17742 N-17741
Figure 60-120-33
P-21878A
1
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-120-35].
Disconnect the harness connector (Item 1) [Figure 60-
120-33] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 35-40 ft.-lb. (47-54 Nm) lubed
Disconnect the harness connector (Item 2) [Figure 60- torque.
120-33] from the handle lock solenoid connector.
Figure 60-120-36
Figure 60-120-34
1 P-21789
P-21832
Figure 60-120-37
1 3
2
P-21802
1 1
P-21801
Calibration Procedure
Figure 60-120-43
1
Stroke Both Handles Fully In and Hold Them
P-24182
B-16626
With the seat bar down, turn the ignition key ON (keyless
panel press RUN/ENTER) [Figure 60-120-41].
2 2
1
1
B-16628
Push the PRESS TO OPERATE button (Item 1) [Figure Fully move both handles out toward the cab side screens
60-120-44] to begin calibration. and hold for one second (Item 2) [Figure 60-120-45].
NOTE: The ACS icon will light up and if you listen Allow both handles to return to neutral.
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the Figure 60-120-46
ignition key is cycled or the loader is started
and a function is operated.
Fully press the heel of the lift and tilt pedals (Item 2)
[Figure 60-120-46] down and hold for one second.
Calibration is complete.
Figure 60-120-47
1
P-24271
1
P-24269
The wire connector (Item 1) [Figure 60-120-49] can be
removed from the sensor wires, using the following
Remove the two bolts (Item 1) [Figure 60-120-47] from procedure:
the end of the foot sensor.
Figure 60-120-50
Installation: Tighten the bolts to 90 in.-lb. (10,2 Nm)
torque. Apply LOCTITE 242 to the threads.
Figure 60-120-48 1
1
1
4
P-24272 P-24273
P-24273
3
2
Remove the wedge (Item 1) [Figure 60-120-50] from the
1 connector.
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-120-48].
1
2
1 3
2
P-21939
Figure 60-120-52
2
P-21790
1
P-21938
Figure 60-120-55
1 1
P-21800 P-21801
Figure 60-120-56
1 3
2
P-21802
1 - Terminal - Black
2 - Terminal - Open
3 - Terminal - Black
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
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
The ACD (Attachment Control Device), automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab
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.
3 5
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6
on the High Flow valve.
RIGHT HAND
17 18
2 1
8
10 1. Front Aux.
2. Front Aux.
3. Auxiliary Detent
11 8. Right Ski (Up) 3
9
9. Right Ski (Down)
16 10. Right Blink
11. Left Blink
16. Float (Yellow in Color)
17. Future Function
P-24802
18. Future Function
P-28316
LEFT HAND
19 20
4 5
4. Rear Aux. (Side Shift
5. Rear Aux. (Side Shift)
12
6. Left Skit (Up)
6 7. Left Ski (Down)
12. Two-Speed (High)
13. Two-Speed (Low)
13 7
14. Horn
15. Inching Control
14
15 (Grey in Color)
19. Future Function
20. Future Function
P-24820
P-28317
Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader. 1
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6
on the High Flow valve.
Adjustment
Figure 60-140-1
2 P-48666
Turn the RPM sensor and the jam nut out from the
P-48665 flywheel. Set a clearance of .050 inch (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-140-2].
When reinstalling the RPM sensor, turn the rpm sensor
(Item 1) [Figure 60-140-1] in until it makes contact with NOTE: New RPM sensors have a plastic tip which is
the engine flywheel. used as a gauge during installation. The
plastic tip is designed to come off after the
Turn the jam nut (Item 2) [Figure 60-140-1] until it engine is started.
contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the RPM sensor when the
sensor is turned back out for adjustment.
Figure 60-150-1
1 2
P16119
Pass Fail
Pass Fail
Adapter
Pass Fail [Figure 60-160-3] If the Actuator Test fails after the
hydraulic oil is warmed, go to the next step and loosen
the bolts that mount the actuator to the control valve.
Column 1 Column 2 Loosen the bolts just enough so the actuator can be
Probable Cause Probable Cause moved slightly up/down or side/side.
1 - Misaligned Assembly 1 - Actuator
Rerun the Actuator Test, if the test passes, check the
2 - Adapter / Pin 2 - End Cap / Center Spring
3 - Wire Harness following probable causes in Column 1 [Figure 60-160-
3 - Spool
4 - Controller 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
Rerun the test to verify.
[Figure 60-160-2] If the initial Actuator Test results in a
fail mode due to a slow return to neutral, follow the 1. Actuator and spool misalignment. Re-tighten the two
troubleshooting tree to pinpoint the probable cause. bolts evenly, turn the first bolt one turn, then turn the
other bolt one turn until both bolts are tight.
Figure 60-160-4
Thickness Difference
on Opposite Sides
Must be Within
0.004 (0.102mm)
P-54928B
Figure 60-160-6
P-26475
1
Figure 60-160-9
P-45240
Figure 60-160-7
Turn the key (Item 1) [Figure 60-160-8] to the RUN
position or press the RUN/ENTER button (Item 1)
[Figure 60-160-9] for power, without starting the loader.
B-19874
P-28063
1 Figure 60-160-11
P-26477A
Figure 60-160-12
1
1 P-45238
Figure 60-160-15
Figure 60-160-13
1 B-19873
P-26476
P-26480
Figure 60-160-16
1
P-26477A
1
Press the PRESS TO OPERATE LOADER Button (Item
P-26477A 1) [Figure 60-160-18] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-16] while holding the left joystick in
position. Figure 60-160-19
Figure 60-160-17
B-19873
P-26474
Figure 60-160-20
2 75-98
3
P-34548
1
Move the throttle (Item 1) [Figure 60-160-22] to high idle.
P-26477A
NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift
Press the PRESS TO OPERATE LOADER Button (Item the seat bar, or return the joystick to the
1) [Figure 60-160-20]. neutral position.
Three audible beeps will sound and the error code (Item The calibration procedure will stop.
2) (75-98) will be displayed if the operator presses the
HOLD FOR CODES (LIGHTS) switch (Item 3) [Figure To return to calibration mode, the operator
60-160-20]. must start the complete procedure from the
beginning.
Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.
WARNING
Figure 60-160-21
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
1
P-45238
Figure 60-160-23 1 2
B-19873
P-64321
Figure 60-160-25
B-19873
P-26483
Figure 60-160-30
1
P-24826
Turn the Key On Lift the seat bar, high enough for the PRESS TO
OPERATE light (Item 2) [Figure 60-160-29] to go OFF.
or
Lower the seat bar.
Press the RUN/ENTER
B-16626
With the seat bar down, turn the ignition key ON (keyless
panel press RUN/ENTER) [Figure 60-160-28].
2 2
1
1
B-16628
Push the PRESS TO OPERATE button (Item 1) [Figure Fully move both handles out toward the cab side screens
60-160-31] to begin calibration. and hold for one second (Item 2) [Figure 60-160-32].
NOTE: The ACS icon will light up and if you listen Allow both handles to return to neutral.
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the Figure 60-160-33
ignition key is cycled or the loader is started
and a function is operated.
Fully press the heel of the lift and tilt pedals (Item 2)
[Figure 60-160-33] down and hold for one second.
Calibration is complete.
Figure 60-170-1
1
P-28302
P-64765
The tools listed will be needed to do the following
procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
170-1] is used by the loaders controllers to sense if the MEL1609-Wheel Speed Sensor Test Harness
drive motor is rotating. The end of the sensor is magnetic [Figure 60-170-2]
and counts the magnetic pulses as a rotating disc
attached to the motor carrier shaft rotates by the sensor MEL1563-Remote Start Tool
end. Multimeter
The speed sensor is sealed with an o-ring (Item 1) Raise the lift arms and install an approved lift arm
[Figure 60-170-1] to keep hydraulic oil inside the motor support device. (See Installing Lift Arm Support Device
carrier and dirt out. on Page 10-20-1.)
Testing (Contd)
Figure 60-170-3
3
2
1
2
1
P-64976
Locate the speed sensor (Item 1) [Figure 60-170-3] on Turn the remote start key to ON position without starting
the top of the right or left hydrostatic motor carrier. the loader.
Remove the transmission cover screw (Item 2) [Figure Take a voltage reading, with the multimeter, at the speed
60-170-3], to loosen the connector clamp. sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-170-4].
Installation: Tighten screw to 15-20 ft.-lb. (20-27 Nm)
torque. The voltage should be approximately 5 volts.
Disconnect the speed sensor wire connector (Item 3) Repeat the procedure for the opposite side speed
[Figure 60-170-3] from the loader harness wire sensor. (If needed.)
connector.
P-64764
P-64762
Figure 60-170-6
1 P-64765
P-64762
Figure 60-170-9
1
1
P-26292
Figure 60-170-10
1
2
P-26295
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-170-10].
Wire Code
1 Red
2 White
3 Black
4 Blue
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 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
Chart (Contd)
WARNING P-4072
Never work on a machine with the lift arms up unless Pull the speed control away from the loader frame and
the lift arms are secured by an approved lift arm disconnect the speed control rod (Item 1) [Figure 70-20-
support device. Failure to use an approved lift arm 2] from the control.
support device can allow the lift arms or attachment
to fall and cause injury or death. Installation: Be sure to install the control rod in the
W-2059-0598 bottom hole of the speed control.
1
1 1
2
N-18878 P-34156
Raise the lift arms and install an approved lift arm device. Installation: Install the stop bracket (Item 1) [Figure 70-
(See Installing Lift Arm Support Device on Page 10-20- 20-3] in the same location. It is necessary for the front
1.) and rear stop on the bracket to be located correctly.
Raise the operator cab. (See Raising The Operator Cab Reverse the removal procedure to install the engine
on Page 10-30-1.) speed control.
Figure 70-30-1
3
3
2
1
P-48866
Remove the exhaust pipe clamp (Item 1) from the muffler (Item 2) [Figure 70-30-1].
Remove both muffler mounting bolts (Item 3) [Figure 70-30-1] from the muffler.
Installation: Tighten the muffler mounting bolts to 25-28 ft.-lb. (34-38 Nm) torque.
Figure 70-40-1
1
1
2
P-28915
2
Remove the lower mounting bolt (Item 1) and engine
P-34449 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Installation: Tighten the three mounting bolts to 25-28
70-40-1] from the air cleaner sensor on the air cleaner. ft.-lb. (34-38 Nm) torque.
Loosen the clamp (Item 2) [Figure 70-40-1] from the Remove the air cleaner from the engine compartment.
hose on the engine manifold.
Reverse the removal procedure to install the air cleaner.
Figure 70-40-2
2
1
P-34450
WARNING P-48551
1
P-45245 P-48242
Loosen the radiator cap (Item 1) [Figure 70-50-1] from Remove the two sta-straps (Item 1) [Figure 70-50-3]
the pressurized expansion tank. holding the pressurized expansion tank fill hose (Item 3)
[Figure 70-50-4].
Figure 70-50-4
1
1
3
2
2
P-48570
P-48554
Remove the pressurized expansion tank (Item 2) with the Figure 70-50-7
pressurized expansion tank fill hose (Item 3) attached.
[Figure 70-50-4].
Figure 70-50-5
3
2
1
P-48553
Figure 70-50-8
P-48841
Figure 70-60-1
1
P0581
1 3
4 2
1
N-00303
1
2
WARNING
N-19188
Figure 70-60-7
1
1
N-19169
Raise the lift arms and install an approved lift arm device. Disconnect the breather hose (Item 1) [Figure 70-60-7]
(See Installing Lift Arm Support Device on Page 10-20- from the electrical harnesses on the loader frame.
1.)
Installation: Make sure the breather hose is unrestricted
Raise the operator cab. (See Raising The Operator Cab when routing.
on Page 10-30-1.)
Remove the fan drive belt (Item 2) [Figure 70-60-7] from
Remove the left gas cylinder mounting bracket (Item 1) the pulley on the blower fan.
[Figure 70-60-5]. (See Gas Cylinder Removal And
Installation on Page 50-20-1.) NOTE: When checking the fan gearbox oil level, be
sure the level does not go above the top of the
shaft in the gearbox [Figure 70-60-7]. Use a
light colored 90W gear lube if the level is low.
S175, S185 Bobcat Loader
70-60-2 Service Manual
COOLING FAN (CONT'D) Figure 70-60-10
Figure 70-60-8
4
1
P13920
3 1 Lower the blower fan from the housing until it rests on the
steering linkage plate [Figure 70-60-10].
N-19376
Figure 70-60-11
Figure 70-60-9
N-19378
P-4301
Remove the strip of sealant along the top of the blower
housing [Figure 70-60-11].
Remove the two mounting bolts (Item 1) [Figure 70-60-
8] and the two spacer tubes (Item 2) [Figure 70-60-8] Installation: Use R.T.V. sealant to reseal the blower
from the blower fan. housing.
Remove the rear mounting bolt (Item 3) [Figure 70-60- Loosen the electrical harnesses from the frame of the
8]. loader.
Remove the front mounting bolt (Item 4) [Figure 70-60- Slide the blower fan and housing forward and remove
8]. both from the loader.
Figure 70-60-14
1
2
1
P-43448
1
CD-9952
Figure 70-60-15
CD-8954
Figure 70-60-16
1
CD-9954
1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.)
7. Long Key 1
8. Shaft (Short)
9. Short Key
10. Long Housing 18
11. Nut
12. Gear
13. Washer 1 6
14. Screw 2
3
15. Square Shim 4
7 4
16. Short Housing 5
17. Bolt
18. Snap Ring (Large)
19. Cap 8
20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug 22
4
12
13 9
15
14 *16
10
21
11
17
12
20
13
14
18
19
TS-1002A
Gearbox Disassembly
Figure 70-60-18
Part Number
2 Tag
P2983
3
1 Remove the four mounting bolts and the part number tag
P-37891 [Figure 70-60-19].
1.
2.
Complete Assembly
Long Housing Assembly
WARNING
3. Long Housing
4. Short Housing Assembly (See Note Below) AVOID INJURY OR DEATH
5. Internal Parts Wear safety goggles to prevent eye injury when
drilling or grinding.
NOTE: The short housing is only available as an W-2108-1186
assembly. (See Gearbox Parts Identification
on Page 70-60-6.) (Order parts from Bobcat Figure 70-60-20
Parts.)
Long Housing
P2999
Loosen the set bolts (Item 1) and remove the pulley (Item
2) [Figure 70-60-18].
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide
Remove the long key (Item 3) [Figure 70-60-18]. hammer tool to remove the seal [Figure 70-60-20].
Figure 70-60-21
P2966
Figure 70-60-24
Remove the small snap ring [Figure 70-60-21].
Figure 70-60-22
P3004
P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-24].
Remove the small shims [Figure 70-60-22]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
Figure 70-60-27
P3298
Support the bearing and press the shaft from the bearing
[Figure 70-60-25].
Figure 70-60-26
P2996
Figure 70-60-28
P2997
Short Housing
Remove the large snap ring from the flange end of the
housing [Figure 70-60-28].
Figure 70-60-29
P2973
Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-31].
Figure 70-60-32
Remove the large shims from the housing [Figure 70-60-
29].
Figure 70-60-30
1
P2998
Figure 70-60-33
P2972
Figure 70-60-34
P3001
Press the bearing, shims and gear from the shaft [Figure
70-60-34].
Gearbox Assembly
Figure 70-60-36
P2960
Long Housing
P2962
Press a bearing on the short keyed end of the long shaft
[Figure 70-60-36].
Install a bearing on the long keyed end of the shaft
[Figure 70-60-38].
Figure 70-60-39
P2965
Install the gear key in the flange end of the shaft [Figure
P2963 70-60-41].
Figure 70-60-42
Install on the bearing, the same number and size shims
that were removed during disassembly [Figure 70-60-
39].
Figure 70-60-40
P2967
Install the small snap ring in the groove above the shims
[Figure 70-60-40].
Figure 70-60-43
P2969
Figure 70-60-46
Install the washer (Item 1) [Figure 70-60-43].
Short Housing
Figure 70-60-44
P2970
Install the large snap ring in the groove above the shims
[Figure 70-60-46].
P2968
Figure 70-60-47
P2976
1
Install the shaft in the housing, tapered end in the bearing
P2971 at the round flange end of the housing [Figure 70-60-49].
Figure 70-60-50
Install the short key (Item 1) [Figure 70-60-47].
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [Figure 70-60-47].
Figure 70-60-48
P2977
Install on the shaft, the same number and size shims that
were removed during disassembly [Figure 70-60-50].
P2975
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-48].
Figure 70-60-51
P2978
Figure 70-60-52
P2973
Figure 70-60-54
P2981
NOTE: For procedures requiring the use of LOCTITE Set the long housing on the short housing with the
#518 adhesive, thoroughly clean and dry sealant.
affected parts before the application of
LOCTITE #518. LOCTITE #518 is a gasket NOTE: If square shims are used, put a small amount
eliminator that cures to a flexible seal of (LOCTITE 518) on both sides of all shims.
between the mounting surfaces.
Figure 70-60-56
The backlash tolerance between the gears should be
0.005-0.008 inch (0,127-0,203 mm).
Part Number
Tag
P2983
Figure 70-60-57
2 1
1.000
(25,4mm)
P-37893
Install the long key (Item 1) and the pulley (Item 2) Hold the locking pliers against the long housing and
[Figure 70-60-57]. rotate the pulley back and forth to read the dial gauge
[Figure 70-60-59].
Install a bolt in the set screw hole to maintain a 1.0 inch
(25,4 mm) distance from the shaft center to the bolt head If the backlash is GREATER than 0.008 inch (0,203 mm),
(to be used with a dial indicator) [Figure 70-60-57]. do the following:
Figure 70-60-60
P2985
Figure 70-60-62
P3089
SHORT HOUSING
Remove the bolts from the flanges and separate the two
housings.
P2986
Compression Checking
Figure 70-70-1
P-48710
MEL10630 - Engine Compression Kit Crank the engine with the starter cranking rpm.
MEL1631 - Compression Adapter
If the measurement is below the allowable limit, check
The engine must be at operating temperature. the cylinder, piston ring, top clearance, valve and cylinder
head.
Remove the glow plugs. (See Glow Plugs Removal And Compression Pressure should be 427-469 PSI (2944,1 -
Installation on Page 70-70-2.) 3233,6 kPa)
Install the correct compression adapter (Item 1) [Figure Allowable Limit (minimum) is 341 PSI (2351,1 kPa)
70-70-1] into the cylinder head.
No more than 10% variance among cylinders.
Figure 70-70-3
P-48711
Figure 70-70-4
2 3
P-48698
P-48702
Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-70-6] from the top of
each glow plug.
Use an ohmmeter to check the glow plugs [Figure 70-70-
4].The resistance should be approximately one ohm. Disconnect the engine harness wire (Item 2) [Figure 70-
70-6] from the glow plug.
Figure 70-70-5
Remove the glow plug connecting strap (Item 3) [Figure
70-70-6].
Figure 70-70-7
1
P-48701
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug (Item 1) [Figure 70-
P-48699
70-5].
Repeat the procedure for each glow plug. Loosen and remove the glow plug (Item 1) [Figure 70-
70-7].
Figure 70-70-8
P-48706
Photo [Figure 70-70-8] shows the glow plug assembly The reading between electrical connector terminal C and
removed from the engine. Inspect the glow plugs and terminal B must be between approximately .35-.4 ohms.
replace when necessary.
Figure 70-70-9
P-48586
Stop the engine and open the rear door [Figure 70-70-9].
Figure 70-70-11
P-48586
Figure 70-70-12
P-48704
3
1
1
3
P-48705
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-14] from the injection pump
P-48700 vent .
Disconnect the high pressure fuel lines (Item 1) [Figure Remove the four oil fill bolts (Item 3) [Figure 70-70-14].
70-70-13] from the fuel injectors.
Figure 70-70-15
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 1
I-2029-0289
P-48730
Figure 70-70-16
P-51683
2
1 Remove the high-idling body (Item 1) [Figure 70-70-17]
from the engine block.
P-48826
Installation: Tighten the high-idling body to 32.6-36.3 ft.-
lb. (44-49 Nm) torque.
Remove the seven mounting bolts (Item 1) from the
intake manifold (Item 2) [Figure 70-70-16]. Figure 70-70-18
1 2
P-4357
Figure 70-70-19
2
2 1
1
1
P-51628
1
Figure 70-70-21
P-51626 INCORRECT
P-51627
Figure 70-70-22
1
1
P-51933
P-4364
Clean the area around the injection pump thoroughly.
Install the shim(s) (Item 1) [Figure 70-70-22] on the Disconnect the high pressure fuel lines (Item 1) [Figure
injection pump mounting surface. For information on the 70-70-24] from the fuel injectors.
number of shims used. (See Timing The Injection Pump
on Page 70-70-12.)
Figure 70-70-23
IMPORTANT
2 Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
1
P-64218
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Figure 70-70-25 2
1
2
3
P-48820
Cap the inlets on the injection pump vent where the Installation: Replace the manifold gasket if it is worn or
hoses were removed [Figure 70-70-25]. damaged.
Remove the four oil fill tube bolts (Item 3) [Figure 70-70- Figure 70-70-28
25].
Figure 70-70-26
1
2
P-51942
Figure 70-70-29
P-51952
P-51953
1
Remove the stop solenoid guide (Item 1) [Figure 70-70-
31].
P-51683
Figure 70-70-32
Figure 70-70-30
1 2
3
P-4357
2
Remove the four mounting bolts (Item 1) and two nuts
(Item 2) [Figure 70-70-32] from the injection pump.
P-51951
Installation: Tighten the mounting bolts to 16-20 ft.-lb.
(22-27 Nm) torque.
Remove the cover plate bolts (Item 1) and nuts (Item 2)
[Figure 70-70-30].
Figure 70-70-33 1
P-4364
1
Install the shim(s) (Item 1) [Figure 70-70-35] on the
injection pump mounting surface. For information on the
P-4359 number of shims used. (See Timing The Injection Pump
on Page 70-70-12.)
Remove the injection pump (Item 1) [Figure 70-70-33]
and shim(s) from the engine. Figure 70-70-36
IMPORTANT 1
1
P-51944
Figure 70-70-37
1 1
P-54133
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
P-4361
I-2028-0289
Timing the injection pump is done by changing the Install a short plastic tube (Item 1) [Figure 70-70-39] in
number of shims between the injection pump and the the number one cylinder port of the injection pump. The
injection pump mounting surface. tube should fit securely in the port and point upward.
Figure 70-70-40
1
Rotation
Direction
1 P-4364
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 .0008 in (.20 mm) shim.
flywheel should be aligned with the mark in the window
(Item 1) [Figure 70-70-40] for the V2003T engine. (2) One hole means .0010 in (.25 mm) shim.
The 8.2 BTDC on the flywheel should be aligned with (4) Three holes means .0014 in (.35 mm) shim.
the mark in the window (Item 1) [Figure 70-70-40] for the
V2203 engine.
Figure 70-70-43
1 1
2 P-48727
Remove the four retainer bolts from the top of the fuel
injectors (Item 1) [Figure 70-70-44].
Remove the high pressure fuel lines from the engine. Remove the injector nozzle holder bolt (Item 1) [Figure
70-70-45] from the cylinder head.
Fuel Injector Removal And Installation (Cont'd) The tool listed will be needed to do the following
procedure:
Figure 70-70-46
OEM1064 - Injector Nozzle Tester
Figure 70-70-47
1
2
P-37583
Nozzle Spraying 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 70-70-48
Correct Incorrect
3EEABAC1P014A
3EEABAC1P013A
Set the injection nozzle to a nozzle tester.
Set the injection nozzle to a nozzle tester, and check the Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/
nozzle spraying condition. cm, 2418 PSI) for 10 seconds.
If the spraying condition is defective, replace the injection If any fuel leak is found, replace the injection nozzle
nozzle assembly. assembly.
Figure 70-70-50
1 2 3 4 5 6 7 8
2 1
B-05569
Figure 70-70-52
3
B-5568
Cylinder Number 1 2 3 4
Adjust the valve clearance as follows:
Figure 70-70-53
4
3
1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
1
2
3
P-48519
WARNING
Remove the nut from the speed control linkage (Item 1)
Never work on a machine with the lift arms up unless and unplug the rear lights electrical connector (Item 2)
the lift arms are secured by an approved lift arm [Figure 70-80-1].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the bracket mounting bolts (Item 3) [Figure 70-
to fall and cause injury or death. 80-1] for the fuel fill to make installation easier.
W-2059-0598
Figure 70-80-2
Put jackstands under the rear corners of the loader.
Figure 70-80-3
1
1
2
P-26965
3
Remove battery cable bracket (Item 1) [Figure 70-80-5].
P-28237
Figure 70-80-6
Figure 70-80-4
1
2
P-34385
1
P-48581
2
1
3
P-48595
2
1
Disconnect glow plug wire (Item 1) [Figure 70-80-9].
P-48586
Disconnect and plug fuel return line (Item 2) [Figure 70-
80-9].
Disconnect the fuel stop wire harness (Item 1) [Figure
70-80-7]. Remove the tie strap (Item 3) [Figure 70-80-9] from
wiring harness clamp and move the wire harness to the
Remove the tie straps (Item 2) [Figure 70-80-7] from left side of loader to allow clearance for engine removal.
wiring harness clamp.
Figure 70-80-10
Disconnect engine oil pressure wire harness (Item 3)
[Figure 70-80-7].
Figure 70-80-8 1
3
4
P-48593
1
2
Disconnect engine coolant hose (Item 1) [Figure 70-80-
P-48585 10].
Figure 70-80-11
2
1
3
1
P-26957
P-26958
1
P-28137
P-28142
1
Mark and disconnect the left drive motor hoses (Item 1)
P-26068 [Figure 70-80-17].
Figure 70-80-18
P-26959 1
Figure 70-80-19
2 1
P-28231
1
P-48583
P-28140
Figure 70-80-22
13
2.5
1-1/2 I.S. Dia.
2-1/2 O.S. Dia. 1
2.5
1 P-48594
28
4 Figure 70-80-24
2
45 9
1
4
2
1
.5 1
.375
.3125 (2)
Figure 70-80-25
P-48596
Spacer
5 Snubbing
Washer
MC-1765
6
Replace all four engine mounts two front and two rear.
Figure 70-90-1
1
P-48850
P-48651
Figure 70-90-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
P-48650 90-7] which fasten the housing on the engine.
P-4231
Figure 70-100-1
1
2 4
2
3
1
P-47243
2
2
2
2
B-14332
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-100-4].
P-47242
2 16
17 9 1 8
13 5 4 12
P-47247
1
1
P-47246
P-47248
P-47252
7
6
8
5 7
5 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-100-14].
PI-9987
Remove bolts (Item 5), nut (Item 6), top and bottom
housing (Item 7), and gasket (Item 8) from the cylinder
Use a valve spring compressor to compress the valve head [Figure 70-100-14].
spring [Figure 70-100-12].
Figure 70-100-13
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Figure 70-100-15 2
1 3
P-51631
2
PI-9988
Figure 70-100-18
B-14335
1. Cylinder Head
Surface
2. Recessing
3. Protrusion
PI-9990
Figure 70-100-21
8.86 (225 mm)
0.460-0.468 2
(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
Press the used valve guide out of the cylinder head using
0.263-0.275 0.98 0.490-0.50
(6,7-7 mm) (25,0 mm) (12.5-12.8 mm) the special driver tool [Figure 70-100-22].
MC-1364
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
To remove and replace the valve guide, make the driver top side. Use the special driver tools (Items 1 & 2)
tool as shown in figure [Figure 70-100-21]. [Figure 70-100-22], press the new guide until the tool
contacts the cylinder head.
PI-9995
Grind the valve face to the correct angle using a valve re- If the seat surface (b) is too wide, use a 30 degree cutter
facer [Figure 70-100-23]. (Item 2) on the intake, and a 15 degree cutter on the
exhaust to get the correct width (Item 3) [Figure 70-100-
Figure 70-100-24 25].
PI-9994
Valve Spring
Figure 70-100-26
A-2759
1 Figure 70-100-29
2
B-3697
P-47254
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-
100-28] with an outside micrometer.
Bend a hook on the end of a 7.87 inch (200 mm) long,
If the clearance exceeds the allowable limit, replace the 0.050 inch (1.2 mm) diameter hard wire [Figure 70-100-
bushing. 29].
If the clearance still exceeds the allowable limit after the Figure 70-100-30
bushing is replace, replace the rocker arm shaft.
P-47255
Figure 70-100-31
P-47258
1
Use a puller and remove the crankshaft pulley. [Figure
70-100-33].
Figure 70-100-32
1
2
1
B-14339
Figure 70-100-35
B-3617B
P-47259
Figure 70-100-36
3
2
B-14340
Figure 70-100-38 1
2
1
P-47262
Figure 70-100-39
PI-10002B
Camshaft Servicing
Figure 70-100-42
B-5001
Figure 70-100-45
A-2761
A-2760
Measure the camshaft journal [Figure 70-100-43].
Calculate the oil clearance. If the clearance exceeds the Put the camshaft in V-blocks. Install a dial indicator
allowable limit, replace the camshaft. [Figure 70-100-45].
1.650-1.652
(41,9-41,95 mm)
1.494-1.495
(37,95-37,97 mm)
MC-1366
P-47264 1 1
P-47265
(0,15 mm)
Oil Pump Gear & Crankgear 0.0016-0.0043 inch Remove the fuel camshaft and fork lever assembly at
(0,042-0,109 mm) the same time [Figure 70-100-51].
Allowable Limit 0.0059 inch
(0,15 mm)
B-3686
Figure 70-100-54
B-3616
2
Measure the clearance between the lobes of the inner
rotor and outer rotor [Figure 70-100-55].
Figure 70-100-56
B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-100-54].
A-2732
PI-10010
PI-10009
Valve Tappets Remove the cylinder head. (See Cylinder Head Removal
And Installation on Page 70-100-1.)
Figure 70-100-59
Remove the top edge from the cylinder bore with a ridge
reamer.
Figure 70-100-61
1
1
2
P-47267
Figure 70-100-60
P-47269
2
1
P-47270
PI-10015
1
Installation: When installing new rings, assemble the
ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
A-2903 3) [Figure 70-100-65].
Figure 70-100-66
3
1
2
5 P-47272
4
Measure the I.D. of the piston pin bore in both horizontal
P-47271 and vertical directions [Figure 70-100-67].
2 1.098-1.1004
(27,9-27,95 mm)
0.984-0.985
(25,0-25,01 mm)
MC-1366
Figure 70-100-71
PI-10017
Figure 70-100-73 1
P-47274
P-47275
Figure 70-100-76 1
2
2
1
P-47278
Figure 70-100-77
1
P-47279
Figure 70-100-80
A-2763
Remove the bearing case and bearing. If the misalignment exceeds the allowable limit, replace
the crankshaft.
Installation: Tighten the bearing case bolts to 34-38 ft.-
lb. (46-51 Nm) torque.
Alignment 0.0008 inch (0,02 mm)
Figure 70-100-81
Tighten the connecting rod bolts to 33-36 ft.-lb. (45-49
Nm) torque.
Figure 70-100-83
120
PI-10021
Figure 70-100-84
PI-10022
Figure 70-100-86
2 2
1 3
B-3618
Install the sleeve guide (Item 1) and stop (Item 2) [Figure If the clearance exceeds the allowable limit, replace the
70-100-86]. crankshaft bearing.
Figure 70-100-87
B-3631
P-48778
Figure 70-100-90 Check the depth (Item 4) of the bearing (Item 2) from the
face of the engine block (Item 3) [Figure 70-100-91].
Installation Tool
This will ensure proper bearing alignment with the
5.12 (130 mm) crankshaft.
0.8
(20 mm) Bearing Number 1 0.1654-0.1772 inch
0.16
(4 mm) Recession (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 70-100-92
B-4066
A-2717
Kubota V2203-M-DI
B-14424
Checking
Description
P-48783
WARNING The oil flows from the fitting (Item 1) on the front of the
engine to the turbocharger and returns to the engine
Turbochargers, operate at high speed and high block through the fitting (Item 2) [Figure 70-110-2] .
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces. The turbocharger internal components are not
W-2257-1196 serviceable.
Figure 70-110-1
P16199
Figure 70-110-3
2 1
P-48598
Figure 70-110-5
P-48599
P16230
Figure 70-110-6
1 1 P-48780
Figure 70-110-9
1
1
2
P-48785
P-48781
Remove the mounting bolts (Item 1) [Figure 70-110-6] &
[Figure 70-110-7] from the oil return line (Item 2) [Figure
70-110-6] & [Figure 70-110-7]. Remove the mounting bolt (Item 1) [Figure 70-110-9]
from the exhaust muffler flange.
Installation: Tighten to 84-132 in.-lb. (9,5-15,0 Nm)
torque. Installation: Tighten to 17-20 ft.-lb. (23,0-27,0 Nm)
torque.
Figure 70-110-10
1
1
P-48601
Figure 70-110-11
P16230
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
TEMPERATURE/PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) See Chart on Page 80-10-3. where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Dessicant
3 Receiver Drier
Status Of R134a_______________________________________________
Identification
Figure 80-20-1 2
1
1
P-24219
Figure 80-20-2
1
1
N-22206
Identification (Cont'd)
Figure 80-20-5
N-22087
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-24227 20-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-20-7]
1) [Figure 80-20-5] is located behind the loader cab. The controls the temperature of the evaporator coil.
unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heat & A/C Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
coils , thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-6
Figure 80-20-8
P-21902
N-22100
Identification (Cont'd)
1
Figure 80-20-9
2
3 4
P-24229
Figure 80-20-10
P-24232
Safety Equipment
WARNING
Figure 80-30-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Figure 80-30-2
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
P16399 knowledge, and experience to service refrigeration
equipment.
W-2373-0500
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-40-1
P-28820
1
Figure 80-40-4
P-28819
Figure 80-40-5
P-48008
1
P-24288
P-48006
It is a good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Remove the recirculating air filter (Item 1) [Figure 80-40-
5] from the rear of the cab. Open the rear door.
Installation: Make sure the arrows on the filter are facing Remove the drive belt cover.
the front of the loader. (Inset) [Figure 80-40-5].
Remove the compressor drive belt cover.
Figure 80-40-6
Check the tension on the compressor belt (Item 1)
[Figure 80-40-7].
P-48007
Figure 80-40-8
1
1
P-48010
Figure 80-40-9
P-24213A P-48011
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See EVAPORATOR on Page 80-190-1.)
WARNING
N-22273
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Figure 80-50-2 support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 80-50-3
N-22411
Cleaning The A/C Evaporator Coil & Heater Coil Figure 80-50-6
(Cont'd)
Figure 80-50-4
1
1
P-48013
P-24288
The access cover is sealed to the heater unit with a foam Open the rear door.
gasket (Item 1) that keeps out dirt and debris. Check the
gasket for rips and tears. Replace as needed. Remove the drive belt cover.
The cover is held in place with screws that are held to the Remove the compressor belt cover.
cover with plastic retainers (Inset) . These help hold the
screws when installing the cover. Check the tension on the compressor belt (Item 1)
[Figure 80-50-6].
Figure 80-50-5
2
1
P-39464
Figure 80-50-7
1
2 1 P-24300
Check to see if the compressor clutch is engaging. Raise the operator cab. (See Raising The Operator Cab
With an operator in the loader seat and the cab door on Page 10-30-1.)
open, turn the loader key switch to RUN (Standard
Panel) OR press the RUN/ENTER Button (Deluxe Disconnect the loader harness (Item 1) [Figure 80-50-9]
Panel),without starting the loader. from the compressor clutch wire.
Push the A/C switch (Item 1) to the ON position. Turn the
blower fan switch (Item 2) [Figure 80-50-7] to the first On Figure 80-50-10
position.
Figure 80-50-8
P-24314
P-21912
If there is no resistance value, replace the compressor
clutch.(See COMPRESSOR on Page 80-110-1.)
If the compressor clutch does not engage, check the
loader fuse (Item 1) [Figure 80-50-8] located on the
control panel in the loader cab.
Figure 80-50-11
1
1
P-24315
Figure 80-50-12
2
1
P-24315
1
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1) [Figure 80-50-14].
Disconnect the loader harness (Item 1) from the pressure If a resistance value is observed, the pressure switch is
switch (Item 2) [Figure 80-50-12]. good.
Figure 80-50-15
N-22259
Figure 80-50-18
N-22259
1
Check the loader harness (Item 1) [Figure 80-50-16] for
voltage. The voltage should be 12 volts.
N-22130
Figure 80-50-19
1 1
N-22260
Disconnect the blower fan wiring connector (Item 1) If there is no resistance value replace the blower fan.
[Figure 80-50-19] from the loader wiring harness. (See HEATER/AC FAN on Page 80-210-1.)
Figure 80-50-22
1 1
N-22260 1
If there is no voltage at the wiring harness, check the Remove the three mount bolts (Item 1) [Figure 80-50-22]
harness for broken wires. from the cab control panel.
Figure 80-50-23
H C
M B
N-22288
Figure 80-50-26
1 1
N-22262
N-22264
The potentiometer will effect the A/C system and also
effect the operation of the heater.
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-50-26] from the A/C switch. If heater valve does not open, or close, or the A/C does
not work, check the potentiometer.
Check the harness for voltage. The voltage should be 12
volts.
At the loader cab, disconnect the loader harness (Item 1)
If there is no voltage at the wiring harness, check the [Figure 80-50-28] from the potentiometer.
harness for broken wires.
Figure 80-50-29
Figure 80-50-27
1
1
2
N-22263
N-22289
If there is voltage at the wiring harness, check the A/C Check the loader harness (Item 1) [Figure 80-50-29] for
switch [Figure 80-50-27] for resistance. voltage. The voltage should be 12 volts.
With the switch in the OFF position there should be no If there is no voltage at the wiring harness, check the
resistance between any of the three terminals on the A/C harness for broken wires.
switch.
Figure 80-50-30
C 1
A
N-22175
B
To check the resistance of the white wire, turn the
N-22290 potentiometer control (Item 1) to the full A/C position
[Figure 80-50-32].
N-22290
Figure 80-50-34
2 3
1
1
N-22284
N-22175
Raise the lift arms and install an approved lift arm
support device.(See Installing Lift Arm Support Device on
To check the resistance of the white wire, turn the Page 10-20-1.)
potentiometer control (Item 1) [Figure 80-50-34] to the
full Heater position. Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to the High Speed position. Turn
Figure 80-50-35 the temperature control (Item 3) [Figure 80-50-36] to the
High A/C position, with the loader ignition switch OFF.
Figure 80-50-37
1
C
A
N-22290
Figure 80-50-38
1
P-48015
2 3
1 P-48009
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Compressor Oil
Figure 80-60-1
N-22243
Compressor Oil Check Remove the compressor from the loader. (See
COMPRESSOR on Page 80-110-1.)
Figure 80-60-2
Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
[Figure 80-60-3].
Figure 80-60-4
1
N-22245
Figure 80-60-3
N-22246
P-16534A
Figure 80-60-5
P-24229
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb, the high side pressure will be around eight times greater than the low side pressure.
Chart
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Chart
Reclamation Procedure
1
Figure 80-100-1
N-23024
P-24230
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Figure 80-100-4
N-22291
If R134a is found , evacuate the system. Use an approved recovery/charging unit [Figure 80-100-
5] to evacuate the system.
Figure 80-100-6
N-22381
Figure 80-100-7
N-22292
Charging Procedure With A Manifold Gauge Set Connect the Red hose (Item 1) [Figure 80-100-10] to the
high pressure port and open the valve.
Figure 80-100-11
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Figure 80-100-9 1
P-24320
1 Figure 80-100-12
P-24318
Figure 80-100-10
P-24321
P-24319
Determine the problem with the A/C system and repair it.
Figure 80-100-14 2
P-24323
P-24322
Charging Procedure (Cont'd) Turn OFF the valve on the refrigerant container, and
hand valves on the manifold gauge set.
Figure 80-100-16
Turn OFF the engine, and remove the A/C charging
equipment from the loader.
P-24324
Figure 80-100-17
2
1
N-22284
Start loader engine, with the remote start switch, and run
at medium speed.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
P-24325
Figure 80-110-3
Figure 80-110-2
P-24327
P-24326
Figure 80-110-4
1.32
1.32
1.32
2
1
1
N-22275
Remove the center armature bolt (Item 1) [Figure 80- Attach the puller to the armature plate using three 8 mm
110-4]. bolts (Item 2) [Figure 80-110-6].
Installation: Tighten the armature bolt to 8-10 ft.-lb. (12- Figure 80-110-7
14 Nm) torque.
Figure 80-110-5
N-22278
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-5] on the armature plate as shown in [Figure 80-
110-7].
To remove the armature plate (Item 1) [Figure 80-110-5]
from the clutch face, you must make an armature plate
puller.
Figure 80-110-8
1
1 N-22283
Figure 80-110-11
Attach a slide hammer puller (Item 1) [Figure 80-110-8]
to the armature puller disk.
Figure 80-110-9
1
N-22369
N-22280
Figure 80-110-12
N-22373
Figure 80-110-15
Remove the pulley from the compressor [Figure 80-110-
12].
Figure 80-110-13
N-22374
Figure 80-110-16
1 1
N-22372
Figure 80-110-17
N-22375
Figure 80-120-1
LIFT HERE
P-48011
WARNING
In the event of a leakage, wear safety goggles.
P-48010
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas. Remove the condenser from the loader [Figure 80-120-
W-2371-0500
3].
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.
Figure 80-120-4
P-24303
WARNING 2
P-24298
Figure 80-130-1
1
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
P-24299
Remove the two A/C hoses (Item 2) [Figure 80-130-2]
from the receiver/drier.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device Cap and plug the hoses and the receiver/drier fittings
on Page 10-20-1.)) with the proper A/C caps and plugs.
Raise the operator cab. (See Raising The Operator Cab Loosen the hose clamps (Item 3) [Figure 80-130-2] that
on Page 10-30-1.) holds the receiver/drier to the mount.
Remove the refrigerant from the A/C system.(See Remove the receiver/drier from the loader.
SYSTEM CHARGING AND RECLAMATION on Page
80-100-1.) NOTE: When replacing a receiver/drier in an A/C
system 1 fl. oz. (30 cc) of PAG oil must be
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper added to the system when recharging.
installation.
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Figure 80-130-3
P-24295
Figure 80-140-1
N-22206
The pressure relief valve (Item 1) [Figure 80-140-1] is This will cause the A/C system to shut down, saving the
located on the receiver drier assembly. compressor.
Figure 80-150-3
P-24299
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Figure 80-150-2
The schraeder valve (Item 1) [Figure 80-150-3] is
located in the A/C high pressure hose and is located
under the pressure switch.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
With a tire valve core removal tool, remove the valve core
from the hose.
Figure 80-160-1
N-22129
Figure 80-160-4
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Figure 80-160-2
N-22119
N-22130
Figure 80-160-5
1
N-22128
N-22126
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Figure 80-160-8
1
1
N-22065
Figure 80-170-1
N-22072
Figure 80-170-2
N-22072
A Blue
1 B White
C Black
N-22071
Figure 80-180-1
N-22073
Raise the lift arms and install an approved lift arm Remove the expansion valve from the loader.
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Figure 80-180-3
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
N-22074
a toxic gas.
W-2371-0500
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Figure 80-180-4
1
1
N-22074
Figure 80-180-5
N-22085
1 N-22075
N-22073
Raise the operator cab.(See Raising The Operator Cab Figure 80-190-4
on Page 10-30-1.)
Figure 80-190-2 1
N-22076
N-22074
Figure 80-190-5
N-22078
Figure 80-200-3
1
N-22128
Remove the evaporator/heater unit from the back of the Figure 80-200-4
cab.(See EVAPORATOR/HEATER UNIT on Page 80-
160-1.)
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system. 2
Figure 80-200-2
N-22089
1
N-22086
Figure 80-200-7
1 1
N-22090
2
Figure 80-200-8
1
1
N-22128
Remove the heater unit from the back of the cab. (See Remove the two mount bolts (Item 1) [Figure 80-200-8]
EVAPORATOR/HEATER UNIT on Page 80-160-1.) from the heater coil.
Figure 80-210-1
N-22099
Figure 80-210-4
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
Raise the operator cab.(See Raising The Operator Cab
on Page 10-30-1.)
N-22097
Figure 80-210-5
1
2
1 1
N-22107
Remove the eight mount bolts (Item 1) [Figure 80-210-5] Figure 80-210-7
from the blower wheel cover.
2
N-22108
Figure 80-210-8
N-22112
Figure 80-210-11
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-8].
Figure 80-210-9
1 N-22111
Figure 80-210-12
1
1
2
N-22103
N-22116
Figure 80-210-14
N-22104
Figure 80-210-15
1 1 1
N-22105
Figure 80-210-16
N-22106
Figure 80-220-1
1
3
N-22155
P-48009
Remove the three mount bolts (Item 1) [Figure 80-220-2]
from the heater valve actuator.
Disconnect the loader wiring harness (Item 1) [Figure
80-220-1]. Figure 80-220-3
N-22156
Figure 80-220-4
1
N-22159
Figure 80-220-7
Remove the three mounting bolts (Item 1) [Figure 80-
220-4] from the heater valve mount plate.
Figure 80-220-5
1
1
N-22160
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) . . . . SPEC-21-1
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 DRIVE
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 SYSTEM
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 ELECTRICAL
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 SYSTEM &
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 ANALYSIS
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Machine Dimensions
Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
B-17328
TIRE DESCRIPTION WIDTH (OVER TIRES) WHEEL TREAD BUCKET WIDTH WIDTH (OVER BUCKET)
10-16.5 TIRES 66.0in. (1676mm) or 54.5in. (1385mm) or 62 62.0in. (1575mm)
60.0in (1524mm) 48.5in. (1232mm) 68 68.0in. (1727mm)
31-15x15 TIRES 74 74.0in. (1880mm)
72.0in. (1829mm) 55.9in. (1420mm)
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
S175 S185
Rated Operating Capacity (ISO) 1750 lb. (794kg) 1850 lb. (839kg)
Tipping Load (SAE Rating) 3900 lb. (1769 kg)
Operating Weight 5808 lb. ( 2635 kg)
SAE Breakout Force-Lift 3400 lb. (15123 N) 3600 lb. (16013 N)
-Tilt 3240 lb. (14412 N) 3550 lb. (15791 N)
Axle Torque 4900 ft.- lb. (6644 Nm)
Travel Speed 0-7.3 MPH (11,7 km/hr.)
Controls
Hydraulic System
S175 S185
Pump Engine Driven, Gear Type
Pump Capacity 16.9 GPM (64 L/min.) at High Idle
Charge Pump Capcity (SJC) 12.8 GPM (48,5 L/min.) at High Idle
High Flow (Option) 26.4 GPM (99,9 L/min.) at High Idle
System Relief at Quick Couplers 3300 PSI (206 Bar)
Filter Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders Doubleacting;
Tilt cylinders have cushioning feature on dump
Bore Diameter: Lift Cylinder (2) 2.50 (63,5)
Tilt Cylinder (2) 2.75 (69,9)
Rod Diameter: Lift Cylinder (2) 1.50 (38,1)
Tilt Cylinder (2) 1.375 (34,9)
Stroke: Lift Cylinder (2) 23.67 (601,2)
Tilt Cylinder (2) 13.19 (335,0)
Control Valve 3-spool, open center type w/float detent on lift and electrically controlled auxiliary
spool.
Fluid Lines SAE standard tubelines, hoses & fittings
Fluid Type BOBCAT FLUID, Hydraulic/Hydrostatic
6903117 - (Two - 2.5 gal. containers)
6903118 - (5 gal.)
6903119 - (55 gal.)
Hydraulic Function Time:
Raise Lift Arms 3.49 Seconds
Lower Lift Arms 2.54 Seconds
Bucket Dump 2.28 Seconds
Bucket Rollback 1.78 Seconds
Electrical
Drive System
S175 S185
Main Drive Hydrostatic 4 wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors.
Final Drive #80 HSOC endless roller chain & sprockets in sealed chaincase with oil
lubrication.
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 (50,8)
Wheel Bolts (8) 9/16
Capacities
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Head
Valves
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinders
Piston Rings
Pistons
Connecting Rod
Oil Pump
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Crankshaft
Timing Gear
Thermostat
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Head
Valves
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Liner
Piston Rings
Pistons
Connecting Rod
Oil Pump
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Crankshaft
Timing Gear
Thermostat
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
Thread
sae grade 5 sae grade 8
size
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(Nm) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
.750 220-245 300-330
(300-330) (410-450)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)
B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].
Figure SPEC-40-3
Nut Nut
Washer
Washer 2
O-ring
O-ring
TS-1619
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-40-4]
the washer is tight against the surface [Figure SPEC-40-
3]. Use the chart [Figure SPEC-40-5 on Page 3] to find the
correct tightness needed (Item 2) [Figure SPEC-40-4]. If
Tubelines And Hoses the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat.
Figure SPEC-40-5
1
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x Ft.-lb.
Diameter Thread Size (Nm)
1/4 7/16 - 20 13 (18)
2
5/16 1/2 - 20 17 (23)
3/8 9/16 - 18 22 (30)
1/2 3/4 - 16 40 (54)
TS-1619
5/8 7/8 - 14 60 (81)
3/4 1-1/16 - 12 84 (114)
Tighten the nut until it contacts with the seat. Make a
7/8 1-3/16 - 12 98 (133) mark across the flats of both the male and female parts of
1 1-5/16 - 12 118 (160) the connection (Item 1) [Figure SPEC-40-7].
1-1/4 1-5/8 - 12 154 (209)
Use the chart [Figure SPEC-40-8 on Page 4] to find the
1-1/2 1-7/8 - 12 163 (221) correct tightness needed (Item 2) [Figure SPEC-40-7]. If
2 2-1/2 - 12 252 (342) the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
Figure SPEC-40-6
Secondary
Seal
P13009
1
P13573
The hex portion of the nut does not contact the surface of Tighten the nut until it just makes metal to metal contact,
the component when the nut is tight. you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Specifications WARNING
Use Bobcat hydraulic/hydrostatic transmission fluid During cold weather (32F [0C] and below), do not
(P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.), operate machine until the engine has run for at least
(P/N 6903119 - 55 Gal.). five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
Hydraulic Fluid Chart stopping. Do not operate controls during warm-up
period.
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Take out existing pages and put in the new pages as listed below:
Printed in U.S.A.
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Take out existing pages and put in the new pages as listed below:
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
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Printed in U.S.A.
TAKE OUT PUT IN REVISION DESCRIPTION
HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC Revised Text
S175 (S/N 525211001 AND ABOVE) S175 (S/N 525211001 -525214999)
(S/N 525311001 AND ABOVE) (S/N 525311001 - 525314999)
S185 (S/N 525011001 AND ABOVE) S185 (S/N 525011001 - 525014999)
(S/N 525111001 AND ABOVE) (S/N 525111001 - 525114999)
(PRINTED APRIL 2004) (PRINTED MAY 2004)
V-0445 V-0445
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Take out existing Sections and put in the new Sections as listed below:
Printed in U.S.A.
TAKE OUT PUT IN REVISION DESCRIPTION
HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC Revised Text
WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION
S175 (S/N 525215000 AND ABOVE) S175 (S/N 525215000 AND ABOVE)
(S/N 525315000 AND ABOVE) (S/N 525315000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE) S185 (S/N 525015000 AND ABOVE)
(S/N 525115000 AND ABOVE) (S/N 525115000 AND ABOVE)
(PRINTED MAY 2004) (PRINTED APRIL 2005)
V-0566 V-0566
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Take out existing Sections and put in the new Sections as listed below:
Printed in U.S.A.
TAKE OUT PUT IN REVISION DESCRIPTION
HYD/HYDRO SCHEMATIC Added
WITH SJC AND HIGH FLOW OPTION
S175 (S/N 525215000 AND ABOVE)
(S/N 525315000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(S/N 525115000 AND ABOVE)
(PRINTED JULY 2005)
V-0716
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
S175, S185 Service Manual (P/N 6902732) Dated (2-06) contains updated service information which replaces the
previous S175, S185 Service Manual (P/N 6902732) Dated (11-03).
Printed in U.S.A.