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Mantto Ingles PDF
Mantto Ingles PDF
CORRECT
P-90216
Never service the Bobcat telescopic
handler without instructions.
Cleaning and maintenance are Disconnecting or loosening any Never work on telescopic
required daily. hydraulic tubeline, hose, fitting, handler with boom up unless
component or a part failure can boom is held by an approved
cause boom to drop. Do not go boom stop. Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator
without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be
performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.
MSW43-EN-0211
CONTENTS
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
A general inspection of the following items must be made after the telescopic handler has had service or repair:
1. Check that ROPS/FOPS 9. Enclosure door latches must
(Including right side window) open and close freely.
is in good condition and is not
modified.
6. Check tires for wear and 14. Inspect for fuel, oil or
pressure. Use only approved hydraulic fluid leaks.
tires.
FW TLS EMEA-0411 SM
18. Check the electrical charging 21. Check for any field
system. modification not completed.
FW TLS EMEA-0411 SM
This notice identifies procedures which must be Have Training with Actual Operation
followed to avoid damage to the machine. • Operator training must consist of a demonstration and
I-2019-0284 verbal instruction. This training is given by your
Bobcat dealer before the product is delivered.
• The new operator must start in an area without
bystanders or structures and use all the controls until
he or she can operate the machine and attachment
DANGER safely under all conditions of the work area. Always
fasten seat belt before operating.
The signal word DANGER on the machine and in the Know the Work Conditions
manuals indicates a hazardous situation which, if not • Know the weight of the materials being handled.
avoided, will result in death or serious injury. Avoid exceeding the Rated Load Capacity of the
D-1002-1107 machine (as indicated on the Load Capacity Charts).
Material which is very dense will be heavier than the
same volume of less dense material. Reduce the size
of load if handling dense material.
Operation
SI VH EMEA-1010 SM
Fire Extinguishers
Starting
Sl VH EMEA-1010 SM
Always use the serial number of the telescopic handler The telescopic handler serial number plate is located on
when requesting service information or when ordering the right side of the frame in front [Figure 1].
parts.
Explanation of telescopic handler serial number:
If any serial number plate is damaged, contact your XXXX XXXXX
Bobcat dealer.
Module 2. - Production
Figure 1 Sequence (Series)
S38967
S38966
Figure 2
B-16315
S38000
The delivery report must be completed by the dealer and
signed by the owner or operator when the Bobcat
telescopic handler is delivered. An explanation of the
form must be given to the owner. Make sure it is complete
[Figure 3].
S38001
BOOM HEAD
[1] BOOM
STOP
SEAT
BELT
BOOM PARKING BRAKE
[1] ROTATING
BEACON
LOAD CAPACITY CHARTS MIRRORS
REAR
WORK
LIGHT
Procedure
WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service. S39237
W-2718-0208
Figure 10-10-1 Put the floor jack under the right side of the front axle. Lift
the telescopic handler and install the second jackstand
[Figure 10-10-2].
Figure 10-10-3
S39236
STOP the engine. Put the floor jack under the left side of
the front axle. Lift the telescopic handler and install the S38065
The operator cab does not provide protection against Figure 10-20-2
hazardous substances. Do not use this machine under
conditions requiring protection against hazardous
substances.
WARNING
1
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or
S38162
death.
W-2906-0211
The cab door can be opened from the outside of the cab
using the latch (Item 1) [Figure 10-20-1] and opened
from the inside of the cab when you push the lever (Item
1) [Figure 10-20-2] (as shown).
Figure 10-20-3
1
S38163
Figure 10-20-6
Turn the handle (Item 1) [Figure 10-20-3] (as shown) to
unlock the window. Push the window fully open until it
latches against the cab.
Figure 10-20-4
1 1
S38385
Figure 10-20-7
1
2
1
1
S38912
S38910
The Cab Light [Figure 10-20-9] is located above the
operator’s right shoulder.
Turn the handle (Item 1) [Figure 10-20-7] (as shown) to
unlock the rear window. Move the lens to the left or the right (Item 1) to turn the
light ON. Move the lens to the centre position (Item 2)
Figure 10-20-8 [Figure 10-20-9] to turn the light OFF.
S38911
Push the rear window open until the handle lock (Item 1)
[Figure 10-20-8] is locked in the open position (as
shown).
Figure 10-30-1
3
2
4
1 1
EM7143
The rear of the trailer must be blocked or supported • Use chains to fasten the machine frame to the
(Item 1) [Figure 10-30-1] when loading or unloading the transport vehicle (Items 2 and 3) [Figure 10-30-2].
telescopic handler to prevent the front end of the trailer Use chain binders to tighten the chains.
from raising up.
• Attach the forks or bucket attachment to the transport
Be sure the transport and towing vehicles are of vehicle (Item 4) [Figure 10-30-2].
adequate size and capacity. For the weight of telescopic
handler, (See Weights on Page SPEC-10-2.).
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807
Procedure
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE S39411
S38174
Procedure (Cont’d)
S38176
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat telescopic handler.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals when making repairs, adjustments
WARNING 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-EN-0903
[1] Check wheel nut torque every 8 hours for the first 24 hours.
[2] Perform service first time, then as indicated in chart.
[3] Check level.
[4] Or every 12 months.
Outer Filter
1
Figure 10-60-1
S38013
S38011
S38055
NOTE: Make sure all sealing surfaces are free of dirt
and debris. DO NOT use compressed air.
Replace the large (outer) filter element only when the Install a new outer element.
yellow ring has reached the red zone on the condition
indicator (Item 1) [Figure 10-60-1]. Figure 10-60-4
3 1
1 S38012
Inner Filter
Figure 10-60-5
S38014
Install the dust cover (Item 2) with the dust extractor (Item
3) [Figure 10-60-4] facing down.
Cleaning
Figure 10-70-1
S38134
Checking Level
Stop the engine and allow the engine to cool. Open the
IMPORTANT
engine cover. (See Opening And Closing on Page 10-
160-1.) AVOID ENGINE DAMAGE
S38010
S38010
IMPORTANT
AVOID ENGINE DAMAGE
When the engine is cool, remove the coolant fill cap
(Item 1) [Figure 10-70-4]. Always use the correct ratio of water to antifreeze.
S38024
Remove the engine block drain plug (Item 1) and drain all
of the coolant into a container. Install and tighten the
engine block drain plug (Item 1) [Figure 10-70-5].
Recycle or dispose of used coolant in an environmentally
safe manner.
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling problems in cold • Biodiesel blend fuel is an excellent medium for
temperatures: microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
TEMPERATURE NO. 2 NO. 1 • Use of biodiesel blend fuel can result in premature
failure of fuel system components, such as plugged
-9°C (+15°F) 100% 0%
fuel filters and deteriorated fuel lines.
Down to -29°C (-20°F) 50% 50%
• Shorter maintenance intervals can be required, such
Below -29°C (-20°F) 0% 100% as cleaning the fuel system and replacing fuel filters
and fuel lines.
At a minimum, low sulfur diesel fuel must be used in this
machine. Low sulfur is defined as 500 mg/kg (500 ppm) • Using biodiesel blended fuels containing more than
sulfur maximum. five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
The following fuels may also be used in this machine: pump and seals.
Apply the following guidelines if biodiesel blend fuel is
• Ultra low sulfur diesel fuel. Ultra low sulfur is defined used:
as 15 mg/kg (15 ppm) sulfur maximum.
• Ensure the fuel tank is as full as possible at all times
• Biodiesel blend fuel - Must contain no more than five to prevent moisture from collecting in the fuel tank.
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly • Ensure that the fuel tank cap is securely tightened.
marketed as B5 blended diesel fuel. B5 blended
• Biodiesel blend fuel can damage painted surfaces,
diesel fuel must meet ASTM D975 (US Standard) or
remove all spilled fuel from painted surfaces
EN590 (EU Standard) specifications.
immediately.
• Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabiliser and
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term
stability and should not be stored for more
than three months.
Filling The Fuel Tank See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Removing Water
WARNING
Stop the engine.
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO Place a suitable container under the water separator in
SMOKING! Failure to obey warnings can cause an order to catch any fuel that might spill. Clean up any
explosion or fire. spilled fuel.
W-2063-0807
Figure 10-80-2
Figure 10-80-1
1
S39063
S38015
Use a clean, approved safety container to add fuel of the When clean fuel drains from the water separator, hand
correct specifications. Add fuel only in an area that has tighten the drain valve (Item 1) [Figure 10-80-2].
free movement of air and no open flames or sparks. NO
SMOKING! Dispose of drained fluid in an environmentally safe
manner.
Install and tighten the fuel fill cap (Item 1) [Figure 10-80-
1].
IMPORTANT
WARNING AVOID ENGINE DAMAGE
Water in the fuel system can cause serious engine
AVOID INJURY OR DEATH
damage. Remove water from the primary fuel filter
Always clean up spilled fuel or oil. Keep heat, flames,
daily.
sparks or lighted tobacco away from fuel and oil. I-2354-0112
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Figure 10-80-3
1
S39065
Remove the two bolts (Item 1) and remove the cover Remove the old filter element from the filter assembly
plate (Item 2) [Figure 10-80-3]. (Item 1) [Figure 10-80-5].
EM9386
Figure 10-80-7
1
S38016
Install the filter assembly (Item 1) [Figure 10-80-7] onto Ensure that dirt can not enter the new filter element. Do
the filter housing. not fill the filter element with fuel before the element is
installed.
Install the screw and washer (Item 2) [Figure 10-80-7].
Use a new seal between washer and filter housing. Install a new filter element with a new seal, and hand
Tighten to 8 N•m (70 in-lb) torque. tighten.
Remove air from the fuel system. (See Removing Air Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-5.) From The Fuel System on Page 10-80-5.)
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
Figure 10-80-9
S0007
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-90-1 CRANKCASE)
S38019
S6808
Open the engine cover and remove the dipstick (Item 1) TEMPERATURE RANGE ANTICIPATED BEFORE
[Figure 10-90-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick [1] Synthetic Oil - Use recommendation from Synthetic
(Inset) [Figure 10-90-1]. Do not overfill. Oil Manufacturer.
WARNING
AVOID INJURY OR DEATH
Figure 10-90-3
S38021
Put clean oil on the new filter gasket, install the filter and
hand tighten until the gasket contacts the surface, then
an additional 1/2 - 3/4 turn.
S38020
Install and tighten the oil drain cap (Item 1) [Figure 10-
90-3].
Figure 10-90-5
WARNING
AVOID INJURY OR DEATH
1
2 Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
WARNING
S38019
S6808 AVOID INJURY OR DEATH
Install oil fill cap, start the engine and let it run for several
minutes.
Stop the engine, and check for leaks at the oil filter.
Figure 10-100-1
S40582
S38033
S40581
Figure 10-100-4
WARNING
AVOID INJURY OR DEATH
HYDRAULIC / HYDROSTATIC FLUID
Diesel fuel or hydraulic fluid under pressure can
RECOMMENDED ISO VISCOSITY GRADE (VG)
penetrate skin or eyes, causing serious injury or
AND VISCOSITY INDEX (VI)
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 doctor familiar with this injury.
W-2072-EN-0909
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
TEMPERATURE RANGE ANTICIPATED sparks or lighted tobacco away from fuel and oil.
DURING MACHINE USE Failure to use care around combustibles can cause
[1] VG 100; Minimum VI 120 explosion or fire.
W-2103-0508
[2] VG 46; Minimum VI 140
[3] Synthetic Fluid; VG 46; Minimum VI 150
[4] Bobcat Hydraulic / Hydrostatic Fluid Figure 10-100-5
Put a new seal on the drain plug. Install the drain plug
(Item 1) [Figure 10-100-5] and tighten.
Figure 10-100-8
1
S40581
S38037
Loosen the nut (Item 1) [Figure 10-100-6].
Rotate the cover (Item 2) [Figure 10-100-6] clockwise. Remove the cover (Item 1) [Figure 10-100-8] at the
bottom of the frame.
Figure 10-100-7
Figure 10-100-9
4
1
3
2 1
S40582
S38038
Removing And Replacing Hydraulic / Hydrostatic See the SERVICE SCHEDULE for the correct service
Filter (Cont’d) intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
S38295 S38238
Remove the filter element (Item 1) [Figure 10-100-10] Place a suitable container below the filter housing and
and discard. remove the filter housing (Item 1) [Figure 10-100-11]
using a socket wrench.
Install new filter element ensuring that element is fully
seated in the filter base. Figure 10-100-12
Start the engine and let the engine run for one minute
(low idle) before operating the boom hydraulics.
Stop the engine and check for leaks at the filter. Check
the fluid level in the reservoir and add as needed. (See
Checking And Adding Fluid on Page 10-100-1.)
1
Install the cover.
WARNING S38296
AVOID INJURY OR DEATH Remove the filter element (Item 1) [Figure 10-100-11]
Always clean up spilled fuel or oil. Keep heat, flames, and discard.
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause Install new filter element ensuring that element is fully
explosion or fire. seated in the filter base.
W-2103-0508
Start the engine and let the engine run for one minute
(low idle) before operating the boom hydraulics.
Stop the engine and check for leaks at the filter. Check
the fluid level in the reservoir and add as needed. (See
Checking And Adding Fluid on Page 10-100-1.)
Figure 10-100-13
S40581
Figure 10-100-14
4
1
3
S40582
Checking And Adding Oil (Planetary Carrier) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-110-1
Figure 10-110-2
S38039
S38040
For oil capacity, (See Fluid Capacities on Page SPEC-10- Reposition the plug hole as shown in [Figure 10-110-1]
4.). For oil type, (See HYDRAULIC / HYDROSTATIC and add gear lube until the lube level is at the bottom
FLUID SPECIFICATIONS on Page SPEC-50-1.). edge of the plug hole (Item 1) [Figure 10-110-1].
Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb) For oil capacity, (See Fluid Capacities on Page SPEC-10-
torque. 4.). For oil type, (See HYDRAULIC / HYDROSTATIC
FLUID SPECIFICATIONS on Page SPEC-50-1.).
Repeat the procedure on the other hubs.
Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)
torque.
Checking And Adding Oil (Rear Differential) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-110-4
Figure 10-110-3
1 1
1
S38062
S38041
With the machine on a level surface remove the three
plugs (Item 1) [Figure 10-110-4] and drain oil into a
Put the machine on a level surface. container. Recycle or dispose of the used lubricant in an
environmentally safe manner.
Remove the plug (Item 1) [Figure 10-110-3]. The oil level
should be at the bottom edge of the plug hole.
Install and tighten the plugs (Item 1) [Figure 10-110-4] to
35 - 50 N•m (26 - 37 ft-lb) torque.
Add oil through the hole if the oil level is below the hole.
Figure 10-110-5
For oil type, (See HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.).
S38042
Figure 10-110-6 2
1
1
1 1
S38048
Add oil through the hole if the oil level is below the hole.
Figure 10-110-9
2
1
2
S38045
S38097
S38098
With the machine on a level surface, remove the plug
(Item 2) [Figure 10-110-10] and drain oil into a container.
Remove the plug (Item 1) [Figure 10-110-9]. The oil level Recycle or dispose of the used lubricant in an
should be at the bottom edge of the plug hole. environmentally safe manner.
Add oil through the hole if the oil level is below the hole. Install and tighten the plug (Item 2) [Figure 10-110-10].
For oil capacity, (See Fluid Capacities on Page SPEC-10- Remove the plug (Item 1) [Figure 10-110-9] and [Figure
4.). 10-110-10] and add oil through the hole.
For oil type, (See HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.). For capacity, (See Fluid Capacities on Page SPEC-10-
4.).
Install and tighten the plug. For type, (See HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.).
Lubrication Locations
Lubricate the following locations on the telescopic Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-2].
handler:
Figure 10-120-3
Figure 10-120-1
1 1
1 2
S38100
S38049
Figure 10-120-4
1
2
1
S38052
Figure 10-120-7
Tilt Cylinder Base End (Item 1) [Figure 10-120-4].
1
Figure 10-120-5
1
2
S38102
Figure 10-130-1
S40622
Figure 10-130-2
1
1
S40623
S40622 The pins (if equipped) (both sides) must extend through
the holes in the attachment mounting frame (Item 1)
[Figure 10-130-4].
The stop plate (Item 1) [Figure 10-130-2] (both sides)
must not be damaged or worn. Inspect stop plate Lubricate the attachment carrier. (See SERVICE
condition. Replace as needed. SCHEDULE on Page 10-50-1.) (See LUBRICATING THE
TELESCOPIC HANDLER on Page 10-120-1.)
Pressure
S38099
WARNING
The correct wheel nut tightening torque is 360 N•m (266 AVOID INJURY OR DEATH
ft-lb) torque [Figure 10-140-1]. Do not inflate tyres above specified pressure. Failure
to use correct tyre mounting procedure can cause an
Rotating explosion which can result in injury or death.
W-2078-EN-0909
Check the tyres regularly for wear, damage and pressure.
For the correct tyre pressure, (See Traction on Page
SPEC-10-4.).
1
Removing The Approved Boom Stop
• Start the engine and raise the boom. Stop the engine.
Figure 10-150-2
WARNING
AVOID INJURY OR DEATH
Never work on a machine with the boom up unless
1 the boom is held by an approved boom stop. Failure
to use an approved boom stop can allow the boom to
drop and cause injury or death.
Service boom stop if damaged or if parts are
missing. Using a damaged boom stop or with
missing parts can cause boom to drop causing injury
or death.
W-2899-1210
S40664
Figure 10-160-1
P-52162
Procedure WARNING
• Stop the telescopic handler on solid, flat and level
ground. Before you exit the operator’s position:
• Put the Travel Direction Control and the Joystick
NOTE: Ensure the machine is parked safely, taking in neutral.
into consideration the surrounding traffic. • Engage the parking brake.
• Retract and lower the boom and attachment flat
• Put the Travel Direction Control in neutral. (See on the ground.
Operation & Maintenance Manual for the correct • Stop the engine.
W-2907-0211
procedure.)
Figure 10-170-1
S38907
DO NOT JUMP.
Open the rear window. (See Operation & Maintenance Figure 10-180-3
Manual for the correct procedure.)
Figure 10-180-1
S38985
Pull the handle (Item 1) [Figure 10-180-1] inward (as Use the safety hammer to break the right rear window.
shown) and push the rear window fully open.
Exit through the right rear window opening.
Figure 10-180-2
Figure 10-180-4
S38169
7197819
• Thoroughly clean the telescopic handler including the • Install a fully charged battery.
engine compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the telescopic handler.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in place.
• Park the telescopic handler in a dry protected shelter.
• Lubricate the telescopic handler.
• Lower the boom all the way and put the attachment (if
equipped) flat on the ground. • Check tyre inflation and remove blocks from under
frame.
• Check tyre inflation and put blocks under the frame to
remove weight from the tyres. • Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put fuel stabiliser in the fuel tank and run the engine correct operation.
a few minutes to circulate the stabiliser to the pump
and fuel injectors. • Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the • Stop the engine and check for leaks. Repair as
following: needed.
6954 DaN
AVOID INJURY OR DEATH (15633 lbf)
• Before lifting, check fasteners on four point lift. 2812 DaN 4142 DaN
• Never allow riders in the cab or bystanders within (6322 lbf) (9312 lbf)
5 m (15 ft) while lifting the machine.
W-2160-0910
Attach the lift hooks to the lifting points (Items 1) [Figure EM7128
10-200-1] and [Figure 10-200-2]:
Figure 10-200-1
S38168
Figure 10-200-2
S38102
Figure 10-210-1
P16117
1
The Traction Lock switch (Item 1) [Figure 10-210-2] is
not used for this machine.
Figure 10-210-3
1
1
S97029
Figure 10-210-4
S38026
Figure 10-210-6
P16119
Kit Includes:
1
7003030 - Remote Start Tool (Service Tool)
6689747 - Telescopic Handler Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS® Service Tool Harness
Figure 10-220-3
1
1
S97029
2
Figure 10-220-4
S38026
Figure 10-220-6
2
S39238
WARNING
AVOID INJURY OR DEATH
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409
Figure 10-220-8
P-76450
Figure 10-220-9
2
2 S39238
1
WARNING
AVOID INJURY OR DEATH
• Lift and block the machine.
S97029
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
Locate the ACD connector (Item 1) [Figure 10-220-10] start the engine with the Service Tool (if
and remove the cap from the connector. applicable).
• See machine Service Manual for more
instructions.
W-2792-0409
Figure 10-220-12
2
1 2
5 3
6 4
P-76441
1
The Remote Start Tool (Service Tool) (Item 1) The computer icon with the right facing arrows (Item 2)
[Figure 10-220-12] has five buttons. [Figure 10-220-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
The STOP button (Item 2) [Figure 10-220-12] is used to and from the computer.
stop the Remote Start Tool (Service Tool) from
communicating and stop the telescopic handler engine. NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
The RUN button (Item 3) [Figure 10-220-12] is used to the RUN button on the remote start tool. Then
turn the Remote Start Tool (Service Tool) on and press the auxiliary (AUX) hydraulics button on
activates the telescopic handler ignition power. The the remote start tool and move the AUXILIARY
button will illuminate to indicate the service tool is active. Hydraulic switch on the telescopic handler to
the right and left several times.
The START button (Item 4) [Figure 10-220-12] is used to
start the telescopic handler engine.
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
LEGEND
1 RESERVOIR: 18 FLUSHING VALVE: 14 Bar (203 psi) 35 SERVO PISTON - Swash Plate
Reservoir Capacity 51 L (53.9 qt)
36 SPEED SENSOR - Driveshaft
19 LOAD SENSE RELIEF VALVE:
2 250 - 260 Bar (3626 – 3771 psi ) 37 SPRING APPLIED PRESSURE RELEASE
FILTER - Hydraulic
20 LOAD SENSE DUMP VALVE (SAPR) – Park brake: Minumum Release
3 SPRING LOADED FILTER BYPASS Pressure 100 Bar (1450 psi)
VALVE – 3,4 Bar (49 psi) 21 ANTICAVITATION/WORK PORT RELIEF
38 PARK BRAKE PRESSURE SWITCH:
VALVE – Boom Cylinder Base End:
4 COLD START CHECK VALVE – With 100 Bar (1450 psi)
280 Bar (4061 psi)
3,0 Bar (43 psi) Spring
22 ANTICAVITATION/WORK PORT RELIEF 39 PRESSURE REDUCING VALVE – Park
5 HYDRAULIC PUMP - Gear type VALVE – Boom Cylinder Rod End: Brake: 120 Bar (1740 psi)
100 Lpm (26.4 gpm @ High Engine Idle 280 Bar (4061 psi) 40 PRESSURE REDUCING VALVE – Service
Brake: 40 Bar (580 psi)
6 HYDRAULIC PUMP - Gear type 23 ANTICAVITATION/WORK PORT RELIEF
38 Lpm (10.0 gpm @ High Engine Idle VALVE – Tilt Cylinder Base End: 41 CHECK VALVE – Park Brake
280 Bar (4061 psi)
7 PRIORTITY VALVE – Implement / Steering 42 SOLENOID ACTIVATED DIRECTIONAL
24 ANTICAVITATION/WORK PORT RELIEF
CONTROL VALVE – Steering Mode
VALVE – Tilt Cylinder Rod End:
8 PRIORTITY VALVE – Fan / Brake 280 Bar (4061 psi) 43 RELIEF VALVE – Brake Pressure:
120 Bar (1740 psi)
9 CHARGE PUMP 25 ANTICAVITATION/WORK PORT RELIEF
38 Lpm (10.0 gpm) @ High Engine Idle VALVE – Telescopic Cylinder Base End: 44 SOLENOID ACTIVATED DIRECTIONAL
280 Bar (4061 psi) CONTROL VALVE – Gear Box
10 RELIEF VALVE – Charge:
26 ANTICAVITATION/WORK PORT RELIEF 45 RELIEF VALVE – Steering:
22 - 25 Bar (152 - 172 psi) @ low engine idle
VALVE – Telescopic Cylinder Rod End: 175 Bar (2538 psi)
27 - 30 Bar (186 - 207 psi) @ high engine idle
280 Bar (4061 psi) 46 RELIEF VALVE – Steering:
11 TRANSMISSION PUMP
27 SELF LEVELING CYLINDER LOCK VALVE: 235 Bar (3408 psi)
175 Lpm (46.2 gpm) @ High Engine Idle
250 Bar (3626 psi ) 47 ANTICAVITATION / RELIEF VALVE –
12 RELIEF/REPLENISHING VALVE - HIGH
28 BOOM CYLINDER LOCK VALVE: Fan Motor: 175 Bar (2538 psi)
PRESSURE (2) - 420 Bar (6092 psi)
380 Bar (5511 psi )
48 PILOT ACTIVATED CONTROL VALVE –
13 SOLENOID ACTIVATED DIRECTIONAL 29 TILT CYLINDER LOCK VALVE: Fan Motor Reverse Portection (If
CONTROL VALVE – Drive Dump Valve 280 Bar (4061 psi ) Equipped)
14 SERVO PRESSURE SENSOR - Forward 30 TELESCOPIC CYLINDER LOCK VALVE:
49 SOLENOID ACTIVATED DIRECTIONAL
280 Bar (4061 psi )
CONTROL VALVE – Fan Reverse (If
15 FILTER – Hydraulic Charge 31 DISPLACEMENT CONTROL VALVE: Equipped)
with Low Speed Solenoid
50 ACCUMULATOR (With Tractor Option
16 SPRING LOADED FILTER BYPASS 32 SHUTTLE VALVE - Drain Only): 80 Bar (1160 psi)
VALVE – 7 Bar (101 psi)
33 RELIEF VALVE 51 TEST PORT – Main Relief Pressure
17 TEST PORT – Charge Pressure NOTE: Unless otherwise specified
34 SHUTTLE VALVE – Drive Pressure springs have NO significant
pressure value.
C1 C2 B1 B2
FRONT AUX / REAR AUX
15
16 MALE
B
OIL COOLER QUICKTACH PWR
CHARGE FILTER
LOCK / UNLOCK
17 U VALVE
P
2 4
V L HYDRAULIC CONTROL VALVE
CF1 EF1 3 1
A
T2
OUTLET
FAN INVERTER
LS1
49
VALVE (IF EQUIPPED) 47 M4 F E M3 MA
48
CF2
IN A
EF2
7
CW ROTATION
9
12
F00B
LS2
OUT
B4
AUXILIARY
8
D FAN MOTOR A4
6 TELESCOPIC CYLINDER
TRACTOR SAFETY 5
VALVE (IF EQUIPPED)
F00A
13 IN WORK / AUX PUMP
11 26
10 12
TRAILER BRAKE VALVE MB
P T
3
Y B
1 2 M5 S L1 L2 4
HYDROSTATIC PUMP
30
U
P COLD START B
TELESCOPIC
A
N B BYPASS VALVE
14 B3
SELF A3
TRAILER BRAKE LEVELING
COUPLER CYLINDER
25
SELF LEVELING VALVE
MAIN OIL 3
31 FILTER
L1 HYDROSTATIC MOTOR
STEERING UNIT M4 24
B
L M3 27
46
46
38 35 A B
32 33
GEARBOX B2
R
TILT
1 2 A A2
TILT CYLINDER
SAHR BRAKE B A HYDRAULIC TANK
Vg min
LS TEMP 23
45 29
T 37 34
P XA XB 22
A
L2
n 36
B1
BOOM
A1
COLLECTOR BLOCK
BOOM
42 CYLINDER
CRAB 21
A4 L4 BOOM CYL LLHV
FWS
B4 R4
TRACTOR
28
4WS 20
ACCUMULATOR 40
INLET
43 (IF EQUIPPED)
SERVICE BRAKE
19
50 39 18
LS 4
T T 51
F PARK BRAKE
41 P LS P
T2 2 T
MF
X
P MACHINE
P2 S OIL FILL
COUPLER
AXLE FRONT
44 AXLE REAR
HYDRAULIC SCHEMATIC
TL470 (S/N ANL711001 – ANL711225)
PRINTED MAY 2012
Printed In Belgium V-1440
(Printed MAY 2012)
7158052 Rev A legend
LEGEND
1 RESERVOIR: 20 SPRING LOADED FILTER BYPASS 37 SHUTTLE VALVE - Drain 57 TEST PORT – Main Relief Pressure
Reservoir Capacity 51 L (13.5 U.S. gal) VALVE: 700 kPa (7 bar) (101 psi)
38 RELIEF VALVE 58 NOT USED FOR THIS MODEL
21 TEST PORT – Charge Pressure
2 FILTER – Hydraulic (2) 39 SHUTTLE VALVE – Drive Pressure 59 NOT USED FOR THIS MODEL
22 FLUSHING VALVE: 1400 kPa (14 bar) (203 psi)
3 SPRING LOADED FILTER BYPASS 40 SERVO PISTON - Swash Plate 60 SOLENOID ACTIVATED DIRECTIONAL
VALVE – 340 kPa (3,4 bar) (49 psi) 23 RELIEF VALVE: 25000 – 26000 kPa CONTROL VALVE – Tractor Safety Valve
41 SPEED SENSOR - Driveshaft
(250-260 bar) (3626 - 3771 psi) 61 TRAILER BRAKE VALVE:
4 COLD START CHECK VALVE – With 42 13000 kPa (130 bar) (1886 psi)
SPRING APPLIED PRESSURE RELEASE
300 kPa (3,0 bar) (43 psi) Spring 24 LOAD SENSE DUMP VALVE (SAPR) – Park brake: Minumum Release 62 BLEED VALVE
5 Pressure 10000 kPa (100 bar) (1450 psi)
IMPLEMENT PUMP:
25 NOT USED FOR THIS MODEL 63 PRESSURE SWITCH- Hydraulic Filter (2):
100 Lpm (26.4 U.S. gpm) @ High Engine Idle 43 PARK BRAKE PRESSURE SWITCH:
250 kPa (2,5 bar) (36 psi)
FAN PUMP: 10000 kPa (100 bar) (1450 psi)
6 26 ANTICAVITATION/WORK PORT RELIEF 64 PRESSURE SENSER
38 Lpm (10.0 U.S.gpm) @ High Engine Idle VALVE – Boom Cylinder Base End: 44 PRESSURE REDUCING VALVE – Park
28000 kPa (280 bar) (4061 psi) Brake: 12000 kPa (120 bar) (1740 psi) 65 NOT USED FOR THIS MODEL
7 PRIORITY VALVE – Implement Pump
27 ANTICAVITATION/WORK PORT RELIEF 45 PRESSURE REDUCING VALVE - Service Brake: 66 NOT USED FOR THIS MODEL
8 PRIORITY VALVE – Fan Pump VALVE – Boom Cylinder Rod End: 30 KPH Models - 4000 kPa (40 bar) (580 psi)
28000 kPa (280 bar) (4061 psi) 40 KPH Models - 8000 kPa (80 bar) (1160 psi) 67 PRESSURE SENSER - Servo
9 NOT USED FOR THIS MODEL
28 ANTICAVITATION/WORK PORT RELIEF 46 CHECK VALVE: 690 kPa (6,9 bar) (100 psi) 68 NOT USED FOR THIS MODEL
10 NOT USED FOR THIS MODEL VALVE – Tilt Cylinder Base End:
47 SOLENOID ACTIVATED DIRECTIONAL 69 NOT USED FOR THIS MODEL
28000 kPa (280 bar) (4061 psi)
CONTROL VALVE – Steering Mode
11 CHARGE PUMP 29 ANTICAVITATION/WORK PORT RELIEF 70 ACCUMULATOR (If Equipped)
38 Lpm (10.0 gpm) @ High Engine Idle VALVE – Tilt Cylinder Rod End: 48 RELIEF VALVE – Brake Pressure:
71 NOT USED FOR THIS MODEL
28000 kPa (280 bar) (4061 psi) 12000 kPa (120 bar) (1740 psi)
12 RELIEF VALVE – Charge:
30 ANTICAVITATION/WORK PORT RELIEF 49 SOLENOID ACTIVATED DIRECTIONAL 72 ACCUMULATOR – Boom Suspension (If
2400 kPa (24 bar) (348 psi) @ High Engine Idle
VALVE – Telescopic Cylinder Base End: CONTROL VALVE – Gear Box Equipped): 5000 kPa (50 bar) (725 psi)
13 TRANSMISSION PUMP: 28000 kPa (280 bar) (4061 psi) 50 ORIFICE: 5mm (0,19 in)
175 Lpm (46.2 U.S.gpm) @ High Engine Idle 73 SOLENOID ACTIVATED DIRECTIONAL
31 ANTICAVITATION/WORK PORT RELIEF CONTROL VALVE – Quick Tach (If Equipped)
14 RELIEF/REPLENISHING VALVE - HIGH VALVE – Telescopic Cylinder Rod End: 51 RELIEF VALVE – Steering:
PRESSURE (2): 42000 kPa (420 bar) (6092 psi) 28000 kPa (280 bar) (4061 psi) 17500 kPa (175 bar) (2538 psi) 74 SOLENOID ACTIVATED DIRECTIONAL CONTROL
52 RELIEF VALVE – Steering: VALVE – Rear Aux. Diverter (If Equipped)
15 SERVO PISTON – Swash Plate 32 SELF LEVELING CYLINDER LOCK VALVE: 75 SOLENOID ACTIVATED DIRECTIONAL
23500 kPa (235 bar) (3408 psi)
25000 kPa (250 bar) (3626 psi ) CONTROL VALVE – Rear Hook (If Equipped)
16 SOLENOID ACTIVATED DIRECTIONAL 53 ANTICAVITATION / RELIEF VALVE –
33 BOOM CYLINDER LOCK VALVE: Fan Motor: 23000 kPa (230 bar) (3356 psi) 76 CHECK VALVE – Quick Tach (If Equipped)
CONTROL VALVE – Drive Dump Valve
38000 kPa (380 bar) (5511 psi )
17 SOLENOID ACTIVATED DIRECTIONAL 54 PILOT ACTIVATED CONTROL VALVE – 77 CHECK VALVE – Front Aux. Drain (If Equipped)
CONTROL VALVE – Forward 34 TILT CYLINDER LOCK VALVE: Fan Motor Reverse Portection (If Equipped)
28000 kPa (280 bar) (4061 psi ) 78 CHECK VALVE (If Equipped):
18 SOLENOID ACTIVATED DIRECTIONAL 35 kPa (0,35 bar) (5 psi)
55 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Reverse 35 TELESCOPIC CYLINDER LOCK VALVE: 79 PRESSURE SENSER – Germain Brake Option
CONTROL VALVE – Fan Reverse (If
19 FILTER – Hydraulic Charge 28000 kPa (280 bar) (4061 psi ) (If Equipped)
Equipped)
36 DISPLACEMENT CONTROL VALVE: 56 ACCUMULATOR (If Equipped): 80 ACCUMULATOR – Germain Brake Option
with Low Speed Solenoid 8100 kPa (81 bar) (1175 psi) (If Equipped)
22 24 33
B
TILT CYLINDER
19 U
WITH LOCK VALVE
P 34
70 21
20 64 72 SELF LEVELLING
A COMPENSATION
CF1 EF1 GEAR PUMP CYLINDER
26
55 54 53 LS1
A1 SELF LEVELLING
HYDROSTATIC PUMP M4 F E M3 MA
VALVE
CF2
B1
IN
A
7 EF2
17 27
13 11 5 BOOM 32
OUT ENGINE LS2
14 8 28
D
IN
B2 FEMALE
29
18 15 12
MB
60 TILT REAR AUX / HOOK
M5 S L1 L2 CYLINDER
TRAILER BRAKE 61 4 DIVERTER VALVE FEMALE
VALVE (OPTIONAL) U 30 (OPTIONAL)
P
P T 35 75
Y
3 67
A3
1 2 B2
B3 B1
N B A2
OIL COOLER
31 A1
C2
C1
TRAILER BRAKE TELESCOPIC
COUPLER (OPTIONAL) HYDROSTATIC MOTOR
L1 M4 36 REAR AUX COUPLER
B DRAIN VALVE
M3
(OPTIONAL)
63 3
A4
STEERING FRONT AUX / REAR AUX
UNIT
52 DIVERTER VALVE
B4
L R GEAR BOX B A
(OPTIONAL)
F D E C
A
43
B
A B
AUXILIARY
Vg min
MAIN OIL FILTER B A L V
42 39 REAR HOOK CYLINDER
2 (OPTIONAL)
62 74
XA XB
1
A
FRONT AUXILIARY
L2 40 37 38 T 77 COUPLERS
2
n TEMP
41 V L
MALE
DRAIN
MALE
HYDRAULIC
RESERVOIR
FEMALE
T LS P
51 2 4 DRAINED COUPLERS
POWER QUICKTACH BLOCK
LOCK / UNLOCK
3 1 VALVE (OPTIONAL) 76
73
POWER QUICKTACH
CYLINDER (OPTIONAL)
COLLECTOR BLOCK
47
A4
L4
B4 R4
50 48 56
4
LS
SERVICE BRAKE
46
PARK BRAKE
T2
3
T
P2 T
S
F
P P X
P0 A3 B3 T4 T0 1 78 AXLE FRONT MF
REAR AXLE
49 45 44
HYDRAULIC SCHEMATIC
79 80
P
U
71
57
HYDRAULIC CONTROL VALVE C2
P LS 23 C1 ACC
72
T
33
22 24
B
TILT CYLINDER
19 U
WITH LOCK VALVE
P 34
70 21
20 64 SELF LEVELLING
A T COMPENSATION
CF1 EF1 GEAR PUMP CYLINDER
26
55 54 53 LS1
A1
V2 V1
SELF LEVELLING
HYDROSTATIC PUMP M4 F E M3 MA
VALVE
CF2
B1
IN
A
7 EF2
17 27
13 11 5 BOOM 32
OUT ENGINE LS2
14 8 28
D
29
18 15 12
61 60 MB
TILT REAR AUX / HOOK
M5 S L1 L2 CYLINDER
4 DIVERTER VALVE FEMALE
N B
U 30 (OPTIONAL)
P
35 75
3 67
A3
Y 1 2 B2
B3 B1
A2
P T
OIL COOLER
31 A1
C2
C1
TELESCOPIC
HYDROSTATIC MOTOR
L1 M4 36 REAR AUX COUPLER
B DRAIN VALVE
M3
(OPTIONAL)
63 3
A4
STEERING FRONT AUX / REAR AUX
UNIT
52 DIVERTER VALVE
B4
L R GEAR BOX B A
(OPTIONAL)
F D E C
A
43
B
A B
AUXILIARY
Vg min
MAIN OIL FILTER B A L V
42 39 REAR HOOK CYLINDER
2 (OPTIONAL)
62 74
XA XB
1
A
FRONT AUXILIARY
L2 40 37 38 T 77 COUPLERS
2
n TEMP
41 V L
MALE
DRAIN
MALE
HYDRAULIC
RESERVOIR
FEMALE
T LS P
51 2 4 DRAINED COUPLERS
POWER QUICKTACH BLOCK
LOCK / UNLOCK
VALVE (OPTIONAL)
3 1 76
73
POWER QUICKTACH
CYLINDER (OPTIONAL)
COLLECTOR BLOCK
47 TRAILER BRAKE
COUPLER (OPTIONAL)
NO BRAKES
A4 FOR 30KPH
L4
MACHINE
B4 R4
50 48 56
HUB RATIO HUB RATIO
1:6 1:6
4
LS
SERVICE BRAKE
46
PARK BRAKE
T2 BEVEL SET
3 BEVEL
RATIO
SET
11/34
T RATIO
HUB RATIO T 11/34 HUB RATIO
P2 S
1:6 1:6
F
P P X
P0 A3 B3 T4 T0 1 78 AXLE FRONT MF
REAR AXLE
49 45 44
HYDRAULIC SCHEMATIC
79 80
P
U
C1 C2 B1 B2
FRONT AUX / REAR AUX
15
16 MALE
B
OIL COOLER QUICKTACH PWR
CHARGE FILTER
LOCK / UNLOCK
17 U VALVE
P
2 4
V L HYDRAULIC CONTROL VALVE
CF1 EF1 3 1
A
T2
OUTLET
FAN INVERTER
LS1
49
VALVE (IF EQUIPPED) 47 M4 F E M3 MA
48
CF2
IN A
EF2
7
CW ROTATION
9
12
F00B
LS2
OUT
B4
AUXILIARY
8
D FAN MOTOR A4
6 TELESCOPIC CYLINDER
TRACTOR SAFETY 5
VALVE (IF EQUIPPED)
F00A
13 IN WORK / AUX PUMP
11 26
10 12
TRAILER BRAKE VALVE MB
P T
3
Y B
1 2 M5 S L1 L2 4
HYDROSTATIC PUMP
30
U
P COLD START B
TELESCOPIC
A
N B BYPASS VALVE
14 B3
SELF A3
TRAILER BRAKE LEVELING
COUPLER CYLINDER
25
SELF LEVELING VALVE
MAIN OIL 3
31 FILTER
L1 HYDROSTATIC MOTOR
STEERING UNIT M4 24
B
L M3 27
46
46
38 35 A B
32 33
GEARBOX B2
R
TILT
1 2 A A2
TILT CYLINDER
SAHR BRAKE B A HYDRAULIC TANK
Vg min
LS TEMP 23
45 29
T 37 34
P XA XB 22
A
L2
n 36
B1
BOOM
A1
COLLECTOR BLOCK
BOOM
42 CYLINDER
CRAB 21
A4 L4 BOOM CYL LLHV
FWS
B4 R4
TRACTOR
28
4WS 20
ACCUMULATOR 40
INLET
43 (IF EQUIPPED)
SERVICE BRAKE
19
50 39 18
LS 4
T T 51
F PARK BRAKE
41 P LS P
T2 2 T
MF
X
P MACHINE
P2 S OIL FILL
COUPLER
AXLE FRONT
44 AXLE REAR
HYDRAULIC SCHEMATIC
TL470 (S/N ANMG11001 – ANMG11202)
(S/N AVM611001 – AVM611050)
PRINTED MAY 2012
Printed In Belgium V-1440
HYDRAULIC SCHEMATIC
TL470 (S/N ANMG11203 – ANMG11252)
(S/N AVM611051 – AVM611054)
(Printed MAY 2012)
7158052 Rev A legend
LEGEND
1 RESERVOIR: 20 SPRING LOADED FILTER BYPASS 37 SHUTTLE VALVE - Drain 57 TEST PORT – Main Relief Pressure
Reservoir Capacity 51 L (13.5 U.S. gal) VALVE: 700 kPa (7 bar) (101 psi)
38 RELIEF VALVE 58 NOT USED FOR THIS MODEL
21 TEST PORT – Charge Pressure
2 FILTER – Hydraulic (2) 39 SHUTTLE VALVE – Drive Pressure 59 NOT USED FOR THIS MODEL
22 FLUSHING VALVE: 1400 kPa (14 bar) (203 psi)
3 SPRING LOADED FILTER BYPASS 40 SERVO PISTON - Swash Plate 60 SOLENOID ACTIVATED DIRECTIONAL
VALVE – 340 kPa (3,4 bar) (49 psi) 23 RELIEF VALVE: 25000 – 26000 kPa CONTROL VALVE – Tractor Safety Valve
41 SPEED SENSOR - Driveshaft
(250-260 bar) (3626 - 3771 psi) 61 TRAILER BRAKE VALVE:
4 COLD START CHECK VALVE – With 42 13000 kPa (130 bar) (1886 psi)
SPRING APPLIED PRESSURE RELEASE
300 kPa (3,0 bar) (43 psi) Spring 24 LOAD SENSE DUMP VALVE (SAPR) – Park brake: Minumum Release 62 BLEED VALVE
5 Pressure 10000 kPa (100 bar) (1450 psi)
IMPLEMENT PUMP:
25 NOT USED FOR THIS MODEL 63 PRESSURE SWITCH- Hydraulic Filter (2):
100 Lpm (26.4 U.S. gpm) @ High Engine Idle 43 PARK BRAKE PRESSURE SWITCH:
250 kPa (2,5 bar) (36 psi)
FAN PUMP: 10000 kPa (100 bar) (1450 psi)
6 26 ANTICAVITATION/WORK PORT RELIEF 64 PRESSURE SENSER
38 Lpm (10.0 U.S.gpm) @ High Engine Idle VALVE – Boom Cylinder Base End: 44 PRESSURE REDUCING VALVE – Park
28000 kPa (280 bar) (4061 psi) Brake: 12000 kPa (120 bar) (1740 psi) 65 NOT USED FOR THIS MODEL
7 PRIORITY VALVE – Implement Pump
27 ANTICAVITATION/WORK PORT RELIEF 45 PRESSURE REDUCING VALVE - Service Brake: 66 NOT USED FOR THIS MODEL
8 PRIORITY VALVE – Fan Pump VALVE – Boom Cylinder Rod End: 30 KPH Models - 4000 kPa (40 bar) (580 psi)
28000 kPa (280 bar) (4061 psi) 40 KPH Models - 8000 kPa (80 bar) (1160 psi) 67 PRESSURE SENSER - Servo
9 NOT USED FOR THIS MODEL
28 ANTICAVITATION/WORK PORT RELIEF 46 CHECK VALVE: 690 kPa (6,9 bar) (100 psi) 68 NOT USED FOR THIS MODEL
10 NOT USED FOR THIS MODEL VALVE – Tilt Cylinder Base End:
47 SOLENOID ACTIVATED DIRECTIONAL 69 NOT USED FOR THIS MODEL
28000 kPa (280 bar) (4061 psi)
CONTROL VALVE – Steering Mode
11 CHARGE PUMP 29 ANTICAVITATION/WORK PORT RELIEF 70 ACCUMULATOR (If Equipped)
38 Lpm (10.0 gpm) @ High Engine Idle VALVE – Tilt Cylinder Rod End: 48 RELIEF VALVE – Brake Pressure:
71 NOT USED FOR THIS MODEL
28000 kPa (280 bar) (4061 psi) 12000 kPa (120 bar) (1740 psi)
12 RELIEF VALVE – Charge:
30 ANTICAVITATION/WORK PORT RELIEF 49 SOLENOID ACTIVATED DIRECTIONAL 72 ACCUMULATOR – Boom Suspension (If
2400 kPa (24 bar) (348 psi) @ High Engine Idle
VALVE – Telescopic Cylinder Base End: CONTROL VALVE – Gear Box Equipped): 5000 kPa (50 bar) (725 psi)
13 TRANSMISSION PUMP: 28000 kPa (280 bar) (4061 psi) 50 ORIFICE: 5mm (0,19 in)
175 Lpm (46.2 U.S.gpm) @ High Engine Idle 73 SOLENOID ACTIVATED DIRECTIONAL
31 ANTICAVITATION/WORK PORT RELIEF CONTROL VALVE – Quick Tach (If Equipped)
14 RELIEF/REPLENISHING VALVE - HIGH VALVE – Telescopic Cylinder Rod End: 51 RELIEF VALVE – Steering:
PRESSURE (2): 42000 kPa (420 bar) (6092 psi) 28000 kPa (280 bar) (4061 psi) 17500 kPa (175 bar) (2538 psi) 74 SOLENOID ACTIVATED DIRECTIONAL CONTROL
52 RELIEF VALVE – Steering: VALVE – Rear Aux. Diverter (If Equipped)
15 SERVO PISTON – Swash Plate 32 SELF LEVELING CYLINDER LOCK VALVE: 75 SOLENOID ACTIVATED DIRECTIONAL
23500 kPa (235 bar) (3408 psi)
25000 kPa (250 bar) (3626 psi ) CONTROL VALVE – Rear Hook (If Equipped)
16 SOLENOID ACTIVATED DIRECTIONAL 53 ANTICAVITATION / RELIEF VALVE –
33 BOOM CYLINDER LOCK VALVE: Fan Motor: 23000 kPa (230 bar) (3356 psi) 76 CHECK VALVE – Quick Tach (If Equipped)
CONTROL VALVE – Drive Dump Valve
38000 kPa (380 bar) (5511 psi )
17 SOLENOID ACTIVATED DIRECTIONAL 54 PILOT ACTIVATED CONTROL VALVE – 77 CHECK VALVE – Front Aux. Drain (If Equipped)
CONTROL VALVE – Forward 34 TILT CYLINDER LOCK VALVE: Fan Motor Reverse Portection (If Equipped)
28000 kPa (280 bar) (4061 psi ) 78 CHECK VALVE (If Equipped):
18 SOLENOID ACTIVATED DIRECTIONAL 35 kPa (0,35 bar) (5 psi)
55 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Reverse 35 TELESCOPIC CYLINDER LOCK VALVE: 79 PRESSURE SENSER – Germain Brake Option
CONTROL VALVE – Fan Reverse (If
19 FILTER – Hydraulic Charge 28000 kPa (280 bar) (4061 psi ) (If Equipped)
Equipped)
36 DISPLACEMENT CONTROL VALVE: 56 ACCUMULATOR (If Equipped): 80 ACCUMULATOR – Germain Brake Option
with Low Speed Solenoid 8100 kPa (81 bar) (1175 psi) (If Equipped)
22 24 33
BOOM
380 bar
CYLINDER pilot ratio
B LHV 4,5:1
TILT CYLINDER
19 U
WITH LOCK VALVE
P 34
70 21
20 64 72 SELF LEVELLING
BOOM
A COMPENSATION
CYLINDER
CF1 EF1 GEAR PUMP ACCU CYLINDER
26 0.075 L
50 bar
55 54 53 LS1
A1 SELF LEVELLING
HYDROSTATIC PUMP M4 F E M3 MA
VALVE
CF2
B1
IN
A
7 EF2
17 27
13 11 5 BOOM 32
OUT ENGINE LS2
14 8 28
D
29
18 15 12
MB
60 TILT REAR AUX / HOOK
M5 S L1 L2 CYLINDER
TRAILER BRAKE 61 59 DIVERTER VALVE FEMALE
VALVE (OPTIONAL) U 30 (OPTIONAL)
P
P T 35 75
Y
3 67
A3
4:1 1 2 B2
B3 B1
N B max P in B A2
130 bar
OIL COOLER
30 A1
C2
C1
TRAILER BRAKE TELESCOPIC
COUPLER (OPTIONAL) HYDROSTATIC MOTOR
L1 M4 36 REAR AUX COUPLER
B DRAIN VALVE
M3
(OPTIONAL)
63 3
A4
STEERING FRONT AUX / REAR AUX
UNIT
52 DIVERTER VALVE
B4
L R GEAR BOX B A
(OPTIONAL)
F D E C
A
43
B
A B
AUXILIARY
Vg min
MAIN OIL FILTER B A L V
42 39 REAR HOOK CYLINDER
2 (OPTIONAL)
62 75
XA XB
1
A
FRONT AUXILIARY
L2 40 37 38 T 77 COUPLERS
2
n TEMP
41 V L
MALE
DRAIN
MALE
HYDRAULIC
RESERVOIR
FEMALE
T LS P
51 2 4 DRAINED COUPLERS
POWER QUICKTACH BLOCK
LOCK / UNLOCK
3 1 VALVE (OPTIONAL)
76
73
POWER QUICKTACH
CYLINDER (OPTIONAL)
COLLECTOR BLOCK
47
NO BRAKES
A4 FOR 30KPH
L4
MACHINE
B4 R4
50 48 51
HUB RATIO HUB RATIO
1:6 1:6
4
LS
SERVICE BRAKE
46
PARK BRAKE
T2 BEVEL SET
3 BEVEL
RATIO
SET
11/34
T RATIO
HUB RATIO T 11/34 HUB RATIO
P2 S
1:6 1:6
F
P P X
P0 A3 B3 T4 T0 1 78 AXLE FRONT MF
REAR AXLE
49 45 44
79
P
80 HYDRAULIC SCHEMATIC
U
71
57
HYDRAULIC CONTROL VALVE C2
P LS 23 C1 ACC
72
T
33
22 24
B
TILT CYLINDER
19 U
WITH LOCK VALVE
P 34
70 21
20 64 SELF LEVELLING
A T COMPENSATION
CF1 EF1 GEAR PUMP CYLINDER
26
55 54 53 LS1
A1
V2 V1
SELF LEVELLING
HYDROSTATIC PUMP M4 F E M3 MA
VALVE
CF2
B1
IN
A
7 EF2
17 27
13 11 5 BOOM 32
OUT ENGINE LS2
14 8 28
D
29
18 15 12
61 60 MB
TILT REAR AUX / HOOK
M5 S L1 L2 CYLINDER
4 DIVERTER VALVE FEMALE
N B
U 30 (OPTIONAL)
P
35 75
3 67
A3
Y 1 2 B2
B3 B1
A2
P T
OIL COOLER
31 A1
C2
C1
TELESCOPIC
HYDROSTATIC MOTOR
L1 M4 36 REAR AUX COUPLER
B DRAIN VALVE
M3
(OPTIONAL)
63 3
A4
STEERING FRONT AUX / REAR AUX
UNIT
52 DIVERTER VALVE
B4
L R GEAR BOX B A
(OPTIONAL)
F D E C
A
43
B
A B
AUXILIARY
Vg min
MAIN OIL FILTER B A L V
42 39 REAR HOOK CYLINDER
2 (OPTIONAL)
62 74
XA XB
1
A
FRONT AUXILIARY
L2 40 37 38 T 77 COUPLERS
2
n TEMP
41 V L
MALE
DRAIN
MALE
HYDRAULIC
RESERVOIR
FEMALE
T LS P
51 2 4 DRAINED COUPLERS
POWER QUICKTACH BLOCK
LOCK / UNLOCK
VALVE (OPTIONAL)
3 1 76
73
POWER QUICKTACH
CYLINDER (OPTIONAL)
COLLECTOR BLOCK
47 TRAILER BRAKE
COUPLER (OPTIONAL)
NO BRAKES
A4 FOR 30KPH
L4
MACHINE
B4 R4
50 48 56
HUB RATIO HUB RATIO
1:6 1:6
4
LS
SERVICE BRAKE
46
PARK BRAKE
T2 BEVEL SET
3 BEVEL
RATIO
SET
11/34
T RATIO
HUB RATIO T 11/34 HUB RATIO
P2 S
1:6 1:6
F
P P X
P0 A3 B3 T4 T0 1 78 AXLE FRONT MF
REAR AXLE
49 45 44
79
P
80 HYDRAULIC SCHEMATIC
TL470 (S/N ANMG11253 & ABOVE)
U
mc-2340
mc-2340
2
mc-2340-3
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, 6
The hydraulic fluid temperature warning light comes ON when hydraulics are 1, 2
operating.
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine rpm. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9
Tightening Procedures
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-1
S38852
Figure 20-20-2
1 2
S38853
S38851
Install a puller (Item 1) and remove the upper pivot pin
(Item 2) [Figure 20-20-4].
Position a wooden block (Item 1) [Figure 20-20-2] under
the lift and self leveling cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-20-3]
and lower the lift cylinder onto a block.
Figure 20-20-5
S38857
Lift and support the base end of the cylinder [Figure 20-
20-7].
S38854
Figure 20-20-8
Figure 20-20-6
1 1
S38856
Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 20-20-8] from the lower pivot pin.
S38855
IMPORTANT
Remove the bolt and nut (Item 1) [Figure 20-20-6] and
separate the lift cylinder and self leveling cylinder. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Installation: Tighten the bolt to 30 - 41 N•m (22 - 30 ft-lb) parts clean. Always use caps and plugs on hoses,
torque. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-20-9
S38858
Parts Identification
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring 2
6. Seal 1 3
7. Set Screw
8. Piston
9. O-ring
10. Back-up Ring
11. Head Gland
12. Wiper 2
9
6
8
7
5 9
2 4
10
11
6
12
EM7533
Disassembly
Figure 20-20-10
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-12
S38827
S38828
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-11].
Disassembly (Cont'd)
Figure 20-20-13
P-29909
Figure 20-20-16
Heat the head gland (Item 1) [Figure 20-20-13].
Figure 20-20-14
S39081
P-29907
Disassembly (Cont'd)
Figure 20-20-17
S39087
Figure 20-20-20
Remove the set screw (Item 1) [Figure 20-20-17].
Figure 20-20-18
1
S39084
Disassembly (Cont'd)
Figure 20-20-21 1
1 1
P-29918
Figure 20-20-22
S39086
Disassembly (Cont'd)
2 3
Figure 20-20-24
1 1
P-29921
2
Remove seal (Item 1), wear ring (Item 2) and wiper (Item
P-29919
3) [Figure 20-20-26] from the head gland.
Figure 20-20-25
P-29920
Assembly
2
2
P-29884
1
Install the wiper (Item 1) and wear ring (Item 2) [Figure
20-20-27] in the head gland. P-29919
Figure 20-20-28
Install the back-up ring (Item 1) and two O-rings (Item 2)
[Figure 20-20-30].
1
P-29883
Assembly (Cont'd)
1 1
Figure 20-20-31
S39085
Figure 20-20-32
1
S39084
Assembly (Cont'd)
Figure 20-20-35
S39092
Figure 20-20-36
P-29887
S39087
Apply Loctite® 243 or equivalent to the set screw (Item 1)
[Figure 20-20-38].
Install the O-ring (Item 1) [Figure 20-20-36] into the
inside of the piston.
Assembly (Cont'd) 2
Figure 20-20-39
P-29907
Clean off any old residue, and apply Loctite® 262 to the
Install the set screw (Item 1) [Figure 20-20-39]. threads of the head (Item 2) [Figure 20-20-41].
Tighten the set screw to 20 N•m (15 ft-lb) torque. Figure 20-20-42
Figure 20-20-40
P-29925
S39082
Use the spanner wrench to tighten the head gland
[Figure 20-20-42].
Lock the set screw with a punch [Figure 20-20-40] on the
edge of the hole.
Tighten the head to 400 - 500 N•m (295 - 370 ft-lb)
torque.
Assembly (Cont'd)
Figure 20-20-43
S39387
NOTE: Do not peen the lock ring for more than 1 - 1,5
mm (0.04 - 0.06 in).
Figure 20-20-44
S38828
Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-44].
Figure 20-30-1
S38852
Figure 20-30-2
1
2
S38853
S38851
Install a puller (Item 1) and remove the upper pivot pin
(Item 2) [Figure 20-30-4].
Position a wooden block (Item 1) [Figure 20-30-2] under
the lift and self leveling cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-30-3]
and lower the lift cylinder onto a block.
1
S38856
Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 20-30-7] from the lower pivot pin.
S38859
Figure 20-30-8
Figure 20-30-6
1
S38858
S38855
Remove the bolt and nut (Item 1) [Figure 20-30-6] and IMPORTANT
separate the lift cylinder and self leveling cylinder.
When repairing hydrostatic and hydraulic systems,
Installation: Tighten the bolt to 30 - 41 N•m (22 - 30 ft-lb) clean the work area before disassembly and keep all
torque. 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
Parts Identification
1. Bushing
2. Housing 1
3. Back-up Ring
4. Seal
5. Piston
6. O-ring 1
7. Spacer
8. Head Gland
9. Wear Ring
10. Wiper
11. Rod
12. Grease Fitting
3
4
3
5
6
7
6
8
4
9
10
11
12
EM7528
Disassembly
Figure 20-30-9
S38833
Figure 20-30-12
S38831
1
Figure 20-30-10
S38834
S38832
Disassembly (Cont'd)
1
Figure 20-30-13
S39421
Figure 20-30-16
Put the rod end of the cylinder in a vise and support the
cylinder rod on a wood block [Figure 20-30-13]. 1
Figure 20-30-14
1
2
S39419
Disassembly (Cont'd)
Figure 20-30-17 3
2
1
S38842
Remove the dust ring (Item 1), wear ring (Item 2) and
S39420 wiper seal (Item 3) [Figure 20-30-19].
Figure 20-30-20
Remove the expander O-ring (Item 1) [Figure 20-30-17].
Figure 20-30-18 2
1
S38843
S38841 Remove the back-up ring (Item 1) and two O-rings (Item
2) [Figure 20-30-20].
Assembly
Figure 20-30-21
S38842
2
Install the dust ring (Item 1), wear ring (Item 2) and wiper
seal (Item 3) [Figure 20-30-22].
Figure 20-30-23
2
1
S38843
S38841
Assembly (Cont'd)
1
Figure 20-30-24
S39421
Figure 20-30-25
S38844
Assembly (Cont'd)
Figure 20-30-28
P-29887
Figure 20-30-31
Clean off any old residue, and apply Loctite® 243 or
equivalent to the threads on the rod [Figure 20-30-28].
Figure 20-30-29
1
1
S39418
Assembly (Cont'd)
Figure 20-30-32
1
S38832
Clean off any old residue, and apply Loctite® 262 to the
threads of the head (Item 2) [Figure 20-30-32].
Figure 20-30-33
S38845
Figure 20-31-1
S38006
Figure 20-31-2
3
1
1
1
S39446
Remove the two nuts (Item 2) and bolts and remove the
lock valve (Item 3) [Figure 20-31-2].
S39098
1
Figure 20-40-4
1
S39069
S39099
Figure 20-40-5
S39102
Figure 20-40-8
Remove the snap ring (Item 1) [Figure 20-40-5] and
washer.
Figure 20-40-6
S39103
WARNING
AVOID INJURY OR DEATH
1
1
S39110
Figure 20-40-10
2
2 1
S39109
1
1 Disconnect the four fittings (Item 1) [Figure 20-40-12].
1
S39111 IMPORTANT
Remove the tie-straps / clamps (Item 1) [Figure 20-40- When repairing hydrostatic and hydraulic systems,
10] from the electrical harness (if equipped). clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Remove the clamps (Item 2) [Figure 20-40-10] from the tubelines and ports to keep dirt out. Dirt can quickly
tubelines. damage the system.
I-2003-0888
Figure 20-40-13
2
1
2
3
S39112
Figure 20-40-14
1
1
S39106
1
Figure 20-40-17
Disconnect the two fittings (Item 1) [Figure 20-40-14].
Figure 20-40-15
S39108
Remove the two bolts (Item 1) [Figure 20-40-15] and Slide the extension cylinder through the tubelines
nuts. [Figure 20-40-17] and remove the cylinder.
Figure 20-40-18 1 1
1 1
S39116
1
Remove the tie-straps (Item 1) [Figure 20-40-20].
S39113
Figure 20-40-21
2 1
1
2
1
S39115
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 20-40-22
2
5
4 3
S39116
Remove the bolt and nut (Item 3) and remove the plate
(Item 4) [Figure 20-40-22].
Parts Identification
1. Housing
2. Safety Valve
3. O-ring
4. Expander O-ring 2
5. Wear ring
6. O-ring
7. Rod 2
8. Back-up Ring
9. Piston
10. Head Gland
11. Wiper
12. Set Screw
5
1 9
6
4
8 12
7
3
10
4
11 8
EM7534
Disassembly
1
Use the following tools to disassemble the cylinder:
Figure 20-40-23
S38918
1
Figure 20-40-26
S38922
Figure 20-40-24
S38919
1
Place a drain pan below the housing and slowly move the
rod (Item 1) [Figure 20-40-26] in and out to remove the
fluid from the cylinder.
S38917
Disassembly (Cont’d)
Figure 20-40-27
1
1
S39425
Figure 20-40-30
Clamp the rod end (Item 1) [Figure 20-40-27] of the rod
assembly in a vise. Support the other end of the rod
assembly with a wooden block.
2
Figure 20-40-28
1
S38923
Disassembly (Cont’d)
Figure 20-40-31 1
S38926
Figure 20-40-34
Remove the wear ring (Item 1) [Figure 20-40-31] from
the piston.
Figure 20-40-32 1
3
1 2
2 S38927
Remove the wiper seal (Item 1), the two wear rings (Item
S38925 2) and the seal (Item 3) [Figure 20-40-34] from the head
gland.
Disassembly (Cont’d)
Figure 20-40-35
2
1
S38928
Assembly
Spanner Wrench 3
2
Cylinder Wrench
Lubricate all O-rings and seals with hydraulic fluid during Install the wiper seal (Item 1) and two wear rings (Item 2)
installation. Always use new O-rings and seals. [Figure 20-40-37] into the head gland.
Figure 20-40-36 Install the seal (Item 3) [Figure 20-40-37] using the seal
installation tool.
2
NOTE: The groove in the seal must point away from
1 the wiper seal.
2 Figure 20-40-38
S38928
S38931
Assembly (Cont’d)
Figure 20-40-39
2
2 S38923
Install the seal (Item 1) and the two O-rings (Item 2) Use the cylinder wrench to install the piston (Item 1) on
[Figure 20-40-39] on the piston. the cylinder rod (Item 2) [Figure 20-40-41].
Figure 20-40-40 Tighten the piston to 414 N•m (305 ft-lb) torque.
1 Figure 20-40-42
S39426
P-29887
Install the backside wear ring (Item 1) [Figure 20-40-40]
on the piston. The second wear ring will be installed at a
later stage. Apply Loctite® 243 or equivalent to the set screw (Item 1)
[Figure 20-40-42].
Assembly (Cont’d)
Figure 20-40-43
S38919
Figure 20-40-46
Install the set screw (Item 1) [Figure 20-40-43] into the
piston.
S38918
Assembly (Cont’d)
Figure 20-40-47
S38917
Carefully peen the lock ring into the groove in the head
gland (Item 1) [Figure 20-40-47].
Figure 20-50-1
1
1
S39069
Figure 20-50-2
S39068
S39071
Install a hoist and lifting strap (Item 1) [Figure 20-50-4] to
the tilt cylinder.
Remove the plastic cap (Item 1) [Figure 20-50-2] from
the boom head.
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 20-50-5
S39389
1
Remove the snap ring (Item 1) and washer (Item 2)
[Figure 20-50-7] from the upper pivot pin.
S39146
Figure 20-50-8
Remove the snap ring (Item 1) and washer (Item 2)
[Figure 20-50-5] from the lower pivot pin.
Figure 20-50-6
1 S39388
Figure 20-50-9
S39075
Parts Identification
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring 2
6. Seal 1 3
7. Set Screw
8. Piston
9. O-ring
10. Back-up Ring
11. Head Gland
12. Wiper 2
9
6
8
7
5 9
2 4
10
11
6
12
EM7533
Disassembly
Figure 20-50-12
1 1
S39076
Figure 20-50-11
S39091
S39077
Disassembly (Cont’d)
Figure 20-50-14
S39080
Figure 20-50-17
Heat the head gland (Item 1) [Figure 20-50-14].
Figure 20-50-15
S39081
1
Support the cylinder rod on a wood block [Figure 20-50-
17].
S39079
Disassembly (Cont’d)
Figure 20-50-18
S39087
S39082
Remove the O-ring (Item 1) [Figure 20-50-20] from the
inside of the piston.
Figure 20-50-19
1
S39084
S39083
Disassembly (Cont’d)
Figure 20-50-22 1
1 1
S39088
Figure 20-50-23
S39089
S39086
Disassembly (Cont’d)
Figure 20-50-26
3 1
S39090
Remove the wiper (Item 1), two wear rings (Item 2) and
seal (Item 3) [Figure 20-50-26] from the head gland.
Assembly
1
Use the following tool to assemble the cylinder:
Lubricate all O-rings and seals with hydraulic fluid during S39088
installation. Always use new O-rings and seals.
Install the head gland (Item 1) [Figure 20-50-29] onto the
Figure 20-50-27
rod.
Figure 20-50-30
3 1
S39090
Install the wiper seal (Item 1), wear rings (Item 2), and
seal (Item 3) [Figure 20-50-27]. S39087
1 2
S39089
Assembly (Cont'd)
Figure 20-50-31
1
S39084
Figure 20-50-32
1 1
P-32047
Assembly (Cont'd)
Figure 20-50-35
1
1
S39082
Install the piston (Item 1) [Figure 20-50-35] onto the rod Figure 20-50-38
and tighten.
Figure 20-50-36
S39082
P-29887
Assembly (Cont'd)
1
Figure 20-50-39
S39390
NOTE: Do not peen the lock ring for more than 1 - 1,5
Install the piston / rod assembly (Item 1) [Figure 20-50- mm (0.04 - 0.06 in).
39] into the housing.
Figure 20-50-42
Clean off any old residue, and apply Loctite® 262 to the
threads of the head (Item 2) [Figure 20-50-39].
Figure 20-50-40
S39077
Removal
Remove:
2
• the front axle. (See Removal And Installation on Page 1
40-30-1.)
or
Figure 20-60-1
S2515
Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-60-3].
2
3 Figure 20-60-4
1
1
S2513
S2514
Removal (Cont’d)
Figure 20-60-5 2
S2519
Figure 20-60-8
Remove the tie rod end (Item 1) [Figure 20-60-5] by
means of a puller.
Figure 20-60-6 1
2
1
S2520
Installation
Figure 20-60-9
S2523
Apply Loctite® 243 to the thread and install the two tie
S2521 rods [Figure 20-60-11]. Tighten the tie rods to 240 - 270
N•m (177 - 199 ft-Ib) torque.
Lubricate the seats of the seals and install the steering Figure 20-60-12
cylinder (Item 1) [Figure 20-60-9] into its seat.
Figure 20-60-10
2
1
S2524
Installation (Cont’d)
Figure 20-60-13
S2525
Figure 20-60-14
S2526
Disassembly
Figure 20-60-15 2
2
S1518
Figure 20-60-16
1
1
3
2
S1519
S1517
Hammer the piston (Item 1) on the rear of the head
(Item 2) [Figure 20-60-18] using a plastic hammer.
With the help of a plastic hammer, push the head
Continue hammering until the head (Item 2) is ejected
(Item 1) inside the cylinder (Item 2) [Figure 20-60-16].
from the cylinder (Item 3) [Figure 20-60-18].
NOTE: The head should line up with the edge of the
cylinder.
Disassembly (Cont’d)
Figure 20-60-19
A
S1520
Assembly
1
Figure 20-60-20
1 2 3
S1523
After applying grease, install the sealing ring (Item 1) on NOTE: In order to facilitate assembly, apply grease to
the shaft, the anti-extrusion ring (Item 2) and the scraper the outer surface of the piston.
ring (Item 3) [Figure 20-60-20] inside the cylinder. Do not roll the seal (Item 1) [Figure 20-60-22].
3 2 1 4
S1524
Assembly (Cont’d)
Figure 20-60-24 1
T18
T18
2
1
S1527
Figure 20-60-27
Apply tool T18 to the shaft on the opposite side of the
head and center it on the cylinder (Item 1) so that it fits
into the piston (Item 2) [Figure 20-60-24].
1
NOTE: Apply a little grease to seals and cylinder.
T18
Figure 20-60-25
1 3
2
S1528
Apply grease to the head seals (Item 1), install the head
onto the piston (Item 2) and push it onto the cylinder
2
(Item 3) [Figure 20-60-27].
S1526
Assembly (Cont’d) 2
Figure 20-60-28
S1531
S1530
Removal
Figure 20-70-1
1
1
S38227
3
Remove the piston (Item 1) [Figure 20-70-3].
Figure 20-70-4
2
S38224
Figure 20-70-2
Remove the cover plate (Item 1) [Figure 20-70-4].
1
2
S38225
Removal (Cont’d)
Figure 20-70-5
1
S38230
Parts Identification
1. O-ring
2. Seal
3. Cylinder
4. Rod
5. Piston
6. Cover Plate
7. Sealant
8. Screw
3 5
6
1
1 1
7
1
EM7541
Disassembly
2
Figure 20-70-6
2 S38231
1
Figure 20-70-7
1
2
S38226
Assembly
Figure 20-70-9
S38228
Figure 20-70-10
1
2
1
S38230
S38226
Installation
Figure 20-70-13
1
2
S38225
Apply Loctite® 510 and install the cover plate (Item 1) Figure 20-70-16
[Figure 20-70-13].
Figure 20-70-14 3
2
1 S38224
S38227 Apply some hydraulic fluid on the control rod and piston
before installing the gear control cylinder (Item 2) [Figure
20-70-16].
Install the piston (Item 1) [Figure 20-70-14].
Install the gear control cylinder (Item 2) with the two bolts
(Item 3) [Figure 20-70-16].
Figure 20-80-1
2
4 1
S38158
5
Start the engine and run at low idle rpm. Press the front
3 auxiliary hydraulics button (Item 1) [Figure 20-80-2].
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 2400 rpm.
1 S39186
Warm the fluid to 60°C (140°F) by turning the restrictor
control (Item 5) [Figure 20-80-1] on the tester to about
Connect the inlet hose (Item 1) from the tester (Item 5) to 6,9 MPa (69 bar) (1000 psi). DO NOT exceed system
the front coupler (Item 2) [Figure 20-80-1]. relief pressure. Open the restrictor control knob and
record the free flow (U.S. gpm) at 2400 rpm.
Connect the outlet hose (Item 3) from the tester (Item 5)
to the rear coupler (Item 4) [Figure 20-80-1]. There should be 95 L/min (25 U.S. gpm) free flow. Turn
the restrictor control (Item 5) [Figure 20-80-1] on the
tester until the main relief opens. The correct pressure
should be 25,5 MPa (255 bar) (3698 psi).
IMPORTANT If adjustment is needed, see [Figure 20-80-3].
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.) IMPORTANT
Figure 20-80-3 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
1 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-80-5
S39398
Figure 20-80-4
S39398
2
Locate the main relief valve (Item 1) [Figure 20-80-5] on
the front upper side of the control valve.
1
Clean the area around the control valve.
S38604
WARNING 1
Figure 20-90-1
Disconnect the four connectors (Item 1) [Figure 20-90-2]
3 from the solenoids.
Figure 20-90-3
BOTTOM VIEW
2
1
1
S39413
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
Parts Identification
2
1
5
5
4
3
4
5
4
1. Block
2. Load Sense Valve
3. Solenoid Valve 4
Stem
4. Solenoid
5. Plug
6. Check Valve
EM9300
Figure 20-90-4 1
3
1
4
2
S39858
6
5 Inspect the O-rings and back-up washer (Item 1)
S39414 [Figure 20-90-6] for damage.
Remove the nut (Item 3) from the solenoid valve stem Figure 20-90-7
and remove the two steering mode solenoids (Item 4)
[Figure 20-90-4].
Figure 20-90-5
S39859
Figure 20-100-1
1
1 1
S39132
Figure 20-100-4
S38084
Figure 20-100-2
1 S39134
1
1
S39131
IMPORTANT
Disconnect the three hoses (Item 1) and the tubeline When repairing hydrostatic and hydraulic systems,
(Item 2) from the brake valve (Item 3) [Figure 20-100-2]. clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
NOTE: Some additional hoses may need to be tubelines and ports to keep dirt out. Dirt can quickly
disconnected from the steering valve in order damage the system.
to disconnect the tubeline. I-2003-0888
Figure 20-100-5
S39135
1
WARNING S38066
Hydraulic fluid escaping under pressure can have Loosen the two bolts (Item 1) and remove the cover (Item
sufficient force to enter a person’s body by 2) [Figure 20-110-1] from the front side of the engine /
penetrating the skin. This can cause serious injury hydrostat assembly.
and possible death if proper medical treatment by a
physician familiar with this injury is not received Figure 20-110-2
immediately.
W-2145-0290
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
S38067
Remove the two bolts that hold the plate (Item 1) and
remove the plate (Item 1) [Figure 20-110-2].
Figure 20-110-3 1
1
1
1
2
S39400
Figure 20-110-6
Loosen the two fittings (Item 1) and remove the tubeline
(Item 2) [Figure 20-110-3].
Figure 20-110-4
2
1
1 1 1
S39401
Parts Identification
Figure 20-110-7
19
22
23 17 16
20
15
24
25
14
17
18 16
9 10
2
4 3
2
1. Fitting
2. O-ring 5 1
6
3. Spring 10 2 7
4. Spring Seat
5. Spool
6. Screen
7. Orifice Spool 18 10
8. Bolt 19 2
18
9. Cover
17 16 7
10. Plug 6
11. Bolt
12. Washer 5
13. Front Cover 17 2
16
14. Seal Ring
15. Pump Housing 13
16. Back-up Ring
17. Seal Ring
18. Holder
19. Gear
20. Spline Shaft
21. Mount Plate
4
22. Thrust Plate
23. Mount Plate 2 3
24. Seal 2
15
25. Snap Ring
1
EM7530
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1 1
damage the system.
I-2003-0888
2
S39437
Figure 20-110-8
Figure 20-110-10
5 4 3 2 1
6
S38103
S39248
Remove the plug (Item 1), O-ring (Item 2), spring (Item
3), spring seat (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-110-10].
Figure 20-110-11
2
1
P-25296
Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque. Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-110-13].
Figure 20-110-12
Cut NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.
Figure 20-110-14
14 mm dia.
(0.550” dia.) 1 2
38 mm
(1.500’’) 19 mm
(0.750’’) B-14674
P-25295
Figure 20-110-15 1
2
3
1 1
2 4
S39351
Assembly: Tighten the bolts to 70 N•m (51 ft-lb) torque. Figure 20-110-18
Figure 20-110-16
1
1
S39252
S39350
Remove both O-rings (Item 1) [Figure 20-110-18] from
the housing.
Remove the housing / gear assembly (Item 1)
[Figure 20-110-16] from the main housing.
Figure 20-110-19 1 1
1 1
2
P-25304
1
Figure 20-110-20
P-25305
1
3
4
P-25310
1 2 2
3 1 3
1
P-25307
P-25313
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system. 1
I-2003-0888
S38799
Drain the radiator. (See Removing And Replacing The
Coolant on Page 10-70-3.)
Remove the four fan guard mount bolts and nuts (Item 1)
Remove the radiator. (See Oil Cooler / Intercooler / [Figure 20-120-2].
Radiator Removal And Installation on Page 70-60-1.)
Flip the fan assembly around.
Figure 20-120-1
Figure 20-120-3
2
1
1
1 S38861
S38796
Figure 20-120-4
S38801
Figure 20-120-5
S38797
Tap on the shaft to release the fan motor from the blade
assembly [Figure 20-120-5].
1. Seal
2. Check Valve
3. Motor Housing
4. Gear Assembly
5. Rear Cover
6. Front Cover
7. Back-up Ring
8. Holder
9. Gear
10. Pin
11. Snap Ring
2
7
3 1
8
1
5 9
8
10 7
1
1 6
10
11
EM7529
Figure 20-120-6
2
1
1
P-53277
1 1
P-53278
P-53282
Figure 20-120-11
P-53283
Figure 20-120-14
P-53256
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-120-14].
Assembly: The open part of the seal goes into the rear
cover first.
Figure 20-120-15
P-53285
1. Seal
2. Back-up Ring
3. Plug
4. Solenoid 5
5. Gear Assembly
6. Check Valve
7. Snap Ring
8. Motor Housing
9. Rear Cover 11
10. Front Cover 9
11. Pin 1
12. Holder
13. Gear
14. Bolts
15. Washers
1
7
12
13
12
2 14
1
11
15
4
11 1
10
11 3
6
1
2 3
EM7531
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
S38804
Figure 20-120-16
Remove the fitting (Item 1) from the “IN” port and the
fitting (Item 2) [Figure 20-120-18] from the “OUT” port.
Figure 20-120-19
1
1
S38802
S38803
Figure 20-120-20 1
S38808
Figure 20-120-21
S38809
Figure 20-120-24
2
S38812
1 1
1 S38813
Figure 20-120-28 1
S38817
Figure 20-120-29
2
1 1
S38816
S38820
1
S38821
1
Remove the two pins (Item 1) and the seal (Item 2)
[Figure 20-120-35] from the motor housing.
S38819
Figure 20-120-36
1
2 1
S38824
Figure 20-120-37 2
1
1
S38825
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-120-39].
S38823
Assembly: The open part of the seal goes into the cover
first.
Remove the back-up ring / seal (Item 1) [Figure 20-120-
37] from the gear holder.
Figure 20-120-40
S38826
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Figure 20-130-1 1
S38294
2
1 Remove the two hoses (Item 1) [Figure 20-130-2] from
the hydraulic tank.
Figure 20-130-3
1
1 3
S38105
2
Loosen the two bolts (Item 1) and remove the cover (Item
2) [Figure 20-130-1].
4
S38080
Figure 20-130-4
S38292
2
Remove the two mounting bolts (Item 1) [Figure 20-130-
S38798 6] from the hydraulic tank.
Figure 20-130-7
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 20-130-4].
Figure 20-130-5
S38293
Figure 20-140-3
1 1
2 1
1
1
S38084
Figure 20-140-2
Remove the four bolts (Item 1) [Figure 20-140-3] and
1 remove the steering valve.
S38125
3 2
S38679
Figure 20-150-3
S38678
1
REF FUNCTION
1 Lower Boom
2 Raise Boom 1
3 Tilt Down
4 Tilt Up
5 Extend Telescopic Boom
6 Retract Telescopic Boom
7 Front Auxiliary Hydraulics B4 (Male Coupler)
8 Front Auxiliary Hydraulics A4 (Female Coupler)
S39181
S39398
14. Install a 7,0 MPa (70 bar) (1000 psi) gauge on the test
9. Locate the test fitting (Item 1) [Figure 20-150-6] and fitting (Item 1) [Figure 20-150-8] located on the P-
remove the cap. port of the control valve.
Figure 20-150-7 15. Start the engine and run the engine at low idle (900
rpm). Record the pressure. The pressure at the gauge
should be within the following range: 1,3 - 1,5 MPa
(13 - 15 bar) (189 - 218 psi).
16. Run the engine at high idle (2315 rpm) and record the
pressure. The pressure at the gauge should be within
the following range: 1,6 - 1,8 MPa (16 - 18 bar) (232 -
261 psi).
S39393
10. Install a 7,0 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-150-7].
11. Start the engine and run the engine at 2315 rpm.
Record the pressure. The pressure at the gauge
should be within the following range: 2,5 - 3,5 MPa
(25 - 35 bar) (363 - 508 psi).
Figure 20-150-9
S38678
7
5
3 18. Remove the two screws (Item 2) [Figure 20-150-10]
and pull out the solenoid valve (“Tilt Up” controller
shown in picture).
4 8
NOTE: Install a cap on the valve opening to prevent
6 dust penetration.
2
S38004 Figure 20-150-11
REF FUNCTION
1 Lower Boom
2 Raise Boom
3 Tilt Down
4 Tilt Up
5 Extend Telescopic Boom
6 Retract Telescopic Boom
7 Front Auxiliary Hydraulics B4 (Male Coupler)
8 Front Auxiliary Hydraulics A4 (Female Coupler) 1
S7171
19. Turn the Ignition key switch ON, but DO NOT start the
engine. Check the function of each solenoid valve by
having another person move the telescopic control
switch (Item 1) [Figure 20-150-11]. The solenoid
valve piston, which can be seen through the valve
orifices (Item 1) [Figure 20-150-11] must be moving
according to the switch movement.
2 3
WARNING
Hydraulic fluid escaping under pressure can have 1
sufficient force to enter a person’s body by 4
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a 5
physician familiar with this injury is not received
S38604
immediately.
W-2145-0290
IMPORTANT Repeat the above step for the bolt (Item 4) [Figure 20-
150-13].
When repairing hydrostatic and hydraulic systems,
Remove the bolt (Item 5) [Figure 20-150-13].
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 20-150-12
S38604
Figure 20-150-14
1
1
1
S38607
Loosen the nuts (Item 1) [Figure 20-150-14] in order to Use care not to damage the tubelines or fittings.
create a gap between the frame and control valve.
Figure 20-150-15
2
S38608
Parts Identification
1. End Housing
2. Auxiliary Valve Section
3. Telescoping Valve Section
4. Tilting Valve Section
5. Lifting Valve Section
6. Inlet-Outlet Valve Section
1 6
2 3 4 5
S38609
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
1
S38611
Mark the valve sections for ease of assembly. (See Parts
Identification on Page 20-150-9.)
Remove the three nuts (Item 1) [Figure 20-150-18] from
Figure 20-150-17 the tie rod bolts.
S38610
Figure 20-150-19 2
1 S38614
Figure 20-150-20
3
2
2
S38615
1
S38613
Remove the O-ring (Item 1), two back-up rings (Item 2)
and O-ring (Item 3) [Figure 20-150-22] from the valve
Remove the nut (Item 1) and valve stem solenoid (Item 2) stem.
[Figure 20-150-20] from the inlet-outlet valve section.
Figure 20-150-23
1
S38693
2
Remove the O-ring (Item 1), back-up ring (Item 2) and O- Figure 20-150-25
ring (Item 3) [Figure 20-150-23] from the main relief
valve.
S38694
Figure 20-150-26
1 1
1
S38697
Figure 20-150-27
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-150-29]
Figure 20-150-30
S38701
Figure 20-150-31
1
S38702
1 1
Remove the O-ring (Item 1) [Figure 20-150-33].
S38700
Figure 20-150-34
1
1
S38705
The relief pressure value (in bar) of the port relief valve is
indicated on the spool assembly (Item 1) [Figure 20-150-
S38703 36].
3
S38705
S38704
Figure 20-150-38
1
1
2
3
S40001
Remove the spring (Item 1) and two shuttle spools (Items Figure 20-150-40
2 and 3) [Figure 20-150-38] from the valve section.
S38694
Figure 20-150-41
1 1
1
S38697
Figure 20-150-42
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-150-44]
Figure 20-150-45
S38701
Figure 20-150-46
1
S38702
1 1
Remove the O-ring (Item 1) [Figure 20-150-48].
S38700
Figure 20-150-49
1
1
S38705
The relief pressure value (in bar) of the port relief valve is
indicated on the spool assembly (Item 1) [Figure 20-150-
S38703 51].
3
S38705
S38704
Figure 20-150-53
1
1
2
3
S40002
S38719
Remove the telescoping valve section (Item 1)
[Figure 20-150-54].
Remove the spring (Item 1) and two shuttle spools (Items
2 and 3) [Figure 20-150-53] from the valve section. Figure 20-150-55
S38694
Figure 20-150-56
1 1
1
S38697
Figure 20-150-57
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-150-59].
Figure 20-150-60
S38701
Figure 20-150-61
1
S38702
1 1
Remove the O-ring (Item 1) [Figure 20-150-63].
S38700
Figure 20-150-64
1
1
S38705
The relief pressure value (in bar) of the port relief valve is
indicated on the spool assembly (Item 1) [Figure 20-150-
S38703 66].
3
S38705
S38704
1
2
3
S40003
Remove the spring (Item 1) and two shuttle spools (Items Figure 20-150-70
2 and 3) [Figure 20-150-68] from the valve section.
S38694
Figure 20-150-71
1 1
1
S38697
Figure 20-150-72
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-150-74]
Figure 20-150-75
S38701
Figure 20-150-76
1
S38702
1 1
Remove the O-ring (Item 1) [Figure 20-150-78].
S38700
Figure 20-150-79
1 1
S38705
1
2
S38719
Figure 20-150-83 1
S38744
1
1
Figure 20-150-86
Remove the tie rods (Item 1) [Figure 20-150-83] from the
end housing.
1
Figure 20-150-84
S38745
1
Remove the O-ring (Item 1) [Figure 20-150-86] from the
S38743 plug.
Figure 20-150-87
S38747
Figure 20-150-90
Remove the plug (Item 1) [Figure 20-150-87].
Figure 20-150-88
1 1
S38748
Testing
6
5 4
IMPORTANT 3
2
S38679
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat NOTE: The valve is shown removed from the
hydraulic fluid. machine for photo clarity.
6 1
5 4
2
3 2
S38705
S38679
1 Lower Boom Port Relief Valve (Rod End) The relief pressure value (in bar) of the port relief valve is
2 Raise Boom Port Relief Valve (Base End) indicated on the end of the assembly (Item 2) [Figure 20-
3 Tilt Down Port Relief Valve (Rod End) 160-5].
Figure 20-160-4
2
S38749
1
Install the port relief valve spool (Item 1), spring (Item 2)
and the plug (Item 3) [Figure 20-160-6]
S38749
IMPORTANT
When repairing hydrostatic and hydraulic systems,
S39431
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Remove the bolt (Item 1) [Figure 20-170-1]. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-170-2
1
1 1
S39428
Figure 20-180-1
S38074
1
Raise the boom and install the boom stop (Item 1) Figure 20-180-3
[Figure 20-180-1].
WARNING
Hydraulic fluid escaping under pressure can have 1 3
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury 2
and possible death if proper medical treatment by a
S38720
physician familiar with this injury is not received
immediately.
W-2145-0290
Remove the hose (Item 1) [Figure 20-180-3] from the
accumulator.
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 telescopic handler does not move 1, 2
The telescopic handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11
Replenishing Valve Function 1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
Figure 30-10-1 because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1
[Figure 30-10-1].
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 30-30-1
1
1
S38670
1
Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-3].
1 Figure 30-30-4
1
S39860
S38247
Remove the five hoses (Item 1) [Figure 30-30-2] from
the hydrostatic drive motor.
Installation: Replace the O-ring (Item 1) [Figure 30-30-
4].
Parts Identification
1. Plug
2. O-ring
3. Spring
4. Poppet
5. Housing
6. Bolt 1
7. Spring Seat
8. Spool 2
9. Gasket
10. Spacer 3
11. Back-up Ring 4
12. Shaft
13. Housing 5
2 1
1
2 2
6 13
3
7
1 2 2
1 1
9
1
7
3
2
1
B-15938
1. Valve Segment
2. Plate
3. Pins
4. Bearing
5. Cylinder
6. Pin
7. Synchronizing Shaft
8. Rollers
9. Bolt
10. Nut
11. Cap
12. Plug
13. O-ring
14. Ring
15. Piston
16. Spring Seat
17. Spring
18. Shaft
19. Bearing
20. Spacer
21. Nut
22. O-ring
23. Seal
24. Housing
B-15937
1. Nut
2. Solenoid
3. Solenoid Shaft
4. O-ring
5. Spring
6. Plug
7. Fitting
8. Bolt
9. Orifice
10. Housing
11. Spool
12. Adjustment Spool
13. End Nut
14. Nut
15. Spring Seat
16. Limiter
B-15939
Disassembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
P-22328
I-2003-0888
Figure 30-30-8
S39402
P-22329
Place the hydrostatic drive motor on a work surface, mark
the sections for correct assembly [Figure 30-30-5].
Remove the solenoid (Item 1) [Figure 30-30-8] from the
Figure 30-30-6 shaft.
1 1
S39403
Disassembly (Cont'd)
Figure 30-30-9 3
P-22333
Figure 30-30-12
Remove and discard the O-ring (Item 1) [Figure 30-30-9]
from the solenoid.
Figure 30-30-10
2
P-22335
2
Disassembly (Cont'd)
Figure 30-30-13
3
2
1 1
P-22338
Figure 30-30-16
Remove the adjusting screw (Item 1), valve spring (Item
2) and spool assembly (Item 3) [Figure 30-30-13] from
the housing.
Figure 30-30-14
1
1
P-22339
Disassembly (Cont'd)
Figure 30-30-17
1
P-27537
Figure 30-30-18
P-27536
Disassembly (Cont'd)
1
Figure 30-30-20
P-22346
1
Lift and remove the end cap (Item 1) [Figure 30-30-22]
P-22344 from the housing.
Figure 30-30-23
Remove and discard the six O-rings (Item 1) [Figure 30-
30-20] from the housing.
Figure 30-30-21 1
1
1
P-22347
1
1
Remove the gasket (Item 1) [Figure 30-30-23] from the
S39404 end cap.
Disassembly (Cont'd)
Figure 30-30-24
S39406
1
Figure 30-30-25
3
1
2
1
S39407
Remove the plug (Item 1), spring (Item 2), spring seat
(Item 3) and spool (Item 4) [Figure 30-30-27] from the
P-22375 housing.
Disassembly (Cont'd)
Figure 30-30-28
1 1
3
S39408
Remove the plug (Item 1), spring (Item 2) and spring seat
P-22378 (Item 3) [Figure 30-30-30] from the housing.
Figure 30-30-31
Remove and discard the O-ring (Item 1) [Figure 30-30-
28] from the plug.
Figure 30-30-29
1
P-22378
Disassembly (Cont'd)
Figure 30-30-32 1
P-22384
Figure 30-30-35
Loosen and remove the relief valve (Item 1) [Figure 30-
30-32] from the housing. 2
Figure 30-30-33 2 1
1 2 3 4 5 2
2
P-22386
Remove the plug (Item 1), O-rings (Item 2), spring (Item
3) and poppet (Item 4) from the relief valve housing (Item
5) [Figure 30-30-33].
Disassembly (Cont'd)
Figure 30-30-36
1
2
P-22503
Remove the mounting plate [Figure 30-30-36] using a NOTE: It is not important that the pistons are
suitable puller. installed in their original position.
P-22378 P-22459
Remove and discard the seal (Item 1) [Figure 30-30-37] Remove the bearing plate (Item 1) [Figure 30-30-39]
from the mounting plate. from the cylinder block.
Disassembly (Cont'd)
Figure 30-30-40
P-22390
Figure 30-30-41
1 P-22505
Disassembly (Cont'd)
Figure 30-30-44
1
P-22446
Remove the ring nut (Item 1) [Figure 30-30-44] from the Figure 30-30-47
shaft.
Figure 30-30-45
2
3
2
1
3
1
P-22447
P-22507 Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-47] from the shaft assembly.
Disassembly (Cont'd) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-48 material can get into the system and cause damage.
Figure 30-30-49
1
2
1
P-22508 2
P-22461
Remove the piston rings (Item 1) [Figure 30-30-48] from
the pistons.
Inspect the running (bronze) surface of the bearing plate
NOTE: If any portion of the shaft assembly, bearings (Item 1) and locating pin holes (Item 2) [Figure 30-30-49]
or races must be replaced, the complete for wear. Replace if damaged or worn.
shaft / bearing assembly must be replaced.
The only serviceable part is the piston rings Figure 30-30-50
(Item 1) [Figure 30-30-48].
P-22462
Inspection (Cont'd)
Figure 30-30-51
1
B-15936
P-22349
Assembly
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-22446
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear or damage. Replace any worn Using a clamp, compress the spring and spring seat
or damaged parts. [Figure 30-30-55].
Always install new seals and O-rings. Lubricate all seals Figure 30-30-56
and O-rings with clean hydraulic fluid before installation.
Figure 30-30-54
1 2 1
P-22441
P-22447
Install the pin (Item 1) [Figure 30-30-56] as shown.
Assembly (Cont'd)
Figure 30-30-57
2
P-22509
1
Using a punch seat the ring nut into the groove in the
P-22453 shaft. [Figure 30-30-59].
Figure 30-30-60
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-57] into the shaft assembly.
Figure 30-30-58
P-22455
P-22505
NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
Assembly (Cont'd)
Figure 30-30-61 1
1
1
1
P-22387
Install a new seal (Item 1) [Figure 30-30-61] into the Figure 30-30-64
mounting plate until it is fully seated.
Figure 30-30-62
1
P-22386
Assembly (Cont'd) 2
Figure 30-30-65
1
13,5 - 14,0 mm
(0.53 - 0.55 in)
P-22440
Figure 30-30-67
B-15933
Piston End
B-15935
Assembly (Cont'd)
Figure 30-30-68
1 1
P-22511
Install the bearing plate (Item 1) [Figure 30-30-68] with Figure 30-30-71
the bronze surface facing up onto the cylinder block.
Figure 30-30-69
1
P-22499
Assembly (Cont'd)
Figure 30-30-72 1
2 2
1
P-22513
2
1
3 1
1
P-22512
P-22511
Assembly (Cont'd)
Figure 30-30-76
1
1
P-22375
Figure 30-30-77
S39405
3
4 P-22511
Assembly (Cont'd)
1
Figure 30-30-80
S39409
Figure 30-30-83
NOTE: Note the position of the hole (Item 1)
[Figure 30-30-80] in the end cap.
Figure 30-30-81
1
3
5 1 4
4 2
P-22378
Assembly (Cont'd)
Figure 30-30-84
1
2
2
3
3 S39408
4
Install the spring seat (Item 1), spring (Item 2) and plug
S39407 (Item 3) [Figure 30-30-86] into the housing and tighten to
41 N•m (30 ft-lb) torque.
Install the spool (Item 1), spring seat (Item 2), spring Figure 30-30-87
(Item 3) and plug (Item 4) [Figure 30-30-84] into the
housing and tighten to 41 N•m (30 ft-lb) torque.
Figure 30-30-85 2
1
1
P-22346
Assembly (Cont'd)
Figure 30-30-88
1
1
P-22339
1
1
Install a new O-ring (Item 1) [Figure 30-30-90] onto the
S39404 plug.
Figure 30-30-91
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-88] to 115 N•m (85 ft-lb) torque.
Figure 30-30-89
P-22338
1
Install the plug (Item 1) [Figure 30-30-91] into the
P-22344 housing.
Assembly (Cont'd)
Figure 30-30-92
1
1
2
P-22333
1
2
3 1
P-22340
P-22336
Assembly (Cont'd)
Figure 30-30-96
1 1
S39403
2
Install the solenoid housing assembly with four bolts
(Item 1) [Figure 30-30-98]. Tighten the bolts to 78 N•m
P-22342
(58 ft-lb) torque.
Figure 30-30-97
P-22343
Figure 30-40-1
S38624
1
Figure 30-40-3
S38625
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
S38626
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the hose (Item 1) [Figure 30-40-3].
I-2003-0888
Figure 30-40-4
S38627
Figure 30-40-5
S38628
Parts Identification
8
10 10
9 11
11
6
7
9 7
6
EM7521
1. Orifice
2. Pin
3. Gasket
4. Filter Screen
5. O-ring
6. Solenoid
7. Plug
8. O-ring
9. Bolt
10. Actuator
11. O-ring
12. Coil
13. O-ring
14. Nut
15. Screw
16. Solenoid, Safety
10
11
16 6
13
14
15
EM7522
1. Roll Pin
2. Valve Plate
3. Retainer
4. Spring Seat
5. Spring
6. Washer
7. Cylinder Block
8. Spring
9. Ball Guide Retainer
10. Slipper Guide
11. Piston
12. Filter Screen
13. Pin
14. Bearing Assembly
15. Swash Plate
16. Piston Pump Housing
16
12
12
13 14
13
11
14
8 15
6 10
9
4
7
2 5
EM7523
1. Bolt
2. O-ring
3. Flange Adapter
4. Gasket
5. Thrust bearing
6. Coupling
7. Seal
8. Pressure Balance Plate
9. Ring
10. Charge Pump Gears
11. Valve Plate 14
12. Charge Pump Housing
13. Bushing
14. Gasket
15. Pin
12
13
15
7
11
10
15
7
4
5
3
9
6
8
EM7524
1. Piston Ring
2. O-ring
3. Servo Piston
4. Block
5. Swash Plate
6. Cylinder
7. O-ring
8. Lock Plate
9. Bolt
10. Snap Ring
11. Bearing
12. Shaft
13. Snap Ring
14. Seal
EM7525
Shaft Disassembly
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,
S38630
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Remove the snap ring (Item 1) [Figure 30-40-7] from the
pump housing
Figure 30-40-6
Figure 30-40-8
1
1
S38629
S38631
Figure 30-40-9
S38634
Figure 30-40-12
Remove the snap ring (Item 1) [Figure 30-40-9] from the
pump housing.
2
Figure 30-40-10
1
3
S38635
Figure 30-40-13
1 4
2 3
3
2 EM1218
S10264
Figure 30-40-14
1 S38636
Figure 30-40-17
1 1
2
S38639
Figure 30-40-20
S38638 1
Figure 30-40-18
1 S38640
EM1220
S38643
EM1225
1 1
2 2
S38645
3
Remove the gasket (Item 1) [Figure 30-40-27].
S38644
Figure 30-40-28
Remove the two bolts (Item 1) first. Then remove the four
bolts (Item 2) [Figure 30-40-25] from the housing.
Figure 30-40-26
1
1
S38647
S38645
S38650
Figure 30-40-32
Mark the piston assembly (Item 1) [Figure 30-40-29]
position. Remove the piston assembly from the cylinder
block.
Figure 30-40-30
1
S38651
Figure 30-40-33
EM1238
Figure 30-40-36
Remove the servo piston assembly (Item 1) [Figure 30-
40-33] from the housing.
Figure 30-40-34
1
1
S38654
Figure 30-40-37
1
1
1 1 1
S38656
S38655
Remove the six screws (Item 1) [Figure 30-40-38] from
the solenoid block.
Remove the two swash plate bearings (Item 1)
[Figure 30-40-37] from the swash plate. Figure 30-40-39
S38657
Figure 30-40-40
1
1
3 EM1706
Figure 30-40-43
Remove the filter retaining ring (Item 1) and filter screen
(Item 2) from the orifice (Item 3) [Figure 30-40-40] in the
solenoid block.
Figure 30-40-41
2
1 1
1
S38667
S38661
Inspection
1
Figure 30-40-44
1
2 3 1
EM1710
Clean all parts in solvent and use air pressure to dry Install new expander O-rings into the grooves in the
them. DO NOT use cloth or paper as small pieces of servo piston. Carefully install the piston seal rings over
material can get into the system and cause damage. the expander rings. Do not overstretch the piston seal
rings.
Check the pressure balance plate (Item 1) and the valve
plate (Item 2) and charge pump gears (Item 3) Lubricate the seal rings and install them into the two
[Figure 30-40-44] for damage or wear. (disassembled) servo cylinders to allow the assembly to
set for 5 minutes for the seal rings to return to their
Figure 30-40-45 original size. Remove the servo cylinders afterwards.
Figure 30-40-47
EM1709 2
S38662
Check the valve plate [Figure 30-40-45], the surface
must be smooth and free of scratches. If scratches can
be felt with a finger nail, replace the part. Check the swash plate bearing race (Item 1) and bearing
rollers (Item 2) [Figure 30-40-47] for wear and damage.
Replace as needed.
Inspection (Cont'd)
Figure 30-40-48
1
S38664
2
S38663 EM1715
S10264
Check the cylinder block bores for wear or scratches Inspect both high pressure relief valves. (See Relief
[Figure 30-40-49]. Valves Disassembly And Assembly on Page 30-40-10.)
If there is any defect in the cylinder block or pistons, the Replace O-rings as needed [Figure 30-40-51].
complete rotating group must be replaced.
IMPORTANT 1
S38654
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear or damage. Replace any worn Install the swash plate (Item 1) [Figure 30-40-53].
or damaged parts.
Figure 30-40-54
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.
Figure 30-40-52
1
1
1
EM1238
Figure 30-40-55
2 2
1 1
S38651
Install the servo piston assembly (Item 1) [Figure 30-40- Figure 30-40-58
55] into the housing.
Figure 30-40-56
1
1
S38651
EM1237 Install the servo cylinder locking plate (Item 1) and both
screws (Item 2) [Figure 30-40-58]. Repeat for the other
side.
Install a new O-ring (Item 1) [Figure 30-40-56] on both
servo cylinders.
Figure 30-40-59
S38648
Figure 30-40-62
Put the piston assemblies (Item 1) [Figure 30-40-59] into
the slipper guide.
Figure 30-40-60
S38647
Figure 30-40-63 2 2
1
1 1
2 2
S38644
Install the gasket (Item 1) [Figure 30-40-63]. Install and gradually tighten the four bolts (Item 1)
[Figure 30-40-65]. Tighten the bolts to 140 N•m (103 ft-
NOTE: Verify that both alignment pins (Item 2) lb) torque.
[Figure 30-40-63] are installed.
Tighten the two bolts (Item 2) to 25 N•m (18.4 ft-lb)
Figure 30-40-64 torque. Now re-check torque of the four bolts (Item 1)
[Figure 30-40-65].
S38645
Figure 30-40-66
1
2 1
S38642
Figure 30-40-69
S39209
Figure 30-40-67
S38641
S38643
Figure 30-40-70
1
EM1220
Install the pressure balance plate (Item 1) [Figure 30-40- Figure 30-40-73
70].
Figure 30-40-71 1
1
2 2 1
1
EM1219
S38639 Install the cover and the four bolts (Item 1) [Figure 30-
40-73]. Tighten the bolts to 92 N•m (68 ft-lb) torque.
Figure 30-40-74 1
S38659
S38660
1
Install the spring (Item 1) and spool (Item 2) [Figure 30- NOTE: Install the filter screen (Item 2) [Figure 30-40-
40-74] into the solenoid block. 76] with the mesh facing outward.
1
1
EM1706 S38658
Install a new O-ring (Item 1) [Figure 30-40-75] onto each Install the two orifices (Item 1) [Figure 30-40-77] into the
solenoid. pump housing. Tighten to 2.5 N•m (22.1 in-lb) torque.
1 1
1 1
1
1
1
S38656
Figure 30-40-79
2
1
S38657
Shaft Assembly
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
S38633
Figure 30-40-81
Figure 30-40-84
1
3
S38635
S38634
Figure 30-40-85
S38630
S38629
Install the coupler gear (Item 1) flush with the pump shaft.
S38668 Fasten the retainer bolt (Item 2) [Figure 30-40-88].
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Rear Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Front Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
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
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21
For photo clarity, the following axle procedures are done • Front Axle Removal (See Removal And Installation on
with the complete axle assembly removed from the Page 40-30-1.), Front Steering Cylinder Removal.
machine. However, the planetary carrier, wheel hub, (See Removal on Page 20-60-1.)
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support
9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Nut
19. Stud
20. Snap ring
S38371
Figure 40-20-1 1 1
S2465X
S2465A
Remove the two securing bolts and lift the planet gear
S2463A carrier (Item 1) [Figure 40-20-3].
Figure 40-20-4
Loosen the two securing bolts (Item 1) [Figure 40-20-1].
Figure 40-20-2
1 2
S2466
S2464A
Figure 40-20-5 1
1
2
S2468
Figure 40-20-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-20-5].
Figure 40-20-6
1
S2469
Figure 40-20-9
1
1
1 1
1
S2473A
Figure 40-20-10
S2474A
1 S2477A
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-20-16
[Figure 40-20-13].
1
Figure 40-20-14
S2478A
Figure 40-20-17
S2479A
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Drive axle
8. Seal
9. Thrust bushing
10. Centering ring
15. Cover
16. Plug
17. Tie rod
18. Grease fitting
19. Tie rod assembly
20. Plug
21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Bushing
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S38372
Figure 40-20-18
1 2
3
3
2
4 S38374
1
Using two levers, remove the top tie rod (Item 1)
complete with front sealing ring (Item 2) and shims
S2591
(Item 3) [Figure 40-20-20].
Figure 40-20-21
Loosen and remove the six bolts (Item 1) from the bottom
tie rod (Item 2) [Figure 40-20-18].
Loosen and remove the four nuts (Item 3), the four 2
washers and the four studs from the top tie rod (Item 4)
1
[Figure 40-20-18]. 3
Figure 40-20-19
S2427
Figure 40-20-22
S2539
Figure 40-20-23
2 4
S1387
Figure 40-20-24
1
2
1 S1402
Figure 40-20-27
Loosen and remove the top and bottom check nuts
(Item 1) from the dowels (Item 2) [Figure 40-20-24]. 1
Figure 40-20-25
S1403
Figure 40-20-28
2 1
S3567
Figure 40-20-29
2
1
S1404
Figure 40-20-30
1
1
S37106
Remove the tie rod from the steering case (See Removal
S37103 on Page 20-60-1.)
Figure 40-20-31
2 1
4
3
S37107
S37104 EM6817
Remove the bolts (Item 1) and washers (Item 2) that
secure the arm (Item 3) to the central body (Item 4)
Pressurize the brakes and, keeping them under pressure, [Figure 40-20-33].
inspect the linings "S" between the discs using tool T1
(Item 1) [Figure 40-20-31]. Minimum "S": 4,5 mm (0.177
in).
Figure 40-20-34
2 1
2
1
S37110
Figure 40-20-35
2
1
1
1
1
1
S37111
S37109
Remove the pin screws (Item 1) that guide the piston
(Item 2) [Figure 40-20-37].
Remove the brake discs (Item 1) [Figure 40-20-35] and
mark their order of assembly. NOTE: If the screws must be replaced, there are
different colors for the different brake gap.
NOTE: If the discs do not need replacing, avoid (See Brake System Assembly (Cont’d) on
switching their position. Page 40-20-41.)
Figure 40-20-38
1
S37112
11. Bolt
12. Crown
13. Washer
14. Planetary gear
15. Differential carrier
16. Snap ring
17. Pin
18. Planet wheel gear
19. Friction washer
20. Snap ring
1. Ring nut
2. Central body
3. Set screw
4. Bolt
5. Middle cover
6. Differential
7. Taper roller bearing
8. Taper roller bearing
9. O-ring
10. Top plug
S38377
Differential Disassembly
Figure 40-20-39
T13
S38864
1
S38862 Apply tool T13 and remove the ring nuts [Figure 40-20-
41].
Mark the position of the ring nuts (Item 1). Remove the NOTE: Clean the threaded parts of the ring nuts.
locking screw (Item 2) from the ring nuts (Item 1) [Figure
40-20-39]. Figure 40-20-42
Figure 40-20-40 1 2
1
1
1
S38865
S38863
S2545
4
2
S1414
S1412
Figure 40-20-47
1
1
2
S1417
Figure 40-20-48
2
1
2
S1418
Figure 40-20-51
T
2 1 2
1
S1422
Insert a tool T between two planet wheel gears (Item 1) Figure 40-20-54
[Figure 40-20-51].
Figure 40-20-52
3
2
3
1 S1423
2
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-20-54].
S1421
Figure 40-20-55
1
2
S1424
Figure 40-20-56
S1425
1. Check nut
2. Flange
3. O-ring
4. Guard
5. Shim washer
6. Seal
7. Ring nut
8. Pinion
9. Internal bearing
10. Spacer
11. Shim
12. Central body
13. External bearing
EM8518
Figure 40-20-57 1
2
2
1
S37165
Figure 40-20-60
If needed, heat the nut (Item 1) of the flange (Item 2)
[Figure 40-20-57] at 80°C (176°F).
1
WARNING
AVOID BURN INJURY
Figure 40-20-58
Remove the seal (Item 1) [Figure 40-20-60].
S37164
Figure 40-20-61
1
S37169
1
Install blocks T23 (Item 1) and, with a puller, press the
S37168 pinion (Item 1) [Figure 40-20-62] complete with internal
bearing, spacer and shims.
Position wrench T22 (Item 1) onto the ring nut and use NOTE: The thrust blocks of the bearings remain in
T21 (Item 2) to hold the pinion. When loose, hold wrench the central body (Item 3) [Figure 40-20-62].
T22 (Item 1) [Figure 40-20-61] and rotate the pinion to
remove the ring nut. Figure 40-20-63
WARNING
AVOID BURN INJURY 3
S37170
Figure 40-20-64
2
1 1
S37173
Figure 40-20-65
S37172
Figure 40-20-67
T25C
DG
T24
T25A S37176
2
1
S1572
Figure 40-20-71 1
GB
GB
S1575
3
4 1
2
1
S37181
Figure 40-20-75
T26 (1)
S1579
Calculate size “B” which will be the first useful value for Figure 40-20-78
calculating the size of the shims that are to be inserted
under the bearing race [Figure 40-20-75].
1
Figure 40-20-76
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Figure 40-20-79
1
3 4 2
S37186
1
Insert shim "S" (Item 1) and the thrust block of the Manually tighten until a rolling torque has been obtained.
internal bearing (Item 2) [Figure 40-20-79] in the central
body. Figure 40-20-82
S37187
2
Insert the stem of a depth micrometer in either side hole
of tool T26C (Item 1) [Figure 40-20-82]. Zero the
S37185 micrometer with a presetting of approximately 3 mm.
T25C
2 1 3
T26 (1)
S1587
Re-install all and insert the spacer (Item 1) between both Figure 40-20-86
bearings (Items 2 and 3) [Figure 40-20-83]; manually
tighten the whole pack.
Figure 40-20-84
H
DDG
T26 (2) 2
1 1
Figure 40-20-87
1
2
1
3 S37194
Install the pinion (Item 1), shim "S1" (Item 2) and spacer Figure 40-20-90
(Item 3) [Figure 40-20-87] in the main body.
Figure 40-20-88
2
S37195
Figure 40-20-93
2
1
S37196
Apply special wrench T22 (Item 1) to the ring nut and bar-
hold T21 (Item 2) [Figure 40-20-91] to the pinion. Lock 3 2
the wrench T22 and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 500
S37198
N•m (368.8 ft-lb).
Figure 40-20-92 Lubricate the outer surface of the new seal (Item 1) and
install it onto the central body (Item 2) using tool T27
(Item 3) [Figure 40-20-93].
Figure 40-20-94
1 2
S37197
NOTE: If torque exceeds the maximum value, then Install the flange (Item 1) complete with the guard (Item
the size of shim "S1" between the bearing and 2) and secure it. For keying the flange (Item 1) [Figure
the spacer needs to be increased. If torque 40-20-94], use a plastic hammer if necessary.
does not reach the set value, increase the
torque setting of the ring nut in different NOTE: Make sure that the guard (Item 2) [Figure 40-
stages to obtain a maximum value of 570 N•m 20-94] is secured onto the flange and that it is
(420.4 ft-lb). not deformed.
Figure 40-20-95
1
S37201
Insert the O-ring and the nut and tighten to 280 - 310
N•m (206.5 - 228.6 ft-lb) torque.
Figure 40-20-96
S37202
Differential Assembly
2
Figure 40-20-97
1
2
S1534
Insert the thrust washer (Item 1) and the planetary gear Figure 40-20-100
(Item 2) in the differential carrier (Item 3) [Figure 40-20-
97].
Figure 40-20-98
1
1
3
S1535
2
1
1
S1538
Lock tool (Item 2) behind the planet wheel gears Figure 40-20-104
(Item 1) [Figure 40-20-101].
Figure 40-20-102
2
1
S1539
Figure 40-20-105
1
1
S1542
Figure 40-20-108
Press the pin all the way down (Item 1) [Figure 40-20-
105].
Figure 40-20-106 1
2
S1543
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.
Figure 40-20-109
1
3
1
S1546
Position the ring gear (Item 1) on the differential carrier Figure 40-20-112
(Item 2) and install the bolts (Item 3) [Figure 40-20-109]
with Loctite® 243.
3
Tighten the bolts to 128 - 142 N•m (95 - 105 ft-lb) torque. 1
2
NOTE: Tighten the bolts using the cross tightening
method.
Figure 40-20-110
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
cover (Item 2) [Figure 40-20-112].
Figure 40-20-113
2 T19
2
S1550
2
1
A
T13
2
S1551
S38864
Install a dial indicator with rotary key “A” through the top
plug hole (Item 1). Position the indicator on the center of
NOTE: If the ring nuts [Figure 40-20-114] are one of the teeth of the ring gear (Item 2) [Figure 40-20-
removed, apply some Loctite® 243 to them. 116] and pre-set it to 1 mm (0.039 in) and reset it.
Tighten ring nuts on the ring gear side until
clearance between pinion and ring gear is
zero. Lock the ring gear. Turn the ring nuts
back 90 - 180°.
Figure 40-20-117
1
S38867
Manually move the ring gear (Item 1) [Figure 40-20-117] Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.3 ft-lb)
in both directions in order to check the existing backlash torque.
between the pinion and the crown.
Install the plug in the hole (Item 1) [Figure 40-20-45]
Figure 40-20-118 after applying flexible gasket compound for seals to the
rims.
T13
S38864
CLEARANCE
RATIO
MINIMUM MAXIMUM
14 – 32 0.18 mm 0.23 mm
(0.0071 in) (0.0091 in)
Figure 40-20-120 2 3
4
2
3
5 1
EM6818
1 S37115
Lubricate the seals and install the piston (Item 1) into the
S37113 arm (Item 2) [Figure 40-20-122].
NOTE: Make sure that the piston seat fits into the
Clean the piston (Item 1) and the seats of slide and seal. stop pin (Item 3) [Figure 40-20-122] inside the
Replace the O-rings (Item 2 and 3) and the back-up rings arm.
(Item 4 and 5) [Figure 40-20-120]. Make sure that the
assembly side is correct. Figure 40-20-123
Figure 40-20-121
1
1
1
S37116
1
2
Facilitate the insertion of the piston (Item 1) [Figure 40-
20-123] by lightly tapping around the edge with a plastic
S37114 hammer.
Figure 40-20-124
1 S37119
Figure 40-20-125
2 1
1
1 S37120
Figure 40-20-128
S37121
Figure 40-20-129
1
T5 T6
1 2 S1399
3
3 Heat the bearing in oil at an approximate temperature of
S1397 100°C (212°F) and install the entire bearing (Item 1) on
the drive axle (Item 2) [Figure 40-20-131].
Using tools T5 and T6, insert the sealing ring (Item 1) Figure 40-20-132
and the bearing (Item 2) in the bearing (Item 3) [Figure
40-20-129].
Figure 40-20-130
2
1
S1400
2 1
Install the snap ring (Item 1) on the axle shaft (Item 2).
After the bearing has cooled, install the O-ring
(Item 3) [Figure 40-20-132].
S1398
Figure 40-20-133
S2592
Insert the drive axle and tighten the top and bottom
dowels (Item 1) [Figure 40-20-133]. Tighten to
maximum 15 N•m (11 ft-lb) torque.
Figure 40-20-134
1
2 1
2
S1507
Figure 40-20-135
T7
1
1
S1496
Pay attention not to damage the dust cover rings and the
Lubricate the bushing (Item 1) and the seat of the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-20-135], using tool T7. Figure 40-20-138
Figure 40-20-136
2
1 2
T8
1
S2395
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).
To be assembled under the upper tie rod
Lubricate the outer surface of the sealing ring (Item 1) (Item 2) [Figure 40-20-138].
and centering ring (Item 2) [Figure 40-20-136]. Install
them into their seat using tool T8.
Figure 40-20-139
1
2
2
3
1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 orientated as shown in the inset. Lubricate the pivot pin
(Item 2) and the seal (Item 1). Install the pivot pin (Item 2)
and the six bolts (Item 3) [Figure 40-20-141]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts in sequence using the
orientated as shown in the inset. Lubricate the pivot pin cross tightening method, to 140 N•m (103 ft-lb) torque.
(Item 2) and the seal (Item 1). Install the pivot pin (Item 2)
[Figure 40-20-139], four studs, four washers and four Check for the correct assembly side of the seal
nuts. (Studs, washers and nuts not shown in photo.) (Item 2) [Figure 40-20-141].
Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-20-140
S38375
Figure 40-20-142
S2568
Figure 40-20-143
S2569
Figure 40-20-144
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-20-146] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-20-147
of the external bearing (Item 1) [Figure 40-20-144]
under the press.
Figure 40-20-145
1
2
1
S2587
Figure 40-20-148
1
T10
3
S1456
1
DOWN
T11
1
2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-20-151].
40-20-149].
Accurately check the orientation.
Figure 40-20-152
S2470A
Figure 40-20-153
S2471A
Figure 40-20-155
1
1
S2647
Figure 40-20-156
1
2
S2466
Figure 40-20-159 1
2
3 2
S2648
Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
For photo clarity, the following axle procedures are done • Rear Axle Removal (See Removal And Installation on
with the complete axle assembly removed from the Page 40-90-1.), Rear Steering Cylinder Removal
machine. However, the planetary carrier, wheel hub, (See Removal on Page 20-60-1.)
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support
9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Nut
19. Stud
20. Snap ring
S38371
Figure 40-21-1 1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-21-3].
Figure 40-21-4
Loosen the two securing bolts (Item 1) [Figure 40-21-1].
Figure 40-21-2
1
1 2
S2466
Figure 40-21-5 1
1
2
S2468
Figure 40-21-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-21-5].
Figure 40-21-6 1
S2469
Figure 40-21-9
1
1
1
1
1
S2473A
Figure 40-21-10
S2474A
Figure 40-21-13 1
1 S2477A
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-21-16
[Figure 40-21-13].
Figure 40-21-14 1
S2478A
Figure 40-21-17
S2479A
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Drive axle
8. Seal
9. Thrust bushing
10. Centering ring
15. Cover
16. Plug
17. Tie rod
18. Grease fitting
19. Tie rod assembly
20. Plug
21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Bushing
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S38372
Figure 40-21-18
1 2
3
3
2
4 S38374
1
Using two levers, remove the top tie rod (Item 1)
complete with front seal (Item 2) and shims (Item 3)
S2591
[Figure 40-21-20].
Figure 40-21-21
Loosen and remove the six bolts (Item 1) from the bottom
tie rod (Item 2) [Figure 40-21-18].
Loosen and remove the four nuts (Item 3), the four
washers and the four studs from the top tie rod (Item 4) 2
[Figure 40-21-18]. 1
3
Figure 40-21-19
S2427A
Figure 40-21-22
1 1
S2540
Figure 40-21-23
3
1 2 3
4
S1387
11. Bolt
12. Crown
13. Washer
14. Planetary gear
15. Differential carrier
16. Snap ring
17. Pin
18. Planet wheel gear
19. Friction washer
20. Snap ring
1. Ring nut
2. Central body
3. Set screw
4. Bolt
5. Middle cover
6. Differential
7. Taper roller bearing
8. Taper roller bearing
9. O-ring
10. Top plug
S38377
Differential Disassembly
Figure 40-21-25
2
S38862
Mark the position of the ring nuts (Item 1). Remove the
S2541 set screw (Item 2) from the ring nuts (Item 1) [Figure 40-
21-27].
Figure 40-21-26
1
S38863
1 S2542
Uniformly heat the ring nuts (Item 1) [Figure 40-21-28]
up to a temperature of 80°C (176°F).
Remove the complete arm (Item 1) [Figure 40-21-26].
Figure 40-21-29 1
T13
S37203
Apply tool T13 and remove the ring nuts [Figure 40-21- NOTE: Support the pieces using a rod.
29].
Figure 40-21-32
NOTE: Clean the threaded parts of the ring nuts.
Figure 40-21-30 4
2
1 2
1
3 1
S1412
1
1 If the bearings need replacing, extract the bearing race
S38865 (Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-21-32].
Remove screws (Item 1) from the middle cover (Item 2) NOTE: Inspect for damaged O-rings (Item 5) [Figure
[Figure 40-21-30]. 40-21-32].
Figure 40-21-33
1
1
2
S1415
Figure 40-21-34
1
S1416
S1414
Remove the shim washer (Item 1) and the planetary gear
(Item 2) [Figure 40-21-36].
Remove the twelve bolts (Item 1) from the crown (Item 2)
[Figure 40-21-34].
Figure 40-21-37 T
2 1 1 2
2
S1419
3
1
2
1
2
S1421
S1418
Figure 40-21-41
1
2
S1424
NOTE: In this condition the tool contains the pin. Repeat the operations for the two remaining pins.
S1423 S1425
Remove the tool with inside the pin of the planet wheel Remove the tool T and remove the planet wheel gears
gear [Figure 40-21-42]. (Item 1) and the relative shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-21-44].
1. Check nut
2. Flange
3. O-ring
4. Guard
5. Swinging support
6. Seal
7. Ring nut
8. Pinion
9. Internal bearing
10. Spacer
11. Shim
12. Central body
13. External bearing
14. Shim washer
EM6813
Figure 40-21-45 1
2
2
1
S37165
Figure 40-21-48
If needed, heat the check nut (Item 1) of the flange (Item
2) [Figure 40-21-45] at 80°C (176°F).
WARNING
AVOID BURN INJURY
Parts may be hot, use gloves when handling parts.
W-2762-1108
S37164
Figure 40-21-49
1
S37169
Remove the seal (Item 1) [Figure 40-21-49]. NOTE: The thrust blocks of the bearings remain in
the central body (Item 3) [Figure 40-21-51].
Figure 40-21-50
Figure 40-21-52
1
2
3
1
S37168
S37170
Position wrench T22 (Item 1) onto the ring nut and use
T21 (Item 2) to hold the pinion. When loose, hold wrench Remove the pinion (Item 1), shims (Item 2) and spacer
T22 (Item 1) [Figure 40-21-50] and rotate the pinion to (Item 3) [Figure 40-21-52].
remove the ring nut.
WARNING
AVOID BURN INJURY
Parts may be hot, use gloves when handling parts.
W-2762-1108
Figure 40-21-53
2
1 1
S37173
Figure 40-21-54
S37172
Figure 40-21-56
T25C
DG
T24
T25A S37176
DG
1
S1572
Figure 40-21-60
S37180
3
4 1
2
1
S37181
Figure 40-21-64
T26 (2)
T24
T26 (1)
S1579
Calculate size “B” which will be the first useful value for Figure 40-21-67
calculating the size of the shims that are to be inserted
under the bearing race [Figure 40-21-64].
1
Figure 40-21-65
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Figure 40-21-68
1
3 4 2
S37186
1
Insert shim "S" (Item 1) and the thrust block of the Manually tighten until a rolling torque has been obtained.
internal bearing (Item 2) [Figure 40-21-68] in the central
body. Figure 40-21-71
S37187
2
Insert the stem of a depth comparator "DDG" in either
side hole of tool T26C (Item 1) [Figure 40-21-71]. Zero
S37185 the comparator with a presetting of approximately 3 mm.
T25C
2 1 3
T26 (1)
S1587
Figure 40-21-73
H
DDG
2
T26 (2)
1
1
T26 (1)
S1588
Figure 40-21-76
1
2
1
3 S37194
Install the pinion (Item 1), shim "S1" (Item 2) and spacer Figure 40-21-79
(Item 3) [Figure 40-21-76] in the main body.
Figure 40-21-77
2
S37195
Figure 40-21-82
2
1
S37196
Apply special wrench T22 (Item 1) to the ring nut and bar-
hold T21 (Item 2) [Figure 40-21-80] to the pinion. Lock 3 2
the wrench T22 and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 500
S37198
N•m (368.8 ft-lb).
Figure 40-21-81 Lubricate the outer surface of the new seal (Item 1) and
install it onto the central body (Item 2) using tool T27
(Item 3) [Figure 40-21-82].
Figure 40-21-83
1
1
S37197
NOTE: If torque exceeds the maximum value, then Install the swing support (Item 1) [Figure 40-21-83].
the size of shim "S1" between the bearing and
the spacer needs to be increased. If torque NOTE: Inspect that the swing support is properly
does not reach the set value, increase the oriented.
torque setting of the ring nut in different
stages to obtain a maximum value of 570 N•m
(420.4 ft-lb).
Figure 40-21-84
4 2 1
S37202
Figure 40-21-85
1
S37201
Insert the O-ring and the nut and tighten it to 280 - 310
N•m (206.5 - 228.6 ft-lb) torque.
Differential Assembly
2
Figure 40-21-87
1
2
S1534
Insert the shim washer (Item 1) and the planetary gear Figure 40-21-90
(Item 2) in the differential carrier (Item 3) [Figure 40-21-
87].
Figure 40-21-88
1
1
3
S1535
1
1
S1538
Lock the tool behind the planet wheel gears Figure 40-21-94
(Item 1) [Figure 40-21-91]. After locking, remove bar
T16C.
Figure 40-21-92
2
1
S1539
Figure 40-21-95
1
S1542
1
Figure 40-21-98
Press the pin all the way down (Item 1) [Figure 40-21-
95].
Figure 40-21-96 1
2
S1543
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.
Figure 40-21-99 1
3 1 2
S1546
Figure 40-21-100
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
cover (Item 2) [Figure 40-21-102].
Figure 40-21-103
2 T19
2
S1550
2
1
A
T13
2
S1551
S38864
Introduce a dial indicator with rotary key “A” through the
top plug hole (Item 1). Position the indicator on the center
NOTE: If the ring nuts [Figure 40-21-104] are of one of the teeth of the crown (Item 2) [Figure 40-21-
removed, apply some Loctite® 243 to them. 106] and pre-set it to 1 mm (0.039 in) and reset it.
Tighten ring nuts on the crown side until
clearance between pinion and crown is zero.
Lock the crown. Turn the ring nuts back 90 -
180°.
Figure 40-21-107
1
S38867
Manually move the crown (Item 1) [Figure 40-21-107] in Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.3 ft-lb)
both directions in order to inspect the existing backlash torque.
between the pinion and the crown.
Install the plug in the hole (Item 1) [Figure 40-21-33 on
Figure 40-21-108 Page 13] after applying flexible gasket compound for
seals to the rims.
Figure 40-21-110
T13
S38864
S2542
Adjust the backlash between the pinion and the crown by
unloosing one of the ring nuts [Figure 40-21-108] and
tightening the opposite to compensate. Re-install the complete arms (Item 1) [Figure 40-21-
110].
Normal backlash: see table
CLEARANCE
RATIO
MINIMUM MAXIMUM
14 – 32 0.18 mm 0.23 mm
(0.0071 in) (0.0091 in)
Figure 40-21-111
T17
1
S1496
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-21-111], using tool T17. Figure 40-21-114
Figure 40-21-112
2
1 2
T8
1
S2395
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.0035
in). To be assembled under the upper pin
Lubricate the outer surface of the sealing ring (Item 2) [Figure 40-21-114].
(Item 1) and centering ring (Item 2) [Figure 40-21-112].
Install them into their seat using tool T8.
Figure 40-21-115
3
2
2
1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 orientated as shown in the inset. Lubricate the pivot pin
(Item 3) and the seal (Item 1). Install the pivot pin (Item 3)
and the six bolts (Item 2) [Figure 40-21-117]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
orientated as shown in the inset. Lubricate the pivot pin torque.
(Item 2) and the seal (Item 1). Install the pivot pin (Item 2)
[Figure 40-21-115], four studs, four washers and four Check for the correct assembly side of the seal
nuts. (Studs, washers and nuts not shown in photo.) (Item 3) [Figure 40-21-117].
Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-21-118
Inspect the correct assembly side of the seal
(Item 1) [Figure 40-21-115].
Figure 40-21-116
S38991
Figure 40-21-119
S2568
Figure 40-21-120
S2569
Figure 40-21-121
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-21-123] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-21-124
of the external bearing (Item 1) [Figure 40-21-121]
under the press.
Figure 40-21-122
1
2
1
S2587
Figure 40-21-125
1
T10
3
S1456
DOWN
T11
1
1
2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-21-128].
40-21-126].
Accurately check the orientation.
Figure 40-21-129
S2470A
1
1
S2471A S2646
Connect the steering bars and install the hub Install the complete crown flange (Item 1) [Figure 40-21-
(Item 1) [Figure 40-21-130]. 132].
Figure 40-21-133
1
1
2
S2466
Figure 40-21-134
1
S2465A
1
The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.
Figure 40-21-137
S1468
Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
S38617
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately. Lift the front of the machine and place jack stands (Item
W-2145-0290
1) [Figure 40-30-2] under the frame as shown.
Relieve hydraulic pressure. Place a block in front and behind one of the rear wheels.
Figure 40-30-1 Remove the eight lug nuts and washers (Item 1)
[Figure 40-30-1] from each front wheel.
S1954
2
Loosen the eight lug nuts and washers (Item 1)
[Figure 40-30-1] on each front wheel.
S1951
Installation: Tighten the lug nuts (Item 1) [Figure 40-30-
1] to 360 N•m (266 ft-lb) torque.
Remove the four bolts (Item 1) from both front fender
mount brackets (Item 2) [Figure 40-30-3].
Figure 40-30-4
1 1
S38298
Figure 40-30-7
S38618
S38619
Figure 40-30-8
1
1
S38622
Figure 40-30-11
S38620
S38623
Adjustment
Figure 40-40-1
S2056
S2056
Figure 40-40-2
S2057
Adjustment
Figure 40-50-1
S38727
2 2
3 4 7. Install the cap (Item 1) [Figure 40-50-2].
WARNING
S38218 UNEXPECTED MACHINE MOVEMENT CAN CAUSE
SERIOUS INJURY OR DEATH
1. Apply hydraulic pressure of 9 - 20,7 MPa (90 - 207 • Block wheels to prevent roll away before
bar) (1300 - 3000 psi) to the brake (using a hand adjusting screws to bypass the park brake
pump or portapower). system.
• Return adjustment screws to the operating
2. Turn the adjustment screw (Item 1) [Figure 40-50-1] position before operating the machine.
W-2808-0909
until the brake is clamped onto the disc. Turn back
90°.
Brake Cylinder Removal Remove the brake cylinder from the machine. (See Brake
Cylinder Removal on Page 40-50-2.)
Figure 40-50-3
Figure 40-50-5
1
2
S38672
S38673
Figure 40-50-6
2
1
3
S38671
S38674
Remove the pressure sensor (Item 1) [Figure 40-50-4]
and its fittings.
Remove the brake pads (Item 1) [Figure 40-50-6] from
Loosen the inner bolt (Item 2) [Figure 40-50-4] until the the brake cylinder.
brake pads show a gap.
Inspect the brake pads (Item 1) [Figure 40-50-6] for
Loosen the two bolts (Item 3) [Figure 40-50-4] and wear.
remove the brake cylinder.
Figure 40-50-7
1
S38721
Figure 40-50-10
Remove the cylinder cover (Item 1) [Figure 40-50-7].
Figure 40-50-8
S38722
2
Assembly: Verify that the Belleville washers are installed
as shown in [Figure 40-50-10].
S38726
Figure 40-50-11
4 1
1
3
2
S38725
Figure 40-50-12
S38724
Figure 40-50-14
1
2 3
1
1 1
S38671
S38251
Position the brake cylinder on the disc.
Remove the front driveshaft. (See Front Driveshaft Install the mounting bolts (Item 1) [Figure 40-50-15] far
Removal And Installation on Page 40-70-1.) enough to support the brake.
Remove the brake cylinder. (See Brake Cylinder Tighten the adjustment screw (Item 2) clockwise until the
Removal on Page 40-50-2.) brake pads are clamped onto the disc. Make sure the bolt
(Item 3) [Figure 40-50-15] does not protrude out far
Remove the four bolts (Item 1) [Figure 40-50-14]. enough to make contact with the mounting bracket at this
time.
Remove the brake disc (Item 2) [Figure 40-50-14].
Figure 40-50-16
Measure the thickness of the brake disc. Replace the
brake disc if thickness is below 9,5 mm (0.374 in).
1
3
2
S38727
Adjustment
Figure 40-60-1
37° - 45°
S2062
S38218
Figure 40-60-2
S2061
Figure 40-70-1
1
1
2
1
1
2
2
S38223
S38220
Remove the four drive shaft mounting bolts (Item 1) and
remove the two clamps (Item 2) [Figure 40-70-3] from
Remove the four drive shaft mounting bolts (Item 1) and the parking brake disc U-joint.
remove the two clamps (Item 2) [Figure 40-70-1] from
the rear axle U-joint. Installation: Apply Loctite® 243 or equivalent to the
threads of the bolts (Item 1) [Figure 40-70-3] and tighten
Installation: Apply Loctite® 243 or equivalent to the to 33 - 41 N•m (24.3 - 30.2 ft-lb).
threads of the bolts (Item 1) [Figure 40-70-1] and tighten
to 33 - 41 N•m (24.3 - 30.2 ft-lb) torque. Figure 40-70-4
Figure 40-70-2
1
1
2 1
2
S38222
S38221
Remove the four drive shaft mounting bolts (Item 1)
[Figure 40-70-4] and remove the two clamps from the
Remove the four drive shaft mounting bolts (Item 1) and front axle U-joint.
remove the two clamps (Item 2) [Figure 40-70-2] from
the gear box U-joint. Installation: Apply Loctite® 243 or equivalent to the
threads of the bolts (Item 1) [Figure 40-70-4] and tighten
Installation: Apply Loctite® 243 or equivalent to the to 33 - 41 N•m (24.3 - 30.2 ft-lb).
threads of the bolts (Item 1) [Figure 40-70-2] and tighten
to 33 - 41 N•m (24.3 - 30.2 ft-lb). Remove the drive shaft out the front of the machine.
Description Lift and block the machine. (See Procedure on Page 10-
10-1.).
There is a bleed screw located on each side of the front
axle differential housing. NOTE: Position the jack stands to allow starting the
machine and driving the wheels.
Air trapped in the brake lines can cause a spongy feel
and / or delayed activation of the service brake. Figure 40-80-1
WARNING
1
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received S39118
immediately.
W-2145-0290
Figure 40-80-2
WARNING
1
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
S2014
Stop the engine and tighten the two inside bleed screws
(Item 1) [Figure 40-80-1] and [Figure 40-80-2].
WARNING
Hydraulic fluid escaping under pressure can have
1 1
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
S39142
Figure 40-90-3
S1954
S1951
Figure 40-90-4 1
2
2
1
1
1 S39144
Remove the four drive shaft mounting bolts (Item 3) Figure 40-90-7
[Figure 40-90-4] and remove the two clamps from the
rear axle U-joint.
Figure 40-90-5
S39145
1
S38075
Figure 40-90-8
1
S39178
S39179 S39143
Remove the two bolts (Item 1) [Figure 40-90-9] from the Have an assistant balance the axle on the jack and lower
front mount bracket. the jack slowly while rolling the axle out from under the
frame [Figure 40-90-11].
Installation: Apply Loctite® 243 or equivalent to the
threads of the bolts (Item 1) [Figure 40-90-9] and tighten
to 33 - 41 N•m (24.3 - 30.2 ft-lb).
Figure 40-100-1
1
S38224
2
Figure 40-100-4
S38234
Figure 40-100-2
1 2
S38235
S38233
3 3
1 S38237
Remove the two mounting bolts (Item 1) [Figure 40-100- Remove the four mounting bolts (Item 3) [Figure 40-100-
5]. 7] from the hydrostatic drive motor.
Figure 40-100-8
S38235
Parts Identification
1. O-ring
2. Vent
3. Cover
4. Seal
5. Shim
6. Ball bearing
7. Cover
8. Flange
9. Ball bearing
10. Elastic pin
11. Pin
12. Housing
13. Bolt
14. O-ring
15. Nut
16. Washer
17. Bolt
18. Cover
19. Bolt
20. Washer
21. Plate
22. Needle bearing
EM6868
23. Shaft
24. Selector sleeve
25. Bolt
26. Plate
27. Magnetic plug
28. Spacer
29. Switch
30. Boot
31. Bolt
32. Spring
33. Ball bearing
34. Ball
35. Cylinder bolt
36. Seal
37. O-ring
38. Cylinder
39. Plug
40. O-ring
41. Rod
42. O-ring
43. Piston
44. O-ring
EM6868
EM6868
Disassembly
Figure 40-100-9
1
2
2
1 1
S38243
Figure 40-100-10
S36543
Disassembly (Cont’d)
Figure 40-100-13
1
3
2
3 2
S36546
1
Remove the screw (Item 1), spring (Item 2) and neutral
position ball (Item 3) [Figure 40-100-15] (hydraulic
S36544
version).
Remove the gear-in-position switch (Item 1), O-ring (Item Figure 40-100-16
2) and washer (Item 3) [Figure 40-100-13].
Figure 40-100-14
3 2 1 2
1
3
S36546
Disassembly (Cont’d)
Figure 40-100-17
1 1
1
2 1
S36554
Figure 40-100-18
1
3 1
S36555
S36553
NOTE: Take care not to damage surfaces.
Disassembly (Cont’d)
Figure 40-100-21
2 1
S36558
Figure 40-100-24
Remove the cover (Item 1) [Figure 40-100-21].
Figure 40-100-22
S36559
Disassembly (Cont’d)
Figure 40-100-25
1 2
S36562
Figure 40-100-28
Remove the oil shield plate (Item 1) [Figure 40-100-25]
only if necessary.
Figure 40-100-26
2
1 1
1
S36563
S36561
Install the oil shield plate (Item 1) with oil inlet facing
upward [Figure 40-100-26].
Disassembly (Cont’d)
Figure 40-100-29
1
2 S36566
Figure 40-100-30
1
2
1 3
2
S36567
Check sliding blocks (Item 1), pin (Item 2), and sliding
coupling (Item 3) [Figure 40-100-30].
Replace if worn.
Disassembly (Cont’d)
Figure 40-100-33
S36570
Figure 40-100-34 1
S36571
Disassembly (Cont’d)
Figure 40-100-37
S36574
Figure 40-100-40
Pull out the sealing ring (Item 1) [Figure 40-100-37].
Figure 40-100-38
S36575
S36573
Install a new sealing ring [Figure 40-100-40].
Disassembly (Cont’d)
Figure 40-100-41
1 2
S36576
Figure 40-100-42
S36577
Assembly
Figure 40-100-43
2
1
S36580
Figure 40-100-46
Install the bearing in the cover of the gear box
[Figure 40-100-43].
Figure 40-100-44
1
1
S36581
Assembly (Cont’d)
Figure 40-100-47
S36584
Figure 40-100-50
Lubricate the lip of the sealing ring (Item 1) [Figure 40-
100-47] with grease.
Figure 40-100-48
S36585
Assembly (Cont’d)
Figure 40-100-51
1
S36588
Figure 40-100-52
1
3 1
S36589
S36587
Assembly (Cont’d)
Figure 40-100-55
1
1
3 1
S36592
Figure 40-100-58
Re-assemble needle bearings (Item 1), gear (Item 2) and
spacer (Item 3) [Figure 40-100-55].
Figure 40-100-56
1 1
S36593
S36591
Assembly (Cont’d)
Figure 40-100-59
3
1 1
2
S36546
Tighten the 14 bolts (Item 1) [Figure 40-100-59] in a Tighten screw to 80 - 100 N•m (59 - 73.8 ft-lb) torque.
crisscross manner to 49 - 51 N•m (36.1 - 37.7 ft-lb)
torque. Figure 40-100-62
Figure 40-100-60
1 2 3 2 3
S36544
S36545
Install the gear-in position switch (Item 1) with washer
(Item 2) and O-ring (Item 3) [Figure 40-100-62].
Lubricate components and install spindle (Item 1), spring
(Item 2) and screw (Item 3) [Figure 40-100-60] Tighten screw (Item 1) [Figure 40-100-62] to 54,2 N•m
(mechanical version). (40 ft-lb) torque.
Assembly (Cont’d)
Figure 40-100-63
S36800
Figure 40-100-64
1 1
S36551
Assembly (Cont’d)
Figure 40-100-66
1
2
S38249
A
Apply Loctite® 510 on the surface, lubricate the sealing
S36801
ring, insert the distance washers and install the cover
(Item 1) with the slot (Item 2) [Figure 40-100-68] facing
upwards.
Measure dimension "A" between the bearing and the box
plane using an depth gauge [Figure 40-100-66]. Figure 40-100-69
NOTE: If parts are not replaced, use disassembled
distance washers.
Figure 40-100-67
B S38250
S = Dimension B – Dimension A
Assembly (Cont’d)
Figure 40-100-70
2
3
S38242
S36546
Install the nut (Item 1) [Figure 40-100-72].
Figure 40-100-71
S38243
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Figure 50-10-1
4 3
2
1
S38077
1
Remove the A/C hose (Item 1) from the drier, and the A/C
S38006 hose (Item 2) [Figure 50-10-2] from the expansion valve.
Figure 50-10-4
2 2
1
S39427
1
Remove the screw (Item 1) [Figure 50-10-5].
S38125
Remove the parking brake lever cover (Item 2) [Figure
50-10-5].
Remove all hoses from the steering valve and the brake
valve except for one hose (Item 1) [Figure 50-10-4]. Figure 50-10-6
1
WARNING 1 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 50-10-7
1
1
S38127
2
Figure 50-10-8
1
1 1
S38126
2
Figure 50-10-11
1
1
S38130
Figure 50-10-12
S38128
Figure 50-20-1
1 1
S38124
Removal
1 Remove the two nuts (Item 1) and the retainer bolt (Item
1
2) [Figure 50-30-3] from the boom pivot pin.
Figure 50-30-4
S38102
S39410
Install two lifting chains to the rear and two chains to the
front of the boom [Figure 50-30-1].
S39166
Figure 50-30-5
S39166
S39169
Carefully lift and install the boom onto the machine
[Figure 50-30-7].
Remove the boom pivot pin [Figure 50-30-5].
Align the holes for installing the boom pivot pin (Item 1)
Figure 50-30-6 [Figure 50-30-7] while lowering the boom with the hoist.
Figure 50-30-8
S39166
2
Carefully lift and remove the boom from the machine
[Figure 50-30-6].
S39167
Install the retainer bolt (Item 1) and the two nuts (Item 2)
[Figure 50-30-8] onto the boom pivot pin.
Installation (Cont’d)
Figure 50-30-9
S39168
Figure 50-30-10
S38102
Figure 50-40-1
1 1
S38932
Figure 50-40-4
Position the boom horizontally using wooden blocks
[Figure 50-40-1].
Figure 50-40-2 1 1
2
1
S39070
Figure 50-40-5
1
1
S38936
Figure 50-40-6
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 50-40-8
S38931
S38937
Figure 50-40-9
S38938
Slide the inner boom from the fixed boom. Before the
inner boom is completely removed, position a hoist and
lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-9].
Figure 50-40-10
S39171
Figure 50-50-1
1
S39188
Figure 50-50-2
1
S38940
Figure 50-60-3
1
S38113
Figure 50-60-2
S38115
Figure 50-70-1
S39067
1
Figure 50-70-2
2
1
S39137
Figure 50-70-5
1 1
S38008
Figure 50-70-8
Fully support the fuel tank using an appropriate lifting
device [Figure 50-70-5].
Figure 50-70-6
1
2
1
1
S38009
2
Figure 50-70-9
S38090
Figure 50-70-12
Remove the bolt (Item 1) [Figure 50-70-9].
S38095
Figure 50-70-13
S38094
Figure 50-80-1
S39147
Figure 50-80-4
Tilt the attachment carrier forward and place it on a flat
surface [Figure 50-80-1].
1
Figure 50-80-2
S39121
Figure 50-80-5
S39122
Figure 50-80-6
S39123
Figure 50-90-1
S39140
Figure 50-90-4
Support the counterweight using a fork lift and pallet
[Figure 50-90-1].
Figure 50-90-2
1
S39141
1
EM7532
Figure 50-100-1
S38680
Figure 50-110-1
1
S39059
1 1
Figure 50-110-2
1
1
S39057
S38299
1
1 1
1
2
S39051
S38732
S39054
Figure 50-120-6
1 S39055
Figure 50-120-9
1
1
1
S39056
Figure 50-130-1
1
1 1
S38732
Figure 50-130-4
Remove the cap (Item 1) [Figure 50-130-1] from the
steering wheel. 1
Figure 50-130-2
1
1
1
1
S39057
2
Remove the four screws (Item 1) [Figure 50-130-4] from
S38732 the steering column cover.
Figure 50-130-5
1
1
1 1
2
S39245
1
Figure 50-130-8
Remove the screws (Item 1) [Figure 50-130-5] from the
windscreen blower.
Figure 50-130-6
1
1 1
1
1
1
S39244
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Front Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
F11 FRC1 (CAB) 20 IGNITION CAB WORK LIGHTS OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
F12 FRC1 (CAB) 20 IGNITION BOOM WORK LIGHTS BLUE WORK LIGHTS ENGINE 8000 THROUGH 8999 TAN TAN
F21 FRC2 (FRAME) 15 IGNITION DRIVE CONTROLLER COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
F22 FRC2 (FRAME) 15 IGNITION WORKGROUP CONTROLLER
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
F23 FRC2 (FRAME) 25 BATTERY ACD BATTERY SUPPLY
F27 FRC2 (FRAME) 15 IGNITION REAR DIVERTER 2 BOOM DRAIN VALVE CONNECTORS ASSIGNMENT PAGE 2
F28 FRC2 (FRAME) 10 IGNITION STOP LIGHTS REVERSE LIGHT BACK UP ALARM
CONTROLLERS CONNECTION PAGE 3, 4
TRACTOR TRAILER BRAKE ITALIAN TRAILER BRAKE
F29 FRC2 (FRAME) 5 IGNITION
VALVE VALVE
ALTERNATOR POWER PAGE 5
F41 FC3 (ENGINE) 25 IGNITION STARTER
EXCITATION
F42 FC3 (ENGINE) 10 IGNITION FUEL SOLENOID FUEL PUMP TEMP. SWITCH
GROUND PAGE 6
F50 MEGAFUSE 100 IGNITION MAIN IGNITION POWER GLOW PLUGS CAN BUS PAGE 7
IGNITION & ENGINE PAGE 8
LOWER CAB PAGE 9
UPPER CAB PAGE 10
TRANSMISSION PAGE 11
BRAKES PAGE 12
FRC 1 STEERING PAGE 13
WORKGROUP PAGE 14
FC 3 FRAME LVL, LLM SYSTEM PAGE 15
7199028 AUXILIARY HYDRAULIC PAGE 16
STANDARD LIGHTS PAGE 17
7179987
RELAYS FUNCTION OPTIONAL LIGHTS PAGE 18
RELAY LOCATION FUNCTION 1
FRC2 (FRAME)
TRACTOR TRAILER BRAKE
(S/N AVM111001 AND ABOVE)
R14 BOOM DRAIN VALVE
C116 FAN INVERTER 2 8 C412 BOOM UP 2 14 C216 FAN INVERTER SWITCH 10 8 T59 CAB BUZZER 1 9
T70 BLUE WORK LIGHT LEFT 1 18
C117 SWASH PLATE SENSOR 4 11 C413 BOOM DOWN 2 14 C219 GEAR SELECT SWITCH 10 11 T60 CAB BUZZER 1 9
T71 BLUE WORK LIGHT LEFT 1 18
C120 DRIVE PUMP FORWARD 2 11 C414 TILT UP 2 14 C220 KEYLESS MODULE (RSS) 6 8 T68 SHUNT KEY 1 15
T72 BLUE WORK LIGHT RIGHT 1 18
C121 DRIVE PUMP REVERSE 2 11 C415 TILT DOWN 2 14 C221 FLASHER RELAY 6 17 T69 SHUNT KEY 1 15
T73 BLUE WORK LIGHT RIGHT 1 18
C123 AC COMPRESSOR CLUTCH 2 9 C416 BOOM EXTEND 2 14 C222 THROTTLE PEDAL SENSOR T90 BRAKE FAIL PRESSURE LAMP 1 12
T76 REVERSE LIGHT 1 17
C130 LOW SPEED 2 11 C417 BOOM RETRACT 2 14 C224 LEFT LEVER 12 9,11,17 T91 BRAKE FAIL PRESSURE LAMP 1 12
T77 REVERSE LIGHT 1 17
C135 DUMP VALVE 2 11 C418 AUX A4 VALVE 2 14 C225 FNR LEVER 6 11 T92 TRAILER INDICATOR LAMP 1 17
C141 1ST/2ND GEAR SWITH 2 11 C419 AUX B4 VALVE 2 14 C227 12V SOCKET 2 9 T93 TRAILER INDICATOR LAMP 1 17
C142 SERVO PRESSURE SENSOR 3 11 C420 RETRACT SWITCH 4 14 C229 CAB TO LLMI SENSOR 8 7, 15 T94 CRAB STEER LAMP 1 13
7,9, 11,
C143 STEERING PRESSURE SENSOR 3 11 C421 CRAB STEER VALVE 2 13 T95 CRAB STEER LAMP 1 13
12, 13,14,
C230 CAB TO FRAME 40
15, 16,17,
C144 INLET PRESSURE SENSOR 3 14 C422 4 WHEEL STEER 2 13 T96 4 WHEEL STEER LAMP 1 13
18
BOOM CONNECTORS ASSIGNMENT
C150 TRACTOR TRAILER BRAKE VALVE 2 12 C423 SAFETY VALVE 2 11 C232 CAB TO UPPER CAB 4 10,11 T97 4 WHEEL STEER LAMP 1 13
CONNECTOR DESCRIPTION PINS SHEET
C158 ENGINE OIL PRESSURE 2 8 C424 HORN 2 9 C233 CAB TO ENGINE 24 5,7,8,19 C601 REAR WIPER MOTOR 2 10
C433 BOOM ACD TO FRAME 8 8,15
C233 ENGINE TO CAB 24 5,7,8,9 C425 STEERING PRESS. SENSOR LS PUMP 3 13 C235 CAB TO IGNITION 1 5 C602 ROOF WIPER MOTOR 3 10
C501 ACD CONNECTOR 7 15
C235 IGNITION TO CAB 1 5 C428 PASSIVE BRAKE VALVE 2 12 C236 CAB TO FRAME LVL 8 15 C603 CAR RADIO SUPPLY 8 10
C504 BOOM WORK LIGHT LEFT 2 19
T1 MEGAFUSE F50 1 5 C431 REAR DIVERTER 1 2 16 C237 LLMI 6 15 C604 CAR RADIO SPEAKERS 8 10
C505 BOOM WORK LIGHT RIGHT 2 19
T2 MEGAFUSE F50 1 5 C432 REAR DIVERTER 2 2 16 C238 LLMC 6 15 C605 FRONT LEFT WORK LIGHT 2 18
T5 GLOW PLUGS RELAY 1 8 C433 FRAME TO BOOM ACD 8 7,14 C240 DISPLAY (BLACK CONNECTOR) 12 7,9,13, 17 C606 FRONT RIGHT WORK LIGHT 2 18
T6 GLOW PLUGS RELAY 1 8 C435 FRONT/REAR DIVERTER SWITCH 2 16 C241 DISPLAY (GRAY CONNECTOR) 12 8 C607 REAR WORK LIGHT 2 18
T7 GLOW PLUGS RELAY 1 8 C436 BOOM ANGLE SENSOR 8 14 C242 WIPER SWITCH 10 9 C608 DOME LIGHT 3 10
T8 GLOW PLUGS RELAY 1 8 C441 1ST/2ND GEAR SWITCH 2 13 C243 FUEL LEVEL SENSOR 2 9 C620 ROOF WIPER SWITCH 10 10
T10 ELECTRONIC BATTERY DISC. 1 5 C444 FRAME LEVELING 1 2 15 C244 CAB TO FUEL LEVEL SENSOR 3 9 C621 BEACON SWITCH 10 10
T11 ELECTRONIC BATTERY DISC. 1 5 C445 FRAME LEVELING 2 2 15 C247 LLMI TO SENSOR 4 15 T32 UPPER CAB GND 1 6
T12 ELECTRONIC BATTERY DISC. 1 5 C451 REAR SHAFT SPEED SENSOR 2 11 C248 LLMC TO SENSOR 4 15 T78 BEACON 1 10
T13 ELECTRONIC BATTERY DISC. 1 5 C452 REAR WHEELS ALLIGNMENT 3 13 C250 KEYLESS PAD (KSS) 6 8 T79 BEACON 1 10
T16 ALTERNATOR B+ 1 8 C453 FRONT WHEELS ALLIGNMENT 3 13 C251 BRAKE INCHING POTENTIOMETER 3 11 T84 SPEAKER RIGHT 1 10
T18 STARTER B 1 8 C455 SERVICE BRAKE PRESSURE SENSOR 3 12 C254 CREEP ENABLE SWITCH 10 11 T85 SPEAKER RIGHT 1 10
T19 STARTER TO MEGAFUSE 1 8 C456 PARK BRAKE PRESSUE SWITCH 2 12 C255 FRAME LEVELING POTENTIOMETER 3 15 T86 SPEAKER LEFT 1 10
T20 STARTER S 1 8 C460 HYDRAULIC QUICTACH VALVE 2 16 C256 JOYSTICK 4 7, 14 T87 SPEAKER LEFT 1 10
TRAILER PRESSURE RELEASE C257 LH SKI SWITCH 10 16
T23 ENGINE GND 1 6 C467 10 12
SWITCH
T30 BATTERY POSITIVE 1 5 C701 BOOM DRAIN VALVE 2 16 C258 ATACH SKI SWITCH 10 16
T31 BATTERY NEGATIVE 1 5 C703 BOOM SUSPENSION VALVE 2 16 C259 RH SKI SWITCH 10 16
T44 ENGINE SPEED SENSOR 1 8 T35 FRAME GND 1 6 C260 STEER MODE SWITCH 10 13
T45 ENGINE SPEED SENSOR 1 8 HYDRAULIC FILER 1 C265 FRONT WASHER MOTOR 2 9
T80 1 14
(CLOGGING INDICATOR 1)
T55 ENGINE COOLANT TEMPERATURE 1 8 HYDRAULIC FILER 1 C267 WASHER SWITCH 10 9
T81 1 14
(CLOGGING INDICATOR 1)
T56 ENGINE COOLANT TEMPERATURE 1 8
T82
HYDRAULIC FILER 2
(CLOGGING INDICATOR 2)
1 14
C270
C272
WARNING SWITCH
10
17
17
WIRING SCHEMATIC
HYDRAULIC FILER 2
T83 1 14
(CLOGGING INDICATOR 2)
A-1 VARIABLE FAN SPEED FDBK B-1 ENGINE OIL PRESSURE A-1 DRIVE PUMP FORWARD RETURN B-1 SERVO PRESSURE SENSOR A-1 BOOM EXTEND RETURN B-1 SPARE
A-2 SAFETY VALVE RETURN B-2 POWER SUPPLY A-2 DUMP VALVE RETURN B-2 POWER SUPPLY A-2 BOOM DOWN RETURN B-2 POWER SUPPLY
A-3 BLUE WORKLIGH RELAY B-3 POWER SUPPLY A-3 LOW SPEED RELAY B-3 POWER SUPPLY A-3 BOOM DRAIN VALVE RELAY B-3 POWER SUPPLY
A-4 FRONT ALIGNMENT LAMP B-4 CRAB STEER VALVE A-4 TRACTOR TRAILER BRAKE RELAY B-4 DRIVE PUMP FORWARD A-4 SPARE B-4 BOOM EXTEND
A-5 STARTER RELAY B-5 4 WHEEL STEER VALVE A-5 SPARE B-5 DRIVE PUMP REVERSE A-5 REAR DIVERTER 2 RELAY B-5 BOOM RETRACT
A-6 REAR ALIGNMENT LAMP B-6 VARIABLE FAN SPEED A-6 BRAKE FAIL PRESSURE LAMP B-6 AUX A4 VALVE A-6 SPARE B-6 BOOM UP
A-7 FAN INVERTER RELAY B-7 WORKLIGHT RELAY A-7 REVERSE LIGHT RELAY B-7 AUX B4 VALVE A-7 BOOM SUSPENSION LIGHT STATUS B-7 BOOM DOWN
A-8 FUEL SOLENOID RELAY B-8 CAN LO 1 A-8 CREEP STATUS B-8 CAN LO 1 A-8 SPARE B-8 CAN LO 1
A-9 GLOW PLUGS RELAY B-9 CAN HIGH 1 A-9 STOP LIGHT RELAY B-9 CAN HIGH 1 A-9 SPARE B-9 CAN HIGH 1
A-10 FRAME LEVELING 1 RETURN B-10 INCHING POTENTIOMETER A-10 DRIVE PUMP REVERSE RETURN B-10 ICVD SWASH PLATE SENSOR 1 A-10 TILT UP RETURN B-10 BOOM ANGLE 2
A-11 FRAME LEVELING POTENTIOMETER B-11 INLET MANIFOLD AIR TRACTOR TRAILER BRAKE A-11 SPARE B-11 SPARE
A-11 B-11 PARK BRAKE PRESSURE SWITCH
RELAY FDBK
A-12 POSITION LIGHTS STATUS B-12 FUEL LEVEL A-12 STOP LIGHT RELAY FDBK B-12 SPARE A-12 SPARE B-12 SPARE
A-13 CRANKING POSITION B-13 FRAME LEVELING 1 A-13 RETRACT SWITCH NO B-13 TILT UP
A-13 HIGH/LOW SPEED B-13 GEAR 1 VALVE/ICVD SWASH PLATE
A-14 CRAB STEER SWITCH B-14 CAN HI 2 A-14 SHUNT KEY POSITION B-14 SPARE
A-14 GEAR SELECTOR SWITCH B-14 SPARE
A-15 ENGINE SPEED B-15 GND A-15 SPARE B-15 GND
A-15 REAR SHAFT SPEED B-15 GND
A-16 STARTER RELAY FDBK B-16 GND A-16 SPARE B-16 GND
A-16 SPARE B-16 GND
A-17 FUEL PUMP RELAY B-17 SENSOR GND (1) A-17 SPARE B-17 SENSOR GND (3)
A-17 SPARE B-17 SENSOR GND (2)
A-18 FRAME LEVELING 2 RETURN B-18 SPARE A-18 BOOM RETRACT RETURN B-18 HYDRAULIC OIL TEMPERATURE
A-18 AUX B4 RETURN B-18 SERVICE BRAKE PRESSURE
A-19 FRONT ALIGNMENT STATUS B-19 SAFETY VALVE A-19 SPARE B-19 TILT DOWN
A-19 SPARE B-19 GEAR 2 VALVE/ICVD DEFEAT
A-20 FUEL SOLENOID RELAY FDBK B-20 CAN LO 2 A-20 SPARE B-20 SPARE
A-20 INLET PRESSURE SENSOR B-20 SPARE
A-21 ACK LH SKI SWITCH DOWN B-21 ATTACHMENT RUN A-21 RETRACT SWITCH NC B-21 IGNITION SIGNAL
A-21 AUTO MODE 1: SMOOTH B-21 IGNITION SIGNAL
A-22 ACD RH SKI SWITCH DOWN B-22 IGNITION POSITION A-22 SPARE B-22 HYDRAULIC QUICKTACH SWITCH
A-22 AUTO MODE 4: CONVERTER 2 B-22 FNR NEUTRAL
A-23 REAR ALIGNMENT STATUS B-23 SENSOR SUPPLY 5V (1)
A-23 SPARE B-23 SENSOR SUPPLY 5V (2) A-23 SPARE B-23 SENSOR SUPPLY 5V (3)
A-24 ACD LH SKI SWITCH UP B-24 LLMC OK
A-24 AUTO MODE 3: CONVERTER 1 B-24 SWASH PLATE SENSOR 2 A-24 SPARE B-24 BOOM ANGLE 1
A-25 SPARE B-25 BATTERY DISCONNECT
A-25 STEERING PRESSURE SENSOR B-25 DUMP VALVE A-25 SPARE B-25 HYDRAULIC QUICKTACH
A-26 SPARE B-26 FRAME LEVELING 2
A-26 BOOM SUSPENSION RETURN B-26 BOOM SUSPENSION A-26 BOOM UP RETURN B-26 REAR DIVERTER 1
A-27 SPARE
A-27 AUX A4 RETURN A-27 TILT DOWN RETURN
A-28 ACD ATTACH SKI SWITCH
A-28 FNR LEVER REVERSE A-28 BOOM DRAIN VALVE RELAY FEEDBACK
A-29 4 WHEEL STEER SWITCH
A-29 AUTO MODE 2: AGGRESIVE A-29 REAR HOOK SWITCH
A-30 ACD RH SKI SWITCH UP
A-30 TRAILER PRESSURE RELEASE SWITCH A-30 REAR AUXILIARY SWITCH
A-31 ACD ATTACH SKI SWITCH
A-31 REAR DIVERTER 2 RELAY FDBK
A-31 FNR LEVER FORWARD
A-32 ENGINE COOLANT TEMPERATURE
HYDRAULIC FILTER CLOGGING A-32 SPARE
A-32
A-33 LORS BAR INDICATOR
A-33 FRONT/REAR DIVERTER SWITCH
A-33 1ST/2ND GEAR SWITCH
A-34 IGNITION FDBK
A-34 SPARE
A-34 LOW SPEED RELAY FDBK
(1) GATEWAY CONTROLLER
J1B-23 POWER SUPPLY 5V J1B-17 GROUND
Connector Designation Sheet Connector Designation Sheet
C251-C INCHING POTENTIOMETER 11 C251-A INCHING POTENTIOMETER 11
C243-B FUEL LEVEL SENSOR 9
ACRONYMS DESCRIPTION
AC AIR-CONDITIONING
POWER
SHT8/D5 20A
1865 RNG/WHT
SHT18/H6
JUMPER
1540 RNG/WHT F11
SHT8/C8 20A
F41 1855 RNG/WHT 1860 RNG/WHT
F50 25A SP2 SHT18/H7
1530 RNG/WHT 1535 RNG/WHT 1545 RNG/WHT
100A SHT8/D7
SP1
1090 RED T1 T2 1525 RNG/WHT F8
SHT8/C7 F42
1945 RNG/WHT 15A
10A 1950 RNG/WHT
1550 RNG/WHT 1555 RNG/WHT SHT9/H5
SHT8/D6
1725 RNG/WHT
SHT8/H8
F7
15A
1995 RNG/WHT
SHT17/H4
1990 RNG/WHT
JUMPER
SHT17/H4
C235 F6
1 1 SP200 15A
1710 RNG/WHT 1710 RNG/WHT 1960 RNG/WHT 1975 RNG/WHT
SHT17/H5
1965 RNG/WHT
SHT17/H6
1575 RNG/WHT
F22 1605 RNG/WHT
15A SP14 SHT14/H8
1595 RNG/WHT
1720 RNG/WHT
1600 RNG/WHT SHT8/H3
SHT14/H8
JUMPER
C100
F21 1750 RNG/WHT
SHT16/H3
1 1 15A F5
1580 RNG/WHT 1580 RNG/WHT 1590 RNG/WHT 1735 RNG/WHT
SP39 SHT12/H8 25A SHT8/H2
1715 RNG/WHT 1730 RNG/WHT
1585 RNG/WHT SP74
SHT12/H8 1740 RNG/WHT
SHT9/H7
1745 RNG/WHT
SHT9/H7
1501 RNG/WHT
SHT12/H6
F29
5A
1689 RNG/WHT
1690 RNG/WHT
SHT12/E7
F28 F4
10A 1870 RNG/WHT 20A
1680 RNG/WHT 1880 RNG/WHT
SHT17/H2 SHT10/H5
1875 RNG/WHT
SHT15/H5
F27
15A
1665 RNG/WHT
SHT16/H8
JUMPER
1625 RNG/WHT
SHT14/H6
1935 RNG/WHT
SHT9/H6
1635 RNG/WHT
SHT13/C7
1940 RNG/WHT
SHT9/H6
1655 RNG/WHT F3
SHT11/D3 10A
F26 1910 RNG/WHT 1930 RNG/WHT
5A SP52 SP9 SHT9/D5
1620 RNG/WHT 1640 RNG/WHT 1660 RNG/WHT SP23
SHT14/D7
1920 RNG/WHT
1645 RNG/WHT SHT9/H4
SHT13/C7
1915 RNG/WHT
SHT11/H7
F25
1610 RNG/WHT 2 2 7,5A
1610 RNG/WHT 1615 RNG/WHT
SHT11/E7
1785 RNG/WHT
SHT14/F2
1830 RNG/WHT
SHT11/H4
F24 1815 RNG/WHT
SHT15/H4
25A 1840 RNG/WHT
SHT11/H2
1700 RNG/WHT 4 4 1700 RNG/WHT 1705 RNG/WHT
SHT14/D2
1820 RNG/WHT
SHT13/H6
F23 F2 1810 RNG/WHT
25A 7.5A SHT15/H3
1020 RED 3 3 1020 RED 1425 RED/WHT 1780 RNG/WHT 1790 RNG/WHT 1805 RNG/WHT
SHT14/D2 SHT16/H4
SP42 1800 RNG/WHT
SHT16/H6
1390 RED/WHT 1825 RNG/WHT
1695 RNG/WHT
SHT8/H6 SHT11/H6
8080 TAN
C109
BATTERY
C233 1350 RED/WHT
SHT10/H7 1850 RNG/WHT
DISCONNECT SHT9/H4
BATTERY F1 1360 RED/WHT 1845 RNG/WHT
1030 RED 16 16 1030 RED SHT8/H8 SHT9/H4
12.0 Volts T11 SP80 20A SP67 SP19
1010 RED 1050 RED 1310 RED/WHT 1340 RED/WHT 1370 RED/WHT 1696 RNG/WHT
SHT8/H8 SHT8/H6
2000 BLK 1000 RED 1040 RED 24 24 1040 RED SP81 1694 RNG/WHT
SP32 SHT8/H6
T31 T30 T10 1 1330 RED/WHT
SHT17/H6
2 1320 RED/WHT
SHT8/H7
T12
1300 RED/WHT
SHT14/F2
WIRING SCHEMATIC
1060 RED
2445 BLK
T23
STARTER
GND
SHT17/C8
2145 BLK
2265 BLK
SP11 2255 BLK 2575 BLK SP33
2585 BLK
2595 BLK
2315 BLK
SHT12/E8
SHT12/E8
SHT16/C5
2720 BLK
SHT14/D1
SHT8/E8
2165 BLK T26 2405 BLK 2840 BLK
LOWER CAB SHT14/E8 SHT18D6
2175 BLK GND 2375 BLK 2850 BLK
SHT8/E8 SHT16/C5 SHT18/D6
SP15 SP66
2440 BLK 2715 BLK 2775 BLK 2635 BLK SHT13/C7
SHT16/C5
2125 BLK
SHT9/E8 2415 BLK 2235 BLK
SP7 SHT14/E8 SHT17/C7
2540 BLK 2115 BLK
SHT9/E7 2460 BLK 2225 BLK
SHT16/C5 SHT17/C4
2955 BLK
SHT9/C5
2205 BLK
2590 BLK 2815 BLK SHT15/G4
SHT8/G6 2160 BLK
SHT14/D7
2790 BLK 2765 BLK SHT16/G2
SHT12/G7
SP8 2780 BLK
2805 BLK 2956 BLK SHT18/C4 SP13
2735 BLK SHT9/C4 2520 BLK
SHT8/G2 SP6 SHT16/D7
2995 BLK 2620 BLK 2215 BLK
SHT9/G8 SHT17/C5
2985 BLK
SHT6/G8 2425 BLK SHT9/E4 2195 BLK
SHT17/C2
2785 BLK
SHT17/G7
2580 BLK
C332
2
5
8
5
/
B
L
K
SHT8/G6
SP24
2
8
2
5
/
B
L
K
2825 BLK 2 2
2
6
2
0
/
B
L
K
SHT18/D5
2890 BLK
SHT10/D5
SP29
2075 BLK 2860 BLK 2695 BLK
SHT8/C7 SHT18/C7
2130 BLK 2700 BLK
SHT8/C5 SHT10/G5
2445 BLK SP3
T23
SHT5/B7 2015 BLK ENGINE
2170 BLK GND
SHT8/D4 2880 BLK
2655 BLK
SHT18/C8 T32
SHT9/C7 2900 BLK UPPER CAB
SHT10/D4
2185 BLK GND
SHT8/D3 2450 BLK
SHT10/D7
2105 BLK
SHT8/C5
2065 BLK
SHT10/D4
2895 BLK
SP10
2865 BLK WIRING SCHEMATIC
2095 BLK 2680 BLK
SHT8/C7 SP5 SHT10/D5
2155 BLK
SHT8/C6
SHT8/C5
2245 BLK TL470 (S/N ANL711001 AND ABOVE)
SHT12/C7
2190 BLK
2480 BLK
(S/N ANMG11001 AND ABOVE)
SHT11/C7 UPPER CAB GROUNDS
(S/N AVM111001 AND ABOVE)
FRAME
T35
2005 BLK
(S/N AVM611001 AND ABOVE)
GND
Sheet 6 of 18
ENGINE GROUNDS
(PRINTED MAY 2012)
Printed In Belgium 7159062 (C)
LOWER CAB FRAME ENGINE 100HP
C240-3
C240-4
CAN LO 1
CAN HI 1
9100 PUR/WHT
9000 PUR
C233
C230
9110 PUR/WHT
9130 PUR/WHT
9150 PUR/WHT
9190 PUR/WHT
9170 PUR/WHT
9010 PUR
9030 PUR
9050 PUR
9090 PUR
9500 PUR/WHT 9 9 12 11
C100
9070 PUR
9500 PUR/WHT
9600 PUR 10 10
12 11
9600 PUR
9320 PUR/WHT
C290
J1B-20
J1B-14
CAN LO 1
CAN LO 1
CAN LO 1
CAN LO 1
J1B-9
J1B-8
CAN HI 1
CAN HI 1
CAN HI 1
CAN HI 1
CAN LO 2
CAN HI 2
C250-2
C250-4
C237-5
C237-6
C238-4
C238-5
9220 PUR
A B
A B
B A C256-2
SP54 9230 PUR
CAN LO 1
9340 PUR/WHT
B A
9240 PUR
6 BLK
5 BLK
SP55 9350 PUR/WHT J2B-9
CAN HI 1
9360 PUR/WHT
9260 PUR
C501 B A
B A
CAN LO 1
J3B-8
J3B-9
CAN HI 1
ACD
ON BOOM
BOOM
WIRING SCHEMATIC
ENGINE,
1694 RNG/WHT
1696 RNG/WHT
1735 RNG/WHT
1320 RED/WHT
1390 RED/WHT
C210
IGNITION
SWITCH
C220
RSS
C250
KSS
C216
FAN
INVERTER IGNITION
1 5 1 5 6 2 8
2730 BLK
1725 RNG/WHT
1370 RED/WHT
1360 RED/WHT
2 4 2 4 3 3 3 7
1720 RNG/WHT
2590 BLK
2580 BLK
2735 BLK
8320 TAN
8290 TAN
3320 LBL
3290 LBL
3270 LBL
3735 LBL
SP34
8300 TAN
3300 LBL
CRANK
BATT
BATT
FAN INVERTOR
IGN FBCK
RUN
C241-1
J1A-34
J1A-13
J1B-22
GATEWAY CONTROLLER
J1B-2
J1B-3
COOLANT TEMP.
FUEL SOLENOID
STARTER FBCK
ENGINE SPEED
FAN INVERTER
GLOW PLUGS
FUEL PUMP
J1A-15
J1B-15
J1B-16
J1B-25
J1A-16
J1A-20
J1A-17
J1A-32
CONTROLLER
STARTER
J1A-5
J1A-8
J1A-9
J1B-1
J1A-1
J1B-6
J1A-7
GND
GND
2165 BLK
2175 BLK
4160 LGN
R6
2630 BRN
4630 LGN
8070 TAN
8020 TAN
8030 TAN
8110 TAN
8120 TAN
8140 TAN
8040 TAN
3750 LBL
3100 LBL
3170 LBL
30 86 FAN
SHT9/E3
INVERTER
87 85 RELAY
SHT6/F8 SHT6/F8
2750 BRN
2570 BLK
4170
SHT18/E5
C233 1 2 3 4 23 15 20 12 13 14 11 6 7 5
1 2 3 4 23 15 20 12 13 14 11 6 7 5
SHT5/H5
2750 BRN
8070 TAN
1555 RNG/WHT
8030 TAN
8120 TAN
8040 TAN
1545 RNG/WHT
1520 RNG/WHT
4170 LGN
8140 TAN
1632 RNG/WHT
SP59
SP92
8080 TAN
2185 BLK
1560 RNG/WHT 1570 RNG/WHT 8050
SP18 D17 SHT6/C8
30 86 R21 30 86 R24 30 86 R25 T5 T8 R22
D2
STARTER FUEL SOLENOID FUEL PUMP GLOW PLUGS
87 85 RELAY RELAY RELAY T7 T6 RELAY
2751 BRN
87 85 87 85
2910 BRN
2630 BRN
3750 LBL
4630 LGN
2170 BLK
3100 LBL
3170 LBL
4180 LGN
2180 BLK
SHT12/C8 SHT5/C7
2055
8020 TAN
8010 TAN
8110 TAN
8100 TAN
8130 TAN
2095 BLK
2155 BLK
2245 BLK
2065 BLK
C158
C114
C116
C115
1 2 A B 2 1 2 1
SP41 SP16
SHT7/B8 1 2 A B 2 1 2 1
SHT6/B8 SHT6/B8
8060 TAN
SHT5/H8
8090 TAN
2075 BLK
1540 RNG/WHT
1090 RED
8000 TAN
D1
1565 RNG/WHT
P
8085 TAN
2085 BLK
2130 BLK
C103
C113
B+ B S
S L 2 1 1 2 1
WIRING SCHEMATIC
T54
TL470 (S/N ANL711001 AND ABOVE)
T
ALTERNATOR STARTER
FUEL
SOLENOID
ENGINE
TEMPERATURE
FUEL
PUMP
GLOW
PLUGS
(S/N ANMG11001 AND ABOVE )
16 OHM 12V SWITCH
(S/N AVM111001 AND ABOVE )
HARNESS ENGINE 100HP PN 7162049 REF (S/N AVM611001 AND ABOVE)
Sheet 8 of 18
(PRINTED MAY 2012)
Printed In Belgium 7159062 (C)
HARNESS LOWER CAB PN 7162047 REF
SHT5/C1 SHT5/C1
LOWER CAB
1745 RNG/WHT
1740 RNG/WHT
1935 RNG/WHT
1950 RNG/WHT
1920 RNG/WHT
1845 RNG/WHT
1850 RNG/WHT
1941 RNG/WHT
1940 RNG/WHT
1942 RNG/WHT
C267 C242
WASHER WIPER
2945 BLK
C211 C212 SWITCH SWITCH
AC SWITCH BLOWER
SPEED 1937 RNG/WHT
INTERNALLY CONNECTED
C224 WITH PIN 1 - SEE SHEET 18/G5
1 5 1 3 4 6 8 14 11 8 LEFT LEVER
(HORN SWITCH) 1
2940 BLK
3 C 3 2 1 4 2 5 7 3 13 7
2620 BLK
7120 WHT
7110 WHT 2935 BLK
7040 WHT
7050 WHT
7020 WHT
7010 WHT
7030 WHT
2930 BLK
4
7080 WHT
7090 WHT
7100 WHT
SHT6/E5
SHT7/G8
C213
C214 HEATER AND
BATTERY +
C240-1
IGNITION
C240-5
THERMOSTAT BLOWER
MODULE 14.00 Amps max.
GATEWAY CONTROLLER
A A B C E
DISPLAY
M CONTROLLER
C240-10
J1B-17
J1B-12
SENSOR GND
C240-2
C B D
FUEL LEVEL
BUZZER
2125 BLK
2540 BLK
GND
7170 WHT
7320 WHT
C283
2425 BLK
7130 WHT
2010 BRN
CAB
BUZZER
SHT6/F8 SHT6/F8
T59 SP40
2710 BRN
SHT6/E5
2750 BRN
2020 BRN
2030 BRN
3330 LBL
7140 WHT
SHT15/G7
P
PRESSURE SHT8/E4
SWITCH
SHT11/D1
C244-B C244-A
B A C
C230 4
C233 B A C
10
B A C 4
10 SP22
B A C
SHT6/G4
7170 WHT
2770 BLK
7140 WHT
C243
SHT6/E5
B A
C424
1 2
2655 BLK
B A
1 2
1930 RNG/WHT
1955 RNG/WHT
1956 RNG/WHT
D18
7040 WHT
7050 WHT
7020 WHT
7010 WHT
7030 WHT
2830 BLK
2955 BLK
2956 BLK
7150 WHT
2650 BLK
FUEL LEVEL
C280
C227
C123
C281
C265
1 2 1 2 4 2 1 6 3 1 2 2 1 SENSOR
33 ~ 297 OHM HORN
3.5 Amps
1 2 1 2 4 2 1 6 3 1 2 2 1
12V SOCKET
15 Amps max. WIRING SCHEMATIC
UPPER CAB
C621 C620
BEACON ROOF WIPER
SWITCH SWITCH
1901 RNG/WHT 1902 RNG/WHT
2 8 1 3
3 7 2 8 7
2700 BLK
1905 RNG/WHT
2705 BLK
1880 RNG/WHT
1350 RED/WHT
1900 RNG/WHT
7060 WHT
7070 WHT
6000 PNK
SHT6/C6
C232 1 4
1 4
1880 RNG/WHT
SP20
1890 RNG/WHT
1895 RNG/WHT
1350 RED/WHT
7060 WHT
7070 WHT
6680 PNK
6000 PNK
2450 BLK
2680 BLK
2890 BLK
2900 BLK
2895 BLK
C604
C603
C602
C608
C601
8 7 4 1 2 7 8 2 3 1 1 2 2 1 4 3
8 7 4 1 2 7 8 2 3 1 1 2 2 1 4 3
RADIO
7200 WHT
7210 WHT
7220 WHT
7230 WHT
SUPPLY
- -
+ +
T84 T85 T86 T87 T78 T79
RIGHT LEFT REAR WIPER ROOF WIPER
SPEAKER SPEAKER DOME LIGHT BEACON
MOTOR MOTOR
4 OHM 4 OHM 10.00 Watts 55.00 Watts
23.00 Watts 26.00 Watts
WIRING SCHEMATIC
TRANSMISSION
1915 RNG/WHT
1825 RNG/WHT
1830 RNG/WHT
1840 RNG/WHT
INTERNALLY CONNECTED C254
C224 C219 CREEP
WITH PIN 1 - SEE SHEET 18/G5 C209
LEFT LEVER C225 GEAR 2641 BLK
1 DRIVE MODE ENABLE
(SPEED SELECTOR) FNR LEVER SELECTOR
SWITCH 3241 LBL
1831 RNG/WHT
1 5 2 8 6 2 8
1.00 k Ohms 1 2
2740 BLK
NOT
CONNECTED
2640 BLK
3240 LBL
12 4 5 6 4 3 2 1 3 7 3 7
2530 BLK
3470 LBL
3510 LBL
3520 LBL
3530 LBL
3670 LBL
3660 LBL
3650 LBL
3640 LBL
3430 LBL
3740 LBL
SHT6/G5
SHT6/G5
C230 21 27 28 26 25 24 23 22 15 3
21 27 28 26 25 24 23 22 15 3
HARNESS FRAME PN 7162050 REF
3470 LBL
3510 LBL
3520 LBL
3530 LBL
3670 LBL
3660 LBL
3650 LBL
3640 LBL
3430 LBL
3240 LBL
HIGH/LOW SPEED
FNR REVERSE
FNR NEUTRAL
FNR FORWARD
GEAR SELECTOR
AGRESSIVE MODE
SMOOTH MODE
CREEP ENABLE
CONV. 2 MODE
CONV. 1 MODE
J2A-28
J2A-31
J2B-22
C240-7
J2A-13
J2A-22
J2A-24
J2A-29
J2A-21
J2A-14
CREEP STATUS
DRIVE CONTROLLER GATEWAY
J2A-8
VSENSOR 1 (5VDC)
INCHING SENSOR
SENSOR GND
SWASH PLATE IN1
DRIVE PUMP REV.
LOW SPEED FBCK
VSENSOR1
J2B-24
J2A-34
J2A-10
J2B-10
J2A-33
J2B-23
J2B-17
J2A-15
J2B-13
J2B-19
J1B-23
J1B-10
DISPLAY
J2B-25
J2A-2
J2A-1
J2B-4
J2B-5
J2B-1
DUMP VALVE
J2A-3
LOW SPEED
CONTROLLER
2045 BRN
5030 YEL
SHT5/D5
3380 LBL
4080 LGN
5041 YEL
4040 LGN
4060 LGN
3140 LBL
SHT15/H7
5665 YEL 2060 BRN
SHT13/D4 SHT12/C5
1615 RNG/WHT
SP84
5060 YEL SP31 2665 BRN
SHT12/C5 SHT13/D4
2041 BRN
5000 YEL
5010 YEL
2050 BRN
R9
LOW
2950 BRN
2670 BRN
2690 BRN
4950 LGN
4670 LGN
4690 LGN
3340 LBL
86
3350 LBL
3435 LBL
3210 LBL
30
SPEED SP77
RELAY
87 85
1.00 k Ohms
4480 LGN
2280 BLK
1 Z1 2
SHT5/E4
SHT9/E3
1655 RNG/WHT
SHT17/E2
2020 BRN
4020 LGN
2240 BLK
2260 BLK
5020 YEL
C100
3155 LBL
5 16 15 6 7 8 9 26 27 29 28 20 10
5 16 15 6 7 8 9 26 27 29 28 20 10
C251
C451
C402
C403
1 2 2 1 2 1 C B A
SHT13/D3 SHT13/D3
1 2 2 1 2 1 C B A
2041 BRN
5455 YEL
5041 YEL
2455 BRN
3210 LBL
2950 BRN
2670 BRN
2690 BRN
4950 LGN
4670 LGN
4690 LGN
4480 LGN
2835 BRN
SP73
REAR SHAFT GEAR 1 GEAR 2 INCHING
5835 YEL SPEED SENSOR VALVE VALVE POTENTIOMETER
SP91 8,8 OHM 12V 8,8 OHM 12V 4,15 KOHM
5435 YEL SHT6/B8
2040 BRN
2435 BRN
5040 YEL
3340 LBL
3350 LBL
3435 LBL
2480 BLK
2210 BLK
WIRING SCHEMATIC
C141
C117
C121
C135
C120
C130
C142
2 1 2 1 2 1 2 1 4 2 3 1 A B C 1 2
1501 RNG/WHT
T91 C467
TRAILER BRAKE
PRESSURE RELEASE
SWITCH
(EMEA)
T90
2
2791 BLK
3091 LBL
Z3 3
1585 RNG/WHT
1590 RNG/WHT
1.00 k Ohms 1 2
2790 BLK
3090 LBL
3000 LBL
SHT6/E8
C230 30
30
3090 LBL
PARK BRAKE
BRAKE FAIL PRESS. LAMP
BATT
BATT
DRIVE CONTROLLER
J2A-30
J2B-2
J2B-3
J2A-6
TRACTOR TRAILER B.V. FDBK
J2B-16
J2B-21
J2A-11
J2A-4
J2B-18
IGN. SIGNAL
GND
GND
4140 LGN
1630 RNG/WHT
2585 BLK
2595 BLK
3390 LBL
1690 RNG/WHT
R12
30 86 TRACTOR TRAILER
SHT6/H1 SHT6/H1 BRAKE VALVE
RELAY
87 85 (EMEA)
2290 BLK
2300 BLK
SHT17/E3 SHT16/D8
19 17
C100
19 17
1632 RNG/WHT
SHT6/G1 SHT11/E3
SHT11/E4
3250 LBL
2250 BLK
2060 BRN
4190 LGN
2190 BLK
5060 YEL
3160 LBL
SHT8/D8
C150
C456
C455
2 1 1 2 B A C
2 1 1 2 B A C
WIRING SCHEMATIC
TRACTOR TRAILER
BRAKE VALVE
9 OHM 12V
PARK BRAKE
PRESSURE
SERVICE BRAKE
PRESSURE
0,5 ~ 4,5V
(S/N ANMG11001 AND ABOVE)
SWITCH
STEERING
1820 RNG/WHT
C200 C260
ICON CLUSTER STEER MODE
FRONT / REAR CRAB STEER 4 WHEEL STEER CRAB / 4 WHEEL
ALIGN. LAMP LAMP LAMP 1821 RNG/WHT
T95 T97
9 2
2400 BLK
2420 BLK
D E T94 T96
1 3 7
2220 BLK
3030 LBL
3040 LBL
3580 LBL
3570 LBL
3400 LBL
3420 LBL
SHT6/G5 SHT6/G5
REF
SHT17/E4 SHT6/G5
FRONT ALIGNMENT
REAR ALIGNMENT
CRAB STEER
4 WHEEL STEER
J1A-14
J1A-29
J1A-4
GATEWAY DRIVE
J1A-6
CONTROLLER CONTROLLER
STEERING PRESSURE
FRONT ALIGNMENT
REAR ALIGNMENT
J1A-19
J1A-23
J2A-25
J1B-4
J1B-5
CRAB STEER
4W STEER
4000 LGN
4220 LGN
3780 LBL
SP83
3635 LBL
3645 LBL
SP82
SP95
4010 LGN
4230 LGN
3455 LBL
C230 1 2 19 20 C100 23
1 2 19 20 23
SHT11/E4 SHT11/D6
2665 BRN
2455 BRN
5665 YEL
5455 YEL
3665 LBL
3455 LBL
4010 LGN
4230 LGN
3635 LBL
3645 LBL
C425
C143
B A C B A C
B A C B A C
SHT5/D4 SHT5/D3
SHT6/F1 SHT6/G4
P P
1635 RNG/WHT
1645 RNG/WHT
2645 BLK
2610 BLK
2230 BLK
C422
C453
1 2 3 1 2 3 2 1 2 1
WIRING SCHEMATIC
1625 RNG/WHT
(CLOGGING (CLOGGING
INDICATOR 1) INDICATOR 2)
5V 5V
C256 P P
JOYSTICK
2200 BLK
2845 BLK
3200 LBL
3845 LBL
1600 RNG/WHT
1605 RNG/WHT
1650 RNG/WHT
4
2625 BLK
SP93
SHT76/G4 SHT6/G4
3840 LBL
SHT6/G4
SHT5/B4 SHT5/D1
HYD. FILTER
IGN. SIGNAL
BATT
BATT
J3B-21
J2A-32
WORKGROUP CONTROLLER DRIVE CONTROLLER GATEWAY CONTROLLER
J3B-2
J3B-3
RETRACT SWITCH NC
1785 RNG/WHT
1300 RED/WHT
ATT RUN (RMT KEY)
BOOM RETRACT RET
BOOM EXTEND RET
BOOM DOWN RET
INLET PRESSURE
AUX A4 RETURN
AUX B4 RETURN
TILT DOWN RET
BOOM RETRACT
BOOM UP RET
SAFETY VALVE
BOOM ANGLE 1
BOOM ANGLE 2
BOOM EXTEND
J3B-15
J3B-16
J3B-23
J3B-17
J3B-24
J3B-10
J3B-18
J3A-13
J3A-21
J3A-26
J3A-10
J3B-13
J3A-27
J3B-19
J3A-18
J2A-27
J2A-18
J2A-20
J1B-19
J1B-21
SENSOR GND
J3B-6
J3A-2
J3B-7
J3A-1
J3B-4
J3B-5
J2B-6
J2B-7
J1A-2
BOOM DOWN
TILT UP RET
TILT DOWN
VSENSOR1
BOOM UP
TILT UP
AUX A4
AUX B4
GND
GND
2405 BLK
2415 BLK
C290
2800 BLK
3700 LBL
3720 LBL
D F E G
D F E G
2920 BRN
4920 LGN
3835 LBL
DIAGNOSTIC
SHT6/F4 SHT6/F4 CONNECTOR
SP26
3710 LBL
SHT6/G8
2070 BRN
5070 YEL
C100 24 C230 38 39 11
24 38 39 11
SP17
SP63
SHT6/E4 SHT5/C5 SHT5/C5 SH6/F4
3710 LBL
2360 BRN
2380 BRN
2320 BRN
2340 BRN
2350 BRN
2330 BRN
2410 BRN
2430 BRN
4360 LGN
4380 LGN
4320 LGN
4340 LGN
4350 LGN
4330 LGN
4410 LGN
4430 LGN
SHT11/D6
1705 RNG/WHT
1425 RED/WHT
2920 BRN
4920 LGN
SHT5/D3
2720 BLK
SHT11/D6
1660 RNG/WHT
2835 BRN
5835 YEL
3835 LBL
2080 BRN
2090 BRN
2140 BRN
5080 YEL
5090 YEL
2160 BLK
3180 LBL
3190 LBL
3440 LBL
3450 LBL
3460 LBL
C433 D H F E G
D H F E G
C423
C144
C A B 2 1
6M PN 7162054 REF
7M PN 7162055 REF
GND GN/YE
C A B 2 1
W/L3 BLK
U/L1 BLK
V/L2 BLK
HARNESS BOOM
8 BLK
C501
P D C 2 1 3
D C 2 1 3
INLET PRESSURE SAFETY
SENSOR VALVE
0,5 ~ 4,5V 5,3 OHM 12V ACD CONNECTOR
LS PUMP
C414
C418
C419
C436
C420
C412
C413
C416
C415
C417
C400
1 4 7 8 2 5 A B 1 3 2 4 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
1 4 7 8 2 5 A B 1 3 2 4 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
WIRING SCHEMATIC
FRAME LVL
1810 RNG/WHT
5010 YEL
C255
FRAME LEVELING
POTENTIOMETER
SHUNT KEY
LLM SYSTEM
T68
1875 RNG/WHT
1815 RNG/WHT
2
1 3 T69
2710 BRN
3010 LBL
3310 LBL
2875 BLK
2815 BLK
SHT9/E3 C238 1 2 C237 1 2 C230 8
1 2 1 2 8
3310 LBL
SHUNT KEY
FRAME LVL
GATEWAY CONTROLLER
PWR SUPPLY
GND
PWR SUPPLY
GND
J1A-11
J3A-14
LLMC CONTROLLER LLMI DISPLAY WORKGROUP
FRAME LVL 1 RET.
J1A-18
J1B-26
SENSOR +
SENSOR +
SENSOR -
SENSOR -
CONTROLLER
FRAME LVL 1
FRAME LVL 2
CAN LO
CAN LO
CAN HI
CAN HI
2990 BRN
4970 LGN
4990 LGN
C236 1 2 3 4
C248
C247
1 2 3 4 4 3 2 1
1 2 3 4
1 2 3 4 4 3 2 1
C229
1 2 3 4 5 6 7 8
2970 BRN
2990 BRN
4970 LGN
4990 LGN
1 2 3 4 5 6 7 8
C444
C445
2 1 2 1
2 1 2 1
FRAME FRAME
LEVELING 1 LEVELING 2 LLM SENSOR
5.3 OHM PWM 5.3 OHM PWM
1805 RNG/WHT
ICON CLUSTER
1801 RNG/WHT
1800 RNG/WHT
1802 RNG/WHT
1750 RNG/WHT
BOOM
1755 RNG/WHT
1765 RNG/WHT
SUSPENSION
C259
HYDRAULIC
C284 C258
C257 ACD RH SKI
C205 QUICKTACH ACD ATTACH SKI
ACD LH SKI SWITCH
6 2 8 REAR AUX POWER SWITCH
1807 RNG/WHT SWITCH
SWITCH SWITCH
1760 RNG/WHT 1770 RNG/WHT 1775 RNG/WHT
OPTION
2 5 8 2 8 2 8 2 8
C 9 2 8
C205
1 7
REAR AUX / HOOK
2395 BLK
SWITCH
3410 LBL
C205
2 8 HYD HOOK 3 6 7 1 3 7 1 3 7 1 3 7
1 3 7 SWITCH
3495 LBL
OPTION
2755 BLK 2760 BLK
2765 BLK
2470 BLK
2396 BLK
3870 LBL
REF
2600 BLK
3800 LBL
3810 LBL
SHT18/E4 3 7
3550 LBL
3540 LBL
3230 LBL
3220 LBL
3610 LBL
3600 LBL
SHT6/G5
SHT6/G5
SHT6/E5
C230 17 7 12 5 13
17 7 12 5 13
3495 LBL
3800 LBL
3810 LBL
3870 LBL
ACD RH SKI UP
HYD. QUICKTACH
DRIVE CONTROLLER
J3A-30
J3A-29
J3B-22
J1A-21
J1A-24
J1A-28
J1A-31
J1A-22
J1A-30
J3A-7
BOOM SUSPENSION RETURN
HYDRAULIC QUICKTACH
REAR DIVERTER 2 FDBK
BOOM DRAIN VALVE
BOOM SUSPENSION
DIVERTER SWITCH
REAR DIVERTER 2
REAR DIVERTER 1
J3A-28
J3A-31
J3A-33
J3B-26
J3B-25
J2B-26
J3A-3
J3A-5
J2A-26
4450 LGN
1670 RNG/WHT
R14 R16 86
30 86 30
BOOM DRAIN REAR
VALVE DIVERTER 2
87 85 RELAY RELAY 87 85
2305 BLK
2300 BLK
4500 LGN
2002 BLK
SHT12/D6
4580 LGN
2395 BLK
4440 LGN
3560 LBL
3370 LBL
2315 BLK
4390 LGN
2520 BLK
2375 BLK
4460 LGN
SHT6/F4
SHT6/H1 D4
D7
2460 BLK
2440 BLK
4470 LGN
4590 LGN
2370 BLK
2390 BLK
C431
C432
C701
C435
C460
C703
2 1 2 1 2 1 A B 2 1 1 2
2 1 2 1 2 1 A B 2 1 1 2
WIRING SCHEMATIC
STD
INTERNALLY CONNECTED
SHT5/C4
1990 RNG/WHT
1995 RNG/WHT
1680 RNG/WHT
SHT5/G1
1967 RNG/WHT
1965 RNG/WHT
1330 RED/WHT
SHEET 10/G2
C272 C270 C224 C224
LIGHTS
WITH PIN 1
FOG LIGHT TRAILER LEFT LEVER LEFT LEVER
WARNING
SWITCH INDICATOR (TURN SWITCH) (HEAD LIGHTS)
SWITCH
LAMP
1987
2 8 T92 1 3 8 9 1 1 6 8
1
10 2965 BLK
3 7 T93 2 5 17 18 SHT6/G8 10 11 2 3 5 7
1980 RNG/WHT
6620 PNK 1977 RNG/WHT
2785 BLK
2985 BLK
6690 PNK
6610 PNK
1985 RNG/WHT
1970 RNG/WHT
JUMPER
6600 PNK
3770 LBL
7,5A
F10
SHT6/E8 SHT6/E8
7,5A
6540 PNK
6500 PNK
F9
3070 LBL
3050 LBL
POSITION LIGHTS STATUS
J1A-12
DISPLAY DRIVE CONTROLLER
C200
LAMP TRAILER(C2)
OUTPUT(49a)
SUPPLY(49)
CONTROLLER
6
4
C221 ICON CLUSTER
POSITION/LOW BEAM
ICON VEHICLE(C)
C240-11
C240-8
REVERSE LIGHT
RELAY LAMPS
TURN SIGNAL
STOP LIGHT
HIGH BEAM
J2A-12
GATEWAY
J2A-9
J2A-7
GND(31)
CONTROLLER F G
5
6010 PNK
1997 RNG/WHT
3130 LBL
6180 PNK
6070 PNK
3690 LBL
6130 PNK
6630 PNK
6700 PNK
2975 BLK
3280 LBL
H
3060 LBL
6230 PNK
2465 BLK
1685 RNG/WHT
R1 R2 R11 R10
LOW 30 86 30 86 HIGH STOP 30 86 30 86 REVERSE
SHT6/G8 BEAM BEAM LIGHT LIGHT
RELAY 87 85 87 85 RELAY RELAY 87 85 87 85 RELAY
SHT6/G8
2550 BLK
2280 BLK
2290 BLK
6190 PNK
2285 BLK
2555 BLK
2545 BLK
6510 PNK SHT12/D7 SHT11/D7
SHT6/G8 SHT18/E5
6550 PNK
C230 40 37 36 32 33 34 35
40 37 36 32 33 34 35
6510 PNK
6130 PNK
6630 PNK
6700 PNK
6230 PNK
6550 PNK
6520 PNK
6560 PNK SP27
SP28
6080 PNK
SP49 SP46 6710 PNK
6010 PNK
SP45 SHT6/E4
6250 PNK
SP48
SHT6/H4 SHT6/F1 6090 PNK SP43
6150 PNK
6650 PNK
6720 PNK
7190 WHT
2195 BLK
SP70 6280 PNK
SHT12/D4
SP71 6730 PNK
C401
6160 PNK
6020 PNK
6660 PNK
6520 PNK
6560 PNK
6140 PNK
6640 PNK
6260 PNK
6090 PNK
6730 PNK
6530 PNK
6570 PNK
6240 PNK
6710 PNK
2265 BLK
2235 BLK
2215 BLK
2225 BLK
BACK UP
ALARM
C302
C305
C304
6030 PNK
6170 PNK
6670 PNK
6740 PNK
6200 PNK
6270 PNK
2145 BLK
4 3 1 5 2 2 6 4 3 1 4 3 1 5 2 2 6 4 3 1
4 3 1 5 2 2 6 4 3 1 4 3 1 5 2 2 6 4 3 1
C307
2 7 1 4 6 5 3
TL470 (S/N ANL711001 AND ABOVE)
2 7 1 4 6 5 3
POSITION STOP FOG TURN LOW HIGH POSITION TURN TRAILER POSITION STOP REV TURN LOW HIGH POSITION TURN
(S/N ANMG11001 AND ABOVE)
REAR LEFT LIGHTS FRONT LEFT LIGHTS PLUG REAR RIGHT LIGHTS FRONT RIGHT LIGHTS
(S/N AVM111001 AND ABOVE)
HARNESS FRAME PN 7162050 REF (S/N AVM611001 AND ABOVE)
Sheet 17 of 18
(PRINTED MAY 2012)
Printed In Belgium 7159062 (C)
HARNESS LOWER CAB PN 7162047 REF
OPTIONAL
1860 RNG/WHT
1865 RNG/WHT
LIGHTS
GATEWAY CONTROLLER
BLUE WK LIGHT
WORK LIGHT
J1A-3
J1B-7
6320 PNK
6390 PNK
6440 PNK
1867 RNG/WHT
R4
CAB WORK R3 R5
30 86 30 86 BLUE WORK 30 86 BOOM WORK
LIGHT
RELAY LIGHT LIGHT
87 85 87 85 RELAY 87 85 RELAY
2560 BLK
2565 BLK
6330 PNK
6400 PNK
2555 BLK
2570 BLK
6450 PNK
SHT17/E3 SHT8/E2
C232 2 C230 29 31
2 29 31
6330
SP30
SHT6/D3
6450 PNK
6340 PNK
6400 PNK
6350 PNK
2850 BLK
2840 BLK
2825 BLK
C333 1 2 C334 1 2 C332 1 2 SHT7/E4
1 2 1 2 1 2
6280 PNK
2780 BLK
SP37
6400 PNK
2825 BLK
6460 PNK
6470 PNK
6420 PNK
6410 PNK
2880 BLK
2860 BLK
2870 BLK
2820 BLK
2810 BLK
C306
6350 PNK
6340 PNK
2850 BLK
2840 BLK
LICENSE PLATE
LIGHT
10.00 Watts
C607
C606
C605
C504
C505
A B A B A B A B A B
A B A B A B A B A B
WIRING SCHEMATIC
HARNESS UPPER CAB PN 7162048 REF HARNESS BLUE LIGHTS HARNESS BOOM WK LIGHTS
(S/N AVM111001 AND ABOVE)
LEFT PN 7178982 REF
RIGHT PN 7179236 REF
6M PN 7169216 REF
7M PN 7178823 REF
(S/N AVM611001 AND ABOVE)
Sheet 18 of 18
(PRINTED MAY 2012)
Printed In Belgium 7159062 (C)
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel Instructions are necessary before operating or
only. servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take 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
Warning light comes ON. 5, 8, 9, 10, 11
Description
Cab
S38028
Figure 60-10-1
Frame 5 7 9 11 13
1 14 17
Figure 60-10-4
2 18
1 3 19
20
2
4 6 8 10 12 16 15
1 S38056
Engine Compartment
Figure 60-10-7
1 3
2 4
6 7
5
8 9
S38030
S38060
S38061
R - Relay
WARNING
AVOID INJURY OR DEATH
Figure 60-20-3
Figure 60-20-1
1
4
1 1
6
3
5
S38032
S38031
Removal And Installation (Cont’d) If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
Figure 60-20-4 operator’s seat and one person to connect and
disconnect the battery cables.
The Key switch must be OFF. The booster battery must
be 12 volt.
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 Telescopic
P-09589 P-09590
Handler. (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
Always clean the battery terminals and cable ends when connected wrong.
I-2345-0311
installing a new or used battery [Figure 60-20-4].
Install the battery hold down plate and tighten the nuts. WARNING
Connect and tighten the battery cables. Connect the AVOID INJURY OR DEATH
ground (-) cable last to prevent sparks.
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Keep arcs, sparks, flames and lighted tobacco away If electrolyte is taken internally drink large quantities
from batteries. When jumping from booster battery of water or milk! DO NOT induce vomiting. Get
make final connection (negative) at machine frame. prompt medical attention.
W-2065-0807
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
Figure 60-20-5
1
1 2
1
1
S39417
Figure 60-20-6 After the engine has started, remove the ground (-) cable
(Item 1) [Figure 60-20-7] first.
Install the battery cover (Item 2) with the three bolts (Item
1 1) [Figure 60-20-5].
DANGER
Be aware that vehicle batteries contain gases that are
S39416 flammable and can explode violently. The following
precautions should be taken before making battery
connection:
Connect the end of the first cable to the positive (+) • Wear eye protection.
terminal of the booster battery. Connect the other end of • Remove all jewelry.
the same cable to the positive (+) terminal (Item 1) • Keep spectators away.
[Figure 60-20-6] of the telescopic handler battery.
In the event of a battery explosion, acid should be
flushed away immediately. Seek medical help as
soon as possible.
D-1032-1210
Figure 60-30-1
1
1 1
2
S38685
Remove the two bolts (Item 1) and remove the cover Remove the alternator.
plate (Item 2) [Figure 60-30-1] from the back side of the
engine compartment.
Figure 60-30-2
S38683
Belt Adjustment
Belt Replacement
2 2
S38683
S38046
Testing Disconnect the ground (-) cable from the battery. (See
Removal And Installation on Page 60-20-1.)
Figure 60-40-1
Turn the Starter switch OFF and remove the key.
Cranking
Motor
2
A-1992 1 3
Connect a jumper wire between S terminal and BAT Disconnect the three wires from the starter ground
terminal [Figure 60-40-1]. terminal (Item 1) [Figure 60-40-3].
If the starter turns but does not turn the engine, the Installation: Tighten the nut to 12 N•m (8.9 ft-lb) torque.
starter drive has a defect.
Disconnect the three wires from the starter positive
Figure 60-40-2 terminal (Item 2) [Figure 60-40-3].
A-1991
Figure 60-40-4
S39233
Figure 60-50-1
1
S38258
Figure 60-50-4
Remove the nut (Item 1) and shift the cover (Item 2)
[Figure 60-50-1] off the rear light support.
Figure 60-50-2 2 2
LEFT REAR LIGHT
1
1
S38255
Figure 60-50-5
1
1
1 1
S38681
Figure 60-50-6
1 1 1
1
S38682
Figure 60-50-7
1
LEFT FRONT LIGHT
2
S38260
Remove the nut (Item 2) and remove the front light (Item
Figure 60-50-8 3) [Figure 60-50-9].
RIGHT FRONT LIGHT
S38257
Figure 60-50-10
2
1 1
S36332
Figure 60-50-11
3
2 1
1
S38687
Figure 60-60-1
S38297
1
Disconnect the signal control wire connector (Item 1)
S39423 [Figure 60-60-3].
Figure 60-60-4
Rotate the Starter switch key (Item 1) [Figure 60-60-1] to
the left and remove the key, to disconnect power supply
from the battery.
2
Figure 60-60-2
1
1
2 S39159
Figure 60-60-5
P-52347
Figure 60-70-1
1 1
S39050
Figure 60-70-2
1 2
S36729
Right Instrument And Indicator Panel Removal And Disconnect the ground (-) cable from the battery. (See
Installation Removal And Installation on Page 60-20-1.)
Disconnect the ground (-) cable from the battery. (See Figure 60-80-3
Removal And Installation on Page 60-20-1.)
Figure 60-80-1
1
1
1
1
1
1
S38688
Figure 60-80-2
S38689
S38731
Pull out the left instrument panel (Item 1) [Figure 60-80-
4].
Disconnect the harness connectors from the back of the
switch panel [Figure 60-80-2]. Reconnect the ground (-) cable to the battery. (See
Removal And Installation on Page 60-20-1.)
NOTE: Mark all connectors for ease of installation.
Figure 60-80-5
S38733
1 1 3
S39433
2
Remove the nut (Item 1) from the connecting rod (Item 2)
S39070 and remove the rod from the boom angle sensor (Item 3)
[Figure 60-90-3].
Remove the two bolts (Item 1) (both sides) and remove Remove the two screws (Item 4) from the boom angle
the cover (Item 2) [Figure 60-90-1] from the back of the sensor (Item 3) [Figure 60-90-3].
boom.
Remove the boom angle sensor (Item 3) [Figure 60-90-
Figure 60-90-2 3].
S39396
Calibration
Figure 60-90-4
2
EM7539
3 1
Figure 60-90-6
S39434
Calibration (Cont’d)
Figure 60-90-7
EM8037
Figure 60-90-8
EM7537
Figure 60-100-1
1
1
S38265
Figure 60-100-4
S38262
1
Flip the wiper covers (Item 1) and remove the two nuts
(Item 2) [Figure 60-100-1]
Figure 60-100-2
2
S38265
S38261
Figure 60-100-5
S38264
Figure 60-100-6
S38263
Figure 60-110-1
1 1
1
1 2
S38270
1
Disconnect the rear window washer tube (Item 1)
S38267 [Figure 60-110-3].
3
2
1
1
S38269
S38268
Figure 60-110-5
1 S38272
Flip open the wiper cover (Item 1) and remove the nut
S38271 (Item 2) [Figure 60-110-7].
Figure 60-110-8
Disconnect the top wiper electrical connector (Item 1)
[Figure 60-110-5].
Figure 60-110-6
1
S38272
2
Remove the nut (Item 1) [Figure 60-110-8].
S38273
Remove the plastic ring and rubber seal (Item 2)
[Figure 60-110-8].
Remove the window washer tube (Item 1) [Figure 60-
110-6]. Remove the nut (Item 3) [Figure 60-110-8].
Remove the cap (Item 2) [Figure 60-110-6]. Remove the top wiper motor from inside the operator
cab.
Figure 60-120-1
1 1
1
1
2
S38270
1
Disconnect the rear window washer tube (Item 1)
S38267 [Figure 60-120-3].
3
2
1
1
S38269
S38268
Figure 60-120-5
1
2
S38277
Remove the two screws (Item 1) [Figure 60-120-5]. Remove the cap (Item 3) [Figure 60-120-7].
3 1
1 2
S38276 S38278
Remove the window washer tube (Item 1) [Figure 60- Remove the nut (Item 1) [Figure 60-120-8].
120-6].
Remove the rear wiper motor inside the operator cab.
Flip open the wiper cover (Item 2) and remove the nut
(Item 3) [Figure 60-120-6].
Figure 60-120-9
S38279
Figure 60-130-1 1
1 1
S39148
S38084
3 1
S39150
1
1
1
S39131
Figure 60-130-5
S39149
S39151
1
Remove the two bolts (Item 1) and remove the brake
1 valve (Item 2) [Figure 60-130-8].
S39132
Figure 60-140-1
1 S39062
Figure 60-140-2
S39061
Calibration
Figure 60-140-4
2
EM7535
Calibration (Cont’d)
Figure 60-140-7
EM7537
Fully press the brake pedal (display is showing [DN]) Press the information button (Item 1) [Figure 60-140-4]
[Figure 60-140-7]. once to return to the engine hour menu.
Figure 60-140-8
EM8037
Figure 60-150-1
1 2
2
3
1
P-76450
Figure 60-160-1
S39067
1
Figure 60-160-2
2
1
S39137
Figure 60-160-5
1 1
S38008
Figure 60-160-8
Fully support the fuel tank using an appropriate lifting
device [Figure 60-160-5].
Figure 60-160-6
1
1
1
1
S38009
1
Figure 60-160-9
S38090
Figure 60-160-12
Remove the bolt (Item 1) [Figure 60-160-9].
Figure 60-160-10
1 S39810
Figure 60-160-13
P-85716
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Figure 60-170-1
1
1
S39172
S39811
Figure 60-170-2
2
2 2
1
S38241
S39205
3
Figure 60-180-2
S0007
Figure 60-180-5
S39203
3. Without attachment and with the attachment carrier 7. Press and release the TEST button (Item 1)
fully tilted up, fully retract and raise the boom [Figure 60-180-3] to record the second calibration
[Figure 60-180-5]. point.
4. Press and release the TEST button (Item 1) 8. To indicate the calibration has been validated, the
[Figure 60-180-3] to record the first calibration point. LED bar (Items 2 and 3) [Figure 60-180-3] lights up
for 3 seconds and the buzzer sounds two times.
5. The orange and red LED’s (Item 3) [Figure 60-180-3]
light up to indicate the system is ready to record the NOTE: If the buzzer sounds and LED’s light up in a
second calibration point. particular configuration, a calibration failure
has occurred. (See System Failure Reports on
Page 60-180-4.)
TIPPING CAN CAUSE SERIOUS INJURY OR DEATH Always perform the LLMI / LLMC calibration test after
system calibration. (See Calibration Test on Page 60-
Keep the boom low, only raise the load 500 mm (20 180-3.)
in) when calibrating the LLMI / LLMC system.
W-2929-1111
Calibration Test
Park the machine on flat level ground and align the front 3
and rear wheels straight ahead.
Figure 60-180-7
S38711
Using the LLMC override switch, decrease the rear axle - the four green LEDs (Item 2) [Figure 60-180-8] light
load pressure by picking up a load and extending the up, calibration is OK.
boom until the machine topples over (rear wheels off the - the orange and red LEDs (Item 3) [Figure 60-180-8]
ground) [Figure 60-180-7]. light up, calibration is out of range. Please redo
calibration of the LLMC system. (See System
NOTE: Do not move or reposition the machine after Calibration on Page 60-180-1.)
decreasing the rear axle load pressure.
NOTE: After pressing the TEST button (Item 1)
Extend the boom for 3 m and place the load on the [Figure 60-180-8] longer than 60 seconds, the
ground. procedure will automatically end and the
system will return to normal mode.
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
Power Supply LLMI Voltage Low Normal Battery voltage
low.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
Internal CRC Error - LLMI, LLMC or Identify the faulty
Program Flash BCC not controller and re-
programmed program.
correctly.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
LLMS LLMI Linked The speed of the - The LLMI linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMI.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMI has the rear axle and do
stopped sending system calibration
CAN frame. again.
LLMC Linked The speed of the - The LLMC linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMC.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMC has the rear axle and do
stopped sending system calibration
CAN frame. again
LLMI/LLMC No motion - The LLMS inputs - Check the harness
Sensor allowed. have been between the LLMS and
Signature swapped between the LLMI/LLMC.
the LLMI and the - Do system calibration
LLMC. again within a time span
- The LLMI and/or of less than 5 minutes.
the LLMC was
reprogrammed.
LLMS Value Shift After 30 seconds: No aggravating Do system calibration
(toward movements again within a time span
stability) possible. of less than 5 minutes.
Shunt is allowed.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
Sensor No motion The difference - Do system calibration
Redundancy 2 allowed. between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
second level. needed.
Switches Retract Switch Boom considered - The retract switch - Check the harness
not retracted while is disconnected between the “boom
this failure is on. - There is a short- retracted” switch and
circuit in the switch the LLMC.
or in the harness. - Check the function of
the switch.
Figure 60-180-9
1
S39246
The LLMI (Longitudinal Load Moment Indicator) (Item 1) The LLMS is equipped with dual electronics, which
[Figure 60-180-9] which is located on the dashboard, independently measure the same load. The first
indicates the stability level of the machine, using a LED measurement is used by the LLMI, while the second
bargraph and a buzzer. measurement is used by the LLMC. The most critical
measurement of both will have priority.
Figure 60-180-10
Figure 60-180-12
S39395
S39424
Figure 60-180-13
S38179
2
The LLMC Override Switch (Item 1) [Figure 60-180-14]
S39396 can be used to override the LLMC.
LLMS Removal
2
Figure 60-180-15
1
S39246
Figure 60-180-16
S39144
LLMS Installation
Raise the boom and install the approved boom stop. (See
the Operation And Maintenance Manual for the correct 1
procedure.)
Figure 60-180-18
S39144
Figure 60-180-21
S39355
Figure 60-180-19 1
2
1
S38075
S39246
Position the LLMS (Item 1) and install the two bolts (Item
2) [Figure 60-180-19].
Figure 60-180-22
S39353
Figure 60-180-23
S39354
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Specifications
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
General
Cylinder Head
Valve Guides
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Exhaust Valves
Intake Valves
Valve Springs
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Crankshaft
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0,10 (0.004)
Journal #1 Mounting
Journal #2 0,08 (0.003)
Journal #3 0,15 (0.006)
Journal #4 0,08 (0.003)
Journal #5 Mounting
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0,25 (0.010) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Main Bearings
Thrust Washers
Cylinder Block
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Cylinder liners
Fuel Injectors
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Turbocharger
Flywheel
Specifications (Cont’d)
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
NOMINAL TEMPERATURE
STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BYPASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
82°C (180°F) 77 - 85°C (170 - 185°F) 92 - 98°C (198 - 208°F) 0.35 (9,0)
Specifications (Cont’d)
Troubleshooting
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue / white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52
Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45
Troubleshooting (Cont'd)
Remove the muffler. (See Removal And Installation on Loosen the screw and disconnect the electrical connector
Page 70-40-1.) (Item 2) [Figure 70-10-2].
Remove the refrigerant from the A/C system. (See Remove the nut and ground wires (Item 3) [Figure 70-
Reclamation And Charging With Recovery / Charging 10-2].
Unit on Page 80-40-1.)
Disconnect the ignition connector (Item 4) [Figure 70-10-
Figure 70-10-1 2] (red / white cable).
Figure 70-10-3
1
1 1
S38137 1
S38138
Remove the three bolts (Item 1) [Figure 70-10-1] from
the fuse mounting plate. Place the fuse mounting plate
on the bottom of the engine compartment. Remove the hose clamps (Item 1) [Figure 70-10-3].
S38141
Figure 70-10-5
1
S38142
1
Figure 70-10-8
S38144
1
Remove the two fuel hoses (Item 1) [Figure 70-10-10].
S38143
NOTE: Mark the hoses for proper assembly.
Remove the A/C hose (Item 1) [Figure 70-10-8] from the Figure 70-10-11
compressor.
Figure 70-10-9
1
2 1
S38145
S38119
1 S38146
Figure 70-10-13
1
1
S38603
Figure 70-10-16
1
1
1
S38601
S38146
S38600
Engine Removal And Installation (Cont’d) The tools listed will be needed to do the following
procedure:
Figure 70-10-20
MEL10630 - Engine Compression Kit
MEL1352 - Compression Adapter
Figure 70-10-21
S38602
P-55631
Figure 70-10-22
P-55632
Figure 70-10-23
P-55633
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Figure 70-20-3
2 2
1
1
3
1
4
3
S38105 1
S38073
Remove the two bolts (Item 1) and the cover (Item 2)
[Figure 70-20-1].
Remove the four drive shaft mounting bolts (Item 1)
Remove the two bolts (Item 3) and the cover (Item 4) [Figure 70-20-3].
[Figure 70-20-1].
Position the drive shaft (Item 2) [Figure 70-20-3] on the
frame floor.
Figure 70-20-4
4 3
2
2
1
S38077
1
3
4 Remove the A/C hose (Item 1) from the drier, and the A/C
S38075 hose (Item 2) [Figure 70-20-6] from the expansion valve.
Loosen the screw and disconnect the electrical connector Remove the heater hoses (Items 3 and 4) [Figure 70-20-
(Item 2) [Figure 70-20-4]. 6] from the heater.
Remove the nut and ground wires (Item 3) [Figure 70- Figure 70-20-7
20-4].
Figure 70-20-5
1
2
3 1
S38107
1
Figure 70-20-8
2
1
1
S38081
1 Figure 70-20-11
S38080
1
Remove the hose (Item 1) [Figure 70-20-9] from the
hydraulic tank.
S38082
Figure 70-20-12
1
1
1
1
S38085
1
1 Remove the two hoses (Item 1 and 2) [Figure 70-20-14]
2 from the steering valve.
S39435
Figure 70-20-15
Remove the six hoses (Item 1) from the manifold (Item 2)
[Figure 70-20-12].
Figure 70-20-13
2
1 1
1
S38119
2 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 70-20-16
1
1
S38106
Figure 70-20-19
Remove the two fuel hoses (Item 1) [Figure 70-20-16].
Figure 70-20-17
1
S38107
NOTE: Make sure the fork tips of the fork lift only
support the engine / hydrostat assembly and
not the machine frame.
Figure 70-20-20
1
S38110
Figure 70-20-21 Pay special attention to route the HVAC hoses out of the
operator cab.
S38109
1 1
S38116
S38084
2
Remove the three bolts (Item 1) and remove the cover 1
(Item 2) [Figure 70-30-1] from the front of the operator
cab.
Figure 70-30-2
S38118
S38117
Figure 70-30-5
S38119
Figure 70-40-1
1
1
1 2
S38120
Figure 70-50-1
S38122
Figure 70-50-2
S38123
Figure 70-60-3
2
3
S38280
1 1
Figure 70-60-4
1 1
S38284
Figure 70-60-5
S38285
S38283
Figure 70-60-8
S38289
With the aid of an assistant, lift and remove the oil cooler
/ radiator assembly from the machine [Figure 70-60-10].
S38286
Figure 70-60-9
3 2
1
S38288
Figure 70-60-11 1
S39195
Figure 70-60-12
S6914
Thermostat Removal And Installation Hang the thermostats in a suitable container filled with
coolant.
Drain the engine coolant until it is below the thermostat
level. Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
Figure 70-60-14 open.
Figure 70-60-16
1 1
S39195
Figure 70-60-15 1 1
P-55782
S39196
Water Pump Removal Drain the radiator. (See Removing And Replacing The
Coolant on Page 10-70-3.)
Remove the coolant from the cooling system.
Figure 70-60-18
Figure 70-60-17
1
1
1
1
2
1
1
S38135
S6913
Clean the gasket surfaces and replace the gasket. Figure 70-60-19
S39124
Remove the two nuts (Item 1) and bolts and remove the
support (Item 2) [Figure 70-60-19].
Figure 70-70-1
1 3
S6915
The engine oil passes from the filter (Item 1) [Figure 70-
P-08834 70-3] to the cylinder block.
Engine oil from the oil pan sump passes through a Engine oil passes from the mainbearings through
strainer (Item 2) [Figure 70-70-1] and pipe to the suction passages in the cylinder block to the journals of the
side of the pump. camshaft. Engine oil passes from the center journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-70-1], shaft, at a reduced pressure, to feed the rocker bushing.
which is installed in the bottom left side of the cylinder The oil passes through a passage in the rocker shaft to
block. The relief valves opens if the oil pressure is too the bearings of the rocker levers. The valve stems, valve
high; this allows some of the engine oil to return to the springs and the tappets are lubricated by splash and oil
sump. mist.
Figure 70-70-2 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
S6449
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-70-2].
Figure 70-70-4
P-08740
P-08745
Remove the oil pan retaining bolts (Item 1) [Figure 70-
70-6].
Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-70-4]. These jets are connected to the oil Remove the pan and gasket.
pressure rail and spray lubricating oil inside the pistons to
keep them cool. Clean the pan in solvent and dry with compressed air.
Oil Filter Adapter Removal And Installation Clean the block surface.
Figure 70-70-5 Installation: Place a new gasket on the oil pan. Place
two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts (Item 1)
2 [Figure 70-70-6] to 22 N•m (16 ft-lb) torque.
1
1
S6915
Remove the four bolts (Item 1) and the filter adapter (Item
2) [Figure 70-70-5].
Oil Screen And Pick-up Tube NOTE: The oil pump has a channel in the body of the
pump. Oil from the front mainbearing passes
Figure 70-70-7 down the channel of the pump to an oil hole in
the idler shaft for lubrication of the idler shaft
bushing.
Figure 70-70-8
1
3
1
P-08834
Tighten the mounting bolts to 22 N•m (16 ft-lb) torque. If there is no spanner wrench, the front timing case cover
must be removed. (See Timing Cover Removal on Page
Tighten the bolt (Item 1) [Figure 70-70-7] for the pick-up
70-110-2.)
tube bracket.
Figure 70-70-9
2
1
1
P-08835
P-08835
Fill the pump with engine oil.
Remove the snap ring (Item 1), idler gear (Item 2) If the number 1 main cap was removed, reinstall and
[Figure 70-70-9], and washer. tighten the bolts to 250 N•m (185 ft-lb) torque.
Remove the bolts and oil pump. If the number one main cap was not removed, install the
pump on the main cap and tighten the bolts to 22 N•m
(16 ft-lb) torque.
Figure 70-70-11
B-05591
B-05588
NOTE: If any part is worn enough to effect
performance replace the complete oil pump.
Check that there is a minimum of 0,076 mm (0.003 in)
backlash between the idler gear and oil pump gear Remove the cover of the oil pump.
[Figure 70-70-11].
Remove the outer rotor and thoroughly clean. Inspect for
End play for the idler gear should be 0,050 - 0,275 mm cracks or other damage.
(0.0019 - 0.0108 in).
Install the outer rotor and check the outer rotor to body
Install the oil screen and pick-up tube. (See Oil Screen clearance [Figure 70-70-12].
And Pick-up Tube on Page 70-70-3.)
Clearance between the outer rotor and body must be
Install the pressure relief valve. 0,152 - 0,330 mm (0.0059 - 0.0129 in).
Install the oil pan. (See Oil Pan Removal And Installation Figure 70-70-13
on Page 70-70-2.)
B-05592
Figure 70-70-14
5
4
1
3
B-05606
B-05593
Rotor end play must be 0,038 - 0,089 mm (0.0014 - Remove the end plate (Item 1), spring (Item 4), and
0.0035 in) for the inner rotor. plunger (Item 5) from the body (Item 2) [Figure 70-70-
15].
Rotor end play must be 0,025 - 0,076 mm (0.0010 -
0.0029 in) for the outer rotor. Clean the parts in solvent and dry with compressed air.
Install the cover and tighten the bolts to 22 N•m (16 ft-lb) Lubricate the bore of the valve body (Item 2), plunger
torque. (Item 5) and the end plate (Item 1) [Figure 70-70-15]
with clean engine oil before assembly.
P-55531
P-55529
Figure 70-80-4
P-55524
Figure 70-80-7
Remove the harness (Item 1) [Figure 70-80-4].
Figure 70-80-5
1
P-55525
Figure 70-80-8
1
1
P-55533
Figure 70-80-11
Remove the four fuel tubelines (Item 1) [Figure 70-80-8].
IMPORTANT
Do not bend the high pressure fuel injection tubes 1
when removing or installing them.
I-2029-0289
Figure 70-80-9
P-55528
P-55527
Fuel Injection Pump Removal (Cont'd) NOTE: The new fuel pump will be supplied with the
pump shaft in the locked position. Do not
Figure 70-80-12 unlock the shaft of the fuel pump until the fuel
pump gear is installed.
Figure 70-80-13
1
1
1
P-55532
P-55532
Install the fuel pump and tighten the three bolts (Item 1)
[Figure 70-80-13] to 25 N•m (18 ft-lb) torque.
Figure 70-80-14
P-55528
Figure 70-80-15
2
1
2
P-55775
Install the gear (Item 1) onto the tapered shaft. Make Retighten the nut (Item 1) [Figure 70-80-16] to 88 N•m
sure the fuel pump gear is correctly in mesh with the idler (65 ft-lb) torque.
gear and install the washer and nut (Item 2) [Figure 70-
80-15]. Do not tighten at this time. Figure 70-80-18
P-55776
Figure 70-80-19
1
1 1
P-55525
Do not overtighten.
Tighten the mount bolt (Item 1) [Figure 70-80-19] to 44
N•m (32 ft-lb) torque.
Figure 70-80-20
P-55533
Figure 70-80-22
P-55522
1
2
P-55523
WARNING
AVOID INJURY OR DEATH
1
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention S6895
from a physician familiar with this injury.
W-2072-0807
Remove the breather hose (Item 1) [Figure 70-80-26].
Figure 70-80-25 Figure 70-80-27
3 3
1
1 2
1
1
S39192
S6896
Remove the three bolts (Item 1) and remove the fuel Remove the bolt (Item 1) and remove the breather fitting
injector cover (Item 2) [Figure 70-80-25]. (Item 2) [Figure 70-80-27].
Remove the three bolts (Item 3) and remove the fuel filter
assembly (Item 4) [Figure 70-80-27].
Figure 70-80-28
1
1
1
2
3
1
P-55614
P-55777
Remove the fuel return hoses (Item 1) and remove the
bolt (Item 2) and clamp (Item 3) [Figure 70-80-30].
Disconnect the four injector tubelines (Item 1) [Figure
70-80-28] from the injector pump. Installation: Tighten bolt to 35 N•m (26 ft-lb) torque.
Installation: Tighten the tubelines to 27 N•m (20 ft-lb)
torque. Figure 70-80-31
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-80-29
1 P-55615
1
Remove the injector from the cylinder head [Figure 70-
1 80-31].
S6897
Figure 70-80-32
1
P-55525
P-55617
Remove the fuel lift pipe (Item 1) [Figure 70-80-34] from
the injector pump, install a suitable pipe with a pressure
Installation: The roll pin must be in the position shown test point and connect a pressure gauge.
[Figure 70-80-32].
Operate the engine at idler for 2 minutes to allow any
Figure 70-80-33 trapped air to be removed.
P-55616
Fuel Lift Pump Removal And Installation Remove the turbocharger. (See Removal And Installation
on Page 70-120-2.)
Figure 70-80-35
Figure 70-80-37
1 1
S38144
P-55625
Figure 70-80-38
1 5 2 1 8
4 3 7
6
S6899
P-55625
Remove the two fuel lines (Item 1) and three bolts (Item
2) [Figure 70-80-36] and remove the fuel lift pump / filter
assembly. Installation: Tighten the bolts in the sequence shown
[Figure 70-80-38] to 40 N•m (30 ft-lb) torque.
Fuel Injector Cover Removal And Installation Drain the engine coolant until it is below the thermostat
level.
Figure 70-80-39
Figure 70-80-40
1
1
1
1
S39192
S39194
Installation: Tighten the bolts to 9 N•m (79.7 in-lb) Remove the fuel injector cover. (See Fuel Injector Cover
torque. Removal And Installation on Page 70-80-12.)
Figure 70-80-41
2
1
S39189
1
1
1
1
S39193
1
7
4 9 2
2 6
S39193
Figure 70-90-1
1
2
1 3
S6900
1
Remove the nut (Item 1) [Figure 70-90-3] from the top of
each glow plug.
Figure 70-90-4
S6895
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-90-2].
P-55629
Figure 70-90-5
P-55630
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-90-5].
Figure 70-90-6
1
2
1 3
S6900
1
Remove the nut (Item 1) [Figure 70-90-8] from the top of
each glow plug.
Figure 70-90-9
2
1
1
S6895
S6901
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-90-7].
Loosen and remove the glow plugs (Item 1) [Figure 70-
90-9].
Removal
P-55681
P-55683
Removal (Cont'd)
8
9 5 1 4
Figure 70-90-13
2
1
10 7
6 2 3
B-23183
Figure 70-90-14
P-8718A
Inspection Make sure the mating surfaces of the head and block are
clean.
Figure 70-90-16
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
2 Figure 70-90-17
2 2
1
3 FRONT TOP
B-5564
Maximum allowed (Item 1) is 0,03 mm (0.0012 in), (Item NOTE: The locating pins (Item 1) are pressed in the
2) is 0,05 mm (0.0019 in) and (Item 3) [Figure 70-90-16] engine block so the head gasket (Item 2)
is 0,05 mm (0.0019 in). [Figure 70-90-17] can be positioned correctly.
The head can be machined removing only a minimum The head gasket is installed with no sealer.
amount. Head thickness must not be less than 117,20
mm (4.614 in). Place the head gasket in position with the Front Top (Item
2) [Figure 70-90-17] marks in the correct position.
Completely clean the rest of the head.
Lower the cylinder head in position.
Inspect for cracks or other damage.
Installation (Cont'd)
225° 270°
Figure 70-90-18
3
2 6 10 7
EM7513
1 4
5 9 8
If no angle gauge is available make a suitable mark on
B-23183 the head bolt corner. Make another mark on the cylinder
head the correct number of flats away [Figure 70-90-20].
Turn the head bolt until the lines match.
Tighten the head bolts to 50 N•m (37 ft-lb) in the
sequence shown [Figure 70-90-18]. Figure 70-90-21
Figure 70-90-19
P-8718A
P-8839 Make sure the push rods seat in the tappet sockets.
Installation (Cont'd)
Figure 70-90-22
1
P-55682
Figure 70-90-25
Install the coolant bypass pipe (Item 1) and two screws
(Item 2) [Figure 70-90-22].
Figure 70-90-23
P-55681
P-55683 Install the glow plugs. (See Glow Plugs Removal And
Installation on Page 70-90-3.)
Install the tubeline (Item 1) [Figure 70-90-23]. Install the fuel injectors. (See Fuel Injectors Removal And
Installation on Page 70-80-8.)
Install the fuel lift pump. (See Fuel Lift Pump Removal
And Installation on Page 70-80-11.)
Rocker Shaft Disassembly And Assembly NOTE: Mark all components so they can be returned
to the same position.
NOTE: Make an identification mark on each rocker
arm assembly in order to show the location. Figure 70-90-27
Figure 70-90-26
4 5
2 3
3
2 P-8720A
P-8719A
Using a valve spring compressor compress the springs
and remove the retainers (Item 1) [Figure 70-90-27].
Remove the clips (Item 1) [Figure 70-90-26] from both
ends of the shaft. Release the compressor and remove the valve spring
cap (Item 2), spring (Item 3), valve seal / spring seat
Remove the rocker arm (Item 2) and spring (Item 3) washer (Item 4) and valve (Item 5) [Figure 70-90-27].
[Figure 70-90-26].
Clean and inspect all components.
Continue to disassemble the rocker shaft.
Figure 70-90-28
35,17 mm
(1.3846 in)
N-00533
B-5552
Check the valve depth as shown in [Figure 70-90-29].
Use the following chart [Figure 70-90-28]. The maximum depth is 2,06 mm (0.0811 in) for both
intake and exhaust valves.
Valve Springs
If the valve is below the limits, install a new valve and
Compressed Height 38,17 mm (1.3846 in)
recheck the valve depth. If it is still below limits a new
Installed Pressure 335 N (75 lbf) valve seat insert must be installed.
4
Outside Diameter (Item 2) [Figure 70-90-30]
Intake and Exhaust 13,034 - 13,047 mm
(0.5131 - 0.5137 in)
3
Interference fit of valve guide to cylinder head: 0,007 -
0,047 mm (0.0003 - 0.0019 in)
2
Overall Diameter (Item 3) [Figure 70-90-30]
Intake and Exhaust 51,00 - 51,50 mm
B-5551
(2.018 - 2.027 in)
Figure 70-90-31
Lift the valve (Item 2) 15,0 mm (0.60 in) and move the
2 valve in and away from the gauge (Item 1) [Figure 70-90-
30]. Record this reading.
B-5566A
If the clearance exceeds 0,13 mm (0.005 in) for intake or
0,15 mm (0.006 in) for exhaust (Item 3) [Figure 70-90-
The valve guides can be inspected for wear with either of 31] the valve guide needs to be replaced.
the operations listed in [Figure 70-90-30] or [Figure 70-
90-31].
Figure 70-90-32
B-5548
Valve Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
4 Figure 70-90-35
1
B-5567
N-00532
Ref. Valve Specifications
1. Intake 128,838 - 129,288 mm
(5.0724 - 5.0901 in) Carefully turn the cutter in a clockwise direction using
Exhaust 128,184 - 128,634 mm even downward pressure. Keep the valve seat as narrow
(5.0466 - 5.0643 in) as possible [Figure 70-90-35].
2. Intake 8,953 - 8,975 mm
Remove any cutting debris.
(0.3525 - 0.3533 in)
Exhaust 8,938 - 8,960 mm
Install the valve and lightly tap.
(0.3519 - 0.3528 in)
3. Intake 46,28 - 46,53 mm Check the valve depth to make sure that it is within limits.
(1.8220 - 1.8319 in) (See Valve Guide Checking on Page 70-90-11.)
Exhaust 41,51 - 41,75 mm
(1.634 - 1.644 in) NOTE: If the valve seat is worn or damaged, a new
4. Intake 1,60 - 1,85 mm valve seat insert can be installed.
(Production) (0.0630 - 0.0728 in)
Intake (Ser- 2,09 mm
vice Maximum) (0.0823 in)
Exhaust (Pro- 1,55 - 1,81 mm
duction) (0.0610 - 0.0713 in)
Exhaust (Ser- 2,06 mm
vice Maximum) (0.0811 in)
Intake / 45° / 30°
Exhaust Valve
Face Angle
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
Figure 70-90-36
4 5
2 3
P-8720A
Figure 70-90-37
N-00531
Remove the rocker shaft assembly. (See Rocker Shaft Compress the valve springs and install the retainers.
Disassembly And Assembly on Page 70-90-9.)
Figure 70-90-39
1 2 3 4 5 6 7 8
2 1
B-5569
Figure 70-90-41
3 Cylinder
B-5568 No. 1 2 3 4
Valve No. 1 2 3 4 5 6 7 8
Valve
Loosen the lock nut (Item 1) [Figure 70-90-39]. 1=Intake I E I E I E I E
E=Exhaust
Turn the adjustment screw (Item 2) [Figure 70-90-39]
until the correct clearance is obtained. Use the following sequence to set the valves [Figure 70-
90-40] and [Figure 70-90-41].
NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [Figure
70-90-39]. a. With the rocker arm rocking (valves 7 and 8) on No.
4 cylinder set clearance at No. 1 cylinder (valves 1
and 2).
Adjust the valve clearance as follows:
b. With the rocker arm rocking (valves 3 and 4) on No.
0,20 mm (0.008 in) Intake 2 cylinder set clearance at No. 3 cylinder (valves 5
and 6).
0,45 mm (0.018 in) Exhaust
c. With the rocker arm rocking (valves 1 and 2) on No.
1 cylinder set clearance at No. 4 cylinder (valves 7
and 8).
d. With the rocker arm rocking (valves 5 and 6) on No.
3 cylinder set clearance at No. 2 cylinder (valves 3
and 4).
Engine Block Description Remove the water pump. (See Water Pump Removal on
Page 70-60-6.)
Figure 70-90-42
Remove the fuel injection pump. (See Fuel Injection
Pump Removal on Page 70-80-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
And Installation on Page 70-70-2.)
1
Remove the turbocharger. (See Removal And Installation
on Page 70-120-2.)
Remove the lift fuel pump. (See Fuel Lift Pump Removal
And Installation on Page 70-80-11.)
P-08837
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
The cylinder block is made of cast iron and provides full
length support for the dry liners. Remove the cylinder head. (See Removal on Page 70-
90-4.)
The liners (Item 1) [Figure 70-90-42] are made of cast
iron. Production liners are a press fit and service liners Remove the timing case and gears. (See Timing Case
are a transion fit. Both types of liners are honed with And Gear Removal on Page 70-110-3.)
silicon carbide tools to a specially controlled finish to
ensure long engine life and low oil consumption. Remove the piston and connecting rod assemblies. (See
Pistons And Connecting Rods Removal on Page 70-100-
Figure 70-90-43 1.)
Remove the rear oil seal and the crankshaft. (See Rear
Oil Seal Removal on Page 70-100-13.)
P-08842
P-08837
• Wear.
Figure 70-90-46
B-05556
Place the tool (Item 1) over the center of the liner (Item
2). Make sure the flat bearing race (Item 3) [Figure 70-
90-46] is against the bottom of the recess.
For the first five hours after the new liners have been Tighten the nut and washer.
installed:
• Do not operate at full load. Turn the handle and press the liner in the bore, stopping
• Do not operate at high speed. when approximately 50 mm (2 in) remains. Apply
• Do not allow engine to idle for extended periods. Loctite® 603 to the outer surface below the flange and to
I-2117-1196 the flange recess.
5 Figure 70-90-48
3 2
1 1
2
B-0507
Lubricate the cylinder bore with engine oil. New piston rings must be used when the cylinder liners
have been replaced.
Start the liner (Item 1) [Figure 70-90-47] in the bore.
Make sure it is started straight. The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2)
With the adapter (Item 2) on the top of the liner, place the [Figure 70-90-48].
bearing (Item 3) [Figure 70-90-47] in the recess at the
top.
The pistons used in the 1000 series engines have two P-08744
compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine Remove the cylinder head. (See Removal on Page 70-
identification number to order new parts. 90-4.)
Remove all the carbon from the top of the cylinder liners.
Figure 70-100-2
1 1
1
1
P-08743
Figure 70-100-3
1
1 1
4
4
B-05570
P-08745
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-100-5] as shown on the connecting rod.
Turn the connecting rods 90° to prevent contact with the
piston cooling jets (Item 1) [Figure 70-100-3]. Push the Figure 70-100-6
piston and rod assemblies out the top of the cylinder.
Figure 70-100-4 1
4
1 1
1 1
3
P-13999
Inspect the crankshaft journals (Item 1) [Figure 70-100- Remove the snap rings (Item 2) [Figure 70-100-6] which
4] for wear or damage. retain the piston pin.
NOTE: Keep all parts together so they can be Push the piston pin (Item 3) [Figure 70-100-6] out by
replaced in their original position. hand. If the pin doesn't push out easily, heat the piston to
40° - 50°C (100° - 120°F) for easier removal.
NOTE: Before installing the pistons check cylinder
bore for wear or damage. (See Cylinder Liner Remove the connecting rod (Item 4) [Figure 70-100-6].
Inspection on Page 70-190-3.)
Figure 70-100-7
B-05571
Figure 70-100-8 3
B-05575
Install the oil control ring over the spring (Item 1) [Figure
B-05572 70-100-9].
Make sure the ring gap is 180° from the latch pin.
Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring Install the cast iron ring with the tapered face (Item 2)
[Figure 70-100-8]. [Figure 70-100-9] in the second groove with the word
TOP or symbol facing the top of the piston.
Use a ring expander to install the piston rings.
New second rings have a green identification mark,
Install the oil spring on the bottom groove of the piston which must be on the left of the ring gap after the ring is
with the latch pin inside both ends of the spring. installed and the piston is upright.
Figure 70-100-10
1 1
P-08754
B-05576
Remove the piston cooling jet assembly (Item 1) [Figure
70-100-11] from the engine block.
With the piston rings installed, check the groove
clearance [Figure 70-100-10]. Figure 70-100-12
3
1
P-08836
Inspect the jet tube (Item 1), mount bolt (Item 2) and
alignment pin (Item 3) [Figure 70-100-12] for damage.
Replace as needed.
Figure 70-100-13
127 mm 127 mm
(5”) (5”)
± 0.25 mm ± 0.25 mm
(0.010”) (0.010”)
55,25 mm
(2.2”)
B-05577
14 mm
(0.55”)
N-00535
Inspecting the connecting rod for distortion [Figure 70-
100-14].
Insert a 1,70 mm (0.067 in) diameter rod of suitable
length, in the jet. NOTE: The large and small end bores must be square
and parallel within the limits of ± 0,25 mm
The tip of the rod must extend out the top of the cylinder (± 0.010 in).
in an area 55,25 mm (2.2 in) of height and 14 mm (0.55
in) of width to provide proper cooling jet alignment to cool Measure this 127 mm (5.0 in) on each side of the
the pistons [Figure 70-100-13]. connecting rod axis on a test fixture.
Press out the old bushing. Clean the bore and remove
any burrs.
Press in the new bushing making sure the oil feed holes
line up.
Piston And Connecting Rod Assembly Apply a light coat of oil to the piston and piston rings.
Figure 70-100-15 NOTE: Make sure the piston ring end gaps are 120°
apart.
Figure 70-100-16
1
P-13999
Install the connecting rod (Item 1), piston pin (Item 2) and
B-05578
two snap rings (Item 3) [Figure 70-100-15] in the piston.
Figure 70-100-17
FRONT
B-05579
When the piston has cleared the cooling jet, rotate the
piston assembly so that the arrow or FRONT mark is
toward the front of the engine [Figure 70-100-17].
1 1
1
P-08743
B-05580
P-08744
Install the upper and lower bearing shells in position Install the oil pick up tube and screen (Item 1) [Figure
making sure the locating tang (Item 1) [Figure 70-100- 70-100-21].
19] is in the correct position.
Install the oil pan. (See Oil Pan Removal And Installation
NOTE: New connecting rod nuts must be installed on Page 70-70-2.)
each time the rod caps are removed.
Checking Piston Height The crankshaft is a chrome-moly forging which has five
main journals. End play is controlled by two half thrust
Rotate the crankshaft until the piston is approximately at washers on both sides of the center mainbearing.
top dead center (T.D.C.).
The mainbearings have steel backs with a aluminium / tin
Using a dial indication gauge, pre-load the plunger on the bearing material. The mainbearing caps are made of cast
top surface of the block and zero the gauge. iron.
Carefully move the dial gauge so that the plunger is on The front and rear oil seals are viton lip seals with a dust
top of the piston above the axis of the piston pin. lip to the outside of the main lip.
Rotate the crankshaft to bring the piston to its highest Crankshaft And Bearings Removal
point. Record this gauge reading.
Figure 70-100-22
When installed, the top surface of the piston is slightly
above the surface of the cylinder block.
1
The height above the surface of the block should be 0,21
- 0,35 mm (0.008 - 0.014 in).
P-08748
Figure 70-100-23
1 1
1 1 1 1
1
P-08750
Figure 70-100-26
Remove the two bolts (Item 1) [Figure 70-100-23]
retaining the bridge piece.
Figure 70-100-24
1 1 1 1 1
P-08753
P-08746
Figure 70-100-27
A-02763
P-08751
Inspect the crankshaft for wear [Figure 70-100-29]. The
maximum wear and out of round of the crank journals is
Remove the crankshaft [Figure 70-100-27]. 0,04 mm (0.0016 in).
Figure 70-100-28 The main journals and the crank pins of standard size
can be machined 0,25 mm (0.010 in), 0,50 mm (0.020 in)
or 0,75 mm (0.030 in).
Figure 70-100-30
P-08753
P-08751
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-100-31].
Make sure the locating pins for the main caps are in
position.
Crankshaft And Bearings Installation (Cont'd) Remove the bolts that retain the seal housing. Remove
the housing.
Figure 70-100-33
Inspect the seal for wear or damage. Replace even if
there is only a small nick or scratch.
P-08755
Figure 70-100-34
P-08756
Rear Oil Seal Housing Positioning Install the new seal in the housing.
Figure 70-100-37
The tool listed will be needed to do the following
procedure;
3
MEL1532 - Rear Crankshaft Seal Installation Tool
4
Figure 70-100-35
B-05581
N-00550
P-08748
Install the seal in the seal housing using the seal
installation tool. Seat the seal to the correct depth
[Figure 70-100-36]. Tighten the bolts (Item 1) [Figure 70-100-38] to 22 N•m
(16 ft-lb) torque.
Figure 70-100-39
B-05583
Figure 70-100-40
P-08841
Remove the pry bar and record the dial indicator reading
[Figure 70-100-40].
1
1 2
P-55602
P-55600
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.
1
Install the water pump. (See Water Pump Installation on
P-55686
Page 70-60-6.)
Do not tighten bolts at this time. Install the oil seal (Item 1) [Figure 70-110-6] into the
housing using the special tool.
Tighten the cover bolts and water pump bolts to 22 N•m
(16 ft-lb) torque. Install crankshaft pulley. (See Crankshaft Pulley Removal
And Installation on Page 70-110-2.)
Figure 70-110-7
P-55689
1
Remove the idler gear (Item 1) [Figure 70-110-9] by
moving the gear assembly forward and lifted over the
front oil seal housing.
Figure 70-110-10
1
P-55684
2 1
Remove the two bolts (Item 1) and remove the coolant
bypass tube (Item 2) [Figure 70-110-7].
Figure 70-110-8
3 1
P-55690
1
P-55688
Timing Case And Gear Removal (Cont'd) Clean the mating surfaces, if the oil pan was not removed
trim the oil gasket flush with the block.
Figure 70-110-11
Figure 70-110-13
1
1 2
2
2
2
2
P-55691
2 P-55692
Figure 70-110-12 After the cover is correctly aligned, tighten the mount
bolts (Item 2) [Figure 70-110-13] to 22 N•m (16 ft-lb)
torque.
1
1 Figure 70-110-14
1
1
1
2
2
2 P-55692
Remove all the timing case mount bolts (Item 1) and the
four bolts (Item 2) [Figure 70-110-12] from the front of
P-55691
the oil pan.
Remove the timing case from the engine. Install the camshaft gear (Item 1) onto the shaft using
alignment pin (Item 2) [Figure 70-110-14] for correct
alignment.
Figure 70-110-15
2
1 P-55688
Figure 70-110-16
1
2
2
P-55684
P-55689
Install the coolant bypass tube (Item 1) using the two
bolts (Item 2) [Figure 70-110-18].
Install the idler gear (Item 1). Make sure the hole (Item 2)
[Figure 70-110-16] is toward the cylinder head. Install the fuel injection pump. (See Fuel Injection Pump
Installation on Page 70-80-4.)
Figure 70-110-21
P-8740
P-8742
Turn the engine over and remove the oil pan mounting
bolts [Figure 70-110-19].
Carefully remove the camshaft (Item 1) [Figure 70-110-
Remove the oil pan and gasket. 21].
Camshaft And Tappets Removal (Cont’d) Clean and inspect the camshaft and tappets for
excessive wear and damage.
Figure 70-110-22
Inspect the camshaft bushing for excessive wear and
damage.
Figure 70-110-23
P-8743
1
1
P-08743
Figure 70-110-24
P-8742
Figure 70-110-25
P-8741
Inspect camshaft end play. The end play for a new engine
is 0,10 - 0,55 mm (0.004 - 0.022 in), service limits 0,60
mm (0.023 in).
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-70-2.)
Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Too Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Too Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35
Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35
2
WARNING 1
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
S39190
Figure 70-120-1
Remove the two bolts (Item 1) and remove the exhaust
elbow (Item 2) [Figure 70-120-2].
Figure 70-120-3
2
1
1
S39191
Figure 70-120-4
1 1
1
P-55624
P-55621
Figure 70-130-1
S39126
Figure 70-130-4
Remove the two bolts (Item 1) and remove the charge
filter (Item 2) [Figure 70-130-1] and its support.
2
Figure 70-130-2 2
1 S39127
Loosen and remove the ten flywheel housing mount bolts Remove the remainder of the bolts (Item 2) [Figure 70-
(Item 1) [Figure 70-130-2]. 130-4]. Remove the flywheel by sliding outward over the
guide studs.
Remove the cover (Item 2) [Figure 70-130-2].
Inspect the flywheel and ring gear for wear or damage.
Installation: Tighten the bolts to 54 - 61 N•m (40 - 45 ft- Replace as needed.
lb) torque.
Installation: Tighten the flywheel bolts to 115 N•m (85 ft-
lb) torque.
Figure 70-130-5 1
2 2
2
2
1
S39128
If removal of the flywheel housing is required, loosen the Installation: Tighten the bolts (Item 2) to 63 N•m (46 ft-
three engine mounting bolts. Lift the engine and install lb) and the bolts (Item 3) [Figure 70-130-7] to 75 N•m
blocks under the oil pan. Lower the engine assembly on (55 ft-lb) torque.
the support blocks (Item 1) [Figure 70-130-5].
Figure 70-130-6
1 1
S39136
Flywheel Inspection Before the ring gear is removed note the position of the
chamfer on the teeth.
Figure 70-130-8
Heat the ring gear enough to expand it and hit it with a
hammer evenly to remove it.
B-05559
Figure 70-130-9
203 mm (8”)
B-05560
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-5
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-6
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-6
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-5
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
Description
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 80-10-2.) 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 80-10-2.).
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 80-10-2.) 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 80-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.). 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 blower fan (Item
6) (See Chart on Page 80-10-2.). 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 blower 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
Components
Figure 80-10-1
1
1 S38077
Figure 80-10-2
S39158
Components (Cont'd)
Figure 80-10-5
1 3 2
S38151
S38077
Safety Equipment
Figure 80-10-8
P-16398
Belt Replacement
Figure 80-20-3
2 2
S38008
1
The fresh air filter is located on the side of the operator
cab. Remove the two nuts (Item 1) and filter cover
(Item 2) [Figure 80-20-1].
Figure 80-20-4
2
1
S38009
S39165
S39386
Remove the bottom mounting bolt and nut (Item 1) Install and tighten the bottom compressor mounting bolt
[Figure 80-20-5] from the compressor. (Item 1) [Figure 80-20-7].
S39153
Cleaning The Condenser Run the air conditioning for about 5 minutes every week
to lubricate the internal components.
Figure 80-20-8
S38023
Figure 80-20-9
S38023
Figure 80-20-10
3
S38202
2
1 Disconnect the connector (Item 1) and the tubes (Items 2
and 3) [Figure 80-20-12].
Figure 80-20-13
Remove the screw (Item 1) [Figure 80-20-10].
2
1 1
S38206
Figure 80-20-14
1
S39430
1
Figure 80-20-15 1
2
1
1
1 S39213
Figure 80-20-18
S39214
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96
°F) and compressor speed of approximately 2000 rpm are:
High pressure side pressure: 1,45 - 1,83 MPa (14.47 - 18,27 bar) (210 - 265 psi)
Low pressure side pressure: 0,10 - 0,23 MPa (1,03 - 2,27 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure
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 12,2 - 13,3°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40°F. to the ambient temperature to get
the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
Start the telescopic handler, engage the parking brake. Inspect the sight glass located on the receiver / drier for
Engage the A/C system with the Blower Fan on high. Run air bubbles. (See REGULAR MAINTENANCE on Page
the telescopic handler at full rpm for approximately 15 80-20-1.)
minutes, with the cab door closed.
Figure 80-30-1
S38194
Figure 80-30-2
P-27746
Figure 80-30-3
S38151
Electrical System
Figure 80-30-4
S38028
S39152
Figure 80-30-7
S39200
Disconnect the connector (Item 1) [Figure 80-30-7] from If there is no power at the clutch, check the wiring
the compressor. harness for broken wires.
S39197
Figure 80-30-10
1
1
2 S39239
Figure 80-30-12
Disconnect the machine harness (Item 1) [Figure 80-30-
10] from the pressure switch.
Figure 80-30-13
1 1
S38151
Figure 80-30-14 1
S36341
1 B
M
N-22288
Figure 80-40-1
1 N-23024
1
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
S39234 • Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
Remove the protective cap and connect the refrigerant substances.
identifier to the low pressure hose (Item 1) [Figure 80- • NEVER SMOKE when there is the possibility of
40-3]. even small amounts of R-134a in the air.
Any servicing work that involves release or addition
Connect the refrigerant identifier to its power source. of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
Follow the steps displayed on the refrigerant identifier equipment, knowledge, and experience to service
screen [Figure 80-40-2]. refrigeration equipment.
W-2373-0611
Figure 80-40-5
2
N-22381
1
NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
S39235 follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they can vary
Connect the Red hose (Item 1) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.
Figure 80-40-6
N-22292
Figure 80-50-1
1
2
S39152
S38046
1
Remove the two bolts (Item 1) and cover (Item 2) [Figure
80-50-1].
1
Figure 80-50-2
S39156
Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
S39157
S39165
S39386
Figure 80-50-6
3
1
2
S39155
Figure 80-50-9
1
S39176
Figure 80-50-12
S39175
S39175
Figure 80-50-13
8 mm 8 mm
(1.25”) (1.25”)
1
8 mm
(1.25”)
P-27524
Remove the center armature nut (Item 1) [Figure 80-50- Figure 80-50-16
13].
Figure 80-50-14
1
P-27522
Figure 80-50-19
P-27521
Figure 80-50-18
Remove the snap ring (Item 1) [Figure 80-50-19] from
the pulley assembly.
Figure 80-50-20
2 1
P-27523
Figure 80-50-21
P-27529
Figure 80-50-24
The pulley assembly and bearing [Figure 80-50-21] must
be replaced as a complete unit.
Figure 80-50-22
1
2
1
P-27530
Figure 80-50-25
P-27531
Figure 80-50-26
P-27527
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
S38196
gas.
W-2371-0611
Figure 80-60-3
2
S38195
S38197
Remove the hose (Item 1) [Figure 80-60-1] from the
condenser.
Slide the condenser (Item 1) [Figure 80-60-3] forward.
NOTE: Install caps and plugs on all fittings.
Remove the hose (Item 2) [Figure 80-60-3] from the
condenser.
S38199
WARNING
Remove the retainer screws (Item 1) and remove the
In the event of a leak, wear safety goggles. Escaping cover (Item 2) [Figure 80-70-2].
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic Figure 80-70-3
gas.
W-2371-0611
2
Figure 80-70-1
1
1 3
1
S39210
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
Figure 80-80-1
2 2
S38077
S38200
WARNING
In the event of a leak, wear safety goggles. Escaping
2
refrigerant can cause severe injuries to eyes. In
1
contact with a flame, R-134a refrigerant gives a toxic
gas.
S38077
W-2371-0611
Remove the operator seat. (See OPERATOR SEAT on Remove the A/C hose (Item 1) from the drier, and the A/C
Page 50-20-1.) hose (Item 2) [Figure 80-90-2] from the expansion valve.
Figure 80-90-3
S39211
2
1
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-90-1].
S39427
1 1
2
S38206
1 4 1
1
2
S38203
S38202
Figure 80-90-8
1
2 1
1
1
1 1
S38213
Figure 80-90-9
1
S39430
Figure 80-90-11
3 2
1
1
2
S38209
1 S38210
Loosen the clamp (Item 2) and retract the flexible hose Remove the evaporator / blower unit from the machine.
(Item 3) [Figure 80-90-11].
Figure 80-90-12
S38212
Lift the rubber cover (Item 1) and retract the flexible hose
(Item 2) [Figure 80-90-12].
The Electronic De-icing Thermostat (EDT) is a micro 2. Over current from clutch output
controller based module that measures evaporator coil
temperature and cycles the compressor clutch to 3. Voltage (Above and below operational limits or
maintain a constant evaporator pressure. Onboard circuit reverse voltage)
protection and diagnostics are also built into the module.
4. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a six second delay before start
up to protect the compressor clutch. 5. Temperature sensor open and short detection
The EDT will turn the clutch on when the evaporator coil
DETECTION
temperature is above 2°C (35.6°F). If the EDT does not MALFUNCTION STATUS LED
INTERVAL
detect any malfunction, it will continue to operate and the
status LED will be lit continuously. When the evaporator Temperature Continuous 1x per second
temperature is below -2°C (28.4°F), the EDT will turn off sensor
the clutch and status LED. Temperature At A/C start up 2x per second
sensor open and
Figure 80-100-1 short detection
Compressor Continuous 3x per second
clutch short to
battery
1
P90576
Figure 80-100-2
2
S38202
S39427
1
2
Remove the screw (Item 1) [Figure 80-100-2].
Figure 80-100-3
S38206
S39428
Figure 80-100-6
1 1
S39241
1
Figure 80-100-9
Remove the bolts (Item 1) and ground wire (Item 2)
[Figure 80-100-6].
Figure 80-100-7
1 1 1
1
1
1
2 1
S39211
WARNING
In the event of a leak, wear safety goggles. Escaping 2
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
S39212
W-2371-0611
Remove the operator seat. (See OPERATOR SEAT on Remove the two mount bolts (Item 1) from the expansion
Page 50-20-1.) valve (Item 2) [Figure 80-110-2].
2
1 1
S38077
S38214
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Dimensions are given for machine equipped with standard tires and can vary with other tire types.
Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Machine Dimensions
Performance
Engine
Controls
Drive System
Traction
Steering
Brakes
Fluid Capacities
Hydraulic System
Electrical System
Alternator 90 A
Battery 110 Ah
Starter 3,2 kW (4.3 hp)
Instrument Panel
The following functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored malfunctions by way of audible and visual indicators.
Gauges
Rev counter
Total operating hours
Job hours
Boom angle
Machine speed
Fuel gauge
Engine coolant temperature gauge
Indicators
Front and rear wheel alignment status
Headlight full beam
Headlight low beam
Position lights
Left and right turn
Trailer turn
Parking brake
Longitudinal stability level
Windscreen wipers
Work lights
Flashing warning lights
Hazard warning lights
Gear Speed Choice
Hydraulic function lock
Rear fog lights
Heater fan
Warning lights
Hydraulic fluid over-temperature
Engine coolant over-temperature
Low oil pressure
Battery not charging
Longitudinal stability alarm
Green - less than 61% of load
Amber - 63 to 68% of load`
Red - over 71% of load
Environmental
Axle
N•M FT-LB
Axle To Frame Mounting Bolts 490 - 550 361 - 405
Brake Housing Hex Bolt 80 59
Brake Housing Spring Bolts 10 7
Brake Housing Stud 120 88
Differential Lock Retainer Bolt 13 10
Fender Mount Bolt 90 - 100 66 - 74
Housing Bolt 320 236
Housing Nut 190 140
Pinion Ring Gear Bolts 13 10
Planetary Cover Bolts 25 18
Planetary Gear Mount Bolts 120 88
Steering Cylinder Bolts 120 88
Tie Rod Jam Nut 250 185
Tie Rod Nut 220 160
Tie Rod Swivel End 406 300
Turn Stop Adjust Jam Nut 150 110
Wheel Nuts 360 266
Boom
N•M FT-LB
Extension Cylinder Base End 180 133
Extension Cylinder Rod End 255 - 285 188 - 210
Wear Pads Front 58 43
Wear Pads Rear 39 29
Drive Box
N•M FT-LB
Cover Bolts 60 44
Inner Housing Bolts 120 88
Mounting Flange Bolts 60 44
Drive Motor
N•M FT-LB
End Cap Bolts 115 85
Mounting Bolts 210 155
Mounting Plate Bolts 63 46
Engine
N•M FT-.LB
A/C Compressor Mount Bolts 120 88
Alternator Mount Bolts 54 45
Starter Mount Bolts 54 45
Hydraulic Pump
N•M FT-LB
Filter Head 122 90
Flange Adapter 122 90
Guide Post Bolts 23 17
Mounting Bolts 106 78
Retaining Plate 13 10
Servo End Cap 13 10
Side Cover Bolts 32 24
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
Figure SPEC-40-1
A-1852
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
40-1].
Flare Fitting
Figure SPEC-40-3
TS-1619
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-3].
Figure SPEC-40-4
1
O-ring Flare
Primary
Seal
TS-1619
*If a torque wrench is used to tighten a new fitting to a **If using the hex flat tightening method to tighten a new
used hose / tubeline. fitting to a new hose / tubeline.
*If a torque wrench is used to tighten a used fitting to a **If using the hex flat tightening method to tighten a new
new hose / tubeline. fitting to a used hose / tubeline.
*If a torque wrench is used to tighten a new fitting to a ***If using the hex flat tightening method to tighten a used
new hose / tubeline. fitting to a new hose / tubeline.
Figure SPEC-40-6 1
P-13573
P-13572
Port Seal Fitting Tighten the nut with a wrench no more than one hex flat
maximum.
Figure SPEC-40-8
Do not over tighten the port seal fitting.
Figure SPEC-40-9
Secondary O-ring Seal
P-13008
2
Port seal and nut, washer and O-ring (O-ring Boss) Do not use port seal fittings when a thread in orifice (Item
fittings use the same tightening torque valve chart. 1) [Figure SPEC-40-9] is used in the port. The orifice
can interfere with the fitting and prevent it from sealing.
If a torque wrench cannot be used, use the following
method. Use an O-ring boss fitting (Item 2) [Figure SPEC-40-9]
as shown.
Specifications WARNING
Use Bobcat Axle/Transmission Oil LS (P/N 6987724), for During cold weather (0°C [32°F] and below), do not
the transfer case, planetaries and axle housings. operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
Use Bobcat Superior SH Hydraulic/Hydrostatic Oil (P/N period is necessary for foot pedal operation and safe
6987721). stopping. Do not operate controls during warm-up
period.
DO NOT use automatic transmission fluids in the
machine or permanent damage to the hydraulic / When temperatures are below -30°C (-20°F), the
hydrostatic system will result. hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311
WARNING
AVOID INJURY OR DEATH