S650 Service - 6987168 enUS SM

Service Manual
Dealer Copy -- Not for Resale
Skid-Steer Loader
S/N A3NV11001 & Above

S/N A3NW11001 & Above
S/N 1MLS11001 & Above
6987168enUS (09-20) (T) Printed in U.S.A. ©2020 Bobcat Company. All rights reserved.
NA iT4 EU S3A
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1694 NA1693

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

NA1674 NA1695 NA1680
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support.
Wear dust mask when grinding cause lift arms to drop. Do not go Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1682 NA1683 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW39-0820
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CONTENTS
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
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FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

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

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


SAFETY &
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
SYSTEM
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must DRIVE
hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach® attachment

correctly installed, functional mounting system wedges and
and in good condition. linkages must function

correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good
correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support, 13. Check for correct function of

replace if damaged. indicator lamps.
HVAC
6. Machine signs (decals) must 14. Check all machine fluid

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

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

the work lights.
FW SSL-0820 SM

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

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

modification not completed.
FW SSL-0820 SM

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

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

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

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

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

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

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

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

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

Dial 811 (USA Only)

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

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

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

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

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

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

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

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

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

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

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

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

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

requesting service information or when ordering parts.
Earlier or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-90466
1
The engine serial number is located on the side of the

engine (Item 1) [Figure 3] behind the alternator.

P109923C
The loader serial number plate (Item 1) [Figure 1] is

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

Combination P-90175
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.

DELIVERY REPORT
Figure 4
B-16315
The delivery report [Figure 4] contains a list of items that

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

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

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
OPERATOR’S
GRAB HANDBOOK
HANDLES
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
[1] BUCKET

STEP
BUCKET
STEPS
[2] OPERATOR CAB

LIFT (ROPS AND FOPS)
CYLINDER LIFT ARM
SUPPORT DEVICE
REAR
GRILLE
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR
NA1667
DOOR TAILLIGHT [3] TIRES NA1668
[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[2] ROPS - Roll-Over Protective Structure per ISO 3471 and FOPS - Falling-Object Protective Structure per ISO
3449, Level I. Level II is available.
[3] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.


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

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

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

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

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

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

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

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

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

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

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cooling System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Cleaning (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-6
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-6

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

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Hydraulic / Hydrostatic Filter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic / Hydrostatic Filter (Hex Head Filter Cap) . . . 10-120-5
Removing And Replacing Hydraulic / Hydrostatic Filter
(Square Head Filter Cap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
Removing And Replacing Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap) . . . . . 10-120-7

Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-8
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-10
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1


LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1



LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-85985
Lift the front of the loader and put jack stands under the
B-7023A axle tubes [Figure 10-10-2].
NOTE: Make sure the jack stands do not touch the

tires. Make sure tires clear floor or any
obstacles.
WARNING

Figure 10-10-3
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
Always park the loader on a level surface.

P-90556
P-85425
WARNING Lift the rear of the loader and install jack stands [Figure
10-10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
23 of 1311 10-10-1 S650 Service Manual


LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
WARNING 1
Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or P-85463A P100009
with missing parts can cause lift arms to drop

causing injury or death. Put jack stands under the rear corners of the loader
W-2572-0407
frame (Inset) [Figure 10-20-1].
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from the storage position.
DANGER

The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Remove attachment from the loader.

P-90567
Have a second person install the lift arm support device

over the rod of one of the lift cylinders [Figure 10-20-2].
The lift arm support device must be tight against the

cylinder rod.

LIFT ARM SUPPORT DEVICE (CONT’D) Removing
Installing (Cont’d) The operator must be in the operator’s seat, with the seat
belt fastened and seat bar lowered, until the lift arm
Figure 10-20-3 support device is removed and the lift arms are lowered
all the way.
NOTE: The lift arm support device should remain

resting on the cylinder barrel when the lift
arms are raised. Service or replace the lift arm
support device if the lift arm support raises
with the cylinder rod.
P100005A Start the engine and raise the lift arms all the way up.
Have a second person remove the lift arm support device

after the lift arms are all the way up.
Lower the lift arms all the way and stop the engine.
P100005
Return the lift arm support device to the storage position
and secure with clamping knobs.
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder [Figure Remove the jackstands.

10-20-3]. The tabs of the lift arm support device must go
past the end of the cylinder (Inset) [Figure 10-20-3].

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

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

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

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

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

Level II
Protection from falling trees, rocks: for machines

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

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

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

P-85463A
Install jack stands under the rear of the loader frame

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

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
P-90512A P-90511A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

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

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

N-20120 P-90565A
Pull down on the bottom of the operator cab until it stops

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

when equipped with options and accessories P-90511A P-90512A
such as cab door, heater, air conditioning,

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

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

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

OPERATOR CAB (CONT’D) Figure 10-30-8
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
P-76461Q
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] will be ON when the door is open, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
1 button is pressed.
[DOOR] will appear in the data display [Figure 10-30-8].

P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the
door is open.
Figure 10-30-7
P-90726L
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] will be OFF when the door is closed, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
button is pressed.

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

• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
WARNING • Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit and
Top Guard (if applicable) to provide added operator
protection in these applications.
W-2737-0917
Figure 10-30-9

NA1026
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.50 in)
thick polycarbonate front door and polycarbonate rear
window [Figure 10-30-9].
Polycarbonate top window (standard item) must be

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

OPERATOR CAB (CONT’D) Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
• Inspect for cracks or damage. Replace if required.
Figure 10-30-10 • Order part number 7171104 if door frame is damaged
and needs to be replaced.
• Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Forestry Door Emergency Exit
Figure 10-30-11
NA1819
Must be used as part of the Forestry Applications Kit to

prevent flying debris and objects from entering the

loader. Kit includes 19,1 mm (0.75 in) thick laminated
polycarbonate front door, polycarbonate side windows 1
and polycarbonate rear window [Figure 10-30-10].
Polycarbonate top window (standard item) must be

installed as part of the Forestry Applications Kit to restrict
material from entering cab openings.
P-100984
• Inspect both emergency exit levers (Item 1) [Figure

10-30-11], linkages and hardware for loose or
damaged parts.
• Repair or replace if necessary.

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

Rear Tie-Down Front Tie-Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-85615A P107253
W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
Figure 10-40-1

P-90561A
Alternate Rear Tie-Down Alternate Front Tie-Down
P-90560A
P-85466
P-85717A P-85599A
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
The rear of the trailer must be blocked or supported (Item during sudden stops or when going up or down slopes
1) [Figure 10-40-1] when loading or unloading the loader [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
1. Lower the bucket or attachment to the floor.
2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie-down

positions [Figure 10-40-2]. (Lift arms shown raised
for clarity.) (Some models have two front tie-down
locations on the transmission.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.


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

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

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


REMOTE START TOOL KIT - MEL1563 Figure 10-60-2
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool Kit 3
MEL1566 - Service Tool Harness Communicator 1
(Computer Interface)
Figure 10-60-1
1
P16117
The traction lock switch (Item 1) [Figure 10-60-2] is used

to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
P16114 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
The Remote Start Tool (Item 1) [Figure 10-60-1] is when testing pressures and flow rate.
required when the service technician is testing the
hydraulic / hydrostatic system, adjusting the steering NOTE: With the engine running; pushing and holding
linkage, and electrical diagnostics. the pressure release switch (Item 3) [Figure
10-60-2] will cause the engine to stop.

REMOTE START TOOL - MEL1563 (CONT'D) Figure 10-60-5
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-3
2
2
1
1
P-85728
Loaders equipped with an attachment harness (Item 1)

P16114 must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
Remove the service tool harness (Item 1) from the cover Connect the service tool harness to the ACD connector
(Item 2) [Figure 10-60-3]. and the loader harness connector.

Figure 10-60-4 NOTE: To monitor, diagnose or load new software
the Service PC must be connected to the
Remote Start Tool.
P-85729
Remove the cap (Item 1) [Figure 10-60-4] from the

loader harness connector.
Connect the service tool harness control to the loader

harness connector.

REMOTE START TOOL - MEL1563 (CONT'D) Remote Start Procedure
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
The Service Tool Harness Communicator (Item 1) is P16115

required to connect Remote Start Tool to the Service PC

(Item 2) [Figure 10-60-6].
The Remote Start Tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Raise the operator cab (if required by the procedure).
Open the rear door of the loader.

REMOTE START TOOL - MEL1563 (CONT'D) Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
1
1
P-85728
Figure 10-60-11
P-85729
Figure 10-60-9
1

2
P-85726
Connect the Remote Start Tool to the engine harness

P-85728
connector (Item 1) [Figure 10-60-10].
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the Remote Start Tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (if equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT - MEL1563 (CONT'D) Figure 10-60-13
WARNING
2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in P16118
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock The traction lock switch (Item 1) [Figure 10-60-13] is
the keypad with a unique password (keyless) or used to turn traction lock ON or OFF. Push the switch to
otherwise disable the starter before working in the override position. The switch will illuminate to indicate
the engine area. traction lock OVERRIDE, in this position the wheels are
W-2457-1110 able to turn.

Figure 10-60-12 The maximum flow / variable flow switch (Item 2) [Figure
10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when testing pressures and flow rate.
NOTE: With the engine running; pushing and holding

1 the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.
WARNING
P16116
• Use traction lock override switch for service work
with seat bar raised.
The Remote Start Tool (Item 1) [Figure 10-60-12] has
• Traction lock is engaged when light is OFF.
three rocker switches.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

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

block and hold for five seconds to release the front

auxiliary pressure [Figure 10-60-14].

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

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

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

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

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

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

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

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

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

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

7217666 (CONT'D)
2
Loader Service Tool Harness - 6689747
Figure 10-61-3
1
1
P-85725
2
Loaders with an attachment control harness (7 pin or 14

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

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

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

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
2 1
1
2
P-76450
P-85726 The Computer Service Tool Harness (Item 1) [Figure 10-

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

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

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

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

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

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

Remote Start Tool (Service Tool).
The tool listed will be needed to do the following
procedure: NOTE: When using a Remote Start Tool (Service
Tool) harness on loaders not equipped with
7217666: Remote Start Tool (Service Tool) Kit an attachment control device, the Remote
Start Tool (Service Tool) harness attachment
Figure 10-61-8 control device connector must be capped.
Figure 10-61-10
2
1
P-76450
P-85725
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-8] is required when the operator cab is in the
raised position for service and the service technician Loaders with an attachment control harness (7 pin or 14
needs to turn on the loader or start the engine. Example: pin), the attachment harness (Item 1) must be
adjusting the steering linkage. disconnected from the loader harness (Item 2) [Figure
10-61-10].
Lift and block the loader.
When the remote start procedure is completed, replace
Raise the lift arms (if required by the procedure) and the loader connector cap (Item 1) [Figure 10-61-10] or
install an approved lift arm support device. reconnect the attachment control harness to the loader
harness.

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

10-61-12] has five buttons.
P-85726
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.

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

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

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

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

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

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


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

Failure to do so will result in excessive wear and early
failures. WARNING
The service schedule is a guide for correct maintenance
of the Bobcat loader. AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
W-2003-0807
Every 10 Hours (Before Starting The Loader)
• Engine Oil - Check level and add as needed.

• Engine Air Filters and Air System - Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System - Clean debris from radiator, hydraulic fluid cooler, air conditioning condenser (if equipped),
and rear grille. Check coolant level COLD and add premixed coolant as needed.
• Fuel Filter - Remove the trapped water.
• Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges - Lubricate with multipurpose lithium based grease.
• Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks - Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
• Bobcat Interlock Control Systems (BICS™) - Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
• Front Horn / Back-up Alarm - Check for proper function.
• Tires - Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the
tire.
• Operator Cab - Check the fastening bolts, washers, and nuts. Check the condition of the cab.
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Wheel Nuts - Perform every 10 hours or daily for the first 30 hours, then as scheduled. Check for loose wheel nuts
and tighten to correct torque.
• Safety Signs and Safety Treads - Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
• Hydraulic Fluid - Check fluid level and add as needed.
• Heater and Air Conditioning Filters (if equipped) - Clean or replace filters as needed.
SS SSL LF EXLF T3 MF EXMF iT4-0118

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
Every 50 Hours
• Hydraulic Hoses and Tubelines - Check for damage and leaks. Repair or replace as needed.
• Final Drive Transmission (Chaincase) - Check fluid level and add as needed.
• Parking Brake, Foot Pedals, Hand Controls and Steering Levers, or Joysticks - Check for correct operation.
Repair or adjust as needed.
• Wheel Nuts - Check for loose wheel nuts and tighten to correct torque.
• Engine / Hydrostatic Drive Belt - Perform at first 50 hours, then as scheduled. Check for wear or damage. Adjust or
replace as needed.
• Engine Oil and Filter - Perform at first 50 hours, then as scheduled. Replace oil and filter.
Every 100 Hours
• Spark Arrester - Empty spark chamber.

• Battery - Check cables and connections.
• Engine Oil and Filter - Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Every 250 Hours or Every 12 Months
• Fuel Filter - Replace filter.

• Engine / Hydrostatic Drive Belt - Check for wear or damage. Adjust or replace as needed.
• Drive Belts (Alternator, air conditioning, water pump) - Check condition. Replace as needed.
• Bobcat Interlock Control System (BICS™) - Check the function of the lift arm bypass control.
• Engine Oil and Filter - Replace oil and filter.
• Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap - Replace the charge filter and the reservoir breather
cap.
• Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator.
Clean the plenum drains.
• Hydraulic / Hydrostatic Filter - Replace the hydraulic / hydrostatic filter.

• Hydraulic Reservoir - Replace the fluid.
• Final Drive Transmission (Chaincase) - Replace the fluid.
• Engine Valves - Adjust the engine valve clearance.
Every 24 Months
• Coolant - Replace the coolant.
SS SSL LF EXLF T3 MF EXMF iT4-0118

AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-2
Figure 10-80-1
3 1 2
NA3271
P100072
It is important to change the air filter element only when

necessary. The service indicator (Item 1) will FLASH. Open the latches (Item 1) and remove the dust cover
Press the information button (Item 3) until the display (Item 2) [Figure 10-80-2].
screen (Item 2) shows the service codes. Service code
[M0117] (Air Filter Plugged) will show in the display Figure 10-80-3

screen (Item 2) [Figure 10-80-1] when air filter change is
necessary.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
P-90523A
Pull the outer filter element (Item 1) [Figure 10-80-3] out

and discard.
NOTE: Make sure all sealing surfaces are free of dirt

and debris. Do not use compressed air.
Install the new outer filter element. Push all the way in
until it contacts the base of the housing.
Install the dust cover and secure the latches [Figure 10-
80-2].

AIR CLEANER SERVICE (CONT’D) Figure 10-80-5
Replacing Filter Elements (Cont’d)
Inner Filter
Only replace the inner filter element under the following

conditions:
• Replace the inner filter element every third time the 1 2

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

engine and run at full rpm. If service code [M0117]
(Air Filter Plugged) is still displayed in the data
display, replace the inner filter element. P100072
Remove the dust cover [Figure 10-80-2] and the outer

filter element [Figure 10-80-3]. Install the dust cover (Item 2) and secure the latches
(Item 1) [Figure 10-80-5].
Figure 10-80-4

1
P-90524A
Remove the inner filter element (Item 1) [Figure 10-80-

4].
NOTE: Make sure all sealing surfaces are free of dirt

and debris. Do not use compressed air.
Install new inner filter element. Push all the way in until it
contacts the base of the housing.
Install the outer filter element [Figure 10-80-3].

ENGINE COOLING SYSTEM Cooling System Identification
Check the cooling system every day to prevent over- NOTE: Identification of the cooling system used on
heating, loss of performance or engine damage. your machine is necessary to perform the
correct cleaning procedure.
Maintenance Platform
Figure 10-90-2
Figure 10-90-1
Earlier Model Later Model
P109009B P109569A
Earlier models have a square coolant tank. Later models

P100040A have a rectangular coolant tank [Figure 10-90-2].

A maintenance platform (Item 1) [Figure 10-90-1] is
available to facilitate access when cleaning the engine
cooling system.
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-4
Cleaning (Earlier Models)
Open the rear door. (See REAR DOOR (TAILGATE) on 1

Page 50-70-1.)
Remove the rear grille. (See REAR GRILLE on Page 50-

60-1.)
Loaders With Air Conditioning 2
Figure 10-90-3
1 P107097A
NOTE: Be careful when raising and lowering the air

2 2 conditioning condenser so that the air
conditioning condenser does not fall on the
3 oil cooler and damage the fins.
Raise the air conditioning condenser (Item 1) and use

low air pressure or water pressure to clean the top of the
oil cooler (Item 2) [Figure 10-90-4].
P107097
Lower the air conditioning condenser (Item 1) [Figure 10-
90-4]. Install the brackets (Item 3) [Figure 10-90-3] and
the bolts (Item 2) [Figure 10-90-3].
Use low air pressure or water pressure to clean the top of
the air conditioning condenser (Item 1) [Figure 10-90-3].
The area between the air conditioning condenser and the

oil cooler will require occasional cleaning. Remove the
bolts (Item 2) and the brackets (Item 3) [Figure 10-90-3].

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Earlier Models) (Cont’d) Unhook the two rubber straps (Item 2) [Figure 10-90-5].
Loaders Without Air Conditioning Figure 10-90-6
Figure 10-90-5
1 1
2
3
2
P100179
P100181
Raise the oil cooler (Item 1) until the bar (Item 2) drops
into position to support the oil cooler. Use low air

Use low air pressure or water pressure to clean the top of pressure or water pressure to clean the top of the radiator
the oil cooler (Item 1) [Figure 10-90-5]. (Item 3) [Figure 10-90-6].
Raise the bar (Item 2) [Figure 10-90-6] slightly and lower

the oil cooler. Fasten the two rubber straps.
Check the cooling system for leaks.
Install the rear grille and close the rear door.

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-8
Cleaning (Later Models)
See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)
1
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
2
3
WARNING
Wear safety glasses to prevent eye injury when any P109572
• When fluids are under pressure. Pivot the air conditioning condenser (Item 1) up and
• Flying debris or loose material is present. rotate the support bar (Item 2) into position. Use low air
• Engine is running. pressure or water pressure to clean the top of the
• Tools are being used. hydraulic fluid cooler and radiator assembly (Item 3)
W-2019-0907
[Figure 10-90-8].

Loaders With Air Conditioning Return the support bar to storage position and lower the
air conditioning condenser.
Figure 10-90-7
Figure 10-90-9
1
1 2
2
P121162
Ensure the air conditioning condenser is installed into the

P109573
two slotted brackets [Figure 10-90-9]. (Left side shown.)
Use low air pressure or water pressure to clean the top of Ensure the clips (Item 1) are properly installed over the
the air conditioning condenser (Item 1) [Figure 10-90-7]. two slotted brackets (Item 2) [Figure 10-90-9]. (Left side
shown.)
Unhook the two rubber straps (Item 2) [Figure 10-90-7].
Fasten the two rubber straps (Item 2) [Figure 10-90-7].
NOTE: The air conditioning condenser fits into two
slotted brackets mounted on the hydraulic NOTE: The air conditioning condenser can be lifted
fluid cooler and radiator assembly. Ensure the out of the two slotted brackets by removing
air conditioning condenser remains the clips. This allows greater access to clean
connected to the brackets when raising and the hydraulic fluid cooler and radiator
lowering. assembly.

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Later Models) (Cont’d) Check the cooling system for leaks.
Loaders Without Air Conditioning Install the rear grille and close the rear door.
Figure 10-90-10
P109717

Use low air pressure or water pressure to clean the top of
the hydraulic fluid cooler and radiator assembly (Item 1)
[Figure 10-90-10].

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant
Checking Level For the service interval for replacing the engine
coolant (See SERVICE SCHEDULE on Page 10-70-1.)
Open the rear door and raise the rear grille.
Open the rear door and remove the rear grille.
Figure 10-90-11
Remove the coolant fill cap (Item 1) [Figure 10-90-11].
Figure 10-90-12
1
1
1
2
2
P109009B P109570A
Check coolant level using the level markers (Item 2)

[Figure 10-90-11] on the tank. Coolant must be between
top and bottom level markers when the engine is cold.

P-85606
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix Disconnect the coolant hose (Item 1) [Figure 10-90-12]
propylene glycol with ethylene glycol. from the oil filter assembly. Drain the coolant into a
container. Connect the coolant hose to the oil filter
Use a refractometer to test the condition of propylene assembly. Recycle or dispose of coolant in an
glycol in your cooling system. environmentally safe manner.
Lower the rear grille and close the rear door. Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-5.)
The correct mixture of coolant to provide a -37°C (-34°F)

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

of water.
AVOID ENGINE DAMAGE Add premixed coolant, 47% water and 53% propylene
Always use the correct ratio of water to antifreeze. glycol to the coolant tank until the coolant level reaches
the lower marker on the tank [Figure 10-90-11].
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine Install the coolant fill cap.
damage.
NOTE: When installing the coolant fill cap, the cap
Too little antifreeze reduces the additives which must be tightened until it clicks.
protect the internal engine components; reduces the
Run the engine until it is at operating temperature. Stop
boiling point and freeze protection of the system.
the engine. Check the coolant level when cool. Add
coolant as needed.
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature Install the rear grille and close the rear door.
engine damage.
I-2124-0497

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
At a minimum, low sulfur diesel fuel must be used in this
machine. Low sulfur is defined as 500 mg/kg (500 ppm) • Biodiesel blend fuel is an excellent medium for
sulfur maximum. microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
U.S. Standard (ASTM D975)
• Use of biodiesel blend fuel may result in premature
Use only clean, high quality diesel fuel, Grade Number
failure of fuel system components, such as plugged
2-D or Grade Number 1-D.
fuel filters and deteriorated fuel lines.
Ultra low sulfur diesel fuel may also be used in this
• Shorter maintenance intervals may be required, such
machine. Ultra low sulfur is defined as 15 mg/kg (15 ppm)
as cleaning the fuel system and replacing fuel filters
sulfur maximum.
and fuel lines.
The following is one suggested blending guideline that
should prevent fuel gelling during cold temperatures: • Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
TEMPERATURE GRADE 2-D GRADE 1-D pump and seals.

Above -9°C (+15°F) 100% 0%
Apply the following guidelines if biodiesel blend fuel is
Down to -21°C (-5°F) 50% 50%
used:
Below -21°C (-5°F) 0% 100%
• Ensure the fuel tank is as full as possible at all times
NOTE: Biodiesel blend fuel may also be used in this to prevent moisture from collecting in the fuel tank.
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed • Ensure that the fuel tank cap is securely tightened.
with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly • Biodiesel blend fuel can damage painted surfaces,
marketed as B5 blended diesel fuel. B5 remove all spilled fuel from painted surfaces
blended diesel fuel must meet ASTM immediately.
specifications.
• Drain all water from the fuel filter daily before
E.U. Standard (EN590) operating the machine.
Use only clean, high quality diesel fuel that meets the • Do not exceed engine oil change interval. Extended
specifications listed below: oil change intervals can cause engine damage.
• Low sulfur diesel fuel defined as 500 mg/kg (500 ppm) • Before vehicle storage; drain the fuel tank, refill with
sulfur maximum 100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.
• Diesel fuel with cetane number of 51.0 and above.
NOTE: Biodiesel blend fuel does not have long term
Clean, high quality diesel fuel that meets the EN590 stability and should not be stored for more
specification may also be used. than three months.
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain
no more than seven percent biodiesel mixed
with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

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

1].
Close the rear door.
WARNING
P100006
Always clean up spilled fuel or oil. Keep heat, flames,
Remove the fill cap (Item 1) [Figure 10-100-1]. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water WARNING

Figure 10-100-3
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
2
Figure 10-100-4

1
P-85508
Loosen the drain (Item 1) [Figure 10-100-3] at the 1 2

bottom of the filter element to remove water from the
filter.
Replacing Element
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on P-85507
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Open the vent (Item 2) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See on Page 10-100- housing.
3.)
Squeeze the hand pump (priming bulb) (Item 1) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
WARNING Close the vent (Item 2) [Figure 10-100-4].
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil level every day before starting the ENGINE CRANKCASE OIL
engine for the work shift. Recommended SAE Viscosity Number
Figure 10-110-1
P-85506 Refer to temperature range anticipated before next

oil change

Must use API Category CI-4 or better, or ACEA E7 or
Park the machine on level ground. Open the rear door
better
and remove the dipstick (Item 1) [Figure 10-110-1].
Do not use API Category FA-4 engine oil
Keep the oil level between the marks on the dipstick. Do [1] Bobcat Synthetic Oil – SAE 5W-40
not overfill.
Bobcat engine oils are recommended for use in this
machine. If Bobcat engine oil is not available, use a good
quality engine oil that meets API Service Category of CI-
4 or better, or ACEA E7 or better [Figure 10-110-2].
IMPORTANT
AVOID ENGINE DAMAGE
Use of API Service Category FA-4 engine oil is not
approved and may cause irreversible damage to the
engine.
I-2384-0916
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Later Models
Removing And Replacing Oil And Filter Figure 10-110-4
Follow the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.)
Run the engine until it is at operating temperature. Stop

the engine.
Open the rear door.
Earlier Models
1
Figure 10-110-3 2
P109086B
The oil drain hose is located behind a cover under the

right rear corner of the loader (Inset) [Figure 10-110-4].
1 Remove the cover mounting bolts (Item 1) and remove

the cover (Item 2) [Figure 10-110-4].
2 Figure 10-110-5
3 P-90497A
P-90499A
The oil drain hose is located behind a cover under the

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

110-3].
Loosen one cover mounting bolt (Item 2) and slide the

cover (Item 3) [Figure 10-110-3] to the rear of the loader. 2
1
P-109087
Remove the oil drain hose (Item 1) from the storage

location and route through the opening (Item 2) [Figure
10-110-5].

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-7
Removing And Replacing Oil And Filter (Cont’d)
Figure 10-110-6
2
P-85506
1
Open the rear door, remove the oil filter (Item 3) [Figure
P-90498A
10-110-7] and clean the filter housing surface.
Use genuine Bobcat filter only.

Remove the oil drain cap (Item 1) [Figure 10-110-6] from
the oil drain hose and drain the oil into a container. Put oil on the new filter gasket, install the filter and hand

Recycle or dispose of used oil in an environmentally safe tighten.
manner.
Remove the oil fill cap (Item 1) [Figure 10-110-7].
Install and tighten the oil drain cap [Figure 10-110-6].
Put oil in the engine. For the correct quantity (See
(Earlier Models) - Install the cover and the cover Capacities on Page SPEC-10-5.) Do not overfill.
mounting bolts [Figure 10-110-3]. Tighten all bolts.
Start the engine and let it run for several minutes. Stop
OR the engine and check for leaks at the filter.
(Later Models) - Remove the oil drain hose from the Remove the dipstick (Item 2) [Figure 10-110-7] and
opening and return to storage location [Figure 10-110- check the oil level.
5]. Install the cover and the cover mounting bolts [Figure
10-110-4]. Tighten all bolts. Add oil as needed if it is not at the top mark on the
dipstick. Install the dipstick and close the rear door.
WARNING
explosion or fire.
W-2103-0508


HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid HYDRAULIC / HYDROSTATIC FLUID

RECOMMENDED ISO VISCOSITY GRADE (VG)
Check the hydraulic / hydrostatic fluid level every day AND VISCOSITY INDEX (VI)
before starting the work shift. Figure 10-120-3
Park the loader on a level surface, lower the lift arms and
place the attachment flat on the ground or tilt the Bob-
Tach® fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1 [2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic

Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
P100010
prevent oxidation and thermal breakdown at operating
temperatures.)
Check the fluid level in the sight gauge (Item 1) [Figure
10-120-1]. Keep the fluid level within the operating range. Use only recommended fluid in the hydraulic system
[Figure 10-120-3]. (See Hydraulic System on Page
Stop the engine, open the rear door and remove the rear SPEC-10-4.)
Figure 10-120-2
WARNING
1 Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508
P100055
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

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

grille and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
Replace the fluid if it becomes contaminated or after 1

major repair.
2
Always replace the hydraulic / hydrostatic filter and the
hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Hydraulic / Hydrostatic Filter Identification
on Page 10-120-4.)
Remove the rear grille. (See REAR GRILLE on Page 50- P100179
60-1.)
Figure 10-120-4 (Earlier Models with Square Coolant Tank) - Raise the
oil cooler (Item 1) until the bar (Item 2) [Figure 10-120-5]
drops into the last position to support the oil cooler. This
will aid in draining the hydraulic fluid.
Figure 10-120-6

1
1
P100055
P100007
Remove the right side access cover bolts (Item 1)

[Figure 10-120-6] and remove the cover. (Lift arms
shown raised for visual clarity.)
P100181
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4].
(Earlier Models with Square Coolant Tank) - unhook

the two rubber straps (Item 2) [Figure 10-120-4].

Removing And Replacing Hydraulic Fluid (Cont’d)
NOTE: The hose used to drain the hydraulic reservoir

is located under the fan motor on earlier
models and behind the fan motor on later
models.
1
Figure 10-120-7
1
P-90506
Remove and clean the hydraulic fill screen (Item 1)

1 [Figure 10-120-8]. Use low air pressure to dry the
2 screen.
2
P109760A P115442A Install hydraulic fill screen and add the correct fluid to the
reservoir until the fluid level is within the operating range

of the sight gauge. (See Capacities on Page SPEC-10-
Remove the clamp (Item 1). Pinch off the hose (Item 2)
5.) and (See Checking And Adding Fluid on Page 10-
[Figure 10-120-7] near the fitting and disconnect hose
120-1.)
from the fitting. Route the hose out the side of the loader
and drain the fluid into a container.
Install the hydraulic fill cap.
Connect the hose to the fitting when the fluid stops
Install the rear grille.
draining.
Recycle or dispose of used fluid in an environmentally
safe manner.
Start the engine and operate the loader hydraulic
controls.
WARNING Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.

AVOID INJURY OR DEATH (See Checking And Adding Fluid on Page 10-120-1.)
explosion or fire.
W-2103-0508
Install the side access cover.
(Earlier Models with Square Coolant Tank) - Raise the

bar supporting the oil cooler and lower the oil cooler.
Fasten the two rubber straps.

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

reservoir.
NOTE: Identification of the hydraulic / hydrostatic

filter used on your machine is necessary to
perform the correct filter replacement
procedure.
Figure 10-120-9
Hex Head Filter Cap
P109922
This model has a square head on the filter cap [Figure

10-120-10]. (See Removing And Replacing Hydraulic /
Hydrostatic Filter (Square Head Filter Cap) on Page 10-
120-6.)

Figure 10-120-11
Bolt-on Filter Cap
P-90500
This model has a hex head on the filter cap [Figure 10-
120-9]. (See Removing And Replacing Hydraulic /
Hydrostatic Filter (Hex Head Filter Cap) on Page 10-120-
5.)
P121075
This model has a filter cap held in place by two bolts

[Figure 10-120-11]. (See Removing And Replacing
Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap) on Page
10-120-7.)

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic / Hydrostatic

Filter (Hex Head Filter Cap)
WARNING
See the SERVICE SCHEDULE for the correct service AVOID INJURY OR DEATH
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Always clean up spilled fuel or oil. Keep heat, flames,
Stop the engine, open the rear door, and remove the rear Failure to use care around combustibles can cause
grille. (See REAR GRILLE on Page 50-60-1.) explosion or fire.
W-2103-0508
Clean the top of the filter housing.
Figure 10-120-12
controls.
WARNING
1

P-90500 enters skin or eyes, get immediate medical attention
W-2072-0807
Remove the filter (Item 1) [Figure 10-120-12] using a
socket wrench.
Stop the engine and check for leaks at the filter.
Figure 10-120-13
(See Checking And Adding Fluid on Page 10-120-1.)
P-85478
Discard the entire filter (Item 1) [Figure 10-120-13].
Clean the surface of the filter housing where the filter seal
contacts the housing.
Install new filter and tighten to 61 N•m (45 ft-lb) torque.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new filter element ensuring that element is fully
seated in the housing.
Filter (Square Head Filter Cap) Install the filter cap and tighten to 25 N•m (18 ft-lb)
torque.
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine, open the rear door, and remove the rear
WARNING
Clean the top of the filter housing. AVOID INJURY OR DEATH
Figure 10-120-14 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508

controls.

WARNING
P100047 AVOID INJURY OR DEATH
Remove the filter cap (Item 1) [Figure 10-120-14].
Figure 10-120-15
W-2072-0807
1

2 P100044 P100046
Remove the filter element (Item 1) [Figure 10-120-15]

and discard.
Remove the O-ring (Item 2) [Figure 10-120-15] and

discard.
Install new O-ring and lubricate with clean oil.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new filter element ensuring that element is fully
seated in the housing.
Filter (Bolt-on Filter Cap) Remove the filter cap O-rings (Item 3) [Figure 10-120-
17] and discard.
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Install new filter cap O-rings and lubricate with clean oil.
Stop the engine, open the rear door, and remove the rear NOTE: The filter cap O-rings are not the same size.
grille. (See REAR GRILLE on Page 50-60-1.) Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and the bolts [Figure 10-120-16].
Figure 10-120-16 Alternate tightening the bolts to draw the cap down
evenly. Tighten the bolts to 27 - 41 N•m (20 - 30 ft-lb)
torque.
1
WARNING
2

explosion or fire.
W-2103-0508
P121075
Remove the bolts (Item 1) and slowly pry the filter cap Start the engine and operate the loader hydraulic
(Item 2) [Figure 10-120-16] off the housing by hand. controls.
Figure 10-120-17
1
WARNING
2
3 from a physician familiar with this injury.
W-2072-0807
P121072A P115686B
Remove the filter element (Item 2) [Figure 10-120-17] Check the fluid level in the reservoir and add as needed.
and discard. (See Checking And Adding Fluid on Page 10-120-1.)
Lubricate the O-ring (Item 1) [Figure 10-120-17] on new

filter element with clean oil.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Earlier Models
Removing And Replacing Hydraulic Charge Filter Figure 10-120-20
The hydraulic charge filter is located under the operator

cab. For the correct service interval (See SERVICE
Raise the operator cab. (See Raising on Page 10-30-2.)

1
Figure 10-120-18
P-85489B
1
Place a suitable container below the filter housing and

remove the filter housing (Item 1) [Figure 10-120-20]
2 using a socket wrench.

Figure 10-120-21
P115884
Unhook the three rubber straps (Item 1) and remove the

lower fan duct (Item 2) [Figure 10-120-18].
NOTE: Identification of the hydraulic charge filter 1

used on your machine is necessary to
perform the correct replacement procedure.
Figure 10-120-19
P-85489A
Remove and discard the filter element (Item 1) [Figure

10-120-21].
Clean the surface of the filter housing and the filter base
where they contact the filter element seal.
P109622B P115441A Put clean oil on the seal of the new filter element. Install
the element on the filter base.
Earlier models use a separate filter housing and filter
Install and tighten the filter housing to 65 - 70 N•m (48 -
element. Later models use a spin-on filter [Figure 10-
52 ft-lb) torque.
120-19].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) All Models
Removing And Replacing Hydraulic Charge Filter Recycle or dispose of used fluid in an environmentally
(Cont’d) safe manner.
Later Models
Figure 10-120-22 WARNING

explosion or fire.
W-2103-0508
1
Install the lower fan duct [Figure 10-120-18].
NOTE: Failure to install the lower fan duct correctly

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

3.)

Put a suitable container below the filter, remove the filter Start the engine and operate the loader hydraulic
(Item 1) [Figure 10-120-22], and clean the filter base. controls.
Put clean oil on the new filter gasket, install the new filter,
and tighten the filter to 37 – 45 N•m (27 – 33 ft-lb) torque.
WARNING
W-2072-0807


HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Breather Cap
See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Stop the engine and open the rear door.

60-1.)
Figure 10-120-23

P100055
Remove the breather cap (Item 1) [Figure 10-120-23]

and discard.
Install new breather cap.
Install the rear grille.

FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Fluid
The chaincase contains the final drive sprockets and

chains and uses the same type of fluid as the hydraulic /
hydrostatic system. (See Hydraulic System on Page
SPEC-10-4.)
Stop the loader on a level surface and stop the engine.
Figure 10-130-1

P107956
Remove the check plug (Item 1) [Figure 10-130-1] from

the front of the chaincase housing. (Lift arms shown
raised for clarity.)
If fluid can be reached with the tip of your finger through

the hole, the fluid level is correct.
If the level is low, add fluid through the check plug hole
until the fluid flows from the hole.
Install and tighten the plug.

FINAL DRIVE TRANSMISSION (CHAINCASE)
(CONT’D)
Removing And Replacing Fluid WARNING

Figure 10-130-2
explosion or fire.
1 W-2103-0508
P-85745
Remove the check plug (Item 1) [Figure 10-130-2] from

the front of the chaincase housing.

Figure 10-130-3
P107281
Pump the fluid out of the chaincase [Figure 10-130-3].
Recycle or dispose of the used fluid in an

environmentally safe manner.
Add fluid through the check plug hole until the fluid flows
from the hole.

BOB-TACH (HAND LEVER) Figure 10-140-2
Inspection And Maintenance

1
Figure 10-140-1
Wedge must contact

lower edge of hole in the
attachment mounting
frame.
P-31233A P-31233
The wedges (Item 1) [Figure 10-140-2] must extend

P-85513A through the holes in the attachment mounting frame.
The spring loaded wedge (Item 1) must contact the lower

Move the Bob-Tach levers down to engage the wedges edge of the holes in the attachment mounting frame (Item
[Figure 10-140-1]. 2) [Figure 10-140-2].

The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208

BOB-TACH (HAND LEVER) (CONT’D)
Inspection And Maintenance (Cont’d)
Figure 10-140-3

NA13065S
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1.) (See LUBRICATING THE LOADER on
Page 10-150-1.)

BOB-TACH (POWER) Figure 10-141-2
This machine may be equipped with a Power Bob-Tach.

1
Figure 10-141-1 2
1 Wedge must contact

lower edge of hole in the
attachment mounting
frame.
P-31233A P-31233
2 The wedges (Item 1) [Figure 10-141-2] must extend

through the holes in the attachment mounting frame.
P-85320A The spring loaded wedges (Item 1) must contact the

lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-141-2].

Push and hold the BOB-TACH “WEDGES UP” switch
(Item 1) until wedges are fully raised. Push and hold the If the wedges do not contact the lower edge of the holes
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure [Figure 10-141-2], the attachment will be loose and can
10-141-1] until the wedges are fully down. come off the Bob-Tach.
The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208

BOB-TACH (POWER) (CONT’D)
Inspection And Maintenance (Cont’d)
Figure 10-141-3

NA13065S
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)

LUBRICATING THE LOADER Figure 10-150-2
Lubrication Locations
Lubricate the loader as specified for the best

performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)
Record the operating hours each time you lubricate the

Bobcat loader.
2
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader.

P-90572A
Tilt the Bob-Tach forward until it contacts the ground. (Not

required on later models with Bob-Tach wedge grease 2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-
fittings that are accessible from the side.) 150-2].
Stop the engine. Figure 10-150-3
Lubricate the following:

Figure 10-150-1
P-90543A
3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-3].

P100011
1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

150-1].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-6
Lubrication Locations (Cont’d)
Figure 10-150-4
P-85720
6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-90542A 150-6].
Figure 10-150-7
4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-4].

Figure 10-150-5
5
7
P-85719
P-85484 7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-

7].
5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

150-5].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-10
Lubrication Locations (Cont’d)
Earlier Models
9
Figure 10-150-8
8
P100012
9. Rear Control Link (Both Sides) (2) [Figure 10-150-

10].
P-85487 Figure 10-150-11

Later Models
Figure 10-150-9
10
8 P-90544A
10. Front Control Link (Both Sides) (2) [Figure 10-150-

11].
P-31308A
8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8]

or [Figure 10-150-9].


TIRE MAINTENANCE Rotating
Wheel Nuts Check the tires regularly for wear, damage and pressure.
Figure 10-160-1 Figure 10-160-2
P-85479 NA1023A
See your SERVICE SCHEDULE for the correct interval to Rear tires usually wear faster than front tires. To keep tire
check the wheel nuts [Figure 10-160-1]. (See SERVICE wear even, move the front tires to the rear and rear tires

SCHEDULE on Page 10-70-1.) to the front [Figure 10-160-2].
When installing wheel nuts, tighten to 217 N•m (160 ft-lb) It is important to keep the same size tires on each side of
torque. the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
When checking wheel nut torque, set the torque wrench tread bars of all the tires must face the same direction.
to 190 N•m (140 ft-lb) to prevent over-tightening.
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for correct pressure before operating
the loader.

TIRE MAINTENANCE (CONT’D)
Mounting
Tires are to be repaired only by an authorized person

using the proper procedures and safe equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a

rubber lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

cause serious injury or death.
During inflation of the tire, check the tire pressure

frequently to avoid over inflation.
WARNING

Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same machine.
I-2057-1010

SPARK ARRESTER MUFFLER Figure 10-170-1
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for

cleaning the spark arrester muffler. (See SERVICE
Do not operate the loader with a defective exhaust 1

system.
P-85509
IMPORTANT
Remove the plug (Item 1) [Figure 10-170-1] from the
This machine is factory equipped with a U.S.D.A. bottom of the muffler.
Forestry Service Approved spark arrester exhaust
system that must be maintained for proper function.
• WITH MUFFLER
The muffler spark chamber must be emptied
WARNING
every 100 hours of operation to keep it in working
condition. When the engine is running during service, the
driving and steering controls must be in neutral and

• WITH SELECTIVE CATALYST REDUCTION (SCR) the parking brake engaged. Failure to do so can
AND / OR DIESEL OXIDATION CATALYST (DOC) cause injury or death.
W-2006-1209
Do not remove or modify the DOC or SCR.
The SCR must be maintained according to the Start the engine and run for about 10 seconds while a
instructions in the Operation & Maintenance second person, wearing safety glasses, holds a piece of
Manual for proper function. wood over the outlet of the muffler. This will force
contaminants out through the cleanout hole.
• WITH DIESEL PARTICULATE FILTER (DPF)
The DPF must be maintained according to the Stop the engine. Install and tighten the plug. Close the
instructions in the Operation & Maintenance rear door.
Manual for proper function.
(If this machine is operated on flammable forest,

brush or grass cover land, the engine must be
equipped with a spark arrester and maintained in
WARNING
working order. Failure to do so will be in violation of
California state law section 4442 PRC. Refer to local
When an engine is running in an enclosed area, fresh
laws and regulations for spark arrester
air must be added to avoid concentration of exhaust
requirements.)
I-2350-1114 fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Stop the engine and open the rear door. W-2050-0807
WARNING
WARNING
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact Stop engine and allow the muffler to cool before
flammable material. Failure to obey warnings can cleaning the spark chamber. Wear safety goggles.
cause injury or death. Failure to obey can cause serious injury.
W-2068-1285 W-2011-1285


PIVOT PINS
Figure 10-180-1
P100004
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure

10-180-1].
Check that the locknuts are tightened to 48 - 54 N•m (35 -

40 ft-lb) torque.


LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat loader has been in storage, it is

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
loader for an extended period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
compartment. • Install a fully charged battery.
• Lubricate the loader. • Remove grease from exposed cylinder rods.
• Replace worn or damaged parts. • Check all belt tensions.
• Park the loader in a dry protected shelter. • Be sure all shields and guards are in place.
• Lower the lift arms all the way and put the bucket flat • Lubricate the loader.
on the ground.
• Check tire inflation and remove blocks from under
• Put blocks under the frame to remove weight from the frame.
tires.
• Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods.

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

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

hydrostatic).
• Replace air cleaner, heater and air conditioning filters.
• Put all controls in NEUTRAL position.
• Remove the battery. Be sure the electrolyte level is

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

condition.


STOPPING THE ENGINE AND LEAVING THE LOADER NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Procedure Deluxe Instrumentation Panel allows
operation of the loader without using a
Stop the loader on level ground. password. (See Password Lockout Feature on
Page 60-200-2.) or (See Password Lockout
Fully lower the lift arms and put the attachment flat on the Feature on Page 60-201-1.)
ground.
Figure 10-200-3
Figure 10-200-1
P-85737A P-85735A
Exit the loader using grab handles, safety tread and steps

P-90525B (maintaining a 3-point contact) [Figure 10-200-3].
Push the engine speed control fully down to decrease the

engine speed [Figure 10-200-1].
WARNING
Engage the parking brake.
Figure 10-200-2 Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
1 1
the ground.
• Stop the engine.
2 • Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
P-90688A P-90214C P-90214A
drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) or The seat bar system must deactivate these functions
press the STOP button (Item 2) [Figure 10-200-2]. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-1110
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Standard Key Panel) to

prevent operation of the loader by unauthorized
personnel.


EMERGENCY EXIT
The front opening on the operator cab and rear window provide exits.
Rear Window Identification
Figure 10-210-1 There are two different procedures for removing the rear
window from your machine:
Latches Rubber Cord
1. This window is equipped with latches (Item 1) [Figure
10-210-1].
2
2. This window is equipped with a rubber cord and tag
(Item 2) [Figure 10-210-1].
1
NOTE: Use these procedures to remove the rear
P-85309B P-64994G
window only under emergency conditions.
Damage to machine may occur.
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 10-210-2 Figure 10-210-4

1
P-85309A P-64994F
Turn both latches (Item 1) [Figure 10-210-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 10-210-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 10-210-3 Figure 10-210-5
P-90676 P-90676
Exit through rear of the operator cab [Figure 10-210-3]. Exit through rear of the operator cab [Figure 10-210-5].

EMERGENCY EXIT (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 10-210-6
Figure 10-210-8
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 10-210-8] up and out

[Figure 10-210-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove. Front Door
OR This machine may be equipped with a front door.
Figure 10-210-7 NOTE: Use this procedure to remove the front door
only under emergency conditions. Damage to
machine may occur.
1
Figure 10-210-9
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools.
P-90725
Turn both knobs (Item 1) [Figure 10-210-7]

counterclockwise until the latches disengage from the Turn both latches (Item 1) [Figure 10-210-9] down until
window frame. Pull the top of the window away from the they disengage from the door frame.
cab and lift up to remove.
Push the door out of the operator cab door frame and exit
through the opening.

EMERGENCY EXIT (CONT’D) Figure 10-210-12
Front Door (Cont’d)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-210-10
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-210-12] on the door. (Bottom
hinge shown.)
2
Figure 10-210-13

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

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

hose (Item 1) (if equipped) [Figure 10-210-10].
Figure 10-210-11
P-90686A
2
3
Install cast washers (Item 2) on door hinges taking care
to match rectangular surfaces. Hold cast washer firmly
against door and rotate latch (Item 1) [Figure 10-210-13]
up to lock cast washer into position. (Bottom hinge
shown.) (Plastic cap shown removed for visual clarity.)
1
Install door on loader.
Install the gas spring socket on the ball stud fitting. Install
P-85588A P-85589A
the clip into the hole in the gas spring socket. Rotate the
clip (Item 1) to lock into position [Figure 10-210-11].
Rotate and pull the clip (Item 1) out of the gas spring Connect electrical connector (Item 2) and washer fluid
socket. Pull the gas spring socket (Item 3) straight off the hose (Item 1) (if equipped) [Figure 10-210-10].
ball stud fitting (Item 2) [Figure 10-210-11].
Remove the door hinges from the loader.


SEAT BELT Figure 10-220-1
Inspection And Maintenance 1
WARNING 3
Failure to properly inspect and maintain the seat belt

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

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

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

retractor (if equipped), hardware or any other obvious
problem should be replaced immediately.
B-22283
The items below are referenced in [Figure 10-220-1].
1. Check the webbing. If the system is equipped with a

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

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

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

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have deteriorated.
See your dealer for seat belt system replacement parts

for your machine.


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

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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Parts Identification (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-9

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
MAIN RELIEF VALVE (LATER MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-2
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-4
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-5
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-6

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31

Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) . . . . . . . . . . . . . . . . 20-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-41-9
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-10
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) . . . . . . . . . . . 20-42-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-42-12
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-17


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) . . . . . . . . . . . . . 20-43-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-6
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-43-11
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-19

Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-28
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-3
Disassembly And Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-7

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & ABOVE) . . . . . 20-121-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

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

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

Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
(PRINTED NOVEMBER 2010)
V-1348legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE
(SCREEN) 33 CHARGE PUMP -
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal)
51,1 L/min (13.5 U.S. gpm) at High Engine Idle
System Capacity . . . . . . 41,6 L (11.0 U.S. gal) 17 CHECK VALVE With 100 kPa 1,0 bar
(14.5 psi) Spring 34 HYDRAULIC PUMP . . . . . . . Gear Type
2 SIGHT GUAGE
18 RESTRICTION . . . . . . 2,0 mm (0.079 in) 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
3 DIFFERENTIAL PRESSURE SWITCH:
19 35 VARIABLE CAPACITY DISPLACEMENT
103 kPa (1,03 bar) (15 psi) PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC PUMP
Normally Closed
ARM BY-PASS
4 FILTER - HYDRAULIC (CANISTER) 36 RELIEF/REPLENISHING VALVE - HIGH
20 LIFT CYLINDER SPOOL - MADE TO PRESSURE: 36500 kPa (365 bar) (5294 psi)
5 SPRING LOADED FILTER BY-PASS RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 37 RELIEF VALVE - CHARGE INLET:
VALVE: 172 kPa (1,7 bar) (25 psi)
21 ANTICAVITATION VALVE 3206 kPa (32,0 bar) (465 PSI) at High
6 DIAGNOSTIC COUPLER Engine Idle With 60 ° C (140 ° F) Fluid
22 PROPORTIONAL RELIEF VALVE – Dealer Copy -- Not for Resale
7 RELIEF VALVE - MAIN: (Fan Speed Regulator): 10797-12300 kPa
24132 kPa (241 bar) (3500 psi) (108 - 123 bar) (1566 - 1784 psi) 38 CHECK VALVE – COLD WEATHER BY-PASS
at Front Quick Couplers 23 SPRING LOADED FILTER BY-PASS VALVE: With 345 kPa (3,45 bar) (50 psi) Spring
8 RELIEF/ANTICAVITATION VALVE - 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
PORT: 27579 kPa (276 bar) (4000 psi) 24 FIXED CAPACITY DISPLACEMENT
9 RELIEF/ANTICAVITATION VALVE - HYDRAULIC MOTOR
PORT (OPTIONAL): 25 FILTER - HYDRAULIC (CANISTER)
27579 kPa (276 bar) (4000 psi)
26 SENSOR – CHARGE PRESSURE –
10 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter
CONTROL VALVE - AUXILIARY
27 ANTICAVITATION VALVE
11 LOAD CHECK VALVE
28 SENSOR – HYD. TEMPERATURE
12 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE 29 RESTRICTION - 1,5 mm (0.06 in)
13 PILOTED ACTIVATED DIRECTIONAL 30 CHECK VALVE - With 1379 kPa (13,8 bar)
CONTROL VALVE - TILT CONTROL
(200 psi) Spring
14 PILOTED ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - LIFT CONTROL
15 SOLENOID ACTIVATED DIRECTIONAL 32 FIXED CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC
CONTROL VALVE - BICS CONTROL
MOTOR
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1348legend (12-2-10)
111 of 1311
INTEGRATED COUPLER BLOCK
12
Male
DRIVE MOTOR
OUT
Male
L HYDRAULIC CONTROL VALVE
31 29
30 12
Female
9
10
10
Auxiliary Spool
32
TILT
CYLINDERS
A B
8
11
BICS CONTROL VALVE

HYDROSTATIC PUMP
Tilt Spool
35
38 8 13
27
11
M4 M
3
14
D C
Lift Spool
36 36
Charge
Inlet
Dealer
8
Copy -- Not for Resale
LIFT
CYLINDERS
37 36 20 18
11 16 16
B A 17 15 ?
IN 2
M M1 7
2 6
36
1
T 19
35
VARIABLE SPEED HYDRAULIC
Oil Cooler 3 RESERVOIR (VENTED)
FAN MOTOR W/ INTEGRATED FILTER 2
34 5
1
33 25 23
4
26
PUMP
SUPPLY
WORKING
B A CIRCUIT
HYDRAULIC FILTER
PILOT
PRESSURE
24 21 DRAIN /
32 RETURN
P DR 22
28
30 WITH NO OPTIONS
29 31
S650 (S/N A3NV11001 & ABOVE)
L
(S/N A3NW11001 & ABOVE)
DRIVE MOTOR
DRAIN / RETURN MANIFOLD
112 of 1311 7170812

PRINTED IN U.S.A.
WITH ALL OPTIONS
S650 (S/N A3NV11001 – A3NV12444)
(S/N A3NW11001 – A3NW11129)
V-1349legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED RELIEF VALVE: 8274 kPa (83 bar) (1200 psi) 57 HIGH PRESSURE SHUTTLE
36
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 37 CHECK VALVE - With 552 kPa (5,5 bar) 58 FIXED CAPACITY DISPLACEMENT
(80 psi) Spring BIDIRECTIONAL HYDROSTATIC
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
38 RELIEF VALVE: 13790 kPa (137 bar) (2000 psi) MOTOR – 2 SPEED
RESTRICT FLOW DURING BOOM
3 DIFFERENTIAL PRESSURE SWITCH: 59 FIXED CAPACITY DISPLACEMENT
DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) 21 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC
psi) Spring And With 0,33 mm (0.013 in) Orifice
Normally Closed MOTOR
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,6 mm (0.025 in) 60 HYDRAULIC BRAKE – SPRING APPLIED –
(Fan Speed Regulator): 10797-12300 kPa 41 SENSOR – HYD. TEMPERATURE PRESSURE RELEASE (SAPR)
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 61 SOLENOID ACTIVATED DIRECECTIONAL
23 SPRING LOADED FILTER BY-PASS VALVE: 42 HYDRAULIC PUMP . . . . . . . Gear Type 87,1
L/min (23.0 U.S. gpm) at High Engine Idle CONTROL VALVE – 2 SPEED
6 DIAGNOSTIC COUPLER 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
43 CHARGE PUMP - 62 CHECK VALVE
24 FIXED CAPACITY DISPLACEMENT 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
7 RELIEF VALVE - MAIN: Dealer Copy -- Not for Resale
HYDRAULIC MOTOR 63 SOLENOID ACTIVATED DIRECECTIONAL
24132 kPa (241 bar) (3500 psi) 44 PILOT ACTIVATED DIRECTIONAL
25 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – MAKE-UP
at Front Quick Couplers CONTROL VALVE - REAR AUXILIARY
8 RELIEF/ANTICAVITATION VALVE - 45 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) 64 FILTER - BRAKE
PORT: 27579 kPa (276 bar) (4000 psi) Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 65 SOLENOID ACTIVATED DIRECECTIONAL
9 RELIEF/ANTICAVITATION VALVE - 27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL CONTROL VALVE – BRAKE
PORT (OPTIONAL): CONTROL VALVE - BUCKET POSITION
27579 kPa (276 bar) (4000 psi) 47 RESTRICTOR - 0,8 mm (0.031 in) 66
VALVE (ON/OFF) HIGH FLOW HYDRAULIC PUMP Gear Type
10 SOLENOID ACTIVATED DIRECTIONAL FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
28
CONTROL VALVE - AUXILIARY 67 RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
11 LOAD CHECK VALVE CONTROL VALVE - BASE 68
CONTROL VALVE - FLOW CONTROL DUMP VALVE – ON / OFF
12 FRONT AUXILIARY MANUAL PRESSURE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi)
69
BLEED-OFF VALVE 30 CHECK VALVE - BUCKET POSITION CONTROL VALVE - ROD Spring
13 PILOTED ACTIVATED DIRECTIONAL VALVE 51 VARIABLE CAPACITY DISPLACEMENT 70 ANTICAVITATION VALVE
CONTROL VALVE - TILT CONTROL 31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
14 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH 71 RIDE CONTROL VALVE
CONTROL VALVE - LIFT CONTROL SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi)
72 HIGH PRESSURE CHAMBER
15 SOLENOID ACTIVATED DIRECTIONAL 32 PILOT ACTIVATED DIRECTIONAL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL CONTROL VALVE - HYDRAULIC 3206 kPa (32,0 bar) (465 PSI) at High 73 LOW PRESSURE CHAMBER
16 FILTER - BICS CONTROL VALVE POWERED BOB-TACH Engine Idle With 60 ° C (140 ° F) Fluid
74 FILTER – BOB-TACH VALVE
(SCREEN) 33 FILTER - BOB-TACH VALVE
17 CHECK VALVE - With 100 kPa 1,0 bar 54 RESTRICTION - 1,5 mm (0.06 in) 75 CHECK VALVE – COLD WEATHER BY-PASS
(14.5 psi) Spring 34 RESTRICTION - 2,26 mm (0.089 in) With 345 kPa (3,45 bar) (50 psi) Spring
55 CHECK VALVE - With 1379 kPa (13,8 bar)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 35 SOLENOID ACTIVATED DIRECTIONAL (200 psi) Spring NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) springs have NO significant
56 DRIVE MOTOR SHUTTLE VALVE
pressure value.
113 of 1311
12
Male
TWO SPEED DRIVE MOTOR (OPTIONAL)
56 54 Male
12
55
Female
HIGH FLOW VALVE (OPTIONAL)
BUCKET POSITIONING VALVE (OPTIONAL)
68 OUT D
HYDRAULIC CONTROL VALVE 29 30
69
X 31
67 28
?
57
W
REAR AUXILIARY COUPLERS (OPTIONAL)
9
C
A
58 59 10
FEMALE MALE 27
60 10 ?
Auxiliary Spool
Z
Base
? Rod ?
6
A B
48
B TILT
50 CYLINDERS
8
49 11
HYDROSTATIC PUMP
46
? ? BICS CONTROL VALVE
51 Tilt Spool
75
47
8 13
70
M4
45 11
M
3
LIFT
D C CYLINDERS
44 14
P - in P - out T
REAR AUXILIARY
52
52
VALVE (OPTIONAL)
Dealer Copy --Lift Spool
Not for Resale
Charge
Inlet BOB-TACH CYLINDER 8
(OPTIONAL) RIDE CONTROL
53 18 (OPTIONAL)
20
BOBTACH VALVE 11 16 16
B A 74 17 15
(OPTIONAL) ?
37 IN
M M1 74 38 7
2
2 36 6
71
DUAL STAGE
ACCUMULATOR
52 52 1
39
19
51 35
? ?
73 72
34 40 PP
DR Oil Cooler RESERVOIR (VENTED)
T 3 2
5
P1 P2 1
42 33 32 4
43 VARIABLE SPEED HYDRAULIC

FAN MOTOR W/ INTEGRATED FILTER
2-SPEED & SAPR BRAKE HYDRAULIC FILTER
64 VALVE (OPTIONAL)
B1 66
65 25 23
B PUMP
64 60 26 SUPPLY
WORKING
B A CIRCUIT
63 PILOT
Z PRESSURE
62 C DRAIN /
P 24 21 RETURN
D 58 59
W
P DR 22
62 61
?
57
A X
A1 HYDRAULIC/HYDROSTATIC SCHEMATIC
T WITH ALL OPTIONS
41
S650 (S/N A3NV11001 - A3NV12444)
55 (S/N A3NW11001 - A3NW11129)
54 56
L DRAIN / RETURN MANIFOLD (PRINTED NOVEMBER 2010)

7170812
114 of 1311 Printable Version Click Here
PRINTED IN U.S.A.
(PRINTED MAY 2014)

V-1419legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED 36 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi) 57 DRIVE MOTOR SHUTTLE VALVE
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 37 CHECK VALVE - With 552 kPa) (5,5 bar) 58 FIXED CAPACITY DISPLACEMENT
(80 psi) Spring BIDIRECTIONAL HYDROSTATIC MOTOR
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO 38 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi) 59 HYDRAULIC BRAKE – SPRING APPLIED –
RESTRICT FLOW DURING BOOM
3 DIFFERENTIAL PRESSURE SWITCH: PRESSURE RELEASE (SAPR)
DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) 21 ANTICAVITATION VALVE 60 PILOT ACTIVATED DIRECTIONAL
psi) Spring And With 0,40 mm (0.016 in) Orifice
Normally Closed CONTROL VALVE – 2 Speed
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0,51 mm (0.020 in)
61 FIXED CAPACITY DISPLACEMENT
(Fan Speed Regulator): 10797 – 12300 kPa 41 SHUTTLE VALVE BIDIRECTIONAL HYDROSTATIC MOTOR
VALVE: 172 kPa (1,7 bar) (25 psi) 42 RESTRICTION - 0,51 mm (0.020 in) 62 CHARGE PUMP -
23 SPRING LOADED FILTER BY-PASS VALVE:
6 DIAGNOSTIC COUPLER 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
43 HYDRAULIC PUMP . . . . . . . Gear Type
7 RELIEF VALVE - MAIN: 24 FIXED CAPACITY DISPLACEMENT 63 HIGH FLOW HYDRAULIC PUMP Gear Type
87,1 L/min (23.0 U.S. gpm) at High Engine Idle
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR Dealer Copy -- Not for Resale 28,4 L/min (7.5 U.S. gal) at High Engine Idle
44 PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 25 FILTER - HYDRAULIC (CANISTER) 64 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
CONTROL VALVE - REAR AUXILIARY
8 RELIEF/ANTICAVITATION VALVE - 45 65 DUMP VALVE – ON / OFF
26 SENSOR – CHARGE PRESSURE – RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
PORT: 27579 kPa (276 bar) (4000 psi)
Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - With 34,5 kPa (0,34 bar)
9 RELIEF/ANTICAVITATION VALVE - 27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL (5.0 psi) Spring
PORT (OPTIONAL): 27579 kPa CONTROL VALVE - BUCKET POSITION 47 RESTRICTOR - 0,8 mm (0.031 in) 67 FRONT AUXILIARY MANUAL PRESSURE
(276 bar) (4000 psi) VALVE (ON/OFF) BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL 28 FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF 68 SENSOR – HYD. TEMPERATURE
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL 69
11 LOAD CHECK VALVE RIDE CONTROL VALVE
CONTROL VALVE - FLOW CONTROL CONTROL VALVE - Female
12 ANTICAVITATION VALVE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL 70 HIGH PRESSURE CHAMBER
30 CHECK VALVE - BUCKET POSITION CONTROL VALVE - Male
13 PILOTED ACTIVATED DIRECTIONAL 71 LOW PRESSURE CHAMBER
VALVE 51 VARIABLE CAPACITY DISPLACEMENT
31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE – BRAKE
CONTROL VALVE - LIFT CONTROL
SPOOL PRESSURE: 36500 kPa (365 bar) (5294 psi) 73 FILTER – BRAKE VALVE
32 PILOT ACTIVATED DIRECTIONAL CONTROL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL 74 CHECK VALVE
VALVE – HYDRAULIC POWERED BOB-TACH 3206 kPa (32, bar) (465 psi)
16 FILTER - BICS CONTROL VALVE at High Engine Idle
With Build-up Valve 207 kPa (2,07 bar) (30 psi) 75 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) With 60 ° C (140 ° F) Fluid
33 FILTER - BOB-TACH VALVE CONTROL VALVE – 2 Speed Shift
17 CHECK VALVE - With 100 kPa (1,0 bar) 54 CHECK VALVE – COLD WEATHER BY-PASS
(14.5 psi) Spring 76 SOLENOID ACTIVATED DIRECTIONAL
34 RESTRICTION - 2,08 mm (0.08 in) With 345 kPa (3,45 bar) (50 psi) Spring
CONTROL VALVE – 2 Speed Make-up
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 55 RESTRICTION - 1,5 mm (0.06 in)
35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) 56 CHECK VALVE - With 1379 kPa 13,8 bar springs have NO significant
(200 psi) Spring pressure value.
115 of 1311
TWO SPEED DRIVE MOTOR (OPTIONAL) Male
56 L
67
57
Male
55
66
Female
RIDE CONTROL
OUT (OPTIONAL)
X
HYDRAULIC CONTROL VALVE (SPOOL VALVE)
71
70 LIFT CYLINDERS
60
W
REAR QUICK COUPLERS

61 58 69
FEMALE MALE
59 10
10
Z Auxiliary Spool
9
A B 48
50
49 8
6 11
46
HYDROSTATIC PUMP BOBCAT INTERLOCK CONTROL SYSTEM
(BICS) BUCKET POSITIONING
VALVE (OPTIONAL)
E1 E2 A1 A2
47 E3
51 Tilt Spool
8 B 28
45 13 29
12
M4
M3
11
27
30
44
2-SPEED & SAPR D C 14 D2
BRAKE VALVE P in P out T
(OPTIONAL) 76 REAR AUXILIARY VALVE
B A D (OPTIONAL)
30
72 52
T
53 52
Dealer Copy -- Not for ResaleLift Spool
8 31 C2
POWER BOBTACH CYLINDER (OPTIONAL)
POWER BOBTACH C1 D1
P
VALVE (OPTIONAL)
B R
20 16
11 16
B1 A1 C 17
B A 37 41 15
73 74
75 36 39 IN 18
2
M2 M1 7
74 6
38
TILT CYLINDERS
1
52 52 Oil Cooler
54 35 42 19
51
D 34 40 FILTER
HYDRAULIC RESERVOIR
T
(VENTED)
43 2 1
33 4
32
62 5
VARIABLE SPEED HYDRAULIC 3

64
65
25 23
63 26 WORKING CIRCUIT
CHARGE
PRESSURE
59 DRAIN / RETURN
B A
Z 24 21
58 P DR 22
61
W
DRAIN/RETURN MANIFOLD
60
X
68
WITH ALL OPTIONS
S650 (S/N A3NV12445 - A3NV18826)
(S/N A3NW11130 - A3NW12750)
55 57
56
L (PRINTED MAY 2014)
TWO SPEEDDRIVE MOTOR (OPTIONAL)
116 of 1311 7170812 (C)

PRINTED IN U.S.A.
(S/N A3NV18227 - A3NV25735)

(S/N A3NW12751 - A3NW13963)
(S/N 1MLS11001 AND ABOVE)
(PRINTED JULY 2017)
V-1470legend
LEGEND
1 RESERVOIR: CHARGE PUMP -
19 PULL BUTTON ACTIVATED 39 57 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle CONTROL VALVE - BUCKET POSITION
DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 40 HYDRAULIC PUMP . . . . . . . Gear Type VALVE (ON/OFF)
87,1 L/min (23.0 U.S. gpm) at High Engine Idle 58 FLOW DIVIDER ADJUSTMENT VALVE
41 VARIABLE CAPACITY DISPLACEMENT
DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM 59 PILOTED ACTIVATED DIRECTIONAL CONTROL
3 BIDIRECTIONAL HYDROSTATIC PUMP
103 kPa (1,03 bar) (15 psi) DOWN BUT NOT DURING BOOM UP VALVE - FLOW CONTROL SPOOL
42 RELIEF/REPLENISHING VALVE - HIGH 60 CHECK VALVE - BUCKET POSITION VALVE
Normally Closed 21 RELIEF VALVE - 24132 kPa (241 bar) PRESSURE: 36500 kPa (365 bar) (5294 psi)
4 FILTER - HYDRAULIC (CANISTER) (3500 psi) (If Equipped)
43 RELIEF VALVE - CHARGE INLET: 61 PILOTED ACTIVATED DIRECTIONAL
SPRING LOADED FILTER BY-PASS 22 ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar) CONTROL VALVE – UNLOADING SPOOL
5
VALVE: 172 kPa (1,7 bar) (25 psi) PROPORTIONAL RELIEF VALVE – (440 +/- 50 psi) at High Engine Idle 62 HIGH FLOW HYDRAULIC PUMP Gear Type
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid 28,4 L/min (7.5 U.S. gal) at High Engine Idle
7 RELIEF VALVE - MAIN:

(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER 63 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
SPRING LOADED FILTER BY-PASS VALVE: BY-PASS With 345 kPa (3,45 bar)
24132 kPa (241 bar) (3500 psi) 24 (50 psi) Spring 64 DUMP VALVE – ON / OFF
at Front Quick Couplers Dealer Copy -- Not for Resale
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
FIXED CAPACITY DISPLACEMENT 45 FRONT AUXILIARY MANUAL PRESSURE
NOTE - If Equipped With Ref. 21: 25 65 CHECK VALVE - With 34,5 kPa (0,34 bar)
HYDRAULIC MOTOR BLEED-OFF VALVE
25855 kPa (258 bar) (3750 psi) (5.0 psi) Spring
26 46 PILOT ACTIVATED DIRECTIONAL
8 RELIEF/ANTICAVITATION VALVE - FILTER - HYDRAULIC (CANISTER) 66 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HYDRAULIC
PORT: 27579 kPa (276 bar) (4000 psi) 27 SENSOR – CHARGE PRESSURE – CONTROL VALVE - REAR AUXILIARY
POWERED BOB-TACH With Build-up
9 RELIEF/ANTICAVITATION VALVE - Fan Filter Valve: 276 kPa (2,76 bar) (40 psi) 67 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE 47 FILTER - BOB-TACH VALVE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in) 48 RESTRICTION - 1,17 mm (0.46 in) CONTROL VALVE - TWO COIL
10 SOLENOID ACTIVATED DIRECTIONAL 69 RESTRICTOR - 0,8 mm (0.031 in)
30 CHECK VALVE - With 1379 kPa 13,8 bar 49 SOLENOID ACTIVATED DIRECTIONAL
(200 psi) Spring CONTROL VALVE (TWO COIL)
11 LOAD CHECK VALVE 70 LOAD SHUTTLE VALVE - BLEED OFF
31 DRIVE MOTOR SHUTTLE VALVE 50 SOLENOID ACTIVATED DIRECTIONAL
12 ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – Ride Control Option 71 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – 2 Speed Shift 51 ACCUMULATOR – Ride Control Option CONTROL VALVE - BASE
13 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT
33 72 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 52 ORIFICE WITH CHECK VALVE: CONTROL VALVE - ROD
14 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT 2,54 mm (0.10 in)
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 53 RELIEF VALVE - 24132 kPa CONTROL VALVE – Fan Reversing Option
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED – (241 bar) (3500 psi)
CONTROL VALVE - BICS CONTROL PRESSURE RELEASE (SAPR)
16 FILTER - BICS CONTROL VALVE 36 SOLENOID ACTIVATED DIRECECTIONAL 54 RESTRICTION - 0,254 mm (0.010 in)
(SCREEN) CONTROL VALVE – BRAKE
55 CHECK VALVE
17 CHECK VALVE - With 100 kPa (1,0 bar) 37 FILTER – BRAKE VALVE
(14.5 psi) Spring SOLENOID ACTIVATED DIRECTIONAL 56 ORIFICE: 1,60 mm (0.063 in)
38
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift
NOTE: Unless otherwise specified springs have
NO significant pressure value.
117 of 1311
DRIVE MOTOR Male
L
45
30 29
31 Male
OUT
HYDRAULIC CONTROL VALVE 65
45
Female
9
RIDE CONTROL
75 (FIELD INSTALLED OPTION) 74
32
33 9
34 NOTE: CUSHIONED
REAR QUICK LIFT CYLINDERS ON
FEMALE COUPLERS MALE 10 LATER MODELS ONLY
35 10 LIFT CYLINDERS
Z
Auxiliary Spool
A B 70
73
72
21
71
68 6
8 11 (BICS)
R
41 TILT BASE
T
E1 E2 A1 A2
TILT ROD E3
69
X Tilt Spool
8 B 58
42 13
2-SPEED & X
SAPR BRAKE 67
VALVE 11
(OPTIONAL) LIFT ROD 57 60
66 14 D2
38
B A M REAR AUXILIARY P in P out T 12
36 M 59
D C VALVE (OPTION)
T LIFT BASE
M
Lift Spool
43 42
POWER BOBTACH CYLINDER
(OPTIONAL) 8 Dealer Copy -- Not for Resale 61 C2
C1 D1
P B A POWER BOBTACH
VALVE (OPTIONAL)
M 20 16
B1
M 55 53 11 15 BUCKET POSITIONING
37 VALVE (OPTIONAL)
IN
2 18
7 16
42 6
42 49
54 17
TILT CYLINDERS
1
D Oil Cooler
19
41 44 48
47 RESERVOIR
T 2 (VENTED)
5 1
R
40 46
39
VARIABLE SPEED HYDRAULIC 3 4

HYDRAULIC FILTER
62
63 64
26 24
WORKING CIRCUIT
27
CHARGE
PRESSURE
22
35 DRAIN / RETURN
B A
25
Z P DR
23
34
33 Printable Version Click Here
32
X
MANUAL WITH ALL OPTION
28
S650 (S/N A3NV18827 - A3NV25735)
(S/N A3NW12751 - A3NW13963)
30 29
31
L DRAIN / RETURN MANIFOLD
(PRINTED MAY 2018)
DRIVE MOTOR
7170813 (G)
118 of 1311
PRINTED IN U.S.A.
(PRINTED JULY 2017)

V-1642legend
LEGEND
1 RESERVOIR: CHARGE PUMP -
19 PULL BUTTON ACTIVATED 39 57 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle CONTROL VALVE - BUCKET POSITION
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 40 HYDRAULIC PUMP . . . . . . . Gear Type VALVE (ON/OFF)
87,1 L/min (23.0 U.S. gpm) at High Engine Idle 58 FLOW DIVIDER ADJUSTMENT VALVE
41 VARIABLE CAPACITY DISPLACEMENT
DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM 59 PILOTED ACTIVATED DIRECTIONAL CONTROL
103 kPa (1,03 bar) (15 psi) DOWN BUT NOT DURING BOOM UP VALVE - FLOW CONTROL SPOOL
42 RELIEF/REPLENISHING VALVE - HIGH 60 CHECK VALVE - BUCKET POSITION VALVE
4 FILTER - HYDRAULIC (CANISTER) (3500 psi) (If Equipped)
43 RELIEF VALVE - CHARGE INLET: 61 PILOTED ACTIVATED DIRECTIONAL
SPRING LOADED FILTER BY-PASS 22 ANTICAVITATION VALVE 3034 +/- 344 kPa (30,3 +/- 3 bar) CONTROL VALVE – UNLOADING SPOOL
5
VALVE: 172 kPa (1,7 bar) (25 psi) PROPORTIONAL RELIEF VALVE – (440 +/- 50 psi) at High Engine Idle 62 HIGH FLOW HYDRAULIC PUMP Gear Type
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid 28,4 L/min (7.5 U.S. gal) at High Engine Idle
7 RELIEF VALVE - MAIN:

(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER 63 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
SPRING LOADED FILTER BY-PASS VALVE: BY-PASS With 345 kPa (3,45 bar)
24132 kPa (241 bar) (3500 psi) 24 (50 psi) Spring 64 DUMP VALVE – ON / OFF
at Front Quick Couplers Dealer Copy -- Not for Resale
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
FIXED CAPACITY DISPLACEMENT 45 FRONT AUXILIARY MANUAL PRESSURE
NOTE - If Equipped With Ref. 21: 25 65 CHECK VALVE - With 34,5 kPa (0,34 bar)
HYDRAULIC MOTOR BLEED-OFF VALVE
25855 kPa (258 bar) (3750 psi) (5.0 psi) Spring
8 RELIEF/ANTICAVITATION VALVE - FILTER - HYDRAULIC (CANISTER) 66 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HYDRAULIC
PORT: 27579 kPa (276 bar) (4000 psi) 27 SENSOR – CHARGE PRESSURE – CONTROL VALVE - REAR AUXILIARY
POWERED BOB-TACH With Build-up
9 RELIEF/ANTICAVITATION VALVE - Fan Filter Valve: 276 kPa (2,76 bar) (40 psi) 67 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE 47 FILTER - BOB-TACH VALVE
(276 bar) (4000 psi) 29 RESTRICTION - 1,5 mm (0.06 in) 48 RESTRICTION - 1,17 mm (0.46 in) CONTROL VALVE - TWO COIL
10 SOLENOID ACTIVATED DIRECTIONAL 69 RESTRICTOR - 0,8 mm (0.031 in)
30 CHECK VALVE - With 1379 kPa 13,8 bar 49 SOLENOID ACTIVATED DIRECTIONAL
(200 psi) Spring CONTROL VALVE (TWO COIL)
11 LOAD CHECK VALVE 70 LOAD SHUTTLE VALVE - BLEED OFF
31 DRIVE MOTOR SHUTTLE VALVE 50 SOLENOID ACTIVATED DIRECTIONAL
12 ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE – Ride Control Option 71 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – 2 Speed Shift 51 ACCUMULATOR – Ride Control Option CONTROL VALVE - BASE
13 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 52 ORIFICE WITH CHECK VALVE: CONTROL VALVE - ROD
14 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT 2,54 mm (0.10 in)
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR 53 RELIEF VALVE - 24132 kPa CONTROL VALVE – Fan Reversing Option
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED – (241 bar) (3500 psi)
16 FILTER - BICS CONTROL VALVE 36 SOLENOID ACTIVATED DIRECECTIONAL 54 RESTRICTION - 0,254 mm (0.010 in)
55 CHECK VALVE
17 CHECK VALVE - With 100 kPa (1,0 bar) 37 FILTER – BRAKE VALVE
(14.5 psi) Spring SOLENOID ACTIVATED DIRECTIONAL 56 ORIFICE: 1,60 mm (0.063 in)
38
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift
NOTE: Unless otherwise specified springs have
NO significant pressure value.
119 of 1311
DRIVE MOTOR Male
L
45
30 29
31 OUT
Male

45
Female
X
51
RIDE CONTROL
9 (OPTION)
T2 ACC
T 52
32
56
33 9
34 REAR QUICK P NOTE: CUSHIONED
COUPLERS MALE 10 LIFT CYLINDERS ON
FEMALE
50 LATER MODELS ONLY
Z
Auxiliary Spool CR2 CR CB CB2
A B 70
72
21
71
68 6
8 11 (BICS)
41 R TI LT BASE
T
E1 E2 A1 A2
TI LT ROD E3
69
X Tilt Spool
8
B 58
42 13
2-SPEED & X
SAPR BRAKE 67
VALVE 11
(OPTIONAL) LI FT ROD 57 60
66 14 D2
38
B A M REAR AUXILIARY P in P out T 12
36 M 59
D C VALVE (OPTION)
T LI FT BASE
M
Lift Spool
43 42
POWER BOBTACH CYLINDER 61
C2
(OPTIONAL) 8
C1 D1
P B A POWER BOBTACH
VALVE (OPTIONAL)
M 20 16
B1
M 55 53 11 15 BUCKET POSITIONING
37 VALVE (OPTIONAL)
IN
2 18
7 16
42 6
42 49
54 17
TILT CYLINDERS
1
D Oil Cooler
19
41 44 48
47 RESERVOIR
T 2 (VENTED)
5 1
R
40 46
39
VARIABLE SPEED HYDRAULIC 3 4

HYDRAULIC FILTER
62
63 64 26 24
27
WORKING CIRCUIT
CHARGE
PRESSURE
1 4 22
35 DRAIN / RETURN
B A
3 2
25
73
Z
34 DR 23 P
33
32
X
28
MANUAL WITH ALL OPTION
30 29
31
(PRINTED MAY 2018)
DRIVE MOTOR
7170812 (K)
120 IN
PRINTED of 1311
U.S.A.
SJC WITH NO OPTIONS
V-1350legend
LEGEND
1 RESERVOIR: 14 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – CHARGE PRESSURE –
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) RESTRICT FLOW DURING BOOM Fan Filter
System Capacity . . . . . . 41,6 L (11.0 U.S. gal) DOWN BUT NOT DURING BOOM UP
29 HYDRAULIC PUMP . . . . . . . Gear Type 87,1 L/min
2 SIGHT GUAGE 15 PILOTED ACTIVATED DIRECTIONAL (23.0 U.S. gpm) at High Engine Idle
30 CHARGE PUMP -
3 DIFFERENTIAL PRESSURE SWITCH: 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
103 kPa (1,03 bar) (15 psi)
CONTROL VALVE - LIFT CONTROL 31 VARIABLE CAPACITY DISPLACEMENT
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 32 RELIEF/REPLENISHING VALVE - HIGH
5 SPRING LOADED FILTER BY-PASS 18 FILTER - BICS CONTROL VALVE PRESSURE: 36500 kPa (365 bar) (5294 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) (SCREEN) 33 RELIEF VALVE - CHARGE INLET:
19 CHECK VALVE - With 100 kPa 1,0 bar 2654
Dealer Copy -- Not for kPa (26,5 bar) (385 psi) at High
Resale
6 DIAGNOSTIC COUPLER
(14.5 psi) Spring Engine Idle With 60 ° C (140 ° F) Fluid
7 RELIEF VALVE - MAIN: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 34 SERVO PISTON – Swash Plate
24132 kPa (241 bar) (3500 psi)
at Front Quick Couplers 21 PULL BUTTON ACTIVATED 35 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE – FORWARD/REVERSE
8 RELIEF/ANTICAVITATION VALVE -
ARM BY-PASS 36 FILTER
PORT: 27579 kPa (276 bar) (4000 psi)
22 SENSOR – HYD. TEMPERATURE
9 RELIEF/ANTICAVITATION VALVE - 37 CHECK VALVE – COLD WEATHER BY-PASS
PORT (OPTIONAL): 27579 kPa 23 ANTICAVITATION VALVE With 345 kPa (3,45 bar) (50 psi) Spring
(276 bar) (4000 psi)
38 RESTRICTION – 1,5 mm (0.06 in)
10 SOLENOID ACTIVATED DIRECTIONAL 24 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797-12300 kPa
CONTROL VALVE - AUXILIARY 39 CHECK VALVE - With 1379 kPa (13,8 bar)
(108 - 123 bar) (1566 - 1784 psi)
(200 psi) Spring
11 LOAD CHECK VALVE
25 SPRING LOADED FILTER BY-PASS VALVE: 40 DRIVE MOTOR SHUTTLE VALVE
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
BLEED-OFF VALVE 26 FIXED CAPACITY DISPLACEMENT 41 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR BIDIRECTIONAL HYDROSTATIC
13 ANTICAVITATION VALVE MOTOR
27 FILTER - HYDRAULIC (CANISTER)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.

121 of 1311
Male
TWO SPEED DRIVE MOTOR (OPTIONAL) 12
39 L OUT Male
40 38 HYDRAULIC CONTROL VALVE (SPOOL

VALVE)
12
Female
10
41 10
A
6
B
8 TILT CYLINDERS
31 37 11
R BICS CONTROL VALVE

TANDEM
T
HYDROSTATIC
DRIVE PUMP
36 35
X
34 15
8
X
11
16 LIFT CYLINDERS
13
M 36
M
A B
M
32 32
Charge
Dealer Copy
8 -- Not for Resale
33 G Inlet
20
A B
M 14 19
M 36 11 18 18 17 ?
IN 2
32 7 6
?
32
X
VARIABLE SPEED HYDRAULIC
34 FAN MOTOR W/ INTEGRATED FILTER
1
X ?
36
35 27
25 RESERVOIR (VENTED) 21
T OIL COOLER 3 2
31 28
R
5 1
29
4
23
30 26 PUMP
SUPPLY
P WORKING
DR 24 HYDRAULIC FILTER CIRCUIT
PILOT
PRESSURE
B A DRAIN /
RETURN
41
SJC WITH NO OPTION
22
40 S650 (S/N A3NV11001 AND ABOVE)
38
39 (S/N A3NW11001 AND ABOVE)
L DRAIN/RETURN
MANIFOLD
DRIVE MOTOR (PRINTED NOVEMBER 2010)
122 of 1311
7170813
PRINTED IN U.S.A.
SJC WITH ALL OPTIONS
S650 (S/N A3NV11001 – A3NV12444)
(S/N A3NW11001 – A3NW11129)
V-1351legend
LEGEND
60 CHECK VALVE – COLD WEATHER BY-PASS
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 39 CHECK VALVE - With 552 kPa (5,5 bar)
With 345 kPa (3,45 bar) (50 psi) Spring
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) (80 psi) Spring
System Capacity . . . . . . 41,6 L (11.0 U.S. gal) 21 PULL BUTTON ACTIVATED 40 FILTER – BOB-TACH VALVE
DIRECTIONAL CONTROL VALVE - LIFT 61 RESTRICTION - 1,5 mm (0.06 in)
2 SIGHT GUAGE 41 RELIEF VALVE : 13790 kPa (137 bar) (2000 psi)
ARM BY-PASS 62 CHECK VALVE - With 1379 kPa (13,8 bar)
3 DIFFERENTIAL PRESSURE SWITCH: 22 RIDE CONTROL VALVE 42 CHECK VALVE - - With 2068 kPa (20,7 bar) (300 (200 psi) Spring
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,33 mm (0.013 in) Orifice 63 DRIVE MOTOR SHUTTLE VALVE
23 ANTICAVITATION VALVE
Normally Closed
43 RESTRICTION - 0,6 mm (0.025 in) 64 HIGH PRESSURE SHUTTLE
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 10797-12300 kPa 44 SENSOR – HYD. TEMPERATURE 65 FIXED CAPACITY DISPLACEMENT
5 SPRING LOADED FILTER BY-PASS (108 - 123 bar) (1566 - 1784 psi) BIDIRECTIONAL HYDROSTATIC
VALVE: 172 kPa (1,7 bar) (25 psi) 45 HYDRAULIC PUMP . . . . . . . Gear Type
MOTOR – 2 SPEED
6 DIAGNOSTIC COUPLER 25 SPRING LOADED FILTER BY-PASS VALVE: 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
66 FIXED CAPACITY DISPLACEMENT
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
7 46 CHARGE PUMP - BIDIRECTIONAL HYDROSTATIC
RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT 51,1 L/min (13.5 U.S. gpm) at High Engine Idle MOTOR
24132 kPa (241 bar) (3500 psi)
HYDRAULIC MOTOR Dealer Copy --47NotPILOT
for Resale
at Front Quick Couplers ACTIVATED DIRECTIONAL 67 HYDRAULIC BRAKE – SPRING APPLIED –
27 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - REAR AUXILIARY PRESSURE RELEASE (SAPR)
PORT: 27579 kPa (276 bar) (4000 psi) 28 SENSOR – CHARGE PRESSURE – 48 RELIEF VALVE: 22753 kPa (228 bar) (3300 68 SOLENOID ACTIVATED DIRECECTIONAL
9 RELIEF/ANTICAVITATION VALVE - Fan Filter psi) CONTROL VALVE – 2 SPEED
SOLENOID ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
PORT (OPTIONAL): 27579 kPa 29 69 CHECK VALVE
CONTROL VALVE - BUCKET POSITION CONTROL VALVE - TWO COIL
(276 bar) (4000 psi) SOLENOID ACTIVATED DIRECECTIONAL
VALVE (ON/OFF) 50 RESTRICTOR - 0,8 mm (0.031 inch) 70
10 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – MAKE-UP
CONTROL VALVE - AUXILIARY 30 FLOW DIVIDER ADJUSTMENT VALVE 71
51 LOAD SHUTTLE VALVE - BLEED OFF FILTER - BRAKE
11 LOAD CHECK VALVE 31 PILOTED ACTIVATED DIRECTIONAL
52 SOLENOID ACTIVATED DIRECTIONAL 72 SOLENOID ACTIVATED DIRECECTIONAL
FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - FLOW CONTROL
12 CONTROL VALVE - BASE CONTROL VALVE – BRAKE
BLEED-OFF VALVE SPOOL
SOLENOID ACTIVATED DIRECTIONAL 73 HIGH FLOW HYDRAULIC PUMP Gear Type
32 CHECK VALVE - BUCKET POSITION 53
13 ANTICAVITATION VALVE CONTROL VALVE - ROD 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
VALVE
LIFT CYLINDER SPOOL - MADE TO VARIABLE CAPACITY DISPLACEMENT 74 RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)
14 33 PILOTED ACTIVATED DIRECTIONAL 54
RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP 75 DUMP VALVE – ON / OFF
CONTROL VALVE - UNLOADING
DOWN BUT NOT DURING BOOM UP RELIEF/REPLENISHING VALVE - HIGH
SPOOL 55
PILOTED ACTIVATED DIRECTIONAL PRESSURE: 36500 kPa (365 bar) (5294 psi) 76 CHECK VALVE - With 34 kPa (0,34 bar) (5.0
CONTROL VALVE - TILT CONTROL psi) Spring
CONTROL VALVE - HYDRAULIC 56 RELIEF VALVE - CHARGE INLET:
16 PILOTED ACTIVATED DIRECTIONAL 2654 kPa (26,5 bar) (385 psi) at High 77 HIGH PRESSURE CHAMBER
POWERED BOB-TACH
CONTROL VALVE - LIFT CONTROL Engine Idle With 60 ° C (140 ° F) Fluid LOW PRESSURE CHAMBER
35 FILTER - BOB-TACH VALVE 78
17 SOLENOID ACTIVATED DIRECTIONAL 57 SERVO PISTON – Swash Plate
CONTROL VALVE - BICS CONTROL 36 RESTRICTION - 2,26 mm (0.089 in)
18 FILTER - BICS CONTROL VALVE 37 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE NOTE: Unless otherwise specified
(SCREEN)
CONTROL VALVE (TWO COIL) 59 FILTER springs have NO significant
19 CHECK VALVE With 100 kPa 1,0 bar
38 RELIEF VALVE : 8274 kPa (83 bar) (1200 psi) pressure value.
(14.5 psi) Spring
123 of 1311
Male
12
62 L
Male
63 61
12
Female
74
BUCKET POSITIONING VALVE
75 OUT (OPTIONAL) D
31 32
HYDRAULIC CONTROL VALVE (SPOOL
X VALVE) 33
30
?
65 64
W
76 9
C
A
66 REAR QUICK COUPLERS
10
67 10 ?
FEMALE MALE
Z
A B
?
51
?
6
29
B
8 TILT CYLINDERS
53
54 60 11
52
R
49
TANDEM
? ?
BICS CONTROL VALVE
T
HYDROSTATIC
59 58
X
50
57 15
8
X
48 11
16 LIFT CYLINDERS
47 13
M 59 P in P out T
M REAR AUXILIARY
A B VALVE (OPTIONAL)
M Dealer Copy -- Not for Resale
55 55
Charge 8
56 G Inlet
BOBTACH CYLINDER (OPTIONAL)
20
A B 22
M 14 19
40 POWER BOBTACH
M 59 11 18
VALVE (OPTIONAL) 18 17 ?
39 IN 2
55 38 40 41 7
? 6
55
X
57
1
X ?
42
59 37 ? ?
58
36 43 PP
DR
OIL COOLER RESERVOIR (VENTED) 21
T 2
54 78 77
R P1 P2
1
45 35 34 5 3
4

2-SPEED & SAPR HYDRAULIC FILTER
71 BRAKE VALVE
B1
73
72 27
B
25 PUMP
67 SUPPLY
71 28 WORKING
CIRCUIT
B A PILOT
69 70 PRESSURE
Z DRAIN /
RETURN
C
P 23
D 66 26
W
68 P DR 24
69 ?
64 65
A X
T
SJC WITH ALL OPTION
44 S650 (S/N A3NV11001 - A3NV12444)
63
62
61 (S/N A3NW11001 - A3NW11129)
L
TWO SPEED DRIVE MOTOR (OPTIONAL) (PRINTED NOVEMBER 2010)
7170813 Printable Version Click Here

124 of 1311
PRINTED IN U.S.A.
(PRINTED MAY 2014)

V-1420legend
LEGEND
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 39 CHECK VALVE - With 552 kPa (5,5 bar) 62 CHECK VALVE - With 1379 kPa (13,8 bar)
Capacity at sight gauge . 10,2 L (2.7 U.S. gal) (80 psi) Spring (200 psi) Spring
21 PULL BUTTON ACTIVATED 40 SHUTTLE VALVE
System Capacity . . . . . . 41,6 L (11.0 U.S. gal) 63 DRIVE MOTOR SHUTTLE VALVE
2 SIGHT GUAGE 41 RELIEF VALVE: 13790 kPa (137 bar) (2000 psi) FIXED CAPACITY DISPLACEMENT
ARM BY-PASS 64
3 22 RIDE CONTROL VALVE 42 BIDIRECTIONAL HYDROSTATIC MOTOR
DIFFERENTIAL PRESSURE SWITCH: CHECK VALVE - With 2068 kPa (20,7 bar) (300
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,33 mm (0.013 in) Orifice 65 HYDRAULIC BRAKE – SPRING APPLIED –
Normally Closed 23 ANTICAVITATION VALVE PRESSURE RELEASE (SAPR)
43 RESTRICTION - 0,51 mm (0.020 in)
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE – 66 PILOT ACTIVATED DIRECTIONAL
(Fan Speed Regulator): 10797-12300 kPa 44 RESTRICTION - 0,51 mm (0.020 in) CONTROL VALVE – 2 Speed
45 SENSOR – HYD. TEMPERATURE 67 FIXED CAPACITY DISPLACEMENT
VALVE: 172 kPa (1,7 bar) (25 psi)
25 SPRING LOADED FILTER BY-PASS VALVE: BIDIRECTIONAL HYDROSTATIC
6 DIAGNOSTIC COUPLER 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 46 NOT USED FOR THIS MODEL MOTOR – 2 Speed
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT PILOT ACTIVATED DIRECTIONAL 68 HYDRAULIC PUMP . . . . . . . Gear Type
47
24132 kPa (241 bar) (3500 psi) HYDRAULIC MOTOR CONTROL
Dealer Copy -- Not for ResaleVALVE - REAR AUXILIARY 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
at Front Quick Couplers 27 FILTER - HYDRAULIC (CANISTER) 48 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) CHARGE PUMP -
8 69
RELIEF/ANTICAVITATION VALVE - 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PORT: 27579 kPa (276 bar) (4000 psi) 28 SENSOR – CHARGE PRESSURE – 49 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter CONTROL VALVE - TWO COIL 70 HIGH FLOW HYDRAULIC PUMP Gear Type
SOLENOID ACTIVATED DIRECTIONAL 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
PORT (OPTIONAL): 29 50 RESTRICTOR - 0,8 mm (0.031 in)
CONTROL VALVE - BUCKET POSITION 71 FILTER - BRAKE
27579 kPa (276 bar) (4000 psi)
VALVE (ON/OFF) 51 LOAD SHUTTLE VALVE - BLEED OFF
10 SOLENOID ACTIVATED DIRECTIONAL 72 SOLENOID ACTIVATED DIRECECTIONAL
CONTROL VALVE - AUXILIARY 30 FLOW DIVIDER ADJUSTMENT VALVE 52 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – BRAKE
11 LOAD CHECK VALVE PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - Female 73 CHECK VALVE
31
CONTROL VALVE - FLOW CONTROL 53 SOLENOID ACTIVATED DIRECTIONAL 74 RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)
SPOOL CONTROL VALVE - Male
BLEED-OFF VALVE
CHECK VALVE - BUCKET POSITION 75 DUMP VALVE – ON / OFF
13 ANTICAVITATION VALVE 32 54 VARIABLE CAPACITY DISPLACEMENT
VALVE BIDIRECTIONAL HYDROSTATIC PUMP CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi)
76
14 LIFT CYLINDER SPOOL - MADE TO 33 PILOTED ACTIVATED DIRECTIONAL RELIEF/REPLENISHING VALVE - HIGH Spring
RESTRICT FLOW DURING BOOM 55
CONTROL VALVE - UNLOADING PRESSURE: 36500 kPa (365 bar) (5294 psi) 77 SOLENOID ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP
SPOOL CONTROL VALVE – 2 Speed Shift
15 PILOTED ACTIVATED DIRECTIONAL 56 RELIEF VALVE - CHARGE INLET:
34 PILOT ACTIVATED DIRECTIONAL 2654 kPa (26,5 bar) (385 psi) at High 78 SOLENOID ACTIVATED DIRECTIONAL
16 CONTROL VALVE - HYDRAULIC Engine Idle With 60 ° C (140 ° F) Fluid CONTROL VALVE – 2 Speed Make-up
PILOTED ACTIVATED DIRECTIONAL POWERED BOB-TACH
CONTROL VALVE - LIFT CONTROL 57 SERVO PISTON – Swash Plate 79 HIGH PRESSURE CHAMBER
17 35 FILTER - BOB-TACH VALVE
SOLENOID ACTIVATED DIRECTIONAL 58 SOLENOID ACTIVATED DIRECTIONAL
80 LOW PRESSURE CHAMBER
CONTROL VALVE - BICS CONTROL 36 RESTRICTION - 2,08 mm (0.08 in) CONTROL VALVE – FORWARD/REVERSE
18 FILTER - BICS CONTROL VALVE 59 FILTER
37 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
(SCREEN) CHECK VALVE – COLD WEATHER BY-PASS
CONTROL VALVE (TWO COIL) 60 springs have NO significant
19 CHECK VALVE - With 100 kPa 1,0 bar With 345 kPa (3,45 bar) (50 psi) Spring
38 RELIEF VALVE: 8274 kPa (83 bar) (1200 psi) pressure value.
(14.5 psi) Spring 61 RESTRICTION – 1,5 mm (0.06 in)
125 of 1311
Male
12
62 L
Male
63 61
12
Female
74
75 OUT (OPTIONAL) D
31 32
HYDRAULIC CONTROL VALVE (SPOOL
X
33
30
67 66
W
76 9
C
A
64 REAR QUICK COUPLERS 10
65 10
FEMALE MALE
Z
A 51 6
B
29
B
8 TILT CYLINDERS
53
54 60 11
52
R
49
TANDEM BICS CONTROL VALVE
T
HYDROSTATIC
59 58
X
50
57 15
8
X
48 11
16 LIFT CYLINDERS
47 13
M 59 T
M REAR AUXILIARY P in P out
M
55 55
Charge
8
56 G Inlet
(OPTIONAL) 20
A B 22
BOBTACH VALVE
M
(OPTIONAL) 14 19
M 59 11 18 18 17
39 IN
40 2
55 7 6
55 38 42
X
41
57 37
1
X
59
58 44
OIL COOLER 3 2 RESERVOIR (VENTED) 21
T D 36 43
54 80 79
R
5 1
35 34
68
4

2-SPEED & SAPR HYDRAULIC FILTER
71 BRAKE VALVE
B1 70
72 27
B
25 PUMP
65 SUPPLY
71 28 WORKING
CIRCUIT
B A PILOT
73 78 PRESSURE
Z DRAIN /
RETURN
C 23
P
D 64 26
W
77 P DR 24
73 66 67
A X
T
SJC WITH ALL OPTION
45 S650 (S/N A3NV12445 - A3NV18826)
63
62
61 (S/N A3NW11130 - A3NW12750)
L
TWO SPEED DRIVE MOTOR (OPTIONAL) (PRINTED MAY 2015)
126 of 1311 7170813 (C)
PRINTED IN U.S.A.
- A3NV25735)
- A3NW13963)
(PRINTED JULY 2017)

V-1471legend
LEGEND
1 RESERVOIR: 20 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 39 CHECK VALVE - With 552 kPa (5,5 bar) 62 CHECK VALVE - With 1379 kPa (13,8 bar)
Capacity at sight gauge . 10,2 L (2.7 U.S. gal) (80 psi) Spring (200 psi) Spring
21 PULL BUTTON ACTIVATED 40 SHUTTLE VALVE
System Capacity . . . . . . 41,6 L (11.0 U.S. gal) 63 DRIVE MOTOR SHUTTLE VALVE
2 SIGHT GUAGE 41 RELIEF VALVE: 13790 kPa (137 bar) (2000 psi) FIXED CAPACITY DISPLACEMENT
ARM BY-PASS 64
3 DIFFERENTIAL PRESSURE SWITCH: 22 RIDE CONTROL VALVE 42 CHECK VALVE - With 2068 kPa (20,7 bar) (300 BIDIRECTIONAL HYDROSTATIC MOTOR
103 kPa (1,03 bar) (15 psi) psi) Spring And With 0,33 mm (0.013 in) Orifice 65 HYDRAULIC BRAKE – SPRING APPLIED –
Normally Closed 23 ANTICAVITATION VALVE 43 RESTRICTION - 0,51 mm (0.020 in) PRESSURE RELEASE (SAPR)
4 FILTER - HYDRAULIC (CANISTER)
24 PROPORTIONAL RELIEF VALVE – 44 RESTRICTION - 0,51 mm (0.020 in) 66 HIGH PRESSURE SHUTTLE With INNER
5 SPRING LOADED FILTER BY-PASS (Fan Speed Regulator): 10797-12300 kPa MAKE-UP SPOOL
VALVE: 172 kPa 1,7 bar (25 psi) (108 - 123 bar) (1566 - 1784 psi) 45 SENSOR – HYD. TEMPERATURE 67 FIXED CAPACITY DISPLACEMENT
6 DIAGNOSTIC COUPLER 25 SPRING LOADED FILTER BY-PASS VALVE: 46 NOT USED FOR THIS MODEL BIDIRECTIONAL HYDROSTATIC
RELIEF VALVE - MAIN: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) MOTOR – 2 Speed
24132 kPa (241 bar) (3500 psi) 26 FIXED CAPACITY DISPLACEMENT 68 HYDRAULIC PUMP . . . . . . . Gear Type
at Front Quick Couplers CONTROL VALVE - REAR AUXILIARY 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
HYDRAULIC MOTOR Dealer Copy -- Not for Resale
NOTE - If Equipped With Ref. 81: 48 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi) CHARGE PUMP -
27 FILTER - HYDRAULIC (CANISTER) 69
25855 kPa (258 bar) (3750 psi) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
8 RELIEF/ANTICAVITATION VALVE - 28 SENSOR – CHARGE PRESSURE – CONTROL VALVE - TWO COIL
Fan Filter 70 HIGH FLOW HYDRAULIC PUMP Gear Type
PORT: 27579 kPa (276 bar) (4000 psi)
SOLENOID ACTIVATED DIRECTIONAL 50 RESTRICTOR - 0,8 mm (0.031 in) 28,4 L/min (7.5 U.S. gpm) at High Engine Idle
9 RELIEF/ANTICAVITATION VALVE - 29
CONTROL VALVE - BUCKET POSITION 71 FILTER - BRAKE
PORT (OPTIONAL): 51 LOAD SHUTTLE VALVE - BLEED OFF
27579 kPa (276 bar) (4000 psi) VALVE (ON/OFF)
72 SOLENOID ACTIVATED DIRECECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 30 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE – BRAKE
CONTROL VALVE - AUXILIARY CONTROL VALVE - Female
PILOTED ACTIVATED DIRECTIONAL 73 NOT USED ON THIS MODEL
11 LOAD CHECK VALVE 31 53 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 74 RELIEF VALVE: 24132 kPa (241 bar) (3500 psi)
CONTROL VALVE - Male
12 FRONT AUXILIARY MANUAL PRESSURE SPOOL
BLEED-OFF VALVE 54 VARIABLE CAPACITY DISPLACEMENT 75 DUMP VALVE – ON / OFF
32 CHECK VALVE - BUCKET POSITION
BIDIRECTIONAL HYDROSTATIC PUMP
13 ANTICAVITATION VALVE VALVE
76 CHECK VALVE - With 34 kPa (0,34 bar) (5.0 psi)
55 RELIEF/REPLENISHING VALVE - HIGH
14 LIFT CYLINDER SPOOL - MADE TO 33 PILOTED ACTIVATED DIRECTIONAL Spring
PRESSURE: 36500 kPa(365 bar) (5294 psi)
RESTRICT FLOW DURING BOOM CONTROL VALVE - UNLOADING RELIEF VALVE - CHARGE INLET: 77 SOLENOID ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP SPOOL 56 CONTROL VALVE – 2 Speed Shift
(S/N A3NV11001 – A3NV23845) and
15 PILOTED ACTIVATED DIRECTIONAL 34 PILOT ACTIVATED DIRECTIONAL (S/N A3NW11001 – A3NW13328) 78 NOT USED ON THIS MODEL
CONTROL VALVE - TILT CONTROL CONTROL VALVE - HYDRAULIC 2654 kPa (26,5 bar) (385 psi)
16 PILOTED ACTIVATED DIRECTIONAL POWERED BOB-TACH (S/N A3NV23846 & ABOVE), (S/N A3NW13329 79 HIGH PRESSURE CHAMBER
CONTROL VALVE - LIFT CONTROL FILTER - BOB-TACH VALVE & ABOVE) and (S/N 1MLS11001 & ABOVE)
35 80 LOW PRESSURE CHAMBER
17 SOLENOID ACTIVATED DIRECTIONAL 3413 kPa (34,1 bar) (495 psi)
36 RESTRICTION - 2,08 mm (0.08 in) 57 SERVO PISTON – Swash Plate RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
CONTROL VALVE - BICS CONTROL 81
18 FILTER - BICS CONTROL VALVE 37 58 SOLENOID ACTIVATED DIRECTIONAL (If Equipped)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL) CONTROL VALVE – FORWARD/REVERSE
(SCREEN) 59 FILTER NOTE: Unless otherwise specified springs have
19 CHECK VALVE - With 100 kPa 1,0 bar 38 RELIEF VALVE: 8274 kPa (83 bar) (1200 psi) NO significant pressure value.
60 CHECK VALVE – COLD WEATHER BY-PASS
(14.5 psi) Spring
Printed in U.S.A. With 345 kPa (3,45 bar) (50 psi) Spring V-1471legend (5-21-14)
61 RESTRICTION – 1,5 mm (0.06 in)
127 of 1311
Male
12
62
Male
L
63 61
OUT
12
HYDRAULIC CONTROL VALVE (SPOOL Female

74
75 (OPTIONAL) D
31 32
9 33
X
30
60 9
76 C
A
67 REAR QUICK COUPLERS 10
10
65 FEMALE MALE
Z
64 6
A B 51
29
53 B
52 TILT CYLINDERS
54 60 81
49 8 11
R BICS CONTROL VALVE
TANDEM
T
HYDROSTATIC
50
59 58 8
X
57 15
X
48 11
16 LIFT CYLINDERS
47 13
M 59 T
M REAR AUXILIARY P in P out
M Dealer Copy -- Not for Resale
55 55
Charge Inlet
8
56 G
(OPTIONAL) 20
A B 22
BOBTACH VALVE
M
(OPTIONAL) 14
M 59 11 18 17
39 IN
40 2
55 7 18
6
55 38 42 19
X
41
57 37
1
X
59
58 44
OIL COOLER 3 2 RESERVOIR (VENTED) 37
T D 36 43
54 80 79
R
1
5
35 34
68
4

HYDRAULIC FILTER
70
27
25 PUMP
65 SUPPLY
2-SPEED & SAPR 28 WORKING
BRAKE VALVE CIRCUIT
71 B1 B A PILOT
PRESSURE
72 Z DRAIN /
RETURN
B
71 23
64 26
P
77 P DR 24 Printable Version Click Here
60 67
A X
DRAIN/RETURN MANIFOLD HYDRAULIC/HYDROSTATIC SCHEMATIC
A1 SJC WITH ALL OPTION
S650 (S/N A3NV18827 - A3NV25735)
T
45 (S/N A3NW12751 - A3NW13963)

61
62 63 (S/N 1MLS11001 AND ABOVE)
L (PRINTED MAY 2018)
7170813 (G)
128 of 1311
PRINTED IN U.S.A.
(PRINTED JULY 2017)

V-1643legend
LEGEND
1 RESERVOIR: 39CHARGE PUMP - 58 CHECK VALVE
19 PULL BUTTON ACTIVATED
Capacity at sight gauge . . 10,2 L (2.7 U.S. gal) 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
DIRECTIONAL CONTROL VALVE - LIFT 59 ORIFICE: 1,6 mm (0.063 in)
System Capacity . . . . . . . 41,6 L (11.0 U.S. gal) ARM BY-PASS 40 HYDRAULIC PUMP . . . . . . . Gear Type
87,1 L/min (23.0 U.S. gpm) at High Engine Idle 60 SOLENOID ACTIVATED DIRECTIONAL
41 VARIABLE CAPACITY DISPLACEMENT CONTROL VALVE - BUCKET POSITION
DIFFERENTIAL PRESSURE SWITCH: RESTRICT FLOW DURING BOOM
3 BIDIRECTIONAL HYDROSTATIC PUMP VALVE (ON/OFF)
103 kPa (1,03 bar) (15 psi) DOWN BUT NOT DURING BOOM UP
42 RELIEF/REPLENISHING VALVE - HIGH 61 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) (3500 psi) (If Equipped) 62 PILOTED ACTIVATED DIRECTIONAL CONTROL
22 43 RELIEF VALVE - CHARGE INLET: VALVE - FLOW CONTROL SPOOL
SPRING LOADED FILTER BY-PASS ANTICAVITATION VALVE 3413 +/- 172 kPa (34,1 +/- 1,7 bar)
5 63 CHECK VALVE - BUCKET POSITION VALVE
VALVE: 172 kPa (1,7 bar) (25 psi) PROPORTIONAL RELIEF VALVE – (495 +/- 25 psi) at High Engine Idle
23
6 DIAGNOSTIC COUPLER (Fan Speed Regulator): 10797 – 12300 kPa With 60 ° C (140 ° F) Fluid 64 PILOTED ACTIVATED DIRECTIONAL
(108 - 123 bar) (1566 - 1784 psi) 44 CHECK VALVE – COLD WEATHER CONTROL VALVE – UNLOADING SPOOL
7 RELIEF VALVE - MAIN: BY-PASS With 345 kPa (3,45 bar)
SPRING LOADED FILTER BY-PASS VALVE: 65 HIGH FLOW HYDRAULIC PUMP Gear Type
24132 kPa (241 bar) (3500 psi) 24 (50 psi) Spring
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 28,4 L/min (7.5 U.S. gal) at High Engine Idle
at Front Quick Couplers
NOTE - If Equipped With Ref. 21: 25 FIXED CAPACITY DISPLACEMENT 45 SERVO PISTON SWASH PLATE 66 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
25855 kPa (258 bar) (3750 psi) HYDRAULIC MOTOR SOLENOID ACTIVATED DIRECTIONAL
46 67 DUMP VALVE – ON / OFF
RELIEF/ANTICAVITATION VALVE - 26 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – Forward / Reverse
8
PORT: 27579 kPa (276 bar) (4000 psi) 47 FILTER 68 CHECK VALVE - With 34,5 kPa (0,34 bar)
Fan Filter (5.0 psi) Spring
9 RELIEF/ANTICAVITATION VALVE - 48 FRONT AUXILIARY MANUAL PRESSURE
PORT (OPTIONAL): 27579 kPa 28 SENSOR – HYD. TEMPERATURE BLEED-OFF VALVE 69 PILOT ACTIVATED DIRECTIONAL
(276 bar) (4000 psi) 49 CONTROL VALVE - REAR AUXILIARY
29 RESTRICTION - 1,7 mm (0.067 in) PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE – HYDRAULIC 70 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
30 CHECK VALVE - With 1379 kPa 13,8 bar POWERED BOB-TACH With Build-up
CONTROL VALVE - AUXILIARY 71 SOLENOID ACTIVATED DIRECTIONAL
(200 psi) Spring Valve: 276 kPa (2,76 bar) (40 psi)
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TWO COIL
50 FILTER - BOB-TACH VALVE
12 72 RESTRICTOR - 0,8 mm (0.031 in)
ANTICAVITATION VALVE 32 PILOT ACTIVATED DIRECTIONAL
51 RESTRICTION - 1,17 mm (0.46 in)
CONTROL VALVE – 2 Speed Shift 73 LOAD SHUTTLE VALVE - BLEED OFF
13 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
33 52
CONTROL VALVE - TILT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE (TWO COIL) 74 SOLENOID ACTIVATED DIRECTIONAL
14 PILOTED ACTIVATED DIRECTIONAL FIXED CAPACITY DISPLACEMENT 53 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
34
CONTROL VALVE - LIFT CONTROL BIDIRECTIONAL HYDROSTATIC MOTOR CONTROL VALVE – Ride Control Option 75 SOLENOID ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL 35 HYDRAULIC BRAKE – SPRING APPLIED – 54 ACCUMULATOR – Ride Control Option CONTROL VALVE - ROD
55 ORIFICE With Check Valve: 76 SOLENOID ACTIVATED DIRECTIONAL
16 FILTER - BICS CONTROL VALVE 36 SOLENOID ACTIVATED DIRECECTIONAL
2,54 mm (0.10 in) CONTROL VALVE – Reversing Fan Option
17 CHECK VALVE - With 100 kPa (1,0 bar) 37 FILTER – BRAKE VALVE 56 RELIEF VALVE - 24132 kPa
(14.5 psi) Spring SOLENOID ACTIVATED DIRECTIONAL (241 bar) (3500 psi)
38 NOTE: Unless otherwise specified springs have
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CONTROL VALVE – 2 Speed Shift 57 RESTRICTION - 0,254 mm (0.010 in) NO significant pressure value.

129 of 1311
DRIVE MOTOR Male
L
48
30 29
31 Male
OUT
48
Female
X
RIDE CONTROL (OPTION)
54
9
T2 ACC
32
T 55
9 59
33 NOTE: CUSHIONED
34 REAR QUICK LIFT CYLINDERS ON
FEMALE COUPLERS MALE 10 P
LATER MODELS ONLY
Z
53
Auxiliary Spool
A B 73 CR2 CR CB CB2
75
21
74
71 6
8 11 (BICS)
R
41 TILT BASE
T
E1 E2 A1 A2
46 72
TILT ROD E3
X 47 Tilt Spool
8
B 61
45
42 13
2-SPEED & X
SAPR BRAKE 70
VALVE 11
(OPTIONAL) LIFT ROD 60 63
69 14 D2
38
B A M 47 REAR AUXILIARY P in P out T 12
36 M 62
A B
VALVE (OPTION)
T LIFT BASE
M
Lift Spool
43 42
(OPTIONAL) 8
Dealer Copy -- Not for Resale 64 C2
G
C1 D1
P POWER BOBTACH
A B
VALVE (OPTIONAL)
M 20 16
B1
M
47 56
58 11 15 BUCKET POSITIONING
37 VALVE (OPTIONAL)
IN
2 18
7 16
42 6
42 52
X 57 17
45 TILT CYLINDERS
1
X 46 D Oil Cooler
47 19
41 44 51
50 RESERVOIR
T 2 (VENTED)
5 1
R
40 49
39
VARIABLE SPEED
HYDRAULIC FAN MOTOR 3 4
W/ INTEGRATED FILTER
HYDRAULIC FILTER
65
66 27
67
26
24
WORKING CIRCUIT
CHARGE
PRESSURE
1 4 22
35 DRAIN / RETURN
B A
3 2
25
76
Z DR 23 P
33 34
32
X
28
SJC WITH ALL OPTION
30 29
31
(PRINTED MAY 2018)
DRIVE MOTOR
7170813 K)
130 of 1311
PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

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

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

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

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

noise.

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

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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

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


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

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

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

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

RELIEF / ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in NEUTRAL position. 4
The lift arms come down with the pedal in the NEUTRAL position. 4, 9, 10, 11
Lift Arm Bypass Control valve stuck. 12

Lift Arm Bypass Control valve stem bent or broke. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-
40-1.)
8. Exceeding the loader’s rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace Lift Arm Bypass Control valve assembly.


CYLINDER (LIFT) Figure 20-20-2
Testing
Lower the lift arms. Stop the engine. Raise the seat bar.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by 2
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
P-90617
immediately.
W-2145-0290
Install a cap (Item 1) [Figure 20-20-2] on the hose and

Figure 20-20-1 tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.

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

(Item 2) [Figure 20-20-2], remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
P-90616
Test only one cylinder at a time. Disconnect the hose

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

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

WARNING
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
NOTE: Remove only one cylinder at a time.
explosion or fire.
WARNING W-2103-0508
Figure 20-20-4
W-2017-0286
2
1
IMPORTANT

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

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

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

Removal And Installation (Cont’d)
Figure 20-20-5
P-90602A
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-5] from the pin (Item 2) on the rod end of the cylinder.

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

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

CYLINDER (LIFT) (CONT'D) Figure 20-20-7
DANGER
1
P-90605
P-90328
AVOID DEATH Install a sling in the middle of the Bob-Tach as shown in

• Disconnecting or loosening any hydraulic (Item 1) [Figure 20-20-7].
can cause lift arms to drop. Using a chain hoist raise the lift arms and install an
• Keep out of this area when lift arms are raised approved lift arm support device on the cylinder that is
unless supported by an approved lift arm connected to the lift arm.

D-1009-0409
Figure 20-20-8
2
WARNING 1

W-2059-0598
P-90823
Install a bolt (Item 1) through the eyelet of the cylinder

and install a strap (Item 2) [Figure 20-20-8] to secure the
cylinder.

Open the rear door.

1
NOTE: When removing the left side lift cylinder the
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Remove the battery (if required). (See Removal And

Installation on Page 60-20-1.)
Figure 20-20-9
P-90827
1
20-11] from the base end of the lift cylinder.
Figure 20-20-12

1
P-90834

20-9] from the pin on the base end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 48 - 54 1

Figure 20-20-10 P-90823
Using a chain hoist remove the lift cylinder (Item 1)

[Figure 20-20-12] from the loader.
P-90825
Remove the grease fitting (Item 1) [Figure 20-20-10]

from the base end of the lift cylinder.
Installation: Tighten the grease fitting to 20 N•m (15 ft-

lb) torque.

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

8
2 9
10
1
8
12
13
14
8
7
15
16
NA1413S

Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

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

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

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

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

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

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

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

the cylinder head.

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

cylinder head.

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

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

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

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

20-21].

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

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

Figure 20-20-23
1
2
3
2 4
P-48036
P-48041 P-48042 NOTE: Clean and dry the rod threads. Install a NEW
NUT with preapplied Loctite® included in the
seal kit or if a new nut is no available use
Install the wiper seal, with the wiper side of the seal (Item Loctite® #242 on threads.
1) toward the outside of the head (Item 2) [Figure 20-20-
23]. Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-25].
Tighten the nut (Item 4) [Figure 20-20-25] to 1491 N•m

(1100 ft-lb) torque.

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

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


CYLINDER (TILT) Figure 20-21-2
Testing
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar. 2 1
Figure 20-21-1
P85852
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic

hose and tighten.
P-85553 engine and press the PTOL button.

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

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

sufficient force to enter a person’s body by
immediately.
W-2145-0290
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the base end of the cylinder.

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

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

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

Stop the engine. Raise the seat bar.
Remove the retainer bolt and nut (Item 1) [Figure 20-21-

3] from the rod end pivot pin.
1
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.
Figure 20-21-4
P-85648
Remove the base end pivot bolt and washer (Item 3)

[Figure 20-21-5].
Remove the retainer nut and washer (Item 1) [Figure 20-

21-6] from the base end pivot pin.
Installation: Tighten the retainer nut to 257,6 N•m (190

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

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

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

1
P-85566
Remove the tilt cylinder from the cylinder base pin (Item
1) [Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Use a 22,2 mm (7/8 in) shaft (Item 1) [Figure 20-21-9]

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

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

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

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

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

EARLIER
Disassembly MODELS
3
Use the following tools to disassemble the cylinder: 2
MEL1074 - O-ring Seal Hook

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

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

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

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

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

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

Models
1
1
P-48040
P109555
Remove the wiper seal (Item 1) [Figure 20-21-18] from
the cylinder head.
Remove the seal (Item 1) [Figure 20-21-15] and [Figure
20-21-16] from the piston. Figure 20-21-19
P-48042
Remove the rod seal (Item 1) [Figure 20-21-19] from the

cylinder head.

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

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

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

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

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

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

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

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

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

21-27] on the cylinder head.
P7425

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

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

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Piston Ring Compressor
Spanner Wrench

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

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

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

must be toward the inside of the cylinder.

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

N-20613
Install the O-ring (Item 2) [Figure 20-22-15] into the
groove on the head.
22-13]. NOTE: Clean and dry the rod threads. Install a NEW

Figure 20-22-14 seal kit or if a new nut is not available use
Loctite® #242 on threads.
Figure 20-22-16
3
2 4
1
P7425

P16294
Install the wiper seal with the wiper toward the outside of
the head. Install the head (Item 1), and spacer (Item 2) [Figure 20-
22-16].
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do

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

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

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


MAIN RELIEF VALVE (EARLIER MODELS)
Description
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic fluid to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-4.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader.

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D) Figure 20-30-1
Testing
1
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
WARNING P-85571
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
cause injury or death.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the

loader.

W-2017-0286
The tools listed will be needed to do the following 2

procedure:
1
TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) FLOW
METER
MEL10006 - Hydraulic Test Kit
NA3267
NOTE: This procedure is for standard loaders,
loaders equipped with ACS option and
loaders equipped with SJC option. The main Start the engine and run at low idle.
relief valve is located in the same place on all
of the loaders. • Press the AUXILIARY HYDRAULICS Button (Item 1)
[Figure 20-30-2] once to engage the auxiliary
Lift and block the loader. (See LIFTING AND BLOCKING hydraulics.
NOTE: The light (Item 2) [Figure 20-30-2] will be on.

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D) Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full rpm.
Testing (Cont’d)
Refer to (See Hydraulic System on Page SPEC-10-4.) for
Figure 20-30-3 both flow and pressure specifications of the hydraulic
system.
Right
Steering
Test the free flow specification.
Lever
Control
With the engine at high idle and hydraulic fluid at 60°C
(140°F) turn the restrictor control on the tester until the
flow through the tester drops to zero. Test the relief
pressure.
If the relief pressure is not correct, stop the engine and

1 adjust the main relief valve.
P-85572
Figure 20-30-4

Joystick Option Only
Right
Steering
1 Lever
Control
P-26697
• Push the front switch (Item 1) [Figure 20-30-3] and

[Figure 20-30-4] to give the front quick couplers a
constant flow of fluid.
• To release from continuous operation, press the front

switch (Item 1) [Figure 20-30-3] and [Figure 20-30-
4] a second time.

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D)
Adjusting

loaders equipped with ACS option and
loaders equipped with SJC option. The main
of the loaders.
Figure 20-30-5
1
2

P-85573
If the pressure is not correct, adjust the main relief valve.

Loosen the locknut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
pressure setting of the new relief valve.

MAIN RELIEF VALVE (EARLIER MODELS) (CONT’D) Figure 20-30-7
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-37689
Clean the area around the control valve. Remove the O-rings and back-up rings (Item 1) [Figure
20-30-7] from the main relief valve.
loaders equipped with ACS option and Clean the main relief valve in clean solvent. Use air
loaders equipped with SJC option. The main pressure to dry the valve.

of the loaders. Install new O-rings and back-up rings. Install the main
relief valve and tighten [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Test the pressure again. (See Testing on Page 20-30-2.)
P-85573
The main relief valve (Item 1) [Figure 20-30-6] is located

at the lower front of the control valve below the lift and tilt
spool connections.
Loosen and remove the main relief valve (Item 1) [Figure

20-30-6].


MAIN RELIEF VALVE (LATER MODELS)
Description
The main relief valve and the optional auxiliary relief

valve (if equipped) limit the hydraulic system pressure by
opening at a certain pressure and allowing the hydraulic
fluid to flow back to the hydraulic reservoir. (See
Figure 20-31-1

P107749A
The relief valves are adjustable and located on the

hydraulic control valve. The main relief valve (Item 1)
[Figure 20-31-1] is located below the spool linkages,
facing the front of the machine. The optional auxiliary
relief valve (Item 2) (if equipped) [Figure 20-31-2] is
located on the top of the control valve facing the left side
of the machine.

MAIN RELIEF VALVES (LATER MODELS) (CONT’D) Figure 20-31-2
Testing
1 3
WARNING
When the engine is running during service, the
driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
2
cause injury or death.
W-2006-1209
The tools listed will be needed to do the following P107936

procedure:
MEL1355-3 - Pressure gauge 34474 KPa (345 bar) Install the gauge (Item 1) and coupler (Item 2) to the test
(5000 psi) hose (Item 3) [Figure 20-31-2].
MEL1723 - Coupler
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased Raise the operator cab. (See Raising on Page 10-30-2.)
locally. Must be rated for pressures above 34474 kPa
(345 bar) (5000 psi). Figure 20-31-3

NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The main relief valve is
located in the same place on all of the loaders.
WARNING 1

physician familiar with this injury is not received P107935
immediately.
W-2145-0290
Connect the test coupler (Item 1) to the control valve
coupler (Item 2) [Figure 20-31-3].
Route the test gauge so it can be used in the operator

cab when lowered. Make sure the hose will not interfere
with any moving parts.
Lower the operator cab. (See Lowering on Page 10-30-

3.)
NOTE: Do not have any attachment connected to the

loader auxiliary quick couplers while testing.

Testing (Cont’d)
Enter the loader and engage the parking brake. Start the
engine.
Increase the engine speed to full rpm and make sure the
hydraulic fluid is at 60°C (140°F).
2
Testing Main Relief Pressure Without Auxiliary Relief 1
Valve
The main relief valve setting is 23,8 - 24,5 MPA (238 -

245 bar) (3450 - 3550 psi).
NA3172
Power loader lift arms down on the stops and monitor the
test gauge for the relief pressure setting.
Press the auxiliary hydraulics button (Item 1) [Figure 20-
If the relief pressure is not correct, stop the engine and 31-4] to activate the auxiliary hydraulics.
adjust the relief valve. (See Main Relief Valve Adjustment
on Page 20-31-4.). NOTE: The auxiliary indicator (Item 2) [Figure 20-31-
4] will illuminate when activated.
Testing Main Relief Pressure If Equipped With Auxiliary

Relief Valve Figure 20-31-5
Right
If equipped with the optional auxiliary relief valve, the Steering
main relief setting is 25,5 - 26,2 MPA (255 - 262 bar) Lever
(3700 - 3800 psi). Control
Power loader lift arms down on the stops and monitor the
test gauge for the relief pressure setting.
If the relief pressure is not correct, stop the engine and 1

adjust the relief valve. (See Main Relief Valve Adjustment
on Page 20-31-4.).
Testing Auxiliary Relief Pressure
The auxiliary relief valve setting is 23787 - 24476 kPa P107006B

(238 - 245 bar) (3450 - 3550 psi).
Move the front auxiliary hydraulic switch (Item 1) [Figure

20-31-5] to the left or right and monitor the test gauge for
the relief pressure setting.
If the relief pressure is not correct, stop the engine and

adjust the relief valve. (See Auxiliary Relief Valve
Adjustment on Page 20-31-5.).
Stop the machine and exit the loader.

MAIN RELIEF VALVES (LATER MODELS) (CONT’D) Main Relief Valve Removal And Installation
Main Relief Valve Adjustment
Figure 20-31-6
IMPORTANT
damage the system.
I-2003-0888
2
Clean the area around the control valve.
1 NOTE: This procedure is for loaders equipped with

P107744 ACS or SJC controls. The main relief valve is
located in the same place on all of the loaders.
Loosen the locknut (Item 1) [Figure 20-31-6].
Figure 20-31-7

Turn the adjustment screw (Item 2) [Figure 20-31-6] in or
out until the pressure is correct. Turning the screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
pressure setting of the new relief valve. 1
P107743
Remove the main relief valve (Item 1) [Figure 20-31-7].

MAIN RELIEF VALVES (LATER MODELS) (CONT’D) Auxiliary Relief Valve Adjustment
Main Relief Valve Removal And Installation (Cont’d) NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The auxiliary relief valve
Figure 20-31-8 is located in the same place on all of the
loaders.
Figure 20-31-9
2
1
P107745A 1
Remove the O-ring (Item 1) and back-up rings (Item 2)

P107747
[Figure 20-31-8] from the relief valve.

Clean the relief valve in clean solvent. Use air pressure to Loosen the locknut (Item 1) [Figure 20-31-9].
dry the valve.
Turn the adjustment screw (Item 2) [Figure 20-31-9] in or
Install a new O-ring (Item 1) and back-up ring (Item 2) out until the pressure is correct. Turning the screw in will
[Figure 20-31-8]. Install the main relief valve and tighten. increase pressure.
Installation: Tighten the relief valve to 51 - 62 N•m (38 - NOTE: If the correct pressure can not be reached,
45 ft-lb) torque. replace the auxiliary relief valve. Test the
pressure setting of the new relief valve.
Test the relief valve. (See Testing on Page 20-31-2.)

Auxiliary Relief Valve Removal And Installation
IMPORTANT 2
damage the system.
I-2003-0888 1
P107627
Clean the area around the control valve. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-31-11] from the auxiliary relief valve.
NOTE: This procedure is for loaders equipped with
ACS or SJC controls. The auxiliary relief valve Clean the relief valve in clean solvent. Use air pressure to
is located in the same place on all of the dry the valve.
loaders.

Install new O-rings (Item 1) and back-up ring (Item 2)
Figure 20-31-10 [Figure 20-31-11]. Install the relief valve and tighten.
Installation: Tighten the relief valve to 51 - 62 N•m (38 -

45 ft-lb) torque.
Test the relief valve. (See Testing on Page 20-31-2.)
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic fluid to flow back to the hydraulic reservoir. (See
P107746
Remove the auxiliary relief valve (Item 1) [Figure 20-31-

10].

HYDRAULIC CONTROL VALVE (STANDARD)
(EARLIER MODELS)
Description
Figure 20-40-1
P-90327
The hydraulic control valve is located inside the main

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

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

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

valve which is adjustable.

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

DANGER Installation on Page 50-90-2.)
NOTE: Mark all tubelines, hoses, and electrical

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

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

P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-40-2
• Keep out of this area when lift arms are raised 3

D-1009-0409 1
WARNING
the lift arms are secured by an approved lift arm 2
support device. Failure to use an approved lift arm P-90187

to fall and cause injury or death. Remove the two bolts (Item 1), move the hose clamp
W-2059-0598
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-40-2] off to the side.
IMPORTANT
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm

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

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-5
(EARLIER MODELS) (CONT’D)
Figure 20-40-3
2
1
P-90270
Disconnect the hose (Item 1) [Figure 20-40-5] that

routes from the control valve to the brake valve.
P-90267
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed

Figure 20-40-6
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-40-3].
Figure 20-40-4 1
P-90271
2

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

20-40-4] from the control valve.

routes from the control valve to the drain manifold.

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

Figure 20-40-7
1 1
2 2
1 1
P-90274
Disconnect the three tubelines (Item 1) [Figure 20-40-9]

that route from the control valve to the junction block at
P-90272 the rear of the loader.
Figure 20-40-10
Remove the tubeline clamp (Item 1) [Figure 20-40-7].

Disconnect the two tubelines (Item 2) [Figure 20-40-7]
that route from the control valve to the front auxiliary
1
hydraulics.
Figure 20-40-8
P-90275

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

[Figure 20-40-10] from the control valve.

HYDRAULIC CONTROL VALVE (STANDARD) Mount Bracket Removal And Installation
Figure 20-40-13
Figure 20-40-11
1
P-90280
P-90276 Support the mounting bracket (Item 1) [Figure 20-40-13].
Figure 20-40-14

routes from the bottom of the control valve to the outlet
2
fitting of the hydraulic pump.
Figure 20-40-12
P-90279
Remove the two control valve mount bolts (Item 1)

[Figure 20-40-14].
P-90278
Remove the two frame bolts (Item 2) [Figure 20-40-14].
Support the control valve and remove the two bolts (Item Installation: Torque the two frame bolts (Item 2) [Figure
1) [Figure 20-40-12]. 20-40-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve from the loader. Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) (CONT'D)
Identification Chart
Figure 20-40-15
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3

H1 J1 C1
P-90307
ITEM DESCRIPTION ITEM DESCRIPTION

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulics Female Coupler E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Male Coupler F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24132 kPa (241,3 bar)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa
(3500 psi)
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (275,8 bar) (4000 psi) (Optional)

(EARLIER MODELS) (CONT'D)
Lift Load Check Valve Removal And Installation

1
Figure 20-40-16
1 4 P-90309
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-18].
P-90308
Inspect the spring (Item 3) and the free movement in the
load check valve (Item 4) [Figure 20-40-18].
Remove the charge tubeline (Item 1) [Figure 20-40-16]

from the BICS™ valve fitting on the top of the lift load Inspect the orifice (Item 5) [Figure 20-40-18] to make
check valve. sure it is not plugged.
Figure 20-40-17
P-90310
Remove the lift load check valve (Item 1) [Figure 20-40-

17] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

Load Check Valve Removal And Installation (Tilt And

Auxiliary)
1
Figure 20-40-19
2
3
4
2
1
P-90312
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-20].
P-90311 Inspect the orifice (Item 3) [Figure 20-40-20] in the

poppet to be sure it is not plugged.
At the front side of the control valve locate the tilt section

Installation: Install a new O-ring (Item 4) [Figure 20-40-
load check valve (Item 1) [Figure 20-40-19]. 20] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
At the front side of the control valve locate the auxiliary torque.
section load check valve (Item 2) [Figure 20-40-19].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
IMPORTANT
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(EARLIER MODELS) (CONT'D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-23

Rod End)
Figure 20-40-21
P-90314
P-90314 Loosen the lift circuit port relief / anti-cavitation valve

(Item 1) [Figure 20-40-23].

At the back side of the control valve, remove the lift Figure 20-40-24
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Figure 20-40-22
3 1
4
P-90315
P-90312 Replace the O-ring (Item 1) [Figure 20-40-24] before

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-40-22].
Inspect the orifice (Item 3) [Figure 20-40-22] in the


22] on the plug and lightly lubricate with oil before
torque.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(EARLIER MODELS) (CONT'D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-27

Installation (Tilt, Base End)
Figure 20-40-25
P-90314
P-90314 Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-40-27] from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)

Figure 20-40-28
[Figure 20-40-25] from the base end of the tilt section.
Figure 20-40-26
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-40-26] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Port Relief Valve Removal And Installation 1
Figure 20-40-29
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-31].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-29] Figure 20-40-32

from the auxiliary circuit of the control valve.
Figure 20-40-30
P-51640
P-90318 Installation: Always use new O-rings (Item 1) [Figure

20-40-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Always use new O-rings (Item 1) [Figure


Plug Removal And Installation
Figure 20-40-33
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-35].
P-68016
Figure 20-40-36
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-33].

Figure 20-40-34
P-51462

1 20-40-36]. Tighten to 54 N•m (40 ft-lb) torque.
P-51460A

20-40-34]. Tighten to 54 N•m (40 ft-lb) torque.

Rubber Boot Removal And Installation
Figure 20-40-37
P-51506
Remove the three screws (Item 1) [Figure 20-40-37] on

the rubber boot retainer plate.
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.
Figure 20-40-38
1
2
P-51701
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-38].

End Cap Block Removal And Installation
Figure 20-40-39
1 1
1 1
P-51699A
1
Figure 20-40-42
P-51697
1
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-39] from the

end cap / spool lock block.
3
Figure 20-40-40
1
P-51701
Remove the four end cap / spool lock block mount screws
(Item 1) [Figure 20-40-41] and [Figure 20-40-42].
1
100 in-lb) torque.
P-90320 Remove the rubber boots and retainer plate (Item 2)

[Figure 20-40-42] from the lift and tilt spools.
Disconnect the tube line (Item 1) [Figure 20-40-40] from Remove the end cap / spool lock block (Item 3) [Figure
the end cap / spool lock block. 20-40-42] from the control valve.

Lift Spool And Detent Removal And Installation
The tool listed will be needed to do the following 1

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap / spool lock block from the control
valve.
Figure 20-40-43
P-90321
Remove the end cap (Item 1) [Figure 20-40-45].
Figure 20-40-46

P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-43]. 2
Installation: Replace the O-ring, and lubricate the o-ring

lightly with grease or oil before installation of the end cap
P-51514
/ spool lock block.
Figure 20-40-44 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-46].
Remove the washer (Item 2) [Figure 20-40-46].
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-44] from the lift spool.


(Cont'd)
Figure 20-40-47
1 P-51516
Put a rag around the detent assembly [Figure 20-40-48].

This will prevent the detent balls and spring from being
1 lost when the detent sleeve is removed.
2
P-51515
Figure 20-40-49

Remove the screws (Item 1) [Figure 20-40-47] from the
detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-47].
Installation: Lubricate the screws and tighten to 10,2 -

11,3 N•m (90 - 100 in-lb) torque.
2 1
3
IMPORTANT
The detent assembly has small springs and balls. Do 2 P-51517
not lose these parts during disassembly and
assembly.
I-2012-0284 Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-49].


(Cont'd)
Figure 20-40-50
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-52].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-53

Remove the lift spool assembly and seal (Item 1) [Figure
20-40-50] from the control valve. 2
Figure 20-40-51
1
3
1
N-18915
Install the spring tool (Item 1) [Figure 20-40-53] over the

P-51519 centering spring (Item 3).
NOTE: Be careful when removing the detent adapter

Remove the lift spool seal (Item 1) [Figure 20-40-51] (Item 2) [Figure 20-40-53] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.

Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-54
N-19009
Remove spring tool (Item 1) [Figure 20-40-56] from the

1 spring assembly.
2
N-18916 Figure 20-40-57

Put a rag around the detent assembly [Figure 20-40-54]. 2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3
Remove the detent adapter with an Allen wrench.

4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-54].
Figure 20-40-55
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-57].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-55]

from the spring assembly.


(Cont'd)
2
Figure 20-40-58
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-60].
N-18918 NOTE: The lift spool will have an internal leak if there
is damage to this O-ring. Always replace the
O-ring and inspect the lift spool before the
Remove the stud from the end of the spool [Figure 20-

control valve is replaced.
40-58].
Figure 20-40-61
Figure 20-40-59
N-18920
N-18963
Removal of the plastic plug:

Install the plastic plug and O-ring in the spool [Figure 20-
Make a center point in the plug using a 1,6 mm (1/16 in) 40-61].
drill.
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill.
Turn a 6-32 tap (Item 1) [Figure 20-40-59] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.


(Cont'd)
2
Figure 20-40-62
O-ring
1 3
2
N-18958
Plastic
Plug
15,2 mm Apply grease on all the detent component surfaces
(0.60 in)
before assembly [Figure 20-40-64].
B-14712 Install the spring (Item 1) [Figure 20-40-64] and detent

balls (Item 2) [Figure 20-40-64] into the adapter (Item 3)
[Figure 20-40-64] and compress with the detent pliers

Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-40-65].
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-62]. Figure 20-40-65
Figure 20-40-63
N-18968
N-18967
Install the detent adapter (Item 1) [Figure 20-40-65] to
the collar.
Clamp the collar (Item 1) [Figure 20-40-63] in a vise.
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.


(Cont'd)
Figure 20-40-66
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-68].
N-19004 Remove the spring tool.
Inspect the alignment of the detent adapter and the

Install the spring tool (Item 1) [Figure 20-40-66] over the washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 10,2 - 11,3 N•m (90 - 100 in-lb).
Figure 20-40-67
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-68].
Figure 20-40-69
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-67].
CD-15051
Install the detent balls and spring [Figure 20-40-69].


(Cont'd)
Figure 20-40-70
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-72].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-72].
Install the mounting screws (Item 2) [Figure 20-40-72].

Hold the detent balls in place with the detent pliers

[Figure 20-40-70]. Installation: Lubricate the screws and tighten to 10 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-40-71
Figure 20-40-73
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-71] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-73].


(Cont'd)
Figure 20-40-74
1
1
P-51512
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-76] on the lift spool.
P-90321 Figure 20-40-77

Install the end cap (Item 1) [Figure 20-40-74].
Figure 20-40-75
P-51511A
Install the O-ring (Item 1) [Figure 20-40-77] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-75] on the

linkage end of the valve.


(Cont'd)
Figure 20-40-78
2
1
P-51697
3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap / spool lock block (Item 1) and the (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
mount bolt (Item 2) [Figure 20-40-78]. 45 ft-lb) torque [Figure 20-40-80].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-78].

100 in-lb) torque.
Figure 20-40-79
P-90320
Connect the tubeline (Item 1) [Figure 20-40-79].

Tilt Spool Removal And Installation
Remove the lift and tilt end cap / spool lock block. (See
End Cap Block Removal And Installation on Page 20-40- 2
14.)
Figure 20-40-81
P-90323
Remove the spool centering block (Item 1) [Figure 20-

1 2
40-83] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

83] and lubricate the O-ring lightly with grease or oil
before installation of the end cap / spool lock block.

P-51521
Figure 20-40-84

20-40-81] from the tilt spool.
Figure 20-40-82
P-51544
2 1 Remove the tilt spool, centering spring, back-up washer

and spool seal [Figure 20-40-84].
P-90321
Assembly: Always use a new spool seal.

from the spool centering block.
Remove the three screws (Item 2) [Figure 20-40-82]

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

in-lb) torque.

Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-85
3
4
1
N-18944A
N-18942
Figure 20-40-88
Put the linkage end of the spool in the vise [Figure 20-
2

40-85].
1
Install the spool tool (Item 1) [Figure 20-40-85] over the
centering spring.
Figure 20-40-86
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

N-19014
Remove the bolt (Item 1) [Figure 20-40-86] holding the

centering spring to the spool.

in-lb) torque.
Remove spring tool from the spring assembly.

Auxiliary Spool Removal And Installation
Figure 20-40-89
1
1
2 3 2
P-51547
2 1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-91] from the auxiliary spool.
P-90321
Figure 20-40-92
Remove the two tubelines (Item 1) [Figure 20-40-89]



in-lb) torque. 2
1
40-89] from the control valve.
Figure 20-40-90
P-51549A
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-92] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

2 20-40-92] must be replaced, replace the
1 retainer on the opposite end also.
P-51546A


20-40-90] must be replaced, replace the
retainer on the opposite end also.

Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-93
1
2
P-51550

Figure 20-40-94
P-51551
Remove the spool (Item 1) [Figure 20-40-94].

Auxiliary Solenoid Removal And Installation
Figure 20-40-95
1
2
P-85528
Remove the screws (Item 1) [Figure 20-40-95] from both

solenoids.
Remove the solenoids (Item 2) [Figure 20-40-95] from

the control valve.
Installation: Tighten the nut to 2,44 - 2,98 N•m (21.6 -

26.4 in-lb) torque.
Figure 20-40-96
P-85556
Remove the O-rings (Item 1) [Figure 20-40-96] from the

solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.1 - 6.1 ohm.

Solenoid Removal And Installation
Figure 20-40-97 1
1
2
P-85528
Remove the solenoid stem (Item 1) [Figure 20-40-99].
P-90310 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-97] from the Figure 20-40-100

solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-97]. 3

2
Figure 20-40-98
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-100] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-98] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-100] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-98] and

[Figure 20-40-100] and new back-up rings (Item 2)
[Figure 20-40-100] on the solenoid stem.

Lock Valve Removal And Installation
Figure 20-40-101 1
1
1
1
2
2
1
2
2 P-51564

[Figure 20-40-103] from the lift lock valve, and replace
P-90310 with new.
Figure 20-40-104
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-101] is for the lift

circuit.
Figure 20-40-102
P-51705
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-

104].
P-90321
Remove the lift lock valve (Item 1) [Figure 20-40-102]

from the back of the control valve.
Installation: Lightly lubricate the lock valve O-rings and


Lock Valve Removal And Installation (Cont’d)
Figure 20-40-105 1
1
1
2
1
2
2
1 2
P-51564

[Figure 20-40-107] from the tilt lock valve, and replace
P-90325 with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-

40-105].

Remove the tilt spool lock solenoid (Item 2) [Figure 20-
40-105].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-106
P-90324
Remove the tilt lock valve (Item 1) [Figure 20-40-106]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
Figure 20-40-110
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-108
1
P-51707
P-90308 Remove the main relief valve (Item 1) [Figure 20-40-

110].
Remove the fitting (Item 1) [Figure 20-40-108] from the Figure 20-40-111

valve.
Figure 20-40-109
P-51463
P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-111].
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Always use new O-rings. Tighten to 52 - 61
109]. N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve

casting.

Check Valve Removal And Installation
Figure 20-40-112
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-40-115
Remove the tubeline (Item 1) [Figure 20-40-112].

Figure 20-40-113
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-40-115].
Remove the check valve fitting (Item 1) [Figure 20-40-

113] from the hydraulic control valve.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER
MODELS)
Description
Figure 20-41-1
P107871


lift, tilt, and auxiliary functions.
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.

the right side control handle / lever. The activated
The hydraulic control valve is designed with two relief

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

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

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Remove the control panel. (See Removal And Installation
MODELS) (CONT’D) on Page 50-100-2.)
Removal And Installation Remove the control linkage. (See Linkage Removal And

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

when tubelines or hoses are removed.
Clean area around control valve.
Open rear door.
Figure 20-41-2
P-90328
AVOID DEATH
3
can cause lift arms to drop. 1

D-1009-0409
2
WARNING
P-90187
support device. Failure to use an approved lift arm Remove the two bolts (Item 1), move the hose clamp
support device can allow the lift arms or attachment (Item 2) to the middle of the hose, and place the fuel inlet
to fall and cause injury or death. assembly (Item 3) [Figure 20-41-2] of to the side.
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888

support device. (See Installing on Page 10-20-1.)
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)

MODELS) (CONT’D)
Figure 20-41-3
P-90267
The fixed end main valve hose assembly is connected to


to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
1) [Figure 20-41-3].
Figure 20-41-4
P-90269



hydraulic pump.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Figure 20-41-7
MODELS) (CONT’D)
Figure 20-41-5
2 2
2
1
P-90272
P-90270 Disconnect the two tubelines (Item 2) [Figure 20-41-7]

hydraulics.

routes from the control valve to the brake valve. Figure 20-41-8

Figure 20-41-6
1
1
P-90273
P-90271

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

MODELS) (CONT’D)
Figure 20-41-9
1 1
1
P-90276
1 Disconnect the hose (Item 1) [Figure 20-41-11] that

P-90274 fitting of the hydraulic pump.
Figure 20-41-12

the rear of the loader.
Figure 20-41-10
1
1
2
P-90278
Support the control valve and remove the two bolts (Item
1) [Figure 20-41-12].
P-90275
Remove the control valve from the loader.

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


MODELS) (CONT’D)
Mount Bracket Removal And Installation
Figure 20-41-13
P-90280
Support the mount bracket (Item 1) [Figure 20-41-13].

Figure 20-41-14
P-90279

[Figure 20-41-14].
Installation: Torque the two frame bolts (Item 2) [Figure

20-41-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) (CONT'D)
Figure 20-41-15
AR
C2 J2 C3
J4
B3 E3
F2 E3 G1
G2
D5 A3
D6
B2 A2 D3
E2
D4 F4 C4
D1 H2
D2
A1
H3 E1
B1
F3 MR

F1 H1 J1 J3
C1
NA5826

D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
J3 Lift Arm Bypass Orifice
(276 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – Without Auxiliary Relief Valve
(276 bar) (4000 psi) 24132 kPa (241 bar) (3500 psi)
Tilt (Rod End) MR Main Relief Valve - With Auxiliary Relief Valve
25511-26200 kPa (255-262 bar) (3700-3800 psi)
AR Auxiliary Relief Valve - If Equipped 23787 - 24476
27579 kPa (276 bar) (4000 psi) (Optional)
kPa (238-245 bar) (3450-3550 psi)
27579 kPa (276 bar) (4000 psi) (Optional)

MODELS) (CONT'D)
Lift Load Check Valve Removal And Installation
IMPORTANT 1
damage the system.
I-2003-0888
P107873
Figure 20-41-16
17] and fitting from the top of the control valve.


Figure 20-41-18
1
1
P107872
2
from the BICS™ valve fitting on the top of the lift load
check valve. 3
4
P107716
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-18].
Inspect the spring (Item 3) and the free movement in the

Inspect the orifice to make sure it is not plugged (Item 5)

[Figure 20-41-18].

MODELS) (CONT'D)
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
Figure 20-41-19 1
2
1 4
3
2 P107624

20-41-20].
P107874 Inspect the orifice (Item 3) [Figure 20-41-20] in the

poppet to make sure it is not plugged.

At the front side of the control valve locate and remove Installation: Install a new O-ring (Item 4) [Figure 20-41-
the tilt section load check valve (Item 1) [Figure 20-41- 20] and lubricate with oil before installing. Tighten the
19]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove

the auxiliary section load check valve (Item 2) [Figure
20-41-19].

interchangeable.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Port Relief / Anti-Cavitation Valve Removal And
MODELS) (CONT’D) Installation (Lift, Base End)

Rod End)
Figure 20-41-21
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-23].

At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-21]. Figure 20-41-24
Figure 20-41-22
1
2
2
1
4
P107952
3
P107624
Remove the O-ring (Item 1) [Figure 20-41-24] from the
port relief / anti-cavitation relief valve.
20-41-22]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-41-24] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-41-22] in the needed.
Installation: Tighten the port relief anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-41- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Port Relief / Anti-Cavitation Valve Removal And
MODELS) (CONT'D) Installation (Tilt, Rod End)

Figure 20-41-25
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-27]
from the rod end of the tilt section.

[Figure 20-41-25] from the base end of the tilt section. Figure 20-41-28
Figure 20-41-26
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.

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

to 47 N•m (35 ft-lb) torque.

MODELS) (CONT'D)
Port Relief Valve Removal And Installation
Figure 20-41-29
P107628

P107628

Figure 20-41-30
1
1
P107629
2
P107630 Remove the O-ring (Item 1) [Figure 20-41-32] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
[Figure 20-41-30] from the port relief plug.

MODELS) (CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-33
P107628

P107628

Figure 20-41-34
2
P107629


MODELS) (CONT'D)
Figure 20-41-37
P107632

(Item 1) [Figure 20-41-39].
P107631
Figure 20-41-40
1) [Figure 20-41-37].

Figure 20-41-38
1
P107633

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

plug.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER End Cap Block Removal And Installation
MODELS) (CONT'D)
Figure 20-41-43
Rubber Boot Removal And Installation
Figure 20-41-41
1
2
1
1 P107772
P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-41-43] from the
end cap block.
Remove the three screws (Item 1) [Figure 20-41-41] on

the rubber boot retainer plate. Figure 20-41-44

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-42
1
2
1 P107666
Disconnect the tubeline (Item 1) [Figure 20-41-44] from

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

(Item 2) [Figure 20-41-42].

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Lift Spool And Detent Removal And Installation
MODELS) (CONT'D)
The tools listed will be needed to do the following
End Cap Block Removal And Installation (Cont’d) procedure:
Figure 20-41-45 MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap block from the control valve.
Figure 20-41-46
2
1
1
P107773
Remove the end cap block mount screw (Item 1) [Figure

20-41-45].
P107776
11,6 N•m (95 - 105 in-lb) torque.
Remove the O-ring (Item 1) [Figure 20-41-46].
Remove the end cap block (Item 2) [Figure 20-41-45]
from the control valve. Installation: Replace the O-ring, and lubricate the O-ring
lightly with grease or oil before installation of the end cap
block.
Figure 20-41-47
P107775


MODELS) (CONT'D)

(Cont’d)
Figure 20-41-48
P107846
NOTE: Do not remove the sleeve detent (Item 1) or

1 retaining ring (Item 2) [Figure 20-41-50] from
the spool centering block. If removed, the
P107779 sleeve detent must be inserted with the
original orientation.

Remove the four screws (Item 1) [Figure 20-41-48] from Figure 20-41-51
the spool centering block.
Figure 20-41-49
2
2
P107845A
1
P107778 NOTE: If removed, use the following for correct

installation: for a radius lift pattern machine,
align the radius side (Item 1) [Figure 20-41-51]
Remove the spool centering block (Item 1) [Figure 20- so it faces the opening of the spool centering
41-49]. block when seated. For a vertical lift pattern
machine, align the vertical side (Item 2)
Remove the O-ring (Item 2) [Figure 20-41-49]. [Figure 20-41-51] so it faces the opening when
seated. Install retaining ring over detent
sleeve.

MODELS) (CONT'D)

(Cont’d)
Figure 20-41-52
P107739
2
41-54].
1
P107790 NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly (Item 1) and O-ring (Item
2) [Figure 20-41-52] from the control valve.
Figure 20-41-53
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-41-55
2
1
1
P107757A
Remove the lift spool seal (Item 1) [Figure 20-41-53]

from the linkage end of the valve.
P107674A

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

(Item 2) [Figure 20-41-55] from the centering
spring, as it is under spring pressure.

MODELS) (CONT'D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-41-56
4
2
1
P107676
Remove spring tool (Item 1) from the spring assembly

2 (Item 2) [Figure 20-41-58].
P107674 Figure 20-41-59

Remove the spring assembly / spring tool (Item 1) from
the spool (Item 2) [Figure 20-41-56]. 2
3 1
NOTE: The detent adapter has two detent balls (Item 4
3) held under pressure from a detent spring
(Item 4) [Figure 20-41-58]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-41-57
P107677
1 Inspect the adapter (Item 1), collar (Item 2), spring (Item
P107675
Remove the detent adapter (Item 1) [Figure 20-41-57]

from the spring assembly.

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-60
1
N-18967
Clamp the collar (Item 1) [Figure 20-41-62] in a vise.
Figure 20-41-63
N-18918

Remove the stud from the end of the spool [Figure 20-
41-60]. 3
Figure 20-41-61 2
P107677
Apply grease on all the detent component surfaces

15,2 mm before assembly [Figure 20-41-63].
(0.60 inch)
Install the spring (Item 1) [Figure 20-41-63] and detent
B-14712B balls (Item 2) [Figure 20-41-63] into the adapter (Item 3)
[Figure 20-41-63] and compress with the detent pliers
(Item 1) [Figure 20-41-64].
Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-41-61].

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-64
P107674
1
Install the spring assembly to the lift spool hand tight
[Figure 20-41-66].
N-18968A Remove the spring tool.
Check the alignment of the detent adapter and the

Install the detent adapter (Item 1) [Figure 20-41-64] to washer.
the collar.
Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb).
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled NOTE: The adapter must fit in the center of the
to the lift spool not the detent balls. Hold the washer.
detent adapter and collar together to prevent
the detent balls and spring from falling out. Figure 20-41-67
Figure 20-41-65 2
P107790
P107675
Lubricate and install a new O-ring (Item 1) [Figure 20-41-
67].
washer, spring, collar, and detent adapter. Lubricate and install a new O-ring (Item 2) [Figure 20-41-
67].
Install the lift spool assembly (Item 3) [Figure 20-41-67]

in the spool bore.

MODELS) (CONT'D)

(Cont'd)
Figure 20-41-68
2
1
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure

2 20-41-70] on the lift spool.
P107779 Figure 20-41-71

Install the spool centering block (Item 1) [Figure 20-41-
68].
Install the four mounting screws (Item 2) [Figure 20-41-

68].
1
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-69
P107776
1
Install an O-ring (Item 1) [Figure 20-41-71] on the control

valve.
P107679A
Install a new spool seal (Item 1) [Figure 20-41-69] on the


MODELS) (CONT'D)

(Cont'd)
Figure 20-41-72
2
2
1
1
3
P107772
4
Use an ohmmeter to measure the lock solenoid coils
resistance.
P107664A The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap block (Item 1) and the mount bolt (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
(Item 2) [Figure 20-41-72]. 45 ft-lb) torque [Figure 20-41-74].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-41-72].

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-73
P107666
Connect the tubeline (Item 1) [Figure 20-41-73].

MODELS) (CONT'D)
Remove the lift and tilt end cap block. (See End Cap
Block Removal And Installation on Page 20-41-15.) 2
Figure 20-41-75
1
P107778

1 41-77] from the control valve.

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

Figure 20-41-78
Installation: Install the spacer (Item 1) and an O-ring

2
(Item 2) [Figure 20-41-75].
Figure 20-41-76
P107780
Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure

20-41-78].
1
P107779 78] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
Remove the four screws (Item 1) [Figure 20-41-76] from


11,6 N•m (95 - 105 in-lb) torque.

MODELS) (CONT'D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-41-79
1
P107647

P107781
in-lb) torque.
Remove the tilt spool seal (Item 1) [Figure 20-41-79].

Remove the spring tool from the spring assembly.
Figure 20-41-82
Figure 20-41-80
2 1
3
1 4
N-18944B
P107646
Put the linkage end of the spool in the vise [Figure 20- 3), and washer (Item 4) [Figure 20-41-82].
41-80].
NOTE: Protect spool before clamping in vise.

centering spring.

MODELS) (CONT'D)
Figure 20-41-83
1
3 2
4
1
2
4
P107783

3 (Item 2) [Figure 20-41-84] from the auxiliary spool.
P107782

Remove the spacer (Item 3) and O-ring (Item 4) [Figure retainer on the opposite end also.
Installation: Lubricate and install an O-ring (Item 4)
NOTE: If the centering spring retainer (Item 2) [Figure [Figure 20-41-84].
retainer on the opposite end also. Figure 20-41-85
Installation: Lubricate and install an O-ring (Item 4)

[Figure 20-41-83].
P107784
Remove the auxiliary spool (Item 1) [Figure 20-41-85].

MODELS) (CONT'D)
Figure 20-41-86 1
2
1
2
2
P107798
1

[Figure 20-41-87] from the solenoid stem.
P107876
resistance.

solenoids. The correct resistance for the coil is 5.1 ohm.
Remove the solenoids (Item 2) [Figure 20-41-86] from Installation: Lubricate and install new O-rings (Item 1)
the control valves. and back-up rings (Item 2) [Figure 20-41-87].
Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9

in-lb) torque.

MODELS) (CONT'D)
Figure 20-41-88
1
1
2
P107876
P107875 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.

solenoid stem.

2
Figure 20-41-89
N-18694


N-18693A
excessive wear.
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.

MODELS) (CONT'D)
Figure 20-41-92
2
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure

20-41-94] is threaded for easier removal and installation.
P107785
Figure 20-41-95
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-

92]. 1 3
2
Figure 20-41-93
P107767
Remove and inspect the spring (Item 2) and BICS™

P107786 valve (Item 3) [Figure 20-41-95].

Installation: Lightly lubricate the lock valve retaining cap

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

MODELS) (CONT'D)
Figure 20-41-96
2
1
P107937

P107788
Figure 20-41-99
Remove the lift spool lock solenoid (Item 1) [Figure 20-

41-96].

1 3
Remove the tilt spool lock solenoid (Item 2) [Figure 20-
2
41-96].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-41-97
P107767

valve (Item 3) [Figure 20-41-99].
1
P107789

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) (LATER Main Relief Valve Removal And Installation
MODELS) (CONT'D)
Figure 20-41-102
Figure 20-41-100
P107787
1
P107693 Remove the main relief valve (Item 1) [Figure 20-41-

102].
Remove the fitting (Item 1) [Figure 20-41-100] from the Figure 20-41-103

valve.
Figure 20-41-101
1
1
P-51463
P-51437 Remove the O-rings (Item 1) [Figure 20-41-103] from the

main relief valve.
Inspect the lift arm bypass orifice (Item 1) [Figure 20-41- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
101].

casting.

HYDRAULIC CONTROL VALVE (STANDARD) (LATER Check Valve Removal And Installation
MODELS) (CONT'D)
Figure 20-41-106
NOTE: The auxiliary relief valve (Item 1) [Figure 20-

41-104] is an optional item and may not be
installed.
Figure 20-41-104
P107693
Figure 20-41-107

P107870

104].
Figure 20-41-105 1
P107786

P107627
Remove the O-rings (Item1) and back-up ring (Item 2)

[Figure 20-41-105] from the auxiliary relief valve.

MODELS) (CONT'D)
Check Valve Removal And Installation (Cont’d)
Figure 20-41-108
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-108].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
(EARLIER MODELS)
Description
Figure 20-42-1 DANGER

1
P-90328
AVOID DEATH
P-90337 • Keep out of this area when lift arms are raised
NOTE: The 90° fitting (Item 1) [Figure 20-42-1] has D-1009-0409

been replaced with a tee fitting on late model
machines.

WARNING
The hydraulic control valve is the hydraulic component Never work on a machine with the lift arms up unless
that uses spools to direct the flow of hydraulic fluid to the the lift arms are secured by an approved lift arm
lift, tilt and auxiliary functions. support device. Failure to use an approved lift arm
The lift and tilt functions in the hydraulic control valve are to fall and cause injury or death.
operated using electronic control handles / levers that W-2059-0598
send an electronic signal to the electronic actuators to
move the lift and tilt spools in the control valve.

IMPORTANT
the right side control handles / levers. The activated
solenoid sends pilot pressure fluid to one side of the When repairing hydrostatic and hydraulic systems,
spool and forces the spool to shift. clean the work area before disassembly and keep all
The hydraulic control valve also contains a main relief tubelines and ports to keep dirt out. Dirt can quickly
valve which is adjustable. damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-42-3

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

Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
P-90267

connections for correct installation. The fixed end main valve hose assembly is connected to
NOTE: Cap and plug all hydraulic connection points to the junction block at the rear of the loader where it
when tubelines or hoses are removed. feeds the base end of both lift cylinders. The hose can
Clean area around control valve. 1) [Figure 20-42-3].

Open rear door.
Figure 20-42-2
3
1
P-90187
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and place the fuel inlet
assembly (Item 3) [Figure 20-42-2] off to the side.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) NOTE: The hose (Item 1) has been relocated to the tee
(EARLIER MODELS) (CONT’D) fitting on top of the load check valve (Item 3)
[Figure 20-42-5] on late model machines.
Figure 20-42-6
Figure 20-42-4
2
1
1
1
P-107219
P-90269

Disconnect the wire harness connectors (Item 1) [Figure routes from the control valve to the brake valve.

Disconnect the hose (Item 2) [Figure 20-42-4] that routes from the control valve to the fan motor.
Figure 20-42-7
hydraulic pump.
Figure 20-42-5
1
P-90271

3 routes from the top of the control valve to the hydraulic
P-90270 filter.

routes from the control valve to the brake valve.


Figure 20-42-8
1 1
2 2
1 1
P-90274
Disconnect the three tubelines (Item 1) [Figure 20-42-

10] that route from the control valve to the junction block
P-90272 at the rear of the loader.
Figure 20-42-11

1
hydraulics.
Figure 20-42-9
P-90275

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


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (In Loader)
Figure 20-42-12
WARNING
W-2059-0598

1
Mark the actuator wiring harness connectors for proper

P-90276 installation.
Figure 20-42-14

fitting of the hydraulic pump.
Figure 20-42-13
P-90330
Unplug the actuator connectors (Item 1) [Figure 20-42-

14] from the loader harness.
P-90278
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-42-13].

Actuator Removal And Installation (In Loader)

(Cont’d)
Figure 20-42-15
1
2
1
P-54568
Inspect the O-ring (Item 1) [Figure 20-42-17] on the face

of the actuator, and replace as needed.
P-54587 Inspect the linkage pin (Item 2) [Figure 20-42-17] and

replace as needed.

Remove the two screws (Item 1) [Figure 20-42-15] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.
Figure 20-42-16
P-54566
Pull the actuator (Item 1) [Figure 20-42-16] away from

the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure

20-42-16] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

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

Actuator Removal And Installation (Out Of Loader)
Figure 20-42-18
P-54339
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-42-20] from the actuator
and the tilt spool.
P-54337 Remove the actuator and linkage pin from the valve.

Figure 20-42-21
Remove the two mount bolts (Item 1) [Figure 20-42-18]
from the tilt actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-42-19
P-54340
1 Inspect the O-ring (Item 1) [Figure 20-42-21] on the face

of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-42-21] and

P-54338 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-42-

19] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
42-19].

Actuator Removal And Installation (Out of Loader)

(Cont’d)
Figure 20-42-22
1 1
P-54343
Using a punch and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-42-24] from the actuator
1 and the tilt spool.
P-54341
Remove the actuator and linkage pin from the valve.

Remove the two mount bolts (Item 1) [Figure 20-42-22] Figure 20-42-25
from the lift actuator.

Figure 20-42-23
P-54340
Inspect the O-ring (Item 1) [Figure 20-42-25] on the face

1 of the actuator, and replace as needed.
P-54342 Inspect the linkage pin (Item 2) [Figure 20-42-25] and

replace as needed.

42-23].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)

(Cont’d)
Figure 20-42-26
4 3
1
3
P-90329

NOTE: The two longer bolts (Item 1) are used to
mount the lift actuator and end cap (Item 2)
[Figure 20-42-26] to the control valve. The two
shorter mount bolts (Item 3) are used to
mount the tilt actuator to the end cap (Item 4)
[Figure 20-42-26].

N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-42-26]

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) (CONT’D)
Figure 20-42-27
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3

H1 J1 C1
P-90307

D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24132 kPa (241,3 bar)
(3500 psi)
(275,8 bar) (4000 psi)
Tilt (Rod End)
27579 kPa (275,8 bar) (4000 psi) (Optional)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
Figure 20-42-30
Figure 20-42-28
P-90308
P-90280 Remove the charge tubeline (Item 1) [Figure 20-42-30]

check valve.
Support the mounting bracket (Item 1) [Figure 20-42-28].

Figure 20-42-31
Figure 20-42-29
2
1
P-90310
P-90279

Remove the two control valve mount bolts (Item 1) 31] and fitting from the top of the control valve.
[Figure 20-42-29].
Remove the two frame bolts (Item 2) [Figure 20-42-29]. tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

20-42-29] to 406 - 447 N•m (300 - 330 ft-lb).

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(EARLIER MODELS) (CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-42-33

(Cont’d)
Figure 20-42-32
2
1
4
5
2
P-90311
3
P-90309 At the front side of the control valve locate the tilt section

Remove and install new O-rings (Item 1) and back-up At the front side of the control valve locate the auxiliary
ring (Item 2) [Figure 20-42-32]. section load check valve (Item 2) [Figure 20-42-33].

interchangeable.
IMPORTANT Figure 20-42-34
damage the system.
I-2003-0888
2
Inspect the spring (Item 3) and the free movement in the 3

4
Inspect the orifice to make sure it is not plugged (Item 5)

[Figure 20-42-32].
P-90312

20-42-34].


torque.

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

Rod End)
Figure 20-42-35
P-90314
P-90314 Loosen the lift circuit port relief / anti-cavitation valve

(Item 1) [Figure 20-42-37].

At the back side of the control valve, remove the lift Figure 20-42-38
section anti-cavitation valve (Item 1) [Figure 20-42-35].
Figure 20-42-36
3 1
4
P-90315

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-42-36].


torque.

(EARLIER MODELS) (CONT’D) Installation (Tilt, Rod End)

Figure 20-42-39
P-90314
P-90314 Remove the tilt port relief / anti-cavitation valve (Item 1)

[Figure 20-42-41] from the rod end of the tilt section.

Figure 20-42-42
[Figure 20-42-39] from the base end of the tilt section.
Figure 20-42-40
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-42-40] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.

Port Relief Valve Removal And Installation 1
Figure 20-42-43
P-90318A

P-90314

Figure 20-42-44
P-51640
P-90318 Installation: Always use new O-rings (Item 1) [Figure



Figure 20-42-47
1
P-51461

(Item 1) [Figure 20-42-49].
P-68016
Figure 20-42-50
1) [Figure 20-42-47].

Figure 20-42-48
P-51462

1 20-42-50]. Tighten to 81,3 N•m (60 ft-lb) torque.
P-51460A

20-42-48]. Tighten to 81,3 N•m (60 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-42-5.) Remove the end cap block from the control valve.
Figure 20-42-51 Figure 20-42-53
1 2

P-90338
P-68042
Disconnect the tube line (Item 1) [Figure 20-42-51] from Remove the O-ring (Item 1) [Figure 20-42-53].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-42-51].
Figure 20-42-54
100 in-lb) torque.
Figure 20-42-52
P-68047
1
P-90339 20-42-54] from the lift spool.

from the control valve.

Lift Spool Removal And Installation (Cont'd)
Figure 20-42-55
1
1
P-68045
1
Remove the lift spool assembly and seal (Item 1) [Figure

P-68043
Figure 20-42-58
Remove the two screws (Item 1) [Figure 20-42-55] from

the lift spool end cap.

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-42-56
P-68046
1 Remove the lift spool seal (Item 1) [Figure 20-42-58]

from the linkage end of the valve.
P-68044
Remove the lift spool end cap (Item 1) [Figure 20-42-56]


Lift Spool Removal And Installation (Cont’d)

1
Figure 20-42-59
N-190146

P-51772
in-lb) torque.

42-59]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-42-62
Figure 20-42-60
3
4 1
1
P-51776
P-51773
centering spring.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) NOTE: The lift spool will have an internal leak if there
(EARLIER MODELS) (CONT’D) is damage to this O-ring. Always replace the
O-ring. Always replace the O-ring and inspect
Lift Spool Removal And Installation (Cont’d) the lift spool before the control valve is
replaced.
Figure 20-42-63
Figure 20-42-65
N-18920
P-74184
Removal of the plastic plug:

Make a center point in the plug using a 1,6 mm (1/16 in) Install the plastic plug and O-ring in the spool [Figure 20-
drill. 42-65].
Drill a hole all the way through the plug using a 2,8 mm Figure 20-42-66
(7/64 in) tap drill.
Turn a 6-32 tap (Item 1) [Figure 20-42-63] into the plug.

Pull the tap and plug out of the spool. Be careful, do not 2
1
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.
1
Figure 20-42-64
P-68046 P-51775
2
1 Remove the spool seal(s) (Item 1) and the back-up

P-74183
Install the O-ring (Item 1) over the nipple on the plastic


Lift Spool Removal And Installation (Cont’d)
Figure 20-42-67
1
2
1
2
3 P-68047
3
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-42-69] on the lift spool.
P-68044
Figure 20-42-70
Install the lift spool assembly (Item 1) [Figure 20-42-67]

in the spool bore.
1
Install the end cap (Item 2) [Figure 20-42-67].
Install the mounting screws (Item 3) [Figure 20-42-67].

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-42-68
P-68042
Install the O-ring (Item 1) [Figure 20-42-70] on the

control valve.
1
Installation: Replace the O-ring, lubricate lightly with oil
or grease before installation of the end cap block.
P-68048
Install the spool seal (Item 1) [Figure 20-42-68] on the


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block
Lift Spool Removal And Installation (Cont’d) Removal And Installation on Page 20-42-17.)
Figure 20-42-71 Figure 20-42-72
2
2
P-68040
P-68049
Install the end cap block (Item 1) and the two mount bolts Remove the spacer (Item 1) and O-ring (Item 2) [Figure
(Item 2) [Figure 20-42-71].

Installation: Tighten the screws to 10,2 - 11,3 N•m (90 - Figure 20-42-73
100 in-lb) torque.
Connect the tubeline (Item 3) [Figure 20-42-71] to the

end cap block.
1
Install the lift and tilt actuators to the control valve.
P-90321
Disconnect the two tubelines (Item 1) [Figure 20-42-73].


in-lb) torque.

Tilt Spool Removal And Installation (Cont’d)
Figure 20-42-74 1
N-18942
1
Put the linkage end of the spool in the vise [Figure 20-
42-76].
P-90342
centering spring.

42-74] from the control valve. Figure 20-42-77

74] and lubricate lightly with oil / grease before
installation of the end cap block.
1
Figure 20-42-75
1
N-19014

P-68052 Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100
in-lb) torque.
Remove the tilt spool, centering spring, back-up washer Remove spring tool from the spring assembly.
and spool seal (Item 1) [Figure 20-42-75].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Spool Removal And Installation
Figure 20-42-80
Tilt Spool Removal And Installation (Cont’d)
Figure 20-42-78
2 1
3
2
4
1
P-90321
N-18944A Disconnect the two tubelines (Item 1) [Figure 20-42-80]

Inspect the adapter (Item 1), collar (Item 2), spring (Item Remove the three screws (Item 2) [Figure 20-42-80]

Figure 20-42-79 Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
2
1 Remove the spool centering block from the control valve.
Figure 20-42-81
2
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up 1

P-68053



Figure 20-42-82
2
2
P-68077
1
P-68054
Figure 20-42-85

Figure 20-42-83
2
1 P-68078
Remove the auxiliary spool (Item 1) [Figure 20-42-85].
P-68076



Figure 20-42-86
1
2
P-90337

solenoids.
Remove the solenoids (Item 2) [Figure 20-42-86].
Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6

- 26.4 in-lb) torque.
Figure 20-42-87
P-85556

solenoid stem.

resistance.

Figure 20-42-88 1
P-90346
P-90337 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.

solenoid stem.

2
Figure 20-42-89
N-18694


N-18693A
excessive wear.
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-42-89] and

[Figure 20-42-91] and new back-up rings (Item 2)
[Figure 20-42-91] on the solenoid stem.

Figure 20-42-92
1
2 P-51792

P-90310
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-42-92] is for the lift circuit.

Figure 20-42-95
Figure 20-42-93
1
1
1
1
1
2
2
2
P-51564
P-90321
[Figure 20-42-95] from the valve, and replace with new.


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
Figure 20-42-98
Figure 20-42-96
1
P-51794
P-90308 Remove the main relief valve (Item 1) [Figure 20-42-98].
Figure 20-42-99
Remove the fitting (Item 1) [Figure 20-42-96] from the

valve.
Figure 20-42-97
1
1
P-90344
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-42-99].
Installation: Always use new O-rings. Tighten to 52 - 61

Inspect the lift arm bypass orifice (Item 1) [Figure 20-42- N•m (38 - 45 ft-lb) torque.
97].

casting.

Check Valve Removal And Installation
Figure 20-42-100
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-42-

102] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-42-103

Figure 20-42-101
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-42-103].


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
(LATER MODELS)
Description
Figure 20-43-1 DANGER
P-90328
AVOID DEATH
P107847 • Keep out of this area when lift arms are raised
The hydraulic control valve is located inside the main D-1009-0409

lift, tilt, and auxiliary functions.
WARNING
The lift and tilt functions in the hydraulic control valve are Never work on a machine with the lift arms up unless
operated using electronic control handles / levers that the lift arms are secured by an approved lift arm
send an electronic signal to the electronic actuators to support device. Failure to use an approved lift arm
move the lift and tilt spools in the control valve. support device can allow the lift arms or attachment
The auxiliary function is operated by pilot pressure. W-2059-0598
the right side control handles / levers. The activated
IMPORTANT
The hydraulic control valve is designed with two relief
valve ports. The main relief valve is used on the 800, 700, When repairing hydrostatic and hydraulic systems,
and 600 series loaders. The auxiliary relief valve is clean the work area before disassembly and keep all
standard on the 800 series and may be present on the parts clean. Always use caps and plugs on hoses,
700 and 600 series. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The relief valves are adjustable and located on the I-2003-0888
hydraulic control valve. The main relief valve port is

adjacent to the actuator side. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

(LATER MODELS) (CONT’D)

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


on Page 50-100-2.)
P-90267

connections for correct installation. The fixed end main valve hose assembly is connected to
NOTE: Cap and plug all hydraulic connection points to the junction block at the rear of the loader where it
when tubelines or hoses are removed. feeds the base end of both lift cylinders. The hose can
Clean area around control valve. 1) [Figure 20-43-3].

Open rear door. Figure 20-43-4
Figure 20-43-2
3
1
3
2 1
P-90269
P-90187
(Item 2) to the middle of the hose, and the place the fuel Disconnect the hose (Item 2) [Figure 20-43-4] that
inlet assembly (Item 3) [Figure 20-43-2] off to the side. routes from the control valve to the drain manifold.

hydraulic pump.

Figure 20-43-5
2 2
1
2
P-90272

1
P107219 Disconnect the two tubelines (Item 2) [Figure 20-43-7]
hydraulics.

routes from the control valve to the brake valve. Figure 20-43-8

Figure 20-43-6
1
1
P-90273
P-90271

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

Figure 20-43-9
1 1
1
P-90276
1 Disconnect the hose (Item 1) [Figure 20-43-11] that

P-90274 fitting of the hydraulic pump.
Figure 20-43-12

the rear of the loader.
Figure 20-43-10
1
1
2
P-90278
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-43-12].
P-90275

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


WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-1.) Remove the two screws (Item 1) [Figure 20-43-14] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.

Figure 20-43-15
Figure 20-43-13
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-43-15] away from

Unplug the actuator connectors (Item 1) [Figure 20-43- the control valve.
13] from the loader harness.
Use a punch to remove the actuator pin (Item 2) [Figure
20-43-15] from the actuator and spool.
Remove the actuator from the hydraulic control valve.

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

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (Out Of Loader)
(Cont’d) Figure 20-43-17
Figure 20-43-16 1
1
2
1
P107802
P-54568
from the tilt actuator.

Remove the O-ring (Item 1) [Figure 20-43-16] on the
face of the actuator. Installation: Tighten the mounting bolts to 10,2 - 11,3
replace as needed. Figure 20-43-18
NOTE: Repeat this procedure to remove the lift

actuator.
P107803

43-18].

Actuator Removal And Installation (Out of Loader)

(Cont’d)
1
Figure 20-43-19
1
P107804
1
from the lift actuator.
P107808 Installation: Tighten the mounting bolts to 10,2 - 11,3


Using a punch and a hammer, remove the actuator Figure 20-43-22
linkage pin (Item 1) [Figure 20-43-19] from the actuator
and the tilt spool.
Figure 20-43-20
1
1
P107805
2 Slide the actuator mount bracket (Item 1) [Figure 20-43-

P-54340 Pull the actuator away from the control valve [Figure 20-
43-22].

face of the actuator.

replace as needed.

4
(Cont’d)
Figure 20-43-23
2
1 3
P107807A
1
NOTE: The two long bolts (Item 1) are used to mount
the lift actuator (Item 2) [Figure 20-43-25] to
the control valve. The two short bolts (Item 3)
P107806 are used to mount the tilt actuator (Item 4)
[Figure 20-43-25].

Using a punch and a hammer, remove the actuator Installation: Tighten the mounting bolts to 10,2 - 11,3
linkage pin (Item 1) [Figure 20-43-23] from the actuator N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-43-25].
and the tilt spool.
Figure 20-43-24
P-54340

face of the actuator.

replace as needed.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) (CONT’D)
Figure 20-43-26
AR
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4
D1
H2
H3 D2
A1
E1
B1
F1 MR C1

H1
J3
J1
NA5825

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulics Female Coupler E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Male Coupler F1 Lift Spool
C1 Load Check F2 Tilt Spool
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
J3 Lift Arm Bypass Orifice
(2756 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – Without Auxiliary Relief
(276 bar) (4000 psi) Valve 24132 kPa (241 bar) (3500 psi)
Tilt (Rod End) MR Main Relief Valve – With Auxiliary Relief Valve
25511-26200 kPa (255-262 bar) (3700-3800 psi)
27579 kPa (276 bar) (4000 psi) (Optional) AR Auxiliary Relief Valve - If Equipped 23787-
24476 kPa (238-245 bar) (3450-3550 psi)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
Figure 20-43-27 IMPORTANT

damage the system.
I-2003-0888
1 Figure 20-43-29
P-90280
Support the mounting bracket (Item 1) [Figure 20-43-27].

Figure 20-43-28 1
2 P107848

check valve.
P100202

[Figure 20-43-28].

20-43-28] to 300 - 330 ft lb (406 - 447 N•m).

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(LATER MODELS) (CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-43-32

(Cont’d)
Figure 20-43-30
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-43-
32].

30] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-43-32].
Figure 20-43-31 interchangeable.
Figure 20-43-33
1
5
1
2
2
3 4 4
P107716
3
P107624
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-43-31].
Inspect the spring (Item 3) and the free movement in the 20-43-33].
Inspect the orifice to make sure it is not plugged (Item 5) poppet to make sure it is not plugged.
[Figure 20-43-31].
33] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

(LATER MODELS) (CONT’D) Installation (Lift, Base End)

Rod End)
Figure 20-43-34
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-43-36].

At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-43-34]. Figure 20-43-37
Figure 20-43-35
1
2
2
1
4
P107952
3
P107624
20-43-35]. Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-43-35] in the needed.
Installation: Install a new O-ring (Item 4) [Figure 20-43- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

(LATER MODELS) (CONT’D) Installation (Tilt, Rod End)

Figure 20-43-38
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-43-40]
from the rod end of the tilt section.

[Figure 20-43-38] from the base end of the tilt section. Figure 20-43-41
Figure 20-43-39
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.

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

to 47 N•m (35 ft-lb) torque.

Port Relief Valve Removal And Installation
Figure 20-43-42
P107628

P107628

Figure 20-43-43
1
1
2
P107629


Port Relief Valve Removal And Installation (Cont’d)
Figure 20-43-46
P107628

P107628

Figure 20-43-47
1
1
2
P107629


Figure 20-43-50
P107632

(Item 1) [Figure 20-43-52].
P107631
Figure 20-43-53
1) [Figure 20-43-50].

Figure 20-43-51
1
P107633

plug.
P107633

plug.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-43-5.) Remove the end cap block from the control valve.
Figure 20-43-54 Figure 20-43-56

2 P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-43-54] from Remove the O-ring (Item 1) [Figure 20-43-56].
the end cap block.
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-43-54].
Figure 20-43-57
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-43-55
1
P107753
1
P107852 20-43-57] from the lift spool.


Lift Spool Removal And Installation (Cont'd)
Figure 20-43-58
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-43-60] from the control valve.
P107854
Figure 20-43-61
Remove the four screws (Item 1) [Figure 20-43-58] from


11,6 N•m (95 - 105 in-lb) torque.
Figure 20-43-59
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-43-61]

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

(Item 2) [Figure 20-43-59] from the control valve.

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

Lift Spool Disassembly And Assembly
Figure 20-43-62
1
P107647

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

43-62]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-43-65
Figure 20-43-63
3
4 1
1
P-51776B
P107646
3), and washer (Item 4) [Figure 20-43-65].
centering spring.

Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-43-17.)
Figure 20-43-66 2
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-43-68].
2 Figure 20-43-69
P107856

Figure 20-43-67
P107770
Remove the spool seal (Item 1) [Figure 20-43-69].
P107769

with oil before installation of the spool centering block.

Tilt Spool Disassembly And Assembly

2 1
Figure 20-43-70
3
N-18944B
3), and washer (Item 4) [Figure 20-43-72].
P107646
Put the actuator end of the spool in the vise [Figure 20-

43-70].
NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-43-71
P107647


in-lb) torque.
Remove the spring tool from the spring assembly.

Figure 20-43-73
2
1
2 P107760

1 (Item 2) [Figure 20-43-75] from the auxiliary spool.
P107758
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.

Figure 20-43-76
Figure 20-43-74
1
2
P107761
1
P107759


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
Figure 20-43-78
Figure 20-43-77
1
2 2
1
1
P107847
P107762 Remove the screws (Item 1) [Figure 20-43-78] from both

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-43-77]. Remove the solenoids (Item 2) [Figure 20-43-78].

Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -
23.9 in-lb) torque.
Figure 20-43-79
P107798

[Figure 20-43-79] from the solenoid stem.

resistance.
The correct resistance for the coil is 5.1 ohm.
Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-43-79].

Figure 20-43-80 1
P107857
P107847 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.

solenoid stem.

2
Figure 20-43-81
N-18694


N-18693A
excessive wear.
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.

Figure 20-43-84
1 2 P107937

P107858
Figure 20-43-87
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-43-

84]. 1 3
Figure 20-43-85 2
1
P107767

P107859 valve (Item 3) [Figure 20-43-87].
Remove the lift lock valve retaining cap (Item 1) [Figure

20-43-85] from the back of the control valve.


Figure 20-43-88
1 P107937

P107860
Figure 20-43-90
Remove the tilt lock valve retaining cap (Item 1) [Figure

20-43-88] from the front of the control valve.
1 3
O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque. 2
P107767

valve (Item 3) [Figure 20-43-90].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
Figure 20-43-93
Figure 20-43-91
1
1 P107862
P107861 Remove the main relief valve (Item 1) [Figure 20-43-93].
Figure 20-43-94
Remove the fitting (Item 1) [Figure 20-43-91] from the

valve.
Figure 20-43-92
1 1
P107659

P-51437 main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-43-
92].

casting.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Check Valve Removal And Installation
Figure 20-43-97
Figure 20-43-95
1 1
P107848
P107863 Remove the tubeline (Item 1) [Figure 20-43-97].
Figure 20-43-98

95].
Figure 20-43-96
2 1
P107864
1
P107627 98] from the hydraulic control valve.
Remove the O-rings (Item 1) [Figure 20-43-96] and

back-up ring (Item 2) [Figure 20-43-96] from the auxiliary
relief valve.

Check Valve Removal And Installation (Cont’d)
Figure 20-43-99
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-43-99].
Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-

lb) torque.


LIFT ARM BYPASS CONTROL VALVE Testing
Description Figure 20-50-1
The lift arm bypass control valve is located on the right

side of the machine.
The lift arm bypass control valve is manually operated by 1

turning the lift arm bypass valve knob (Item 1) [Figure
20-50-1] 90 degrees clockwise, then pull up and hold the
lift arm bypass control knob until the lift arms slowly
lower. The valve releases the hydraulic fluid from the
base end of the lift cylinder(s) which allows the lift arm to
slowly come down to the transport position.
P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms

slowly lower.
The knob should return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
3
DANGER
2
P-85670
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the jam nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
• Keep out of this area when lift arms are raised Remove the lift arm bypass control knob (Item 1).
unless supported by an approved lift arm Remove the jam nut (Item 2) from the valve shaft [Figure

20-50-2].
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING
2
W-2059-0598
Lower the lift arms.
Raise the operator cab. (See Raising on Page 10-30-2.) 1
P-85671
Disconnect and cap the hydraulic tubeline and hose (Item

1) [Figure 20-50-3].
Remove the two mounting bolts and nuts (Item 2) [Figure

20-50-3].
Installation: Tighten the mounting bolts to 21 - 23 N•m

(180 - 200 in-lb) torque.
Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.

Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
Reverse the removal procedure to install the lift arm lb) torque.
bypass valve in the loader.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.


HYDRAULIC PUMP Start the engine and run at low idle rpm. Press the
Auxiliary hydraulics button. Engage the front auxiliary
Description with the trigger on the right handle or joystick. Make sure
the tester is connected correctly. If no flow is indicated on
The hydraulic pump is attached to the end of the the tester, the hoses are connected wrong. With the
hydrostatic pumps and is located on the right side of the hoses connected correctly, increase the engine speed to
loader between the hydraulic control valve and the full rpm*.
engine.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic pump is a combination of gear pumps that control clockwise on the tester so it reads about 6895
provide hydraulic flow to several hydraulic systems. kPa (68,9 bar) (1000 psi).
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700
supplies flow to the hydraulic fan motor and charge psi).
pressure to the hydrostatic pump.
Turn the restrictor control (Item 2) [Figure 20-60-1] on
A seal kit is available to service the hydraulic pump. If any the tester counterclockwise to obtain free flow, the flow
of the main components of the pump are damaged, the should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
entire pump must be replaced. gpm). Start turning the restrictor clockwise, causing more
restriction on the flow. The L/min (U.S. gpm) should drop
Pump Test At Quick Couplers off slightly until the pressure reaches approximately
21374 kPa (213,7 bar) (3100 psi). At approximately
The tools listed will be needed to do the following 21374 kPa (213,7 bar) (3100 psi) the flow should start
procedure: decreasing rapidly until the pressure reaches 23787 -

24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi). At
TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter 23787 - 24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi)
MEL10006 - Fitting Kit the flow should be at 0 L/min (0 U.S. gpm). Turn the
restrictor (Item 2) [Figure 20-60-1] counterclockwise to
Figure 20-60-1 free flow. Shut the auxiliary hydraulics off.
1 If flow and pressure specifications are not obtained, go to

Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-4.)

for system relief pressure and full rpm.
2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

the front auxiliary quick couplers.
This procedure will require one operator in the cab and

one operator running the tester.

HYDRAULIC PUMP (CONT'D) Figure 20-60-2
Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7217666 - Remote Start Tool Kit 2

TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter
MEL10006 - Fitting Kit
1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve fitting (Item 2) [Figure 20-60-2] (Inset).
Lift and block the loader. (See LIFTING AND BLOCKING Figure 20-60-3

WARNING
1 2
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-60-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-2] on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
IMPORTANT
I-2024-0284
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

control on the tester to about 6895 kPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*.

On the Remote Start Tool engage the auxiliary
hydraulics, the light will come ON. Pull the trigger on the
right handle or joystick for fluid flow to the quick coupler
(fluid pressure will go over main relief). Record the
highest pressure (psi) and flow (L/min [U.S. gpm]). The
high pressure flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100

%=
FREE FLOW (L/min [U.S. gpm])
A low percentage may indicate a failed pump.


Earlier Models
Direct Pump Test (Charge Section)

procedure:
1
MEL1563 or 7217666 - Remote Start Tool Kit
WARNING
P114639
Failure to use jackstands can allow the machine to Figure 20-60-5
W-2017-0286 Later Models
Lift and block the loader. (See LIFTING AND BLOCKING 1


WARNING
P115656
support device can allow the lift arms or attachment Disconnect the inlet hose (Item 1) [Figure 20-60-4] or
to fall and cause injury or death. [Figure 20-60-5].
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.
Connect the Remote Start Tool. (See REMOTE START

TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)

HYDRAULIC PUMP (CONT'D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
Figure 20-60-6 rpm*.

psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

1 2 approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
P-90580

Connect the INLET hose (Item 1) [Figure 20-60-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-4]
*Refer to the Hydraulic Schematics for pump flow and

or [Figure 20-60-5] of the pump. Connect the OUTLET
rpm.
hose (Item 2) [Figure 20-60-6] from the tester to the inlet
fitting on the fan (Item 1) [Figure 20-60-4] or [Figure 20-
60-5].
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

to fall and cause injury or death. 1
W-2059-0598
1
1
1
DANGER
P-90180
Disconnect and cap the four hoses (Item 1) [Figure 20-

60-7] from the hydraulic pump.
Remove the Power Bob-Tach block (if equipped). (See

P-90328 Removal And Installation on Page 20-120-1.)
AVOID DEATH Figure 20-60-8

D-1009-0409
IMPORTANT 1

clean the work area before disassembly and keep all P106593
Remove the bracket mounting bolt / nut (Item 1) [Figure
damage the system.
I-2003-0888
20-60-8].
Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28

Lift and block the rear of the loader. (See LIFTING AND ft-lb) torque.
BLOCKING THE LOADER on Page 10-10-1.)


Figure 20-60-9
1
1
2
1
P-43940 P-43938A
3
Replace the O-ring (Item 1) [Figure 20-60-10] on the
P-90509 hydraulic pump.
Reverse the removal procedure to install the hydraulic

Disconnect and cap the outlet hoses (Item 1) [Figure 20-
pump.

Remove the two mounting bolts (Item 2) [Figure 20-60-9]
and [Figure 20-60-9] from the hydraulic pump.
Installation: Clean the threads and apply Loctite® 242 to

the mounting bolts and tighten to 75 - 85 N•m (55 - 60 ft-
lb) torque.
Remove the hydraulic pump (Item 3) [Figure 20-60-9]

from the loader.

HYDRAULIC PUMP (CONT'D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-11 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
1 Check for hydraulic leaks.

P100685
Figure 20-60-12
P100352
Attach a push button starter switch (MEL1712) (Item1)

[Figure 20-60-11] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-12].

Figure 20-60-13
1. Bolt
2. Charge Pump End Section
3. Section Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
13. Auxiliary Pump Center Section
14. Auxiliary Pump End Section
15. Shaft Seal
7
8
9 4

10 3
2
3
4
6 5
8
7
11 8
10
11
14 3
3 12
4
6 13
4 8
15
P-66540

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-60-9.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 1)

NOTE: Position the wear plate (Item 4) [Figure 20-60-

13] as shown with the bronze side toward the
gears.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage, the complete
pump must be replaced.

HYDRAULIC PUMP (HIGH FLOW) This procedure will require one operator in the cab and
one operator running the tester.
Description
Start the engine and run at low idle rpm. Press the
The hydraulic gear pump is attached to the end of the Auxiliary hydraulics button. Engage the front auxiliary
hydrostatic pumps and is located on the right side of the with the trigger on the right handle or joystick. Make sure
loader between the hydraulic control valve and the the tester is connected correctly. If no flow is indicated on
engine. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump is a combination of gear pumps full rpm*.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. control clockwise on the tester so it reads about 6895
This supplies flow to the hydraulic fan motor and charge kPa (68,9 bar) (1000 psi).
pressure to the hydrostatic pump.
NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700
The high flow hydraulic pump has an additional pump psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched Turn the restrictor control (Item 2) [Figure 20-61-1] on
from a button on the panel in the cab. the tester counterclockwise to obtain free flow, the flow
should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
A seal kit is available to service the hydraulic pump. If any gpm). Start turning the restrictor clockwise, causing more
of the main components of the pump are damaged, the restriction on the flow. The L/min (U.S. gpm) should drop
entire pump must be replaced. off slightly until the pressure reaches approximately

21374 kPa (213,7 bar) (3100 psi). At approximately
Pump Test At Quick Couplers 21374 kPa (213,7 bar) (3100 psi) the flow should start
decreasing rapidly until the pressure reaches 23787 -
The tools listed will be needed to do the following 24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi). At
procedure: 23787 - 24132 kPa (237,9 - 241,3 bar) (3450 - 3500 psi)
the flow should be at 0 L/min (0 U.S. gpm). Turn the
TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter restrictor (Item 2) [Figure 20-61-1] counterclockwise to
MEL10006 - Fitting Kit free flow. Shut the auxiliary hydraulics off.
Figure 20-61-1 If flow and pressure specifications are not obtained, go to

Direct Pump Testing. (See Direct Pump Test (Standard
1 Section) on Page 20-61-2.)

2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.
Install a hydraulic tester (Item 1) [Figure 20-61-1] onto

the front auxiliary quick couplers.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) NOTE: The control panel is shown removed for photo
clarity.
Direct Pump Test (Standard Section)
Figure 20-61-2
procedure:

2
WARNING
1
1
of the frame before running the engine for service. 2
P-90178 P-90176
W-2017-0286
Disconnect the OUTLET hose (Item 1) that comes from

Lift and block the loader. (See LIFTING AND BLOCKING the gear pump, and connects to the control valve fitting
THE LOADER on Page 10-10-1.) (Item 2) [Figure 20-61-2] (Inset).

Raise the lift arms and install an approved lift arm Figure 20-61-3
WARNING
1 2
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) P-90580

TOOL KIT - MEL1563 on Page 10-60-1.) or (See Connect the INLET hose (Item 1) [Figure 20-61-3] from
REMOTE START TOOL (SERVICE TOOL) KIT - the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
7217666 on Page 10-61-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-3] from the tester to the control valve fitting (Item
2) [Figure 20-61-2] on the control valve.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool Kit
tester, the hoses are connected wrong. With the hoses TWX-RFIK200-S-6 204 L/min (54 U.S. gpm) Flow Meter
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

psi). DO NOT exceed system relief pressure. Open the
WARNING
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*. Put jackstands under the front axles and rear corners
On the Remote Start Tool engage the auxiliary Failure to use jackstands can allow the machine to
hydraulics, the light will come ON. Pull the trigger on the fall or move and cause injury or death.
right handle or joystick for fluid flow to the quick coupler W-2017-0286
(fluid pressure will go over main relief). Record the
highest pressure (psi) and flow (L/min [U.S. gpm]). The Lift and block the loader. (See LIFTING AND BLOCKING
high pressure flow must be at least 80% of free flow. THE LOADER on Page 10-10-1.)
%= HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 Raise the lift arms and install an approved lift arm

FREE FLOW (L/min [U.S. gpm]) support device. (See Installing on Page 10-20-1.)

WARNING
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-6
Direct Pump Test (Charge S ection) (Cont’d)
Figure 20-61-4
Earlier Models
1 1 2
P-90580

P114639 the tester to the OUTLET hose (Item 1) [Figure 20-61-4]
or [Figure 20-61-5] of the pump. Connect the OUTLET
hose (Item 2) [Figure 20-61-6] from the tester to the inlet
Figure 20-61-5 fitting on the fan (Item 1) [Figure 20-61-4] or [Figure 20-
Later Models 61-5].

1
IMPORTANT
I-2024-0284
tester, the hoses are connected wrong. With the hoses
P115656 connected correctly, increase the engine speed to full
rpm*.
Disconnect the inlet hose (Item 1) [Figure 20-61-4] or
[Figure 20-61-5].
psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
[U.S. gpm]) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

%=
*Refer to the Hydraulic Schematics for pump flow and

rpm.

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-7] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:

MEL10003 or MEL1744 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit


7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
Direct Pump Test (High Flow Section) (Cont'd) button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
Figure 20-61-8 flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.
1 Warm the fluid to 60°C (140°F) by turning the restrictor

psi).
NOTE: DO NOT EXCEED 25511 kPa (255,1 bar) (3700

psi).
2 [U.S. gpm]) at full rpm. Increase the restriction and the
flow should drop to 0 L/min (0 U.S. gpm) between 24132
kPa (241,3 bar) (3500 psi) and 25511 kPa (255,1 bar)
P-90183 (3700 psi).
If pressure readings are not obtained go to the High Flow

Disconnect the high flow pump OUTLET hose (Item 1) Valve, relief valve adjustment procedure.(See High Flow
from the high flow check valve INLET fitting (Item 2) Relief Valve Removal And Installation on Page 20-61-8.)

[Figure 20-61-8].
Record the highest pressure (psi) and flow (L/min [U.S.
Figure 20-61-9 gpm]). The high pressure flow must be at least 80% of
free flow.

%=
1 2 *Refer to Hydraulic Schematics Legend for system relief

pressure and full rpm.
P-90580

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-8]. Connect the OUTLET hose (Item 2)
[Figure 20-61-9] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-8].
Lower the cab.

High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
[Figure 20-61-12] will need to be turned 90° clockwise
and retested with the procedure above. (90° turn equals
approximately 1379 kPa (13,8 bar) (200 psi).)
NOTE: If the relief screw has been turned in 1/4 turn

and the pressure remains the same, go to the
high flow relief valve removal and installation 1
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-8.) If relief
valve has been tested and is okay, go to the 2 P-45443
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-14.) Locate the high flow relief valve (Item 1) [Figure 20-61-
11] along the right side of the engine.
Remove right rear wheel. (See Wheel Nuts on Page 10-
160-1.) Remove the plug (Item 2) [Figure 20-61-11] located on
the bottom of the high flow relief valve.
Figure 20-61-10

Figure 20-61-12
P-90577 1
P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-10]

from the access cover and remove the cover from the NOTE: [Figure 20-61-12] shows adjusting the relief
loader. screw.
If the pump reaches 25511 kPa (255,1 bar) (3700 psi)

and there is flow stop the engine. The relief screw must
be turned 90° counterclockwise and retested with the
procedure above.

High Flow Relief Valve Removal And Installation
1
WARNING
W-2017-0286
Remove right rear wheel. (See Wheel Nuts on Page 10- P-45444
160-1.)
Figure 20-61-13 Locate the high flow relief valve through rear door along
the right side of the engine.
Remove the relief valve (Item 1) [Figure 20-61-14] from

the pump.
1

Installation: Tighten the relief valve to 41 - 47 N•m (30 -
35 ft-lb) torque.
Figure 20-61-15
1 1
P-90577
3
Remove the mounting bolts (Item 1) [Figure 20-61-13]
from the access cover and remove the cover from the 2
loader.
P-45459
Inspect the relief valve and replace the two O-rings (Item
1) and back-up ring (Item 2) [Figure 20-61-15].
If the relief valve is bad, it must be replaced as a

complete unit.
Remove the plug (Item 3) and replace the O-ring [Figure

20-61-15].

Solenoid Removal And Installation 2
Figure 20-61-16
P-45461
NOTE: Mark the pump housing (Item 1) [Figure 20-61-

P-43958 18] for proper installation of the solenoid
valve cartridge.
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 2) [Figure 20-61-18].
connector (Item 1) [Figure 20-61-16] from the high flow

pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-17
Figure 20-61-19
P-45460
P-45462
Remove the solenoid nut (Item 1) [Figure 20-61-17].

Replace the O-ring (Item 1) [Figure 20-61-19].
Remove the solenoid (Item 2) [Figure 20-61-17].
Replace the O-ring and back-up ring (Item 2) [Figure 20-
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 - 61-19].
72 in-lb).

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)
Never work on a machine with the lift arms up unless 1

1
W-2059-0598
DANGER 1
1
P-90184

Disconnect and cap the inlet hoses (Item 1) [Figure 20-
61-20] from the front of the hydraulic pump.
Figure 20-61-21
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT P-90185

clean the work area before disassembly and keep all Disconnect and cap the hoses (Item 1) [Figure 20-61-21]
parts clean. Always use caps and plugs on hoses, from the back of the hydraulic pump.
damage the system. Remove the Power Bob-Tach block (if equipped). (See
I-2003-0888 Removal And Installation on Page 20-120-1.)
Lift and block the rear of the loader. (See LIFTING AND


Figure 20-61-22
1
P-43940 P-43938A
3 Replace the O-ring (Item 1) [Figure 20-61-24] on the

P-90509A hydraulic pump.
Reverse the removal procedure to install the hydraulic

Remove the bracket mounting bolt / nut (Item 1) [Figure pump.
20-61-22].

Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28
ft-lb) torque.
Figure 20-61-23
3
P-90509A
Disconnect and cap the outlet hoses (Item 1) [Figure 20-

Remove the two mounting bolts (Item 2) [Figure 20-61-

22] and [Figure 20-61-23]from the hydraulic pump.

Remove the hydraulic pump (Item 3) [Figure 20-61-23]

from the loader.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-61-25 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
1 Check for hydraulic leaks.

P100685
Figure 20-61-26
P100352
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-61-25] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-61-26].

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Figure 20-61-27
21
1. Stem
22
2. Valve
5 3. Wear Plate
4 4. Seal Section
3
6 5. Rear Housing
6. Bolt
7. Preload Seal
8. Load Seal
22 9. Spline Connector
24 10. Pin
11. Gear Set
1 12. Gear Housing
10 13. Gear Housing
2

14. Gear Set
3
11 15. Gear Housing
8 9
7 16. Gear Set
23 4 17. Center Housing
10
17 12 18. Center Housing
19. Front Housing
4 20. Shaft Seal
3
21. High Flow Relief
22. Seal
10 23. Nut
3 24. Coil
9 14
8
7
4
10 13
18
4
3
10
4
8
7
4 15
16
19
20
10
MS1456S

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-13.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 6)

NOTE: Position the wear plate (Item 3) [Figure 20-61-

27] inlets and traps as shown with the bronze
side toward the gears on all wear plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage is visible. The
complete pump must be replaced.
NOTE: The relief valve and the solenoid can be

replaced along with the O-rings and back-up
rings.

HYDRAULIC / HYDROSTATIC FILTERS Housing Removal And Installation
Description
The hydraulic / hydrostatic filters help to remove

contaminants from the fluid when the hydraulic /
DANGER
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
The main filter removes contaminants before entering

gear pumps including fluid returning from the main valve.
The charge flow filter removes contaminants after the P-90328

charge pump.
AVOID DEATH
D-1009-0409

WARNING
W-2059-0598

HYDRAULIC / HYDROSTATIC FILTER (CONT’D) Remove and plug the two hoses (Item 1) [Figure 20-70-
2] from the bottom of the hydraulic / hydrostatic filter
Housing Removal And Installation (Cont’d) housing.
Figure 20-70-1 Figure 20-70-3
1
2
1
P-90010 1 P-90537
NOTE: Hex head filter shown but the procedure is the Remove the two bolts (Item 1) [Figure 20-70-3].
same for all filters.

Remove the hydraulic / hydrostatic filter housing from the
Raise the lift arms and install an approved lift arm loader.
Drain the fluid from the reservoir. (See Removing And

Disconnect the electrical connector (Item 1) [Figure 20-

70-1] from the hydraulic / hydrostatic filter sender.
Disconnect and plug the three hoses (Item 2) [Figure 20-

70-1] from the hydraulic / hydrostatic filter housing.
Figure 20-70-2
P-90011

HYDRAULIC FLUID RESERVOIR Figure 20-80-2
Description
The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid. 1
The hydraulic fluid reservoir is located behind the

operator’s cab under the rear grille on the right side of the
loader.

P-90579
Remove the two bolts, (Item 1) [Figure 20-80-2] nuts,
Raise the operator cab. (See Raising on Page 10-30-2.) and bracket
Remove the rear grille. (See REAR GRILLE on Page 50- Remove the hydraulic fluid reservoir from the loader.
60-1.)
Installation: Tighten the mount bolts and nuts to 21,7 -

Drain the fluid from the reservoir. (See Removing And 24,4 N•m (16 - 18 ft-lb) torque.
Remove the Hydraulic / Hydrostatic Filter Housing. (See

Housing Removal And Installation on Page 20-70-1.)
Figure 20-80-1
P-90013
Remove the clamp and the hose (Item 1) [Figure 20-80-

1].

HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen

60-1.)
Figure 20-80-3
P-90506

Remove the hydraulic fluid reservoir breather cap
[Figure 20-80-3] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-3] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER Removal And Installation
Description Earlier Models
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil. IMPORTANT
The oil cooler is located underneath the rear grille When repairing hydrostatic and hydraulic systems,
between the A/C condenser (if so equipped) and the clean the work area before disassembly and keep all
radiator. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Remove the rear grille from the loader. (See REAR

GRILLE on Page 50-60-1.)
Figure 20-90-1
1 2

3
P-85938
Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-1] and
pull hose out.
Cap or plug all hoses and fittings.

OIL COOLER (CONT’D) NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
Removal And Installation (Cont’d) together.
Earlier Models (Cont’d) Lift up the oil cooler and remove the cooler from the
loader.
Figure 20-90-2
Later Models
2 The oil cooler and radiator are removed from the loader
1 as a unit. (See Radiator / Oil Cooler Removal And
P-85936

Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-2] and
pull hose out.
Cap or plug all hoses and fittings.
Figure 20-90-3
4 4
2
5
3
P-85905
Undo the rubber straps (Item 1) [Figure 20-90-3]
Remove the bolts (Item 2) and remove the condenser

guards (Item 3) [Figure 20-90-3].
Remove the clips and pins (Item 4) [Figure 20-90-3].
Remove the bolt (Item 5) [Figure 20-90-3] from the prop

rod.

BUCKET POSITION VALVE Cover the fuel tank inlet.

The Bucket Position Valve is an option that allows the
operator to hold the attachment at the same angle from
the ground to maximum lift height without using the tilt
function. 3
The bucket position valve is mounted to the inside lower
right rear side of the loader frame.
See Hydraulic Schematic for more circuit information. 2
DANGER
1 P-90197
Disconnect the wire harness connector (Item 1) [Figure

20-100-2] from the bucket position shut-off solenoid.
Disconnect the cap the two tubelines (Item 2) [Figure 20-

100-2].
P-90328
Remove the solenoid nut, coil, and stem (Item 3) from the
AVOID DEATH
bucket positioning valve [Figure 20-100-2].
Installation: Put oil on O-rings and back-up rings and
tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
torque.
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
D-1009-0409
torque. Overtightening may cause valve failure.
Drain the hydraulic reservoir. (See Removing And NOTE: The engine is shown removed for photo
Replacing Hydraulic Fluid on Page 10-120-2.) clarity.
Figure 20-100-1 Figure 20-100-3
1
1 2
2
P-90187 N-18191
(Item 2) to the middle of the hose, and the place the fuel Inspect the solenoid stem and replace the O-rings (Item
inlet assembly (Item 3) [Figure 20-100-1] off to the side. 1) and the back-up ring (Item 2) [Figure 20-100-3].

BUCKET POSITION VALVE (CONT'D) Cover the fuel tank inlet.
Solenoid Testing Figure 20-100-5
Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
DANGER
1 P-90197
NOTE: The engine is shown removed for photo

clarity.
P-90328 NOTE: Mark all hoses and tubelines for correct

installation.
AVOID DEATH
• Disconnecting or loosening any hydraulic Disconnect the electric solenoid connector (Item 1)
tubeline, hose, fitting, component or a part failure [Figure 20-100-5].
• Keep out of this area when lift arms are raised Figure 20-100-6
D-1009-0409
Drain the hydraulic reservoir. (See Removing And 1

Figure 20-100-4
3 2
4 3
1
P-90188
Disconnect and cap the tilt base inlet hose (Item 1), the
tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-6]
that route from the control valve.
2
P-90187
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-100-4] off to the side.

BUCKET POSITION VALVE (CONT'D) Figure 20-100-9
Figure 20-100-7
P-90190A
2
1
Remove the mounting screws (Item 1) [Figure 20-100-9].
P-90189A
Remove the bucket position valve from the loader.
Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-7]

from the valve block.
Figure 20-100-8
2
2
1
P-90197A
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-8] that route from the lift cylinders.

BUCKET POSITION VALVE (CONT'D) Figure 20-100-12
Figure 20-100-10
3
1
2
1 3
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-12]. Inspect for
wear, replace the O-ring.
Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
stem (Item 3) [Figure 20-100-10]. ft-lb) torque.

Assembly: Tighten the nut to a maximum of 8 N•m (6 ft- Figure 20-100-13
lb) torque. Overtightening may cause valve failure.
Assembly: Put oil on O-rings and back-up rings and

tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
1
torque. 2 3
Figure 20-100-11
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-13].
Inspect all parts and replace as needed. Install a new O-

P-90195 ring on the plug before installing.
Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

Remove the flow adjustment valve and O-ring (Item 1) ft-lb) torque.
[Figure 20-100-11].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.
NOTE: Always install new O-rings before any parts

are installed into the valve. Inspect the parts
for wear or damage and replace as needed.

REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts fluid from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Solenoid coil do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
4.6 - 5.7 ohm.
Figure 20-110-3

P9137

110-1]. Coil wires do not have polarity. Correct resistance
is 8.6 - 9.5 ohm.
P9137
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
110-3]. Coil wires do not have polarity. Correct resistance
for the solenoid coil with a molded connector is 8.1 - 9.9
ohm.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-5
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-5].
can cause lift arms to drop. Figure 20-110-6

D-1009-0409
1
Put jackstands under the rear corners of the loader.


P100810
Figure 20-110-4
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-6] from the main harness.
P-90583
Disconnect and cap the tubelines (Item 1) [Figure 20-

110-4].

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-7 assembly.
Inspect cartridges, check valves, solenoid valves and
2 sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure to dry them.
Install new O-rings and back-up rings.
Inspect diverter valve cavities for contamination. Wash
1 valve in clean solvent. Use air pressure to dry.
Figure 20-110-8
P-90581
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-7].

1
1
P-48751
Figure 20-110-9
P-48752
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-110-8] and [Figure 20-

110-9] are located all over the diverter valve and can be
removed for clean out purposes.
Assembly: Put oil on O-rings and back-up rings. Tighten

to 13,6 N•m (10 ft-lb) torque.

Disassembly And Assembly (Cont'd)
IMPORTANT
damage the system.
I-2003-0888
P-48755
Figure 20-110-10
Figure 20-110-13
1
2
2

1
P-48755
P-48757
Figure 20-110-11
Remove the differential sensing valve (Item 1) [Figure

20-110-12] and [Figure 20-110-13] from diverter valve
and inspect the O-rings and back-up rings (Item 2)
[Figure 20-110-13] for damage.
2
2 2
Assembly: Put oil on O-ring and back-up rings. Tighten
1 to 68 - 75 N•m (50 - 55 ft-lb) torque.
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-10]

and [Figure 20-110-11] from diverter valve and inspect
the O-rings and back-up rings (Item 2) [Figure 20-110-
11] for damage.
Assembly: Put oil on the O-rings and back-up rings.

Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

Figure 20-110-14
P-48759
1
Figure 20-110-17
P-48753
Remove the relief valve (Item 1) [Figure 20-110-14].

Figure 20-110-15
1
2
P-48760
1
NOTE: Before removing the solenoid coils mark the
coils for proper alignment.
P-48754 Remove the nut (Item 1) [Figure 20-110-16] and [Figure

20-110-17] from the solenoid valve stem.
Inspect the O-rings and back-up rings (Item 1) [Figure Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
20-110-15] for damage. torque.
Assembly: Put oil on O-ring and back-up rings. Tighten Remove the spacer (Item 2) and solenoid valve coils
to 27 - 34 N•m (20 - 25 ft-lb) torque. (Item 3) [Figure 20-110-17].

Figure 20-110-18
1
1
P-48762
Figure 20-110-20
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.

Remove the nuts (Item 1) [Figure 20-110-18] from the
solenoid valve stems.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

2 2
torque. 1 1
P-48763
Remove the solenoid valve stem (Item 1) [Figure 20-

110-19] and [Figure 20-110-20] and inspect the O-rings
and back-up rings (Item 2) [Figure 20-110-20] for
damage.

to 27 - 34 N•m (20 - 25 ft-lb) torque.

Figure 20-110-21
P-48765
Remove the plug (Item 1) [Figure 20-110-23].

P-48763A
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
Figure 20-110-22 Figure 20-110-24

1 2
1
P-48764 P-48766
Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-21] and [Figure 20-110-22] and inspect the O-rings 24] for dirt and debris.
and back-up rings (Item 2) [Figure 20-110-22] for
damage. Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
torque.
to 41 - 47 N•m (30 - 35 ft-lb) torque.

Figure 20-110-25
1
1
P-48758
Remove the plugs (Item 1) [Figure 20-110-27].

P-48765
Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-110-25]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all

Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up rings.
Figure 20-110-26
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
P-48786
Remove the orifice (Item 1) [Figure 20-110-26].
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.

BOB-TACH (POWER) BLOCK Removal And Installation
Description
The Power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
WARNING
and dismounting the attachments.
The Power Bob-Tach is operated by a switch on the right the lift arms are secured by an approved lift arm
switch panel. support device. Failure to use an approved lift arm
The Power Bob-Tach block is mounted on the right side to fall and cause injury or death.
of the machine in front of the engine on the back side of W-2059-0598
the hydraulic pump.
DANGER

P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-2
Removal And Installation (Cont'd) 1
NOTE: Earlier models shown. The photos may appear

different for later models but the procedure is
the same.
2 4
Figure 20-120-1
3
3
1
3
P-90969
Mark the hydraulic hoses for proper installation.
Disconnect and cap the outlet hose (Item 1) [Figure 20-

120-18] from block.
P-90968 Remove the hydraulic muffler (if equipped) (Item 2)

[Figure 20-120-18] from block.
Lift and block the loader. (See LIFTING AND BLOCKING Disconnect and cap the hoses (Item 3) [Figure 20-120-
THE LOADER on Page 10-10-1.) 18] from block.
Raise the lift arms and install an approved lift arm Remove the four mounting bolts (Item 4) [Figure 20-120-
support device. (See Installing on Page 10-20-1.) 18] from block.
Raise the operator cab. (See Raising on Page 10-30-2.) Installation: Tighten the mounting bolts to 48 - 54 N•m
Replacing Hydraulic Fluid on Page 10-120-2.) Remove the Power Bob-Tach block.
Disconnect and cap the two electrical solenoid

connectors (Item 1) [Figure 20-120-1] from the loader
electrical harness.

Disassembly And Assembly (Earlier Models)
Figure 20-120-3
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-4].

Clean the block (Item 1) [Figure 20-120-3] to remove dirt plug.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-120-5
Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-

lb) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-5].
Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.

Disassembly And Assembly (Earlier Models) (Cont'd)
Figure 20-120-6
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-120-8].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-120-6]. will be altered.

Installation: Oil the check valve and O-rings and tighten Figure 20-120-9
the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.
Figure 20-120-7
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-120-9], and replace

the O-ring.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-
(Item 2) [Figure 20-120-7]. lb) torque.
Replace the O-rings and back-up rings (Item 3) [Figure

20-120-7] on the check valve and piston assembly.

Figure 20-120-10 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-120-12].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.

Figure 20-120-13
Installation: Tighten the orifice screw to 8,1 - 10,8 N•m
Figure 20-120-11
1
1
2
P-48386

P-48127
Installation: Tighten the solenoid stem to 27,1 - 34 N•m
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-11].
Remove the solenoid nut (Item 2) [Figure 20-120-11].
Installation: Tighten the solenoid valve stem nut to 1,7 -

5,1 N•m (15 - 45 in-lb) torque.

Figure 20-120-14
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-16].
Installation: Tighten the screened orifice plug to 14,9 -

Remove the armature assembly (Item 1) [Figure 20-120- 16,3 N•m (11 - 12 ft-lb) torque.
14].

Figure 20-120-17
Figure 20-120-15
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 120-17] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
120-15].
NOTE: If the solenoid stem is damaged (Item 1)
inspect the armature assembly (Item 2) for
damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new Power Bob-Tach block
assembly from Bobcat parts [Figure 20-120-
15].

Disassembly And Assembly (Later Models)
IMPORTANT 2
When repairing hydrostatic and hydraulic systems, 1

damage the system.
I-2003-0888
P100769
Figure 20-120-18
Clean the block (Item 1) to remove dirt before

disassembly. Block ports are labeled for correct
assembly.[Figure 20-120-19].

1

Installation: Tighten the plug to 67,8 N•m (50 ft-lb)
torque.
Figure 20-120-20
3
P100820
Do not remove these plugs (Item 1) [Figure 20-120-18].

1
NOTE: Do not remove the two plugs located next to
the outlet port. A new Power Bob-Tach valve 2
will be required if tampered with. All other
plugs can be removed.
4
P100770
Remove plug (Item 1), spring (Item 2) and spool (Item 3)

[Figure 20-120-20] and inspect. Replace damaged parts
as needed.

plug.

Disassembly And Assembly (Later Models) (Cont'd)
Figure 20-120-21
P100826
Remove the plug (Item 1) [Figure 20-120-23], and

P100823 replace the O-ring.

Remove the plug (Item 1) [Figure 20-120-21], and torque.
replace the O-ring.

Figure 20-120-24
torque.
Figure 20-120-22
2 P100821
1
Remove the orifice screw (Item 1) [Figure 20-120-24].
P107069
Installation: Tighten the orifice screw to 8,1 - 10,8 N•m
Remove the spool (Item 1), spring (Item 2) and the orifice
(Item 3) [Figure 20-120-22]. Inspect the spring, spool
and orifice replace as needed.
Installation: Clean threads on the orifice and apply

Loctite® 603. Tighten the orifice (Item 3) [Figure 20-120-
23].

Figure 20-120-25
P100827
Remove the solenoid coil stem (Item 1) [Figure 20-120-

P100774 27].
Installation: Tighten the solenoid coil stem to 27,1 N•m

NOTE: Mark the solenoid coil orientation for ease of (20 ft-lb) torque.
installation.

Figure 20-120-28
Remove the solenoid coil nut (Item 1) [Figure 20-120-
25].
Installation: Tighten the solenoid coil valve stem nut to 2 2 2

6,8 N•m (5 ft-lb) torque.
Figure 20-120-26
1 1 1 1
1 P100776
Replace the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-120-28].
P100773
Remove the first solenoid coil (Item 1) and the second

solenoid coil (Item 2) [Figure 20-120-26].

Figure 20-120-29
P100840


Remove the fitting (Item 1) [Figure 20-120-29]. torque.

Figure 20-120-30 Figure 20-120-32
1
1
P100829 P100841
Replace the O-ring (Item 1) [Figure 20-120-30]. Remove the filter assembly (Item 1) [Figure 20-120-32],
inspect and replace as needed.

Figure 20-120-33
P100845

Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.

replace the O-ring. Figure 20-120-36

torque.
Figure 20-120-34
2
1
P100839

replace the O-ring.
P100843
torque.
Remove the shuttle seat (Item 1) and check ball (Item 2)
[Figure 20-120-34]. Inspect the shuttle seat and check
ball, replace as needed.

Figure 20-120-37
2
1
P100838
Remove the spring (Item 1) and the check ball (Item 2)

P100835 [Figure 20-120-39]. Inspect and replace as needed.
Figure 20-120-40
Remove the spring (Item 1) and the check ball (Item 2)
[Figure 20-120-37], inspect and replace as needed.

Figure 20-120-38
P100853
Using a small diameter tool remove the pilot piston (Item

P100837 1) [Figure 20-120-40].

replace the O-ring.

torque.

Figure 20-120-41
P100852


Remove pilot piston (Item 1) [Figure 20-120-41]. torque.

Figure 20-120-42 Figure 20-120-44
2 2
1
2
P100834 P100849
Inspect the pilot piston (Item 1), the back-up rings (Item Remove the annular orifice shaft (Item 1) and the annular
2) and the O-ring (Item 3) [Figure 20-120-42] for damage orifice shaft guide (Item 2) [Figure 20-120-44], inspect
and replace as needed. and replace as needed.

Figure 20-120-45 1
P100854
Remove the O-ring (Item 1) [Figure 20-120-47] and

P100850 replace.

replace the O-ring.

Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
Figure 20-120-46
P100851

replace the O-ring.

torque.

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND
A3NW13834 & ABOVE)
Description
The Power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The Power Bob-Tach is operated by a switch on the right

switch panel.
The Power Bob-Tach block is mounted on the right side

of the machine in front of the engine on the back side of
the hydraulic pump.

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND Figure 20-121-2
A3NW13834 & ABOVE) (CONT'D)
Testing Relief Valve
1
WARNING
not use your bare hand. Wear safety goggles. If fluid P106674
W-2072-0807 Disconnect the hose (Item 1) [Figure 20-121-2] from the
cylinder base end port.
Figure 20-121-3
WARNING

explosion or fire. 1
W-2103-0508
The following tools are required for this procedure:

MEL1355 hydraulic test kit.
Figure 20-121-1 P122238
Install the gauge (Item 1) [Figure 20-121-3] between the

hose and cylinder base end port and tighten.
engine.
Push and hold the BOB-TACH “WEDGES DOWN” Switch

(Front Accessory Panel).
Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

121-1].
Push and hold BOB-TACH “WEDGES UP” switch until

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

Testing Relief Valve (Cont’d)
Figure 20-121-4
P122229
NOTE: Relief valve removed from block for photo

clarity.
If adjustment is required loosen the jam nut (Item 1) and

turn the adjusting screw (Item 2) [Figure 20-121-4]
clockwise to increase pressure or counterclockwise to
decrease pressure.
Test the relief valve setting after adjustment has been

made.

BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND NOTE: After repairing a machine that required the
A3NW13834 & ABOVE) (CONT'D) Power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
Removal And Installation make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
WARNING Maintenance Manual, the electrical

connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
Never work on a machine with the lift arms up unless inspection to verify the wedges function
the lift arms are secured by an approved lift arm correctly.
support device can allow the lift arms or attachment Lift and block the loader. (See LIFTING AND BLOCKING
to fall and cause injury or death. THE LOADER on Page 10-10-1.)
W-2059-0598

DANGER
Remove the fan duct. (See Fan Duct Removal And

Installation on Page 70-50-4.) or (See Fan Duct Removal
And Installation on Page 70-51-4.)
Figure 20-121-5
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT P122161
When repairing hydrostatic and hydraulic systems, Disconnect the two wire connectors (Item 1) [Figure 20-
clean the work area before disassembly and keep all 121-5] from the solenoid coils.
damage the system.
I-2003-0888

Figure 20-121-6
2 2
P122162
Disconnect and cap the hose (Item 1) [Figure 20-121-6]

from block.
Disconnect and cap the hoses (Item 2) [Figure 20-121-6]

from block.
Figure 20-121-7
1 1
1
1
P122157
Remove the four mounting bolts (Item 1) [Figure 20-121-

7].

Remove the Power Bob-Tach block.

IMPORTANT 3

1
damage the system. 2
I-2003-0888
4 P122197
Figure 20-121-8
Remove plug (Item 1), spring (Item 2) and spool (Item 3)
[Figure 20-121-9] and inspect. Replace damaged parts
as needed.

torque.

1
plug.
Figure 20-121-10
1
P122196
Do not remove these plugs (Item 1) [Figure 20-121-8].
NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.
1
P122198
NOTE: Mark the solenoid coil orientation for

installation.
Remove the coil nut (Item 1) [Figure 20-121-10].
Installation: Tighten the solenoid coil valve stem nut to



2
Figure 20-121-11
P122201
3

1 2) [Figure 20-121-13].
P122199
Figure 20-121-14
Remove the first solenoid coil (Item 1), the spacer (Item
2) and the second solenoid coil (Item 3) [Figure 20-121-

11].
Figure 20-121-12
2
1
P122202
Remove the fitting (Item 2) [Figure 20-121-12] and

1 replace the O-ring (Item 1) [Figure 20-121-14].
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-121-

12].
Installation: Tighten the solenoid stem to 27,14 N•m

(20 ft-lb) torque.

Figure 20-121-15
P122206
1
Replace the O-ring (Item 1) and remove the screened
orifice (Item 2) [Figure 20-121-18]. Inspect and replace
P122203 as needed.
Figure 20-121-18
Remove the plug (Item 1) [Figure 20-121-15] and

replace the O-ring.

torque. 1
Figure 20-121-16
P122205

1
torque.
P122205
Installation: Tighten the plug (Item 1) [Figure 20-121-

16] to 17,6 N•m (13 ft-lb) torque.

Figure 20-121-19
2
3 1
P122209
2
Replace the O-ring (Item 1) and remove the orifice insert

1 (Item 2) [Figure 20-121-21]. Inspect and replace as
P122207 needed.
Figure 20-121-22
Remove the O-ring (Item 1), the spring (Item 2) and the
check ball (Item 3) [Figure 20-121-23]. Inspect and

replace as needed.
Figure 20-121-20
1
P122210
Remove the relief valve (Item 1) [Figure 20-121-22].
P122208 Installation: Tighten the relief valve to 20 N•m (15 ft-lb)

torque.

torque.

Figure 20-121-23
P122212

2) [Figure 20-121-23].

Figure 20-121-24
P122213
NOTE: After repairing a machine that required the

Power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function
correctly.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
For FFH/FH connector block. (See Disassembly And
The front auxiliary hydraulic coupler block is the Assembly (FFH/FH) on Page 20-130-4.)
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers Figure 20-130-3
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm.
There are two different coupler blocks that can be used

on the machine. To determine which coupler block is
used, check the supplier part number on the male
coupler.
1
Figure 20-130-1
1
P115535

If unable to identify the supplier part number on the male
coupler of an internally mounted coupler block, remove
the internally mounted coupler block from the lift arm.
(See Removal And Installation on Page 20-130-2.) The
supplier part number (Item 1) [Figure 20-130-3] is
located on the back of the block.
NOTE: FFI/FI couplers will continue to be available

P115537 but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
Figure 20-130-2
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and

[Figure 20-130-2] is located on the male coupler.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (FFI/FI)
(CONT’D)
Figure 20-130-5
All Models
1
IMPORTANT 2

3
damage the system.
I-2003-0888
P-90003
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.
1
Figure 20-130-6
1
1
1
P-85281
Remove the two mounting bolts (Item 1) [Figure 20-130- 1

4].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
Remove the fittings (Item 1) [Figure 20-130-6].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-9
(CONT’D)
Disassembly And Assembly (FFI/FI) (Cont’d)

1
Figure 20-130-7
2
2 1
2
2 1
2
1 P-34665

[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
Remove the springs (Item 1) [Figure 20-130-7].

1
fittings and coupler body.
Figure 20-130-8
P-34664

[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and

P-34701 lightly lubricate with oil before installation.
Press center of male couplers down and inspect the seal

(Item 1) [Figure 20-130-14] for damage and replace as
needed.

(CONT’D)
Disassembly And Assembly (FFH/FH) 1

2
Figure 20-130-11
2 1
1 2
2
1
2
1
P115529B
Remove the springs (Item 1) [Figure 20-130-13].
P-90002 Remove the O-rings (Item 2) [Figure 20-130-13] from the

fittings.
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].

Installation: Tighten the coupler fittings (Item 1) [Figure
20-130-11] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-12
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-12].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.

(CONT’D)
Disassembly And Assembly (FFH/FH) (Cont’d)
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-17] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].

Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-15].
Replace the case drain coupler (Item 2) [Figure 20-130-

15] as an assemble if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-16] and replace coupler if damaged.


AUTOMATIC RIDE CONTROL
Description
The automatic ride control is an option that provides a

smoother ride, reduced load spillage, and improved
machine control when traveling over uneven ground with
heavy loads or in heavy digging applications.

AUTOMATIC RIDE CONTROL (CONT'D)

WARNING
Open the rear door.
Remove the rear grille and engine cover. (See REAR
GRILLE on Page 50-60-1.)
explosion or fire.
WARNING W-2103-0508

support device. Failure to use an approved lift arm WARNING
to fall and cause injury or death. RIDE CONTROL ACCUMULATOR INSTALLED
W-2059-0598
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
DANGER circuit before servicing.

See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Drain the hydraulic fluid reservoir. (See Removing And

Figure 20-140-1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure 3
D-1009-0409
2
IMPORTANT P121154
When repairing hydrostatic and hydraulic systems, Disconnect the harness (Item 1) [Figure 20-140-1] from
clean the work area before disassembly and keep all the bottom of the filter.
tubelines and ports to keep dirt out. Dirt can quickly Remove the two bolts (Item 2) and reposition the fuel
damage the system. filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888

AUTOMATIC RIDE CONTROL (CONT'D) Figure 20-140-4
Figure 20-140-2 2
P122354
Reposition the clamp (Item 1) and remove the fuel fill

P122353
hose (Item 2) [Figure 20-140-4] from the tank.
Cover the fuel tank inlet.

Remove the two bolts (Item 1) [Figure 20-140-2].
Figure 20-140-5
Figure 20-140-3

1
P128342
P122355
Disconnect the three connectors (Item 1) [Figure 20-

Remove the hose (Item 1) [Figure 20-140-3]. 140-5] from the manifold.


2
Figure 20-140-6
1
1
P128335
Remove the two nuts (Item 1) and the accumulator /

P128096 manifold assembly (Item 2) [Figure 20-140-8].
Remove the hose (Item 1) [Figure 20-140-6].

Figure 20-140-7
P128339
Remove the two hoses (Item 1) [Figure 20-140-7] from

the manifold.

AUTOMATIC RIDE CONTROL (CONT'D)
Checking The Pressure In The Accumulator
The nitrogen charge in the accumulator will decrease

IMPORTANT
over time. This will result in decreased effectiveness of
the automatic ride control benefits. When repairing hydrostatic and hydraulic systems,
NOTE: The signs of a low accumulator charge parts clean. Always use caps and plugs on hoses,
include: excessive lift arm movement, tubelines and ports to keep dirt out. Dirt can quickly
reduced ride control performance, or loss of damage the system.
I-2003-0888
ride control function.
Remove the automatic ride control assembly. (See

The tools listed will be needed to do the following WARNING

procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020. Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
WARNING W-2103-0508

support device can allow the lift arms or attachment WARNING
W-2059-0598 RIDE CONTROL ACCUMULATOR INSTALLED
DANGER control for 5 seconds to release pressure from lift
circuit before servicing.
See Operation & Maintenance Manual or Service
W-3015-0816
P-90328
AVOID DEATH
D-1009-0409

Checking The Pressure In The Accumulator (Cont’d)
Figure 20-140-9
1
P128488
Make sure the manual bleed valve (Item 1) is closed.

P128321 Install the tool / gauge (Item 2) [Figure 20-140-11] onto
the accumulator.
Figure 20-140-12
accumulator.

Figure 20-140-10
1
1
2
P128489
P128322 Turn the T-handle (Item 1) [Figure 20-140-12]

counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
Loosen the Allen screw (Item 1) [Figure 20-140-10]
TIMES).
approximately 1/4 turn.
Pressure in the accumulator should be 915 psi [63 bar].
Close the valve by turning the T-handle (Item 1) [Figure

20-140-12] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-12].
Remove the tool / gauge from the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-10] to 20

N•m (15 ft-lb) torque.

Adding Nitrogen To The Accumulator
Remove the automatic ride control assembly. (See


procedure:
1
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
Wear safety glasses to prevent eye injury when any P128322
• Pressurized fluids and springs or other stored
energy components. Loosen the Allen screw (Item 1) [Figure 20-140-14]
• Flying debris or loose material is present. approximately 1/4 turn.
• Tools are being used. Figure 20-140-15
W-2505-0604

1
WARNING
RIDE CONTROL ACCUMULATOR INSTALLED
control for 5 seconds to release pressure from lift
circuit before servicing.
See Operation & Maintenance Manual or Service 2 P128488
W-3015-0816
Install the tool / gauge (Item 1) [Figure 20-140-15] onto
Figure 20-140-13 the accumulator.
Make sure the manual bleed valve (Item 2) [Figure 20-

140-15] is closed.
P128321

accumulator.

Adding Nitrogen To The Accumulator (Cont’d)

1
Figure 20-140-16
2
1
P128491
Turn the T-handle (Item 1) [Figure 20-140-18]

P128490 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Install the hose (Item 1) [Figure 20-140-16] to the tool on
the accumulator. Pressure in the accumulator should be 915 psi [63 bar].

Figure 20-140-17 Slowly open the valve on the nitrogen tank. Close the
valve by turning the T-handle (Item 1) [Figure 20-140-18]
until the accumulator pressure is correct. Close the valve
on the nitrogen tank.
1
Close the valve by turning the T-handle (Item 1) [Figure
20-140-18] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-18].
Remove the hose from the tank and the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-14] to 20

P128327
Install the other end of the hose / fitting (Item 1) [Figure

20-140-17] to the nitrogen tank.

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N

A3NW11001 - A3NW12724) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N

A3NW12725 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-11
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-6
HYDROSTATIC MOTOR CARRIER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-7
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-50-4
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-14
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-6
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
TWO-SPEED / BRAKE VALVE (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 -

A3NW12724) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND

A3NW12725 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost do to internal leakage in the components
of the hydrostatic system.

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

(See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and/or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
The hydrostatic motors do not have an internal brake.
Inside the end cap of the hydrostatic motor, there is a

shuttle valve. The shuttle valve helps to keep the motor
cool by mixing case drain fluid with cooled low pressure
fluid from the charge circuit. The shuttle valve is shifted
by the high pressure fluid coming from the hydrostatic
pumps. If the shuttle valve sticks, a delay or lack of drive
may or may not be felt in the controls and/or an
overheated hydrostatic motor will result.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

HYDROSTATIC DRIVE MOTOR (CONT’D) Drain the hydraulic reservoir. (See Removing And
Remove the motor cover.
Mark the hoses for correct installation.

DANGER Figure 30-20-1
1
2
P-90328
AVOID DEATH
• Keep out of this area when lift arms are raised P-90510

Disconnect the case drain hose (Item 1) [Figure 30-20-
D-1009-0409
1].
Disconnect the high pressure hoses (Item 2) [Figure 30-

20-1].

the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment 2
to fall and cause injury or death. 1 1
W-2059-0598
1
1
IMPORTANT
clean the work area before disassembly and keep all P-90495
Remove the ten mounting bolts (Item 1) [Figure 30-20-
damage the system.
I-2003-0888
2].
Installation: Tighten the mounting bolts to 149 N•m (110

Lift and block the loader. (See LIFTING AND BLOCKING ft-lb) torque.
NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
Raise the lift arms and install an approved lift arm the cam ring to the motor, and do not have to
support device. (See Installing on Page 10-20-1.) be removed, to remove the motor from the
Raise the operator cab. (See Raising on Page 10-30-2.) loader.
Remove the motor / cam ring section from the loader.

HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-3
P5405
Remove the piston / roller section (Item 1) [Figure 30-20-

3] from the loader, if it was not removed with the motor /

cam ring.
Figure 30-20-4
12 1
11
13
10 2
9 3
8 4
7 5
6
N-22535
Remove and replace O-ring (Item 13) [Figure 30-20-4]

with new O-ring
Installation: Install the O-ring (Item 1) by pressing the O-

ring into the groove starting at the 12 o’clock position
then 6, 2, 10, 3 9, 4, 8, 5, 7, 1 and 11 [Figure 30-20-4]
until the O-ring is fully seated in the groove.
NOTE: Do not roll, kink or stretch O-ring in to groove

and verify the O-ring is completely flush with
no protrusions.
To remove the motor carrier. (See Removal And


HYDROSTATIC DRIVE MOTOR (CONT’D)
1. Distributor
2. Spring
3. Seal
4. O-ring
5. Plug
6. Washer
7. Spool
8. Rear Housing
9. Stop Pin
10. Bolt
11. Shim
12. Poppet 3
13. Cam 3
14. Roller 2
1
15. Piston
16. Block
4
5
4

4
6 2
7
2
5
4
3
3
9
14
15 4
10
4 10
4 12
11
2
4
4
5
13
16
B-17125

HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-6
IMPORTANT 2 1

damage the system.
I-2003-0888
P5765
Figure 30-20-5
Apply low air pressure to each port in the cylinder block

1 to remove the roller (Item 1) and piston / ring assembly
(Item 2) [Figure 30-20-6].
Inspect the cylinder block surface and the roller / piston

assemblies for scratches or wear.

NOTE: Put all the roller / piston assembly back in
their original position.
Assembly: Install the roller (Item 1) in the piston (Item 2)

[Figure 30-20-6].
N-17861 Assembly: Dip the roller / piston assembly into oil and
install into the bore in the cylinder.
Remove the piston / roller section (Item 1) [Figure 30-20- Repeat for each roller / piston assembly.
5] from the motor.
Assembly: Install the motor on the loader and tighten the

mount bolts to 149 N•m (110 ft-lb) torque.
NOTE: Before operating the hydrostatic motor, make

sure it is full of fluid. There are several
methods to fill the motor with fluid; (1) with
the case drain hose disconnected, fill the
motor with fluid through the case drain port;
(2) with the case drain hose disconnected,
BICS™ brake locked, engine running, stroke
the steering lever until fluid comes out of the
case drain port.

Disassembly And Assembly (Cont'd) 1
Figure 30-20-7 2
N-17864
Remove the stop pin (Item 1) from the rear motor housing
N-17860 (Item 2) [Figure 30-20-9].
Assembly: Install the stop pin and tighten to 10 - 12 N•m

Remove the two cam ring mounting bolts (Item 1) (7 - 9 ft-lb) torque.
[Figure 30-20-7].

Figure 30-20-10
Assembly: Install the two cam ring mounting bolts and
tighten to 67,8 N•m (50 ft-lb) torque.
3
Figure 30-20-8
1
1
4
2
N-17868
NOTE: The distributor removal, is best accomplished

N-17863 by lifting the housing (Item 2) [Figure 30-20-
10] 50,8 - 76,2 mm (2 - 3 in) above a wooden
surface, and dropping the housing.
Remove the cam ring (Item 1) [Figure 30-20-8] from the
motor housing. Assembly: Install the stop pin (Item 1) [Figure 30-20-9]
and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.
Inspect the cam ring for surface scratches or wear.
Assembly: Install the distributor (Item 2) [Figure 30-20-
Assembly: Install the cam ring (Item 1) [Figure 30-20-8] 10] into the housing.
and align the mounting bolt holes.
Assembly: Align the distributor hole (Item 3) [Figure 30-
20-10] with the stop pin. When aligned correctly, the
distributor can be depressed slightly.
Assembly: Install and lightly smear grease on the O-ring

(Item 4) [Figure 30-20-10].

Figure 30-20-11 5
1 2 3 4
1
N-17872
Remove, inspect and install the plug (Item 1), spring

N-17869 (Item 2), shim (Item 3) and poppet (Item 4) [Figure 30-
20-13].
Remove and replace the two seals and back-up O-rings Assembly: Remove and replace the O-ring (Item 5)
(Item 1) [Figure 30-20-11] on the distributor. [Figure 30-20-13].

Inspect the distributor and springs (Item 2) [Figure 30- Assembly: Tighten the plug to 12 - 15 N•m (9 - 11 ft-lb)
20-11] for damage or surface scratches. torque.
Assembly: Put grease on the springs to hold them in Figure 30-20-14

place.
Assembly: Install the springs into the distributor.

5
Figure 30-20-12
2 3 4 2 1
1
N-17871
Remove, inspect and install the plug (Item 1), springs

(Item 2), spool (Item 3) and washer (Item 4) [Figure 30-
N-17866 20-14].
Assembly: Remove and replace the O-ring (Item 5)

Remove the two seals (Item 1) [Figure 30-20-12] from [Figure 30-20-14].
the housing and replace with new seals.
Assembly: Tighten the plug to 25 - 30 N•m (18 - 22 ft-lb)
Remove the two O-rings and replace with new O-rings. torque.
The O-rings are located under the seals.
Assembly: Lightly smear grease over the seals.


HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N
A3NV11001 - A3NV17774 AND S/N A3NW11001 -
A3NW12724)
WARNING
Description
The hydrostatic motors are driven by high pressure from the lift arms are secured by an approved lift arm
the hydrostatic pumps. support device. Failure to use an approved lift arm
This hydrostatic motor contains a spring applied pressure to fall and cause injury or death.
release braking system to stop the loader. This braking W-2059-0598
system is located on the end of the hydrostatic motor.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing case
drain fluid with cooled low pressure fluid from the charge
circuit. The shuttle valve is shifted by the high pressure
IMPORTANT
fluid coming from the hydrostatic pumps. If the shuttle
valve sticks, a delay or lack of drive may or may not be
felt in the controls and / or an overheated hydrostatic
motor will result.
There are two hydrostatic motors mounted to motor damage the system.
I-2003-0888

Removal And Installation THE LOADER on Page 10-10-1.)

DANGER support device. (See Installing on Page 10-20-1.)
Drain the hydraulic reservoir. (See Removal And

P-90328
AVOID DEATH
D-1009-0409

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Disconnect the hydraulic hose (Item 3) [Figure 30-21-2]
A3NV11001 - A3NV17774 AND S/N A3NW11001 - that goes to the make-up port on the two-speed / brake
A3NW12724) (CONT’D) block.
Figure 30-21-3
Figure 30-21-1
P-90257
P-90256
Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]

that goes to the drain manifold.
Remove the motor cover mount bolts (Item 1) [Figure 30-

21-1].
Figure 30-21-4
Remove the motor cover from the loader.

1
Figure 30-21-2
3 1
P-90257
2 Remove the eight flange bolts (Item 1) [Figure 30-21-4]

from the high pressure hoses on the motor.
P-90258

that goes to the two-speed port on the two-speed / brake
block.

that goes to the brake port on the two-speed / brake
block.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Figure 30-21-7
A3NV11001 - A3NV17774 AND S/N A3NW11001 -
A3NW12724) (CONT’D)
12 1
11
13
10 2
Figure 30-21-5
9 3
2 3 8 4
7 5
6
N-22535
4 1 Remove and replace O-ring (Item 13) [Figure 30-21-7].
Installation: Install the O-ring (Item 1) by pressing the O-

P100901 ring into the groove starting at the 12 o’clock position
then 6, 2, 10, 3, 9, 4, 8, 5, 7, 1 and 11 [Figure 30-21-7]
Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-21-5]. Re-tighten all bolts to 48 - 54 N•m (35 -
40 ft-lb) torque in the same sequence.
no protrusions.
Figure 30-21-6
P-90496
Remove the ten (12 mm) mount bolts (Item 1) [Figure

30-21-6] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold

the cam ring to the motor and do not have to
be remove for motor removal.
Remove the motor from the loader.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 - A3NV17774 AND S/N A3NW11001 - A3NW12724)
(CONT’D)
Ref. Description
10
1. Roller 10
2. Piston
3. Ring 10
4. Clamp 10
5. Block 10
6. Cam 10
7. Quad Ring
8. Distributor 9
8
9. Spring 7
10. Seal/O-ring
11. Poppet
12. Shim 1 6
13. O-ring
14. Plug 2
15. Pin
16. Housing
17. Washer 3
18. Quad Ring 6
19. Bushing 3
20. Shaft
21. Dowel 4 4 24

22. Bolt 22
3 23
23. Shim
24. Brake Disc 16
25. Snap Ring
26. Seal 21
27. Clamp 1314
28. Piston
29. Spring 9 20
17
30. Gasket 12 19
31. Cover 9 18
14
16
11
12 13
25
9 17
9 22
13 31
12
30
14
22
29
15 13
28
27
13
26
MS1467S

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N NOTE: Remove and / or tighten the bolts one turn at
A3NV11001 - A3NV17774 AND S/N A3NW11001 - a time to maintain equal preload on the end
A3NW12724) (CONT’D) cap and the brake spring.
Disassembly
Figure 30-21-10
Figure 30-21-8
1
2
N-22492
1
N-22489
Remove the cover plate from the brake housing.

NOTE: Install a mark on the motor, brake, and motor

Remove the cover plate gasket (Item 1) [Figure 30-21-
carrier housings for correct assembly [Figure
10].
30-21-8].
Remove the brake spring (Item 2) [Figure 30-21-10] from
NOTE: Always protect any sealing surfaces. Any
the brake housing.
scratches or marks will cause premature
failure.
NOTE: Mark the top side of the brake spring for
proper installation.
Place the cam sealing surface (Item 1) [Figure 30-21-8]
on a protective material.
Figure 30-21-11
Drain the fluid from the motor casing.
Figure 30-21-9
1
2
N-22493
Remove the piston from the brake housing (Item 1)

N-22490
[Figure 30-21-11].
Remove the twelve mounting bolts (Item 1) [Figure 30- NOTE: The use of air pressure through the brake line
21-9] from the brake cover plate. connection (Item 2) [Figure 30-21-11] will aid
in piston removal.
Inspect the brake piston for damage and replace the seal.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
Disassembly (Cont'd) 1
Figure 30-21-12
P-69985
Remove the brake discs (Item 1) [Figure 30-21-14] from

the brake shaft. Mark the position of the brake discs and
the shims.
P-69973
Figure 30-21-15
Remove the five mounting bolts (Item 1) [Figure 30-21-

12] from the brake housing.
1
Remove the brake housing (Item 2) [Figure 30-21-12]
2
from the rear housing.
Figure 30-21-13
P-69978
Remove the two-speed spool (Item 1) [Figure 30-21-15]

from the housing assembly.
1 Remove and discard the O-rings (Item 2) [Figure 30-21-

15] on the housing.
P-73062
Protect the sealing surface. Remove the snap ring (Item

1) [Figure 30-21-13] to remove the seal from the brake
housing.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
A3NV11001 - A3NV17774 AND S/N A3NW11001 -
A3NW12724) (CONT’D) NOTE: Current motor housings are provided with
break off plugs (Item 2) [Figure 30-21-17] on
the side of the flushing spool housing. Earlier
motors were equipped with threaded plugs.
Figure 30-21-16
Figure 30-21-18
2
4
3
N-22501
P-73057
Inspect the spool (Item 1), the spring (Item 2), washer

(Item 3) and the snap ring (Item 4) and replace as
Remove the flushing spool assembly (Item 1) [Figure 30-
needed [Figure 30-21-16].
21-18] from the housing.
NOTE: If the two speed spool (Item 1) [Figure 30-21-
Figure 30-21-19
16] is damaged the entire rear housing
assembly has to be replaced.
NOTE: S/N A3NT14900, A3NU12252 and above 1

loaders incorporate an inner make-up spool 2 4 3
inside the two speed spool (Item 1) [Figure 30-
21-16]. The make-up spool is disassembled,
both the make-up spool and the two speed
spool will be damaged.
Figure 30-21-17
N-22504
Remove the spring (Item 1), washer (Item 2) and rear

spring (Item 3) from the spool (Item 4) [Figure 30-21-19].
2
Inspect all parts and replace as needed.
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-21-

17] from the housing.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
Figure 30-21-20
1
2
3
1
N-22507
Inspect the poppet (Item 1), shim (Item 2) and spring

(Item 3) for wear and replace as needed [Figure 30-21-
22].
P-69981
Figure 30-21-23

housing.
Installation: Tighten the plug to 22 N•m (18 ft-lb) torque. 1 1

Figure 30-21-21
P-73058
Remove the two (8 mm) cam ring mount bolts (Item 1)

[Figure 30-21-23].
Turn the housing, cam ring, and rotating group assembly

P-69982 over and place on a stand. Remove the cam ring from the
housing.
Remove the poppet assembly (Item 1) [Figure 30-21-21]
from the housing.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
Figure 30-21-24
N-22511
Protect the sealing surfaces. Remove the roller / piston

assembly (Item 1) [Figure 30-21-26] from the cylinder
block.
N-22510
Inspect all roller and piston assemblies for wear and

replace as needed.
Protect the sealing surfaces. Inspect the cam ring inside

surface for wear and scratches [Figure 30-21-24].
NOTE: Put all roller / piston assembles back in the
original bore.
Figure 30-21-25
Figure 30-21-27
1
1
N-22509
P-73059
Remove the cylinder block (Item 1) [Figure 30-21-25]

from the housing.
Remove the shaft from the distributor [Figure 30-21-27].
NOTE: The end of the shaft with the snap ring (Item 1)
housing.
[Figure 30-21-27] must be toward the brake
housing during assembly.
Remove the distributor from the housing.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
1
Figure 30-21-28
N-22523
Remove the bushing (Item 1) [Figure 30-21-30] from the

distributor, if worn or scratched.
P-69984 Figure 30-21-31
NOTE: The distributor removal is best accomplished

by lifting the housing (Item 1) [Figure 30-21-
28] 2 - 3 inches above a wooden surface, and
dropping the housing [Figure 30-21-28].
Figure 30-21-29
2 1
1
N-22519
2
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) from the distributor [Figure 30-21-31].
N-22521
Protect the sealing surfaces. Remove the locating pin

(Item 1) [Figure 30-21-29] from the distributor.
Remove the springs (Item 2) [Figure 30-21-29] from the

distributor.
Inspect the springs, distributor surface and bushing for

damage or wear and replace as needed.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
1
Assembly
NOTE: Always use new O-rings and seals during

motor and brake assembly.
Figure 30-21-32
N-22525
Install a new bushing (Item 1) [Figure 30-21-34] in the

distributor if the old bushing was removed.
1
Install new O-rings and seals on the distributor [Figure
30-21-35].

N-22511 NOTE: When installing seals, apply a light coating of
oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals, allow
During installation of pistons in the bore, position the
30 minutes for the seals to set on the
piston ring gap 180° from one piston to the next. One
distributor before installing the distributor in
piston installed with the gap to the right, the next piston
the housing.
installed with the gap to the left.
Figure 30-21-35
Dip each of the roller / piston assemblies (Item 1) [Figure
30-21-32] in oil and replace back its original bore.
Figure 30-21-33
P-73060
Using a small amount of grease, install the springs into

N-22518 the distributor valve (Item 1) [Figure 30-21-35].
Apply a small amount of grease to the locating pin (Item

1) [Figure 30-21-33] and install the locating pin in the
housing

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
1
Assembly (Cont'd)
Figure 30-21-36
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

21-38].
N-22515 Install the cam ring to the rear housing. Apply liquid
adhesive (Loctite® 243) to the two cam ring mounting
bolts. Install the bolts finger tight.
Install the distributor (Item 1) [Figure 30-21-36] in the

housing. Protect the sealing surface of the distributor.
Figure 30-21-39
Figure 30-21-37
1
1
P-69983
P-73061
Turn the motor so that it sets on the cam ring, and

cylinder block [Figure 30-21-39].
The pin in the distributor must align with the hole in the
housing (Item 1) [Figure 30-21-37]. Use a hand press to
NOTE: Be careful when turning or moving the motor
push the distributor in place.
so the cylinder block stays in the motor
housing and the sealing surfaces are
When installed correctly, the distributor will spring back
protected.
slightly when pushed by hand into the housing.
Tighten the two cam ring mounting bolts (Item 1) [Figure
30-21-39] to 35 - 39 N•m (26 - 29 ft-lb) torque.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
A3NW12724) (CONT’D) 1
Assembly (Cont'd)
2
Figure 30-21-40
P-69986
Install the brake housing (Item 1) [Figure 30-21-42] on

the motor housing.
P-69978 Apply liquid adhesive (Loctite® 243) to the five mounting

bolts. Install the bolts (Item 2) [Figure 30-21-42] and
tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque.
Install new o-rings (Item 1) [Figure 30-21-40] on the

housing assembly and apply grease to the o-rings.
Figure 30-21-43
Install the two speed spool (Item 2) [Figure 30-21-40].
Install the shaft into the distributor [Figure 30-21-40].
Figure 30-21-41 1
P-73064
If needed, install the shims first, then install the brake

disc pack starting with an outer disc (Item 1) [Figure 30-
21-43] and alternating with an inner disc, throughout the
N-18347 pack.
End the disc pack with an outer disc

Clamp the disc pack in a vise and measure the height
[Figure 30-21-41]. The height must be 31,1 mm (1.22
in).
The normal thickness of the individual brake disc is 1 mm

(0.039 in).
If any individual disc's thickness is 0,95 mm (0.037 in) or

less, replace the complete disc pack.

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
Assembly (Cont'd)
Figure 30-21-44 1
2
N-22493
Install the piston (Item 1) [Figure 30-21-46] in the brake

housing.
P-73055 Figure 30-21-47
Install the brake seal (Item 1) [Figure 30-21-44].

NOTE: Install the seal with the metal case end 2
towards the brake pack.
1
Install the snap ring (Item 2) [Figure 30-21-44] to secure
the seal in the brake housing.
Install a new O-ring (Item 3) [Figure 30-21-44] in the

seal.
Figure 30-21-45
N-22492
Install the brake spring (Item 1) [Figure 30-21-47].
1 Install the end plate gasket (Item 2) [Figure 30-21-47].
N-22498
Lightly coat the piston with oil and install a new piston

A3NV11001 - A3NV17774 AND S/N A3NW11001 -
Assembly (Cont'd)
Figure 30-21-48
N-22490
Install the brake end cover (Item 1) [Figure 30-21-48].

Install the twelve end cover mount bolts and tighten
evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.


HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Removal And Installation
A3NV17775 & ABOVE AND S/N A3NW12725 &
ABOVE)
Description DANGER
The hydrostatic motors are driven by high pressure from
the hydrostatic pumps.
This hydrostatic motor contains a spring applied pressure

release braking system. This braking system is located
on the end of the hydrostatic motor.
The hydrostatic motor contains a shuttle valve. The

P-90328
shuttle valve helps to keep the motor cool by mixing case
drain fluid with cooled low pressure fluid from the charge AVOID DEATH
circuit. The shuttle valve is shifted by the high pressure • Disconnecting or loosening any hydraulic
fluid coming from the hydrostatic pumps. If the shuttle tubeline, hose, fitting, component or a part failure
valve sticks, a delay or lack of drive may or may not be can cause lift arms to drop.
felt in the controls and / or an overheated hydrostatic • Keep out of this area when lift arms are raised
motor will result. unless supported by an approved lift arm
There are two hydrostatic motors mounted to motor D-1009-0409

WARNING
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888




ABOVE) (CONT'D)

2
Figure 30-22-1
1 P107950

that goes to the drain manifold.
P106586 Remove the eight flange bolts (Item 1) [Figure 30-22-3]

from the high pressure hoses on the motor.
Remove the four bolts (Item 1) and cover (Item 2) [Figure

30-22-1].
Figure 30-22-2
1
2
P107951

that goes to the two-speed port on the two-speed / brake
block.

that goes to the brake port on the two-speed / brake
block.

ABOVE) (CONT'D)
12 1
11
13
10 2
Figure 30-22-4
9 3
2 3 8 4
7 5
6
N-22535
4 1
Remove and replace O-ring (Item 13) [Figure 30-22-6]
with new O-ring
P100901 Installation: Install the O-ring (Item 1) by pressing the O-

ring into the groove starting at the 12 o’clock position
then 6, 2, 10, 3, 9, 4, 8, 5, 7, 1 and 11 [Figure 30-22-6]
Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-22-4]. Re-tighten all bolts to 48 - 54 N•m (35 -
40 ft-lb) torque in the same sequence.
no protrusions.
Figure 30-22-5
P-90496
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

22-5] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold

the cam ring to the motor and do not have to
be remove for motor removal.
Remove the motor from the loader.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE)
(CONT'D)
1. Roller
2. Piston 11
3. Ring 11
4. Clamp 11
5. Ring 11
6. Block 11
7. Cam 11
8. Quad Ring
9. Distributor 10
10. Spring 9
8
11. Seal/O-ring
12. Poppet
13. Spool 1 7
14. Spring
15. O-ring 2
16. Plug
17. Pin
18. Housing 3
19. Washer 6
20. Quad Ring
21. Bushing 5
22. Shaft 4 4 26

23. Dowel 24
24. Bolt 5 25
25. Shim
26. Brake Disc 18
27. Snap Ring
28. Seal 23
29. Clamp 1516
30. Piston 14 22
31 Spring 19
32. Gasket 13 21
14 20
33. Cover
16
18
12
13 15
27
14 19
14 24
15 33
13
32
16
24
31
17 15
30
29
15
28
MS1467S

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N NOTE: Remove and / or tighten the bolts one turn at
A3NV17775 & ABOVE AND S/N A3NW12725 & a time to maintain equal preload on the end
ABOVE) (CONT'D) cap and the brake spring.
Disassembly
Figure 30-22-9
Figure 30-22-7
1
2
N-22492
1
N-22489
Remove the cover plate from the brake housing.

NOTE: Install a mark on the motor, brake, and motor

Remove the cover plate gasket (Item 1) [Figure 30-22-9].
carrier housings for correct assembly [Figure
30-22-7].
Remove the brake spring (Item 2) [Figure 30-22-9] from
NOTE: Always protect any sealing surfaces. Any the brake housing.
scratches or marks will cause premature
failure. NOTE: Mark the top side of the brake spring for
proper installation.
Place the cam sealing surface (Item 1) [Figure 30-22-7]
on a protective material. Figure 30-22-10
Drain the fluid from the motor casing.

Figure 30-22-8
1
2
N-22493
Remove the piston from the brake housing (Item 1)

N-22490 [Figure 30-22-10].
Remove the twelve mounting bolts (Item 1) [Figure 30- NOTE: The use of air pressure through the brake line
22-8] from the brake cover plate. connection (Item 2) [Figure 30-22-10] will aid
in piston removal.
Inspect the brake piston for damage and replace the seal.

ABOVE) (CONT'D)
Disassembly (Cont'd) 1
Figure 30-22-11
P-69985
Remove the brake discs (Item 1) [Figure 30-22-13] from

the brake shaft. Mark the position of the brake discs and
the shims.
P-69973
Figure 30-22-14
Remove the five mounting bolts (Item 1) [Figure 30-22-

11] from the brake housing.
1
Remove the brake housing (Item 2) [Figure 30-22-11]
2
from the rear housing.
Figure 30-22-12
P-69978
Remove the two-speed spool (Item 1) [Figure 30-22-14]

from the housing assembly.
1 Remove and discard the O-rings (Item 2) [Figure 30-22-

14] on the housing.
P-73062
Protect the sealing surface. Remove the snap ring (Item

1) [Figure 30-22-12] to remove the seal from the brake
housing.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
ABOVE) (CONT'D) Figure 30-22-17
Figure 30-22-15
1
1
2
4 P-73057
3
Remove the flushing spool assembly (Item 1) [Figure 30-
N-22501 22-17] from the housing.
Figure 30-22-18
Inspect the spool (Item 1), the spring (Item 2), washer

(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-22-15].
1
NOTE: If the two speed spool (Item 1) [Figure 30-22- 2 4 3
15] is damaged the entire housing assembly
has to be replaced.
NOTE: There is an inner make-up spool inside the

two speed spool (Item 4) [Figure 30-22-15].
The make-up spool is not serviceable. If the
two speed spool is disassembled, both the
make-up spool and the two speed spool will
be damaged.
N-22504
Figure 30-22-16
1 Remove the spring (Item 1), washer (Item 2) and rear

spring (Item 3) from the spool (Item 4) [Figure 30-22-18].
Inspect all parts and replace as needed.
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-22-

16] from the housing.

ABOVE) (CONT'D)
Figure 30-22-19
1
2
3
1
N-22507
Inspect the poppet (Item 1), shim (Item 2) and spring

(Item 3) for wear and replace as needed [Figure 30-22-
21].
P-69981
Figure 30-22-22

housing.
Installation: Tighten the plug to 22 N•m (18 ft-lb) torque. 1 1

Figure 30-22-20
P-73058
Remove the two (8 mm) cam ring mount bolts (Item 1)

[Figure 30-22-22].
Turn the housing, cam ring, and rotating group assembly

P-69982 over and place on a stand. Remove the cam ring from the
housing.
Remove the poppet assembly (Item 1) [Figure 30-22-20]
from the housing.

ABOVE) (CONT'D)
Figure 30-22-23
N-22511
Protect the sealing surfaces. Remove the roller / piston

assembly (Item 1) [Figure 30-22-25] from the cylinder
block.
N-22510
Inspect all roller and piston assemblies for wear and

replace as needed.
Protect the sealing surfaces. Inspect the cam ring inside

surface for wear and scratches [Figure 30-22-23].
NOTE: Put all roller / piston assembles back in the
original bore.
Figure 30-22-24
Figure 30-22-26
1
1
N-22509
P-73059
Remove the cylinder block (Item 1) [Figure 30-22-24]

from the housing.
Remove the shaft from the distributor [Figure 30-22-26].
NOTE: The end of the shaft with the snap ring (Item 1)
housing.
[Figure 30-22-26] must be toward the brake
housing during assembly.
Remove the distributor from the housing.

ABOVE) (CONT'D)
1
Figure 30-22-27
N-22523
Remove the bushing (Item 1) [Figure 30-22-29] from the

distributor, if worn or scratched.
P-69984 Figure 30-22-30
NOTE: The distributor removal is best accomplished

by lifting the housing (Item 1) [Figure 30-22-
27] 50,8 - 76,2 mm (2 - 3 in) above a wooden
surface, and dropping the housing [Figure 30-
22-27].
Figure 30-22-28 1
N-22519
2
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) from the distributor [Figure 30-22-30].
N-22521
Protect the sealing surfaces. Remove the locating pin

(Item 1) [Figure 30-22-28] from the distributor.
Remove the springs (Item 1) [Figure 30-22-28] from the

distributor.
Inspect the springs, distributor surface and bushing for

damage or wear and replace as needed.

ABOVE) (CONT'D)
1
Assembly
NOTE: Always use new O-rings and seals during

motor and brake assembly.
Figure 30-22-31
N-22525
Install a new bushing (Item 1) [Figure 30-22-33] in the

distributor if the old bushing was removed.
1
Install new O-rings and seals on the distributor [Figure
30-22-34].

N-22511 NOTE: When installing seals, apply a light coating of
oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals, allow
During installation of pistons in the bore, position the
30 minutes for the seals to set on the
piston ring gap 180° from one piston to the next. One
distributor before installing the distributor in
piston installed with the gap to the right, the next piston
the housing.
installed with the gap to the left.
Figure 30-22-34
Dip each of the roller / piston assemblies (Item 1) [Figure
30-22-31] in oil and replace back its original bore.
Figure 30-22-32
P-73060
Using a small amount of grease, install the springs into

N-22518 the distributor valve (Item 1) [Figure 30-22-34].
Apply a small amount of grease to the locating pin (Item

1) [Figure 30-22-32] and install the locating pin in the
housing.

ABOVE) (CONT'D)
1
Assembly (Cont'd)
Figure 30-22-35
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

22-37].
N-22515 Install the cam ring to the rear housing. Apply liquid
adhesive (Loctite® 243) to the two cam ring mounting
bolts. Install the bolts finger tight.
Install the distributor (Item 1) [Figure 30-22-35] in the

housing. Protect the sealing surface of the distributor.
Figure 30-22-38
Figure 30-22-36
1
1
P-69983
P-73061
Turn the motor so that it sets on the cam ring, and

cylinder block [Figure 30-22-38].
The pin in the distributor must align with the hole in the
housing (Item 1) [Figure 30-22-36]. Use a hand press to
NOTE: Be careful when turning or moving the motor
push the distributor in place.
so the cylinder block stays in the motor
housing and the sealing surfaces are
When installed correctly, the distributor will spring back
protected.
slightly when pushed by hand into the housing.
Tighten the two cam ring mounting bolts (Item 1) [Figure
30-22-38] to 35 - 39 N•m (26 - 29 ft-lb) torque.

ABOVE) (CONT'D) 1
Assembly (Cont'd)
Figure 30-22-39
1 2
2
P-69986
Install the brake housing (Item 1) [Figure 30-22-41] on

the motor housing.
P-69978 Apply liquid adhesive (Loctite® 243) to the five mounting

bolts. Install the bolts (Item 2) [Figure 30-22-41] and
tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque.
Install new O-rings (Item 1) [Figure 30-22-39] on the

housing assembly and apply grease to the O-rings.
Figure 30-22-42
Install the two speed spool (Item 2) [Figure 30-22-39].
Install the shaft into the distributor [Figure 30-22-39].
Figure 30-22-40 1
P-73064
If needed, install the shims first, then install the brake

disc pack starting with an outer disc (Item 1) [Figure 30-
22-42] and alternating with an inner disc, throughout the
N-18347 pack.
End the disc pack with an outer disc

Clamp the disc pack in a vise and measure the height
[Figure 30-22-40]. The height must be 31,1 mm (1.22
in).
The normal thickness of the individual brake disc is 1 mm

(0.039 in).
If any individual discs thickness is 0,95 mm (0.037 in) or

less, replace the complete disc pack.

ABOVE) (CONT'D)
Assembly (Cont'd)
Figure 30-22-43 1
2
N-22493
Install the piston (Item 1) [Figure 30-22-45] in the brake

housing.
P-73055 Figure 30-22-46
Install the brake seal (Item 1) [Figure 30-22-43].

NOTE: Install the seal with the metal case end 2
towards the brake pack.
1
Install the snap ring (Item 2) [Figure 30-22-43] to secure
the seal in the brake housing.
Install a new O-ring (Item 3) [Figure 30-22-43] in the

seal.
Figure 30-22-44
N-22492
Install the brake spring (Item 1) [Figure 30-22-46].
1 Install the end plate gasket (Item 2) [Figure 30-22-46].
N-22498
Lightly coat the piston with oil and install a new piston

ABOVE) (CONT'D)
Assembly (Cont'd)
Figure 30-22-47
N-22490
Install the brake end cover (Item 1) [Figure 30-22-47].

Install the twelve end cover mount bolts and tighten
evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.


HYDROSTATIC MOTOR CARRIER
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission chain
case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case fluid from the hydrostatic motor case drain
fluid.
The hydrostatic motor carriers are made to fit on both the

right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (CONT’D) Remove the control pedal linkages. (See Linkage
Figure 30-30-1
DANGER
1
P-90328
AVOID DEATH
P5467A
• Keep out of this area when lift arms are raised Remove the six mounting bolts (Item 1) [Figure 30-30-1]
unless supported by an approved lift arm from the carrier.
D-1009-0409 Installation: Tighten the mounting bolts to 461 - 488

Slide the motor carrier toward the rear and remove the
rear drive chain.

W-2059-0598

THE LOADER on Page 10-10-1.) 1
Raise the lift arm and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

P5489A
Remove the fluid from the chain case. (See Removing
And Replacing Fluid on Page 10-130-2.)
NOTE: For removal and installation of the motor
Remove the center chain case cover. (See Center Cover carrier secure the front drive chain to the
Removal And Installation on Page 40-30-2.) chain case with wire (Item 1) [Figure 30-30-2].
Remove the front axle sprocket. (See Axle, Sprocket And
Slide the motor carrier out of the chain case far enough to
Bearings Removal And Installation on Page 40-20-4.)
install a chain and chain hoist to the carrier (Item 2)
If the motor carrier is removed from the right side, remove [Figure 30-30-2].
the lift arm bypass valve, (See Removal And Installation
on Page 20-50-2.) and remove the control panel. (See Pull the motor carrier away from the chain case and out
Removal And Installation on Page 50-100-2.) of the loader [Figure 30-30-2].

HYDROSTATIC MOTOR CARRIER (CONT'D)
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring

1
2
3
7
8
TS-1227B

HYDROSTATIC MOTOR CARRIER (CONT'D) Figure 30-30-5
Disassembly
Figure 30-30-3
P-76544
Remove the snap ring (Item 1) [Figure 30-30-5] from the

P5760 shaft.
Figure 30-30-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-30-3] in the housing.

Figure 30-30-4
P5766
Use a hydraulic press to remove the shaft from the

housing [Figure 30-30-6].
P5768
Put the motor carrier in a hydraulic press [Figure 30-30-

4].
Put a small amount of pressure on the shaft to release

the preload on the snap ring.

Disassembly (Cont’d)
Figure 30-30-7
P5761
Install the bearing puller tool under the bearing flange,

use the hydraulic press to remove the bearing from the

shaft [Figure 30-30-7].
Figure 30-30-8
2
1
P5763
Remove the two seals (Item 1) [Figure 30-30-8] from the

housing.
NOTE: Some machines use a one piece double lip

seal.
Inspect the bearing cup (Item 2) [Figure 30-30-8] (both

sides) and replace as needed.

HYDROSTATIC MOTOR CARRIER (CONT'D) Figure 30-30-11
Assembly
Clean all parts in solvent and dry with compressed air. 1

Replace any worn or damaged parts. Apply oil to and
install new O-rings.
The tool listed will be needed to the following procedure:
MEL1431 - Seal Driver Tool
Figure 30-30-9
2
P5767
1
Install the bearing on the shaft [Figure 30-30-11].
Use a pipe (Item 1) [Figure 30-30-11] with O.D. that

seats on the I.D. of the bearing.

Figure 30-30-12
P5764
1
Install the first seal (Item 1) [Figure 30-30-9] into the

housing with the seal lip facing down.
Use the tool (Item 2) [Figure 30-30-9] to install the seal.
Figure 30-30-10
P135120
1 Install the seal protector tool (Item 1) [Figure 30-30-12]

over the splines on the shaft to protect the seal during
installation.
P5762
Install the second seal (Item 1) [Figure 30-30-10] into the

housing with the seal lip facing up.

Assembly (Cont’d)
Figure 30-30-13
P5769

install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) using the tool (MEL1431)(Item

2) [Figure 30-30-13].
After the bearing is seated. Install the snap ring on the

shaft and reposition the motor carrier to allow back press
operation.
NOTE: Slight press pressure may be used to preload

both bearings. After installation of the snap
ring a back press operation may be necessary
to reduce the preload and remove the
clearance from between the snap ring and the
main bearing.
Use the press and apply pressure to the end of the spline
shaft to reduce preload and clearance.


HYDROSTATIC MOTOR CARRIER (SJC)
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission
chaincase.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case fluid from the hydrostatic motor case drain
fluid.
The hydrostatic motor carrier with (SJC) uses a speed

sensor installed in the motor carrier housing. The speed
sensor senses a disc that is fixed to the shaft in the motor
carrier.
NOTE: Speed sensors have been eliminated on late

model machines. Earlier models may or may
not have been upgraded to allow the removal

of the speed sensors. Disconnecting speed
sensors requires updating the software
version (79.7 or newer) and hydrostatic pump
calibration.
A brake disc is installed on each hydrostatic motor

carrier. The brake disc is mounted to the shaft in the
motor carrier (single speed loaders only).
The hydrostatic motor carriers are made to fit on both the

right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Figure 30-31-1
DANGER 1
1
P-90328
P5467A
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the six mounting bolts (Item 1) [Figure 30-31-1]
tubeline, hose, fitting, component or a part failure from the carrier.
Installation: Tighten the mounting bolts to 461 - 488
support. Replace if damaged. Figure 30-31-2
D-1009-0409

2
WARNING
W-2059-0598

THE LOADER on Page 10-10-1.) P5489A
Raise the lift arms and install an approved lift arm Slide the motor carrier toward the rear and remove the
support device. (See Installing on Page 10-20-1.) rear drive chain.
Raise the operator cab. (See Raising on Page 10-30-2.) NOTE: For removal and installation of the motor
Remove the fluid from the chaincase. (See Removing carrier secure the front drive chain to the
And Replacing Fluid on Page 10-130-2.) chain case with wire (Item 1) [Figure 30-31-2].
Remove the center chaincase cover. (See Center Cover Slide the motor carrier out of the chaincase far enough to
Removal And Installation on Page 40-30-2.) install a chain and chain hoist to the carrier (Item 2)
[Figure 30-31-2].
Remove the brake disc. (Single speed loaders only) (See
Disc Removal And Installation on Page 40-10-1.) NOTE: When installing the motor carrier into the
Remove the front axle sprocket. (See Axle, Sprocket And loader, use caution to protect the wheel speed
Bearings Removal And Installation on Page 40-20-4.) washer from damage.
If the motor carrier is removed from the right side, remove

the lift arm bypass valve, (See Removal And Installation
on Page 20-50-2.) and remove the control panel. (See

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Ref. Description
1. Snap Ring
2. Bearing
3. Race
4. Seal
5. Housing
6. Speed Washer
7. Shaft
8. Cover
7
5

6 8
2 3
4 3
2
1
* Speed washer (Item 6) and cover (Item 8) have been removed on late model machines.
* Housing (Item 5) will no longer be machined to allow the installation of speed sensors.
PE3328SA

Disassembly
Figure 30-31-3
P-28155

P5760 shaft.
Figure 30-31-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-31-3] in the housing.

Figure 30-31-4
P5766
Use a hydraulic press, remove the shaft from the housing

P-76540 [Figure 30-31-6].
Put the motor carrier in a hydraulic press [Figure 30-31-

4].
Put a small amount of pressure on the shaft to release

the preload on the snap ring.

Figure 30-31-7
P-28158
Use the hydraulic press to remove the bearing from the

P-76462 shaft [Figure 30-31-9].
Figure 30-31-10
NOTE: The bearing (Item 1) [Figure 30-31-7] and the
wheel speed washer (Item 2) [Figure 30-31-7],

must both be replaced, due to damage to the
wheel speed washer from removing the
bearing.
NOTE: The wheel speed washer (Item 2) [Figure 30-

31-7] has been removed on late model
1
machines and can be eliminated on older
machines that have been upgraded to allow
the removal of the speed sensors.
Figure 30-31-8
P-76464
1
Remove the wheel speed washer (Item 1) [Figure 30-31-
10] from the shaft.
P-28157
Install the bearing puller tool (Item 1) [Figure 30-31-8]

under the bearing flange, between the bearing and the
speed washer.

Figure 30-31-11
P-28164
Remove the two seals (Item 1) [Figure 30-31-11] from

the housing.

NOTE: Some machines use a one piece double lip
seal.
Inspect the bearing cup (Item 2) [Figure 30-31-11] (both

sides) and replace as needed.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Models With One Piece Double Lip Seal
Assembly Clean all parts in solvent and dry with compressed air.
Models With Two Seals install new O-rings.
Clean all parts in solvent and dry with compressed air. The tool listed will be needed to the following procedure:
install new O-rings. 7304800 - Seal Driver Tool
The tool listed will be needed to the following procedure: Figure 30-31-14
Figure 30-31-12
2
2 1

P127119
Apply grease to the seal driver tool (Item 1) and install

P5764 the seal (Item 2) [Figure 30-31-14] onto the tool.
Figure 30-31-15
Install the first seal (Item 1) [Figure 30-31-12] into the
housing with the seal lip facing down. 1
Figure 30-31-13
P127120
P5762
Install the second seal (Item 1) [Figure 30-31-13] into the

housing with the seal lip facing up.

Assembly (Cont'd)
Figure 30-31-16
1
1
P-76539
Install the bearing on the shaft [Figure 30-31-18].

P-76541
Use a pipe (Item 1) [Figure 30-31-18] with O.D. that
The wheel speed washer, has one alignment pin (Item 1) seats on the I.D. of the bearing.
[Figure 30-31-16].
Seat the bearing on the shaft, down against the wheel

Inspect the new wheel speed washer with a straight speed washer.
edge, to be sure it is square [Figure 30-31-16].
NOTE: The wheel speed washer should be tight on
If the washer is more than 2,03 mm (0.080 in) out of the shaft.
square, it must be replaced.
Figure 30-31-17 Figure 30-31-19
P135120
P-76542
Inspect the wheel speed washer for damage to the

Install the seal protector tool (Item 1) [Figure 30-31-19]
magnetic surface (Item 1) [Figure 30-31-17].
over the splines on the shaft to protect the seal during
installation.
NOTE: Do not contact the magnetic surface of the
wheel speed washer (Item 1) [Figure 30-31-
17], with a magnet. This may cause damage to
the magnetic surface.
Install the wheel speed washer on the shaft [Figure 30-

31-17].
Align the one pin (Item 2) [Figure 30-31-17] in the

sprocket.

Assembly (Cont'd)
Figure 30-31-20

P-5769
Install the shaft / bearing assembly into the housing.
Install the bearing (Item 1) using the tool (MEL1431)

(Item 2) [Figure 30-31-20].
After the bearing is seated. Install the snap ring on the

shaft and reposition the motor carrier to allow back press
operation.
NOTE: Slight press pressure may be used to preload

both bearings. After installation of the snap
ring a back press operation may be necessary
to reduce the preload and remove the
clearance from between the snap ring and the
main bearing.
Use the press and apply pressure to the end of the spline
shaft to reduce preload and clearance.


CHARGE PRESSURE Testing
Charge pressure is a supply of fluid to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
2 4
hydraulic control valve. 1 3
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre- P-43196
programmed into the main controller and are based on
loader type and options installed.
The tools needed to test charge pressure, hydraulic hose
(Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic gauge
6895 kPa (68,9 bar) (1000 psi) (Item 3), adapter fitting (P/
N 93F-5) (Item 4) [Figure 30-40-1] and MEL1563 or

7217666 Remote Start Tool Kit.
WARNING
W-2059-0598
Raise the loader lift arms and install an approved lift arm
Place the loader on jackstands. (See LIFTING AND


CHARGE PRESSURE (CONT’D) Figure 30-40-4
Testing (Cont’d)
Figure 30-40-2
1
1
2
3 3
2
P-90301
Install the tee-fitting (P/N 13K-5) (Item 1) [Figure 30-40-

P-43197 4].
Install the hose (Item 2) [Figure 30-40-4], that was

Connect the gauge (Item 1), to the adapter fitting (P/N disconnected from the motor, to the tee-fitting.
93F5) (Item 2) [Figure 30-40-2].

Install the hose (Item 3) [Figure 30-40-4], that is
Connect the hydraulic hose (Item 3) [Figure 30-40-2] to attached to the pressure gauge, to the tee-fitting.
the adapter fitting. Tighten all connections.
Tighten the hydraulic fittings.
Figure 30-40-3
7217666 on Page 10-61-1.)
Start the loader and warm the hydraulic fluid to 140

degrees Farenheit.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 140 degree
1
Farenheit is 2688 - 3378 kPa (27 - 33 bar) (390 - 490 psi)
with the pump in neutral.
NOTE: If the machine is equipped with SJC option

P-90302 the charge pressure should be set at 2930 -
3620 kPa (29,3 - 36,2 bar) (425 - 525 psi) at
60°C (140°F) fluid @ High idle.
Disconnect the hydraulic hose (Item 1) [Figure 30-40-3].

CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-40-5
P-90302
Disconnect the wire (Item 1) [Figure 30-40-5] from the

sender.

Remove the sender (Item 2) [Figure 30-40-5] from the
motor.
Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.
NOTE: Replace the O-ring on the sender.

CHARGE PRESSURE (CONT'D) Figure 30-40-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-40-6 Remove the plug, spring and poppet [Figure 30-40-7].
Inspect the poppet, spring and poppet seat for wear or

1 damage.
Figure 30-40-8

P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-40-6].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
There are several different thickness of the shims (Item 1)
[Figure 30-40-8] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is approximately 55,2 kPa

(0,55 bar) (8 psi) increase in pressure. Do not
add more than 5 shims without retesting. If
testing is still low more shims may be added.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2688 - 3378 kPa (27 - 33 bar) (390 - 490 psi) with the
pump in NEUTRAL.

CHARGE PRESSURE (CONT'D) Figure 30-40-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
P-64435
I-2003-0888
Figure 30-40-9 Inspect the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-40-10] used to adjust the charge pressure.
1 NOTE: 1,0 mm (0.039 in) shim (Item 1) [Figure 30-40-

10] = 390 kPa (3,9 bar) (56.6 psi) in pressure
change. Adding shims increases charge
pressure. Removing shims decreases charge
pressure.
The charge pressure should be set at 2930 - 3620 kPa

P-64431 (29,3 - 36,2 bar) (425 - 525 psi).
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-9].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.


HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the fluid cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT'D) Figure 30-50-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1)
clean the work area before disassembly and keep all [Figure 30-50-2] to loosen the pulley from the pump
parts clean. Always use caps and plugs on hoses, drive shaft.
damage the system. NOTE: DO NOT strike puller or pump shaft with a

I-2003-0888 hammer. Internal pump damage may result.
Figure 30-10-1 Remove the nut and washer from the pump drive shaft.
Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-3
P-90221
1
1
Loosen the nut (Item 1) [Figure 30-10-1] on the
hydrostatic pump drive shaft.
P-90223
Installation: Tighten the nut to 258 - 325 N•m (190 - 240
ft-lb) torque
30-50-3].
Installation: Tighten the mounting bolts and nuts to 88 -

95 N•m (65 - 70 ft-lb) torque.

HYDROSTATIC PUMP (CONT'D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Startup on Page 20-60-8.)
Figure 30-50-4
P-90224

at the hydraulic pump mounting bracket.

Installation: Tighten mounting bolt to 125 - 135 N•m (90
- 100 ft-lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydraulic Pump
Startup on Page 20-60-8.)

HYDROSTATIC PUMP (CONT’D) If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
Replenishing / High Pressure Relief Valve Removal
And Installation The pressure setting for a new high pressure relief valve
is 36197 kPa (365 bar) (5294 psi).
Figure 30-50-5
P-43857
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-50-5] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.
Figure 30-50-6
P-66670
Remove the high pressure relief valve (Item 1) [Figure

30-50-5] and [Figure 30-50-6] from the pump.
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)

torque.
Inspect for damage and replace as needed.

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10

18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

HYDROSTATIC PUMP (CONT'D) Figure 30-50-9
Disassembly
Figure 30-50-7
3
1
1 3
2
N-19571
1 Remove the pump coupler (Item 1) [Figure 30-50-9].

P-43858
Remove the large O-ring (Item 2) [Figure 30-50-9].
Remove the four mounting bolts (Item 1) [Figure 30-50- Remove the two small O-rings (Item 3) [Figure 30-50-9].
7].

Figure 30-50-10
Figure 30-50-8
1 1
N-19550
N-19570
Remove the four bolts (Item 1) [Figure 30-50-10] from

Separate the two hydrostatic pumps [Figure 30-50-8]. the pump housing end cap.

HYDROSTATIC PUMP (CONT’D) Figure 30-50-13
2
1
Figure 30-50-11
N-17194
2
Inspect the valve plate locating pin (Item 1) [Figure 30-
N-19551 50-13] for wear and replace if needed.
Inspect the needle bearing (Item 2) [Figure 30-50-13] for

Remove the pump housing end cap (Item 1) [Figure 30- wear and replace if needed.
50-11].

Figure 30-50-14
Remove the gasket (Item 2) [Figure 30-50-11].
Figure 30-50-12
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-50-14]

from the pump.
Remove the valve plate (Item 1) [Figure 30-50-12].
Inspect the valve plate for wear. (Both Sides.)

3 3
Figure 30-50-15
1 1
3 2
3
2
N-17200
Inspect the ball guide retainer (Item 1) and washer (Item

N-17198 2) [Figure 30-50-17] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-50-17] from the

Remove the slipper guide and pistons (Item 1) [Figure cylinder block.
30-50-15] from the cylinder block.

Inpsect the cylinder block for wear and replace as
Inspect all the pistons (Item 2) [Figure 30-50-15] for needed.
wear and replace the rotating group as needed.
Inspect pins (Item 3) [Figure 30-50-17] to see if they are
Figure 30-50-16 all the same length.
Figure 30-50-18
1
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-50-
16] from the cylinder block.
Remove the thrust plate (Item 1) [Figure 30-50-18] from
the pump housing.

Figure 30-50-19
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-50-21] from
N-17481 the pump housing and remove the drive shaft and
bearing from the housing.
Remove the drive shaft key (Item 1) the snap ring (Item Figure 30-50-22
2) and the support washer (Item 3) [Figure 30-50-19]

from the drive shaft end of the pump.
Figure 30-50-20
N-17241
Remove the snap ring (Item 1) [Figure 30-50-22] from

N-17239 the drive shaft and remove the bearing.
Inspect the bearing for wear and replace if worn.

Use a seal puller and remove the seal (Item 1) [Figure
30-50-20] from the pump housing.

Figure 30-50-23
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-50-25] from the pump housing.
Figure 30-50-26
Inspect the pump shaft (Item 1) [Figure 30-50-23] for
wear and replace if needed.

Figure 30-50-24
N-17245
1 1
Inspect the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-50-26] for wear and replace as needed.
Remove the four mount bolts (Item 1) [Figure 30-50-24]

from the lower trunnion cover. Remove the cover.

Figure 30-50-27
1
2
1 N-17250
1
Inspect the seal (Item 1) [Figure 30-50-29] in the upper

N-17246 trunnion cover and replace if needed.
Figure 30-50-30
Inspect the dust seal on the pintle shaft.

Remove the four mount bolts (Item 1) from the pump
housing and remove the linkage bracket (Item 2) [Figure
30-50-27].
Figure 30-50-28
N-17248
1 Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-50-30] from the pump housing.
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-50-

28].

1
Figure 30-50-31
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-50-33] and

N-17249 remove the swash plate and lower bearing from the pump
housing.
Inspect the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-31] and replace as needed.

Figure 30-50-32
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-50-32] from
the swash plate shaft.

Assembly
Figure 30-50-34
1
1
2
N-17249
Install the tapered bearing (Item 1) [Figure 30-50-36] on

N-17253 the swash plate shaft.
Figure 30-50-37
Install the lower bearing (Item 1) [Figure 30-50-34] on
the swash plate.

Figure 30-50-35
N-17248
Install the bearing race (Item 2) [Figure 30-50-36] and O-

N-17252 ring (Item 3) [Figure 30-50-36] as shown in [Figure 30-
50-37].
Install the swash plate and bearing into the pump

housing [Figure 30-50-35].

Assembly (Cont’d)
Figure 30-50-38
1 N-17245
Figure 30-50-41
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-50-38]

and cover.

Figure 30-50-39
2
N-17244
1
1 Install the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-50-40] at the lower trunnion as shown in
[Figure 30-50-41].
N-17246
Install the linkage bracket (Item 2) and the four mounting

bolts (Item 1) [Figure 30-50-39] and tighten to 24 - 30
Install the dust seals onto the pintle shafts

Assembly (Cont’d)
Figure 30-50-42
1 1 N-17241
Install the bearing and snap ring (Item 1) [Figure 30-50-

N-17243 44] on the pump shaft.
Figure 30-50-45
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-50-42].

Install the four mounting bolts (Item 1) [Figure 30-50-42]
and tighten to 24 - 30 N•m (18 - 22 ft-lb) torque.
Figure 30-50-43
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
50-45].
Install the snap ring (Item 1) [Figure 30-50-45].

N-17242
Install the snap ring (Item 1) [Figure 30-50-43] on the

pump shaft.

Assembly (Cont’d)
1
1
Figure 30-50-46
1
1 3
1 2
N-17200
Install the four slipper pins (Item 1) [Figure 30-50-48]

N-17239 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the seal (Item 1) [Figure 30-50-46] into the pump and install into the ball guide retainer (Item 3) [Figure 30-
housing. 50-48].

Figure 30-50-47 Figure 30-50-49
3
2
N-17481 N-17199
Install the washer (Item 1), snap ring (Item 2) and the Install the ball guide retainer and washer (Item 1) [Figure
drive shaft key (Item 3) [Figure 30-50-47]. 30-50-49] onto the slipper holddown pins.

Assembly (Cont’d)
1
2
Figure 30-50-50
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-50-52] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-50-53
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
50-50].
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing. 2
1
Figure 30-50-51
N-17196
The bearing cage (Item 1) [Figure 30-50-53] will

protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

N-17197 50-53] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-50-51].

Assembly (Cont’d)
1 1
Figure 30-50-54
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-50-56] to 47 - 61
Coat the backside of the valve plate with petroleum jelly Figure 30-50-57
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-50-54].
The notch (Item 1) [Figure 30-50-54] on the valve plate

must engage the locating pin.
Figure 30-50-55 1
2
1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-50-57].
Install the large new O-ring (Item 2) [Figure 30-50-57].
N-19551 Install the pump coupler (Item 3) [Figure 30-50-57].
Coat a new end cap gasket (Item 1) [Figure 30-50-55]

with petroleum jelly and install onto the end cap.

HYDROSTATIC PUMP (CONT’D)
Assembly (Cont’d)
Figure 30-50-58
N-19570
Install the two pumps together [Figure 30-50-58].

Figure 30-50-59
1
P-43858
Tighten the four bolts (Item 1) [Figure 30-50-59] to 47 -


HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The end caps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1

P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jack stands. (See LIFTING AND Disconnect the electrical harness connectors (Item 1)
BLOCKING THE LOADER on Page 10-10-1.) [Figure 30-51-3] from both sides of the hydrostatic
pump.
Removal:
WARNING

of the frame before running the engine for service. IMPORTANT
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
Raise the operator cab. (See Raising on Page 10-30-2.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-51-2 I-2003-0888
Figure 30-51-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
51-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.
Installation: Tighten to 10,4 N•m (7.7 ft-lb) torque.

Hydraulic Controller Removal And Installation

(Cont'd)
1
Figure 30-51-5
1 2
3 P-90210
2
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 10,4
N•m (7.7 ft-lb) torque. Ensure bolts are tightened to
P-90210 specifications.
NOTE: When a hydraulic controller is replaced, the

Remove the controller (Item 1) [Figure 30-51-5] from the hydrostatic pumps must be calibrated. (See

pump. Hydraulic Controller Neutral Adjustment on
Page 30-51-26.)
Remove the controller gaskets (Item 2) [Figure 30-51-5]
from the pump.
Installation:
Figure 30-51-6
2 2
P-90209
NOTE: Do NOT remove the three screens (Item 2)

[Figure 30-51-6] they will be damaged during
removal and must be replaced.
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in

the center of the servo piston groove (Item 1) [Figure 30-
51-6].
Use a small amount of grease on a new gasket and

install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].

Remove the hydrostatic pump / engine assembly from

Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-51-9] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-51-8 Remove the pump pulley from the pump drive shaft.
Figure 30-51-10
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-51-8] on the
hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 30-51-10].
ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D)
Removal And Installation (Cont’d) (Earlier Model)
Figure 30-51-11
P-90224

11] at the hydraulic pump mounting bracket.

Installation: Clean threads and apply Loctite® 242 to the
mounting bolts and tighten to 125 - 135 N•m (90 - 100 ft-
lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-51-6.)

Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before startup.
Figure 30-51-12

1
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-51-12].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic fluid until the hydraulic fluid flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

1. O-ring 3
2. Bolt 4 1
1
3. End Housing
4. Right Rotating Assembly
5. Timing Pin 6
5
6. Bearing 7
7. Spacer/Coupler
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer
12. Steel Cover 9
13. Hydraulic Controller 8 2
14. High Pressure Relief 1
15. Case Housing 1
10
16. Plug
17. Dowel Pin 11
18. Charge Pressure Relief 2
19. Left Servo 12
20. Right Servo
21. Left Rotating Assembly 16 2
22. End Housing 2 14
17

16
15 13
13
18 20
14
22 19
5
2 6
21
8 1
9 1
1
10
11
12 2
2 P-90240

High Pressure Relief And Bypass Valve
Figure 30-51-13
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-51-15]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-15] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-13] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-13].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 36197 kPa (365 bar)
Figure 30-51-14 (5294 psi).
4
3
2 1
P-64436
Inspect the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-14], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-14]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-51-14] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-51-16 1 4 5
3 6
2
1 P-64435
Inspect the O-ring (Item 1) [Figure 30-51-17].

P-64431
Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-51-17] for damage or foreign material. Ensure
The charge relief valve (Item 1) [Figure 30-51-16] is the poppet moves freely in it’s bore.
located on the back of the hydrostatic pump.

Inspect the sealing ring (Item 4) [Figure 30-51-17] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Assembly: Tighten charge relief valve to 70 N•m (52 ft-
lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-51-17].
NOTE: 1,0 mm shim (Item 6) [Figure 30-51-17] = 300

kPa (3,0 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.

HYDROSTATIC PUMP (SJC) (CONT'D) Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.
Disassembly And Assembly Note the connectors facing each other.
Remove the hydrostatic pump / engine assembly from Figure 30-51-20

Page 70-10-7.)
Remove the hydrostatic pump. (See Removal And

Installation on Page 30-51-4.) 1
Figure 30-51-18
2
1 1 P-90228
Remove the mounting bolts (Item 1) for the swash plate

angle sensor (Item 2) [Figure 30-51-20].

Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.
P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-51-

18]. (See Hydraulic Controller Removal And Installation
on Page 30-51-2.)
Figure 30-51-19
3 3
2 2
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-19].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-19] from both sides.

HYDROSTATIC PUMP (SJC) (CONT'D) Right End Housing
Disassembly And Assembly (Cont'd) Figure 30-51-23
Figure 30-51-21
3
1
1
1
P-64445
P-90217
Left End Housing
Assembly: Note the slotted portion (Item 1) of the Figure 30-51-24

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-51- 3 1
21].
Figure 30-51-22
1
2
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
P-90218 [Figure 30-51-23] and [Figure 30-51-24].
Assembly: Alternately, tighten mount bolts to 130 N•m

Inspect and replace the O-ring (Item 1) [Figure 30-51- (96 ft-lb) torque.
22].

Figure 30-51-25
P-64466
Ensure servo follower (Item 2) [Figure 30-51-26] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-27].
Pull the end housings from the case housing [Figure 30- Figure 30-51-28
51-25].

Figure 30-51-26
1 1 2
2
P-64463
P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-51-28] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-26].

Figure 30-51-29
RIGHT SIDE
P-64454
Figure 30-51-30

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-51-29] and

[Figure 30-51-30] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-51-29] and [Figure 30-51-30] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

Disassembly And Assembly (Cont'd) LEFT SIDE

Figure 30-51-31 1
2
RIGHT SIDE
1 P-64503
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
P-64455 31] and [Figure 30-51-32] in the case housing with the
notch (Item 1) [Figure 30-51-33] and [Figure 30-51-34]
that does not go through the valve plate.
Figure 30-51-32
Align the shoulder of the roller bearing (Item 2) [Figure

LEFT SIDE 30-51-31] and [Figure 30-51-32] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-33] and [Figure
30-51-34].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.
1
2
P-64502
Figure 30-51-33
RIGHT SIDE
1
2
P-64456

Figure 30-51-35
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-37].

B25012
Figure 30-51-38
Right Side Rotating Group [Figure 30-51-35].

Figure 30-51-36
1
P-64475
Remove the pistons (Item 1) [Figure 30-51-38] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-36].


1
Figure 30-51-39
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64476 41].
Figure 30-51-42
Inspect the pistons for scoring and scratches. Ensure the
holes (Item 1) [Figure 30-51-39] in the slippers, are not
1

plugged.
Figure 30-51-40
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-42]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-51-40].


3
Figure 30-51-43
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-51-45].
Remove the swash plate from the end cap housing (Item
Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-45].
1) [Figure 30-51-43].

Remove the slide ring (Item 3) [Figure 30-51-45], ensure
Figure 30-51-44 it pivots freely.
Figure 30-51-46
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-44] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in end cap housing (Item 2) [Figure 30-51-46].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-51-44] are not bent or damaged.

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-51-47
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-

P-64481 49].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-49] on them. The edges face towards
swash plate (Item 1) [Figure 30-51-47]. the outside of the end cap housing

Figure 30-51-48 Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-51-49].

2
Figure 30-51-50
2 1
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-48].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-51-48] on swash plate.
Replace O-ring (Item 1) [Figure 30-51-50].
Inspect wear surfaces (Item 2) [Figure 30-51-50] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

Figure 30-51-51
LEFT SIDE
1
P-76742
The pump seal (Item 1) [Figure 30-51-53] is removed by

P-64486 inserting a screw into the seal and prying out.
Figure 30-51-54
Figure 30-51-52
RIGHT SIDE

1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-51-51] and a rubber mallet.
[Figure 30-51-52] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-51-54] and remove
bearing.

Figure 30-51-55
1 1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 30-

51-57].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-51-58

B25013
Servo Piston Assembly [Figure 30-51-55].

1
The Servo Piston Assembly [Figure 30-51-55] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-51-56
P-90231
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-58].
P-64490
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-56].

Figure 30-51-59
P-64466
Assembly: Align the servo piston so the guide slot

P-90237 (Item 1) [Figure 30-51-61] is parallel to the drive shaft
centerline. Measure with a straight-edge [Figure 30-51-
60].
Slide the servo piston assembly out of the bore. [Figure
30-51-59]. Figure 30-51-62

Figure 30-51-60
2
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-51-62] from the pump housing.

Figure 30-51-63 1
1
2
2
P-64496
3 Remove the servo cover (Item 1) [Figure 30-51-65] from

P-64494 the servo piston.

Each servo has a pair of bushings (Item 1), O-rings (Item cover.
2) and square-cut seals (Item 3) [Figure 30-51-63].

Figure 30-51-66
Figure 30-51-64
1
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-51-66] from the

Remove the locknut (Item 1) [Figure 30-51-64] from the servo piston.
servo piston.
Assembly: Tighten locknut to 30 N•m (22 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The tools listed will be needed to do the following
procedure:
Figure 30-51-67
1 The pump Mechanical Neutral Adjustment sets the
2 position of the servo piston and pump swash plate
relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.
Place the loader on jack stands. (See LIFTING AND

WARNING
P-64498
Remove the piston stop adjustment mechanism (Item 1) Failure to use jackstands can allow the machine to
[Figure 30-51-67] from the servo piston. fall or move and cause injury or death.

W-2017-0286
Inspect mechanism for broken parts.
Raise the lift arms, and install an approved lift arm
Replace O-ring (Item 2) [Figure 30-51-67]. support device. (See Installing on Page 10-20-1.)
Figure 30-51-68 Raise the operator cab. (See Raising on Page 10-30-2.)

7217666 on Page 10-61-1.)
Disconnect the swash plate angle sensors in the

2 electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
1 adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
If equipped, disconnect the speed sensors located on the

top of the drive motors. This prevents uncommanded
P-64502 wheel movement error codes from occurring during
adjustments.
Bearings (Item 1) [Figure 30-51-68] in case housing are
replaced by using a press and bearing driver.
Inspect center coupler (Item 2) [Figure 30-51-68].

WARNING
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-69
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-71] from the

P-64973 MA ports on the bottom of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-69] Figure 30-51-72

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-51-70
1 1
1
1
1 1
P-90243
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-72]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51711 kPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the
Remove the plugs (Item 1) [Figure 30-51-70] from the Pump Mechanical Neutral setting.
MB ports on the front side of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-73
1 1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-51-75]

P-90226 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the Pump Neutral Adjustment locknut (Item 1)
[Figure 30-51-73]. Figure 30-51-76

Start the loader using the Remote Start Tool and run at
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-74
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90238

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The tools listed will be needed to do the following
procedure:
Figure 30-51-77
The Hydraulic Controller Neutral Adjustment aligns the

pump swash plate and the control spool so that a zero
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
2 adjusted or removed or after the Pump Mechanical
Neutral setting is adjusted. Ensure the Pump Mechanical
Neutral setting is correct before performing Hydraulic
Controller Neutral Adjustments.
1
NOTE: Procedure is shown for the left side hydraulic
controller. Procedure is the same for the right
P-90238 side hydraulic controller, except you
disconnect the electrical connectors for the
right side hydraulic controller and connect
While holding the adjustment screw (Item 1) in position, pressure gauges in the X1 and X2 ports on the
tighten the locknut (Item 2) [Figure 30-51-77] to 30 N•m right side of the pump.

(22 ft-lb) torque.
Place the loader on jack stands. (See LIFTING AND
Shut loader OFF. BLOCKING THE LOADER on Page 10-10-1.)
Remove the hydraulic hose from the X1 and X2 ports on

the pump. Install the plugs and tighten to 25 N•m (18 ft-
lb) torque.
WARNING
Remove the pressure gauges from the MA and MB ports Put jackstands under the front axles and rear corners
on the pump. Install the plugs and tighten to 25 N•m (18 of the frame before running the engine for service.
ft-lb) torque. Failure to use jackstands can allow the machine to
W-2017-0286
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical
Neutral Adjustment is done. (See Hydraulic Raise the lift arms, and install an approved lift arm
Controller Neutral Adjustment on Page 30-51- support device. (See Installing on Page 10-20-1.)
26.)

7217666 on Page 10-61-1.)

Hydraulic Controller Neutral Adjustment (Cont’d)
WARNING
immediately.
W-2145-0290
P-64975
Figure 30-51-78
Install 3447 kPa (34,5 bar) (500 psi) pressure gauges in
the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting.
1
Figure 30-51-81

1 1
P-90239
Disconnect the hydraulic controller connectors (Item 1)

[Figure 30-51-78] from the loader wiring harness for the
hydraulic controller you are adjusting.
P-90236
Figure 30-51-79
Loosen the locking screw (Item 1) [Figure 30-51-81].
Start the loader using the Remote Start Tool and run at
an idle.
1
2
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
P-90226
Remove the X1 plug (Item 1) and X2 plug (Item 2)

[Figure 30-51-79] pertaining to the side of the
hydrostatic pump you are adjusting.

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-82
P-90236

P-90236 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-51-85

in system pressure. Mark the position of the adjustment
screw.
Figure 30-51-83
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-51-85] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-83] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

DRIVE BELT Belt Replacement
Belt Adjustment Stop the engine and open the rear door.
The drive belt does not need adjustment. The belt has a Remove the battery. (See Removal And Installation on
spring loaded idler which constantly maintains the correct Page 60-20-1.)
belt tension.
Figure 30-60-3
Stop Adjustment
Figure 30-60-1
1
2
P-85518

Remove the drive belt shield bolt (Item 1) [Figure 30-60-
3].
P-90470
Figure 30-60-4
Loosen the spring loaded idler adjustment bolt (Item 1)

and insert a 12,7 mm (1/2 in) breaker bar (Item 2)
[Figure 30-60-1] into the slot provided in the stop arm as
shown. 1
Figure 30-60-2
P-90467
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
toward the back of the loader to unseat the shield from
the top and bottom drive belt shield mounting bolts.
P109784A Remove the drive belt shield (Item 2) [Figure 30-60-4].
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-60-2] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-1] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D) Maintain torque on the stop arm and tighten the spring
loaded idler adjustment bolts (Item 1) [Figure 30-60-6] to
Belt Replacement (Cont’d) 105 - 115 N•m (78 - 85 ft-lb) torque.
Figure 30-60-5 NOTE: This procedure is required to preload a new

drive belt in order to achieve the correct stop
adjustment after the initial belt break-in
period.
1
Figure 30-60-7
Top Mounting Bolt
2
1
P-90470
P-90468A
Loosen the spring loaded idler adjustment bolts (Item 1).

Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 30- Bottom Mounting Bolt

60-5] into the slot provided in the stop arm as shown and
push breaker bar down to release tension on drive belt.
2
Tighten the adjustment bolts (Item 1) [Figure 30-60-5] to
hold the spring loaded idler off the drive belt.
Remove the drive belt from the hydrostatic pump pulley

and flywheel pulley. Inspect the pulleys for wear.
P-90469A
Install new drive belt.
Loosen the spring loaded idler adjustment bolts (Item 1) Position the drive belt shield over the drive belt shield
[Figure 30-60-5] and allow the idler to contact the drive mounting bolts and slide the drive belt shield toward the
belt. front of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-60-7].
Figure 30-60-6
P115669
Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
torque wrench (Item 2) [Figure 30-60-6] into the slot
provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated.

DRIVE BELT (CONT’D)
Belt Replacement (Cont’d)
Figure 30-60-8
P-85518
Install the drive belt shield bolt (Item 1) [Figure 30-60-8].

Install the battery. (See Removal And Installation on
Page 60-20-1.)
NOTE: The stop arm MUST be adjusted after 50 hours

operation with the new drive belt. (See Stop
Adjustment on Page 30-60-1.)
See the SERVICE SCHEDULE for the correct

service interval after the initial 50 hour
adjustment. (See SERVICE SCHEDULE on
Page 10-70-1.)

DRIVE BELT (CONT’D) Figure 30-60-10
Tensioner Pulley Removal And Installation
Remove the engine air cleaner. (See Housing Removal

1
Remove the belt. (See Belt Replacement on Page 30-60-
1.) 2
Figure 30-60-9
P-85741

2 10].
Remove the tensioner pulley (Item 2) [Figure 30-60-10].
Installation: Apply Loctite® 242 to the mounting bolts

(Item 1) [Figure 30-60-10].
P-85520
Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a 12,7 mm (1/2 in) breaker bar (Item 2) [Figure 30-
60-9] into the slot provided in the stop arm as shown and
push breaker bar down to release tension on drive belt.
Tighten adjustment bolt (Item 1) [Figure 30-60-9] to hold

the spring loaded idler off the drive belt.

DRIVE BELT (CONT'D) Figure 30-60-13
Tensioner Pulley Disassembly And Assembly
Figure 30-60-11
1
1
1
P-90303
3 Disassembly the tensioner pulley as shown [Figure 30-

P-90306 60-13].
Inspect the parts for wear and replace as needed.

Loosen the two bolts (Item 1) [Figure 30-60-11] but do
not remove. NOTE: The wheel and arm assembly (Item 1) [Figure

30-60-13] are not serviceable and must be
Release the spring tension by allowing the adjustment replaced as a complete assembly.
plate (Item 2) to slide past the tensioner pulley stop (Item
3) [Figure 30-60-11].
Remove the two bolts (Item 1) and the adjustment plate

(Item 2) [Figure 30-60-11].
Figure 30-60-12
P-90304
Remove the pivot sleeve (Item 1) [Figure 30-60-12].


TWO-SPEED / BRAKE VALVE (S/N A3NV11001 -
A3NV17774 AND S/N A3NW11001 - A3NW12724)
Description
Figure 30-70-1
P-90507
The two-speed / brake valve (Item 1) [Figure 30-70-1] is

located in front of the hydrostatic pump. The high range is
selected by a switch located on the right handle for
manual loaders and on the left joystick for SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure fluid to the shift spool in
each motor. The charge pressure hydraulic fluid shifts the
spools allowing the motors to move into high range.
When low range is selected, the solenoid is de-energized
and the shift spools are spring returned to low range.

TWO-SPEED / BRAKE VALVE (S/N A3NV11001 - Figure 30-70-2
A3NV17774 AND S/N A3NW11001 - A3NW12724)
(CONT’D)
1
Valve Block Removal And Installation
DANGER
2
2
P-90437
P-90328 Remove the steering shock (Item 1) [Figure 30-70-2].

AVOID DEATH
• Disconnecting or loosening any hydraulic Mark all hydraulic hoses for proper installation.
can cause lift arms to drop. Disconnect the five hydraulic hoses (Item 2) [Figure 30-
• Keep out of this area when lift arms are raised 70-2] from the two speed / brake valve block.

D-1009-0409
WARNING 1
W-2059-0598
P-90425
WARNING Disconnect the three hydraulic hoses (Item 1) [Figure

30-70-3] from the two speed/brake valve block.
W-2017-0286


TWO-SPEED / BRAKE VALVE (S/N A3NV11001 -
A3NV17774 AND S/N A3NW11001 - A3NW12724)
(CONT’D)
Valve Block Removal And Installation (Cont’d)
Figure 30-70-4
P-90444

30-70-4] from the two speed solenoid.

30-70-4] from the brake solenoid and make-up valve.
Figure 30-70-5
P-90446


A3NV17774 AND S/N A3NW11001 - A3NW12724)
(CONT’D)
Valve Block Disassembly And Assembly 1
Figure 30-70-6
1
2
N-22580
1
Replace the back-up rings (Item 1) and O-rings (Item 2)

[Figure 30-70-8].
P-90548 Figure 30-70-9

1
Mark all hydraulic hoses and fittings for proper

installation.
Remove the hydraulic fittings (Item 1) [Figure 30-70-6]

from the valve block. 4
Figure 30-70-7 2
1
2
P-90550
Remove the two bolts (Item 1) from the brake valve

solenoid (Item 2) [Figure 30-70-9].
Remove the electrical solenoid nut (Item 3) from the

make-up solenoid (Item 4) [Figure 30-70-9].
P-90549 Assembly: Tighten the nut to 6,78 - 9,5 N•m (60 - 84 in-
lb) torque.
Remove the check valves (Items 1 and 2) [Figure 30-70-
7] from the two-speed valve.
NOTE: The check valves (Items 1 and 2) [Figure 30-

70-7] are interchangeable.

A3NV17774 AND S/N A3NW11001 - A3NW12724)
(CONT’D)
Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-10
P-90552
Remove the make-up solenoid (Item 1) [Figure 30-70-

12] from the valve block.
P-90435 Figure 30-70-13
Use a test meter and test the solenoid coils (Item 1)

[Figure 30-70-10] for resistance.
The resistance value for the solenoid coil can be found on

the electrical schematic.
Figure 30-70-11
1 N-22584
Assembly: Always install new O-rings and back-up rings

[Figure 30-70-13]. Tighten the solenoid valve to 27,1
P-90551



A3NV17774 AND S/N A3NW11001 - A3NW12724)
(CONT’D)
Figure 30-70-14 1
P-90547
1
Use a test meter and test the solenoid (Item 1) [Figure
30-70-16] for resistance.
P-90553 The resistance value for the solenoid coil can be found on
Remove the plugs (Item 1) [Figure 30-70-14] from the

Assembly: Always install new O-rings and back-up
two speed/brake valve block.
rings.
Replace the O-ring [Figure 30-70-14] on the plugs.
Figure 30-70-15
P-90554
Remove the two speed solenoid bolts (Item 1) [Figure

30-70-15].

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 &
ABOVE AND A3NW12725 & ABOVE)
Description
Figure 30-71-1
P-90507
The two-speed / brake valve (Item 1) [Figure 30-71-1] is

located in front of the hydrostatic pump. The high range is
selected by a switch located on the right handle for
manual loaders and on the left joystick for SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure fluid to the shift spool in
each motor. The charge pressure hydraulic fluid shifts the
spools allowing the motors to move into high range.
When low range is selected, the solenoid is de-energized
and the shift spools are spring returned to low range.

TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & Figure 30-71-2
ABOVE AND A3NW12725 & ABOVE) (CONT'D)
Valve Block Removal And Installation 1
DANGER
2
2
P-90437
P-90328
Remove the steering shock (Item 1) [Figure 30-71-2].
AVOID DEATH
Mark all hydraulic hoses for proper installation.
Disconnect the five hydraulic hoses (Item 2) [Figure 30-
71-2] from the two speed / brake valve block.

D-1009-0409 Figure 30-71-3
WARNING
1
W-2059-0598
P-90425
WARNING Disconnect the three hydraulic hoses (Item 1) [Figure

30-71-3] from the two speed/brake valve block.
W-2017-0286


Valve Block Removal And Installation (Cont’d)
Figure 30-71-4
P-90444

30-71-4] from the two speed solenoid.

30-71-4] from the brake solenoid and make-up valve.
Figure 30-71-5
P-90446


TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & Figure 30-71-8
Valve Block Disassembly And Assembly
Mark all hydraulic hoses and fittings for proper

installation.
Figure 30-71-6 1
1
1 P107100


P107098

Figure 30-71-9
Remove the hydraulic fittings (Item 1) [Figure 30-71-6]

Figure 30-71-7 1
4
P107101
2
3
P107099
Remove the two bolts (Item 1) from the brake valve
solenoid (Item 2) [Figure 30-71-7]. Assembly: Always install new O-rings [Figure 30-71-9]
and back-up rings.
Remove the electrical solenoid nut (Item 3) from the
make-up solenoid (Item 4) [Figure 30-71-7].
Assembly: Tighten the bolts (Item 1) [Figure 30-71-7] to

Assembly: Tighten the nut (Item 3) [Figure 30-71-7] to

6,78 - 9,49 N•m (60 - 84 in-lb) torque.

Figure 30-71-10
P107104
Remove the make-up solenoid (Item 1) [Figure 30-71-

10] from the valve block.
Assembly: Always install new O-rings and back-up rings

[Figure 30-71-10]. Tighten the solenoid valve to 27,1
Figure 30-71-11
1
1
2 2 2
P107103
Replace the back-up rings (Item 1) and O-rings (Item 2)

[Figure 30-71-11].


DRAIN MANIFOLD Figure 30-80-2
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic fluid to the reservoir.
2
Drain Manifold Removal And Installation
IMPORTANT 2
2
P100002
damage the system. Disconnect the wiring harness from the fluid temperature
I-2003-0888 switch (Item 1) [Figure 30-80-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the three hoses (Item 2) [Figure 30-80-2].
Drain the hydraulic reservoir. (See Removing And Mark and cap all hoses and tubelines.

Figure 30-80-3
Figure 30-80-1
1
1
1
2
P100003
P100001
Remove the two hoses (Item 1) [Figure 30-80-3].

Remove the tubeline (Item 1) [Figure 30-80-1] from the
drain manifold. Remove the two bolts and nuts (Item 2) [Figure 30-80-3].
Mark and cap all hoses and tubelines. Mark and cap all hoses and tubelines.


DRIVE SYSTEM
BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3


BRAKE (SINGLE SPEED) Disc Removal And Installation
Description Raise the loader lift arms and install an approved lift arm
Figure 40-10-1
WARNING
1 to fall and cause injury or death.
W-2059-0598
Raise the loader operator cab. (See Raising on Page 10-

30-2.)
P-85491
Remove the control panel from the loader. (See Removal
The brake is used to hold the machine in place. The
brake is operated by a switch (Item 1) [Figure 40-10-1] Remove the center chaincase cover. (See Center Cover

located on the front accessory panel. Removal And Installation on Page 40-30-2.)
The brake is applied by a spring-loaded wedge that drops Remove the traction lock assembly.
into two notched brake discs attached to the motor carrier
shafts. An electric solenoid is sent power from a relay to Figure 40-10-2
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the
discs.
The hold signal will be interrupted and the wedge will 1

drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
For more information on the brake. (See Description on

Page 60-120-1.)
N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.

BRAKE (SINGLE SPEED) (CONT’D) Figure 40-10-4
Disc Removal And Installation (Cont’d)
Figure 40-10-3
N-19082A
1 Figure 40-10-5
N-19105
Inspect the traction lock guides (Item 1) [Figure 40-10-3]

and the brake disc for damage or wear and replace as

necessary. (See Inspecting on Page 60-120-3.)
N-19083A
A snap ring pliers with 90° tips are necessary for

removing the parking brake disc.

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

BRAKE (TWO-SPEED)
Description
Figure 40-11-1
P-85413F
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-11-1]

located on the front accessory panel.
The brake is a spring applied pressure release system,

which is self contained on the end of each drive motor.
The brake block solenoid is sent power from a relay to

open the circuit which releases the charge pressure fluid
to the brakes. The charge pressure fluid pushes the
spring away from the brake discs allowing the drive motor
to move.
A signal from the main Bobcat controller holds the brake

solenoid open to allow constant flow of the charge
pressure fluid to hold the spring away from the brake
discs.
When the hold signal is interrupted the solenoid will close

the circuit and the charge fluid will be shut off an the
spring will apply the brakes. This will happen if the engine
rpm drops below a set rpm, the seat bar sensor fails or if
there is a break in the wires for the brake block solenoid.


DRIVE COMPONENTS
Description

NA1285
The drive components consist of the chaincase, drive chains, sprockets, axles shafts, hubs, drive motor carrier and a brake
(Single speed only).
The two-speed brake is part of the two-speed drive motor.
The chaincase is partially filled with hydraulic fluid to lubricate the chains and bearings.
On the bottom of the chaincase, these is a cover for access to the fuel tank drain plug.

DRIVE COMPONENTS (CONT’D) Figure 40-20-2
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool

MEL1242 - Power Ram (may be used if desired)

1
NOTE: If the axle and bearings are being replaced,
also loosen the sprocket mounting bolt inside
the chaincase before lifting and blocking the P4849
loader. (See Axle, Sprocket And Bearings
Install puller (Item 1) [Figure 40-20-2] on the wheel hub.
Remove the tire / wheel assembly. (See Mounting on
Page 10-160-2.)
Remove the front chaincase cover. (See Front Cover

WARNING

NEVER STAND IN-LINE OF THE HUB WHEN
Remove the fluid from the chaincase. (See Removing
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
Figure 40-20-1
W-2186-0395
Remove the hub from the axle.
2 Figure 40-20-3
1
2
P4850
Remove the bolts (Item 1) [Figure 40-20-1] and plate.
Installation: Tighten the bolts to 240 - 260 N•m (175 - P4848

190 ft-lb) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1] Remove the key (Item 1) [Figure 40-20-3] from the axle.
across from each other.

DRIVE COMPONENTS (CONT’D)
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-4
P4817
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end into the axle seal.

Remove the axle seal.
Figure 40-20-5
P4814
Installation: Place the seal with the lip facing in [Figure

40-20-5].
Installation: Use a hammer, install the new axle seal

until the tool (MEL1407) is flush with the edge of the axle
tube [Figure 40-20-5].

DRIVE COMPONENTS (CONT’D) Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Axle, Sprocket And Bearings Removal And
Installation Remove the front chaincase cover. (See Front Cover
procedure: Remove the fluid from the chaincase. (See Removing
MEL1242 - Port-a-Power
MEL1202 - Axle Bearing Service Set Figure 40-20-6
NOTE: The procedure shown for removal and

installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the 2
same for the rear axle.
DANGER 1

P-68196
Remove the axle sprocket bolt (Item 1) and backing

P-90328 washer (Item 2) [Figure 40-20-6].
AVOID DEATH Installation: Tighten the axle sprocket bolt to 699 - 726
• Disconnecting or loosening any hydraulic N•m (515 - 535 ft-lb) torque.
can cause lift arms to drop. Remove the axle hub. (See Axle Seal Removal And
• Keep out of this area when lift arms are raised Installation on Page 40-20-2.)
D-1009-0409
WARNING
W-2059-0598
Raise the lift arms and install an approved lift arm P-4158A
Lift and block the loader. (See LIFTING AND BLOCKING Install a Port-a-Power ram between the two sprockets
THE LOADER on Page 10-10-1.) [Figure 40-20-7].

DRIVE COMPONENTS (CONT’D) NOTE: Hold the axle during removal because it will
slide freely after the bearing is removed from
Axle, Sprocket And Bearings Removal And the mounting surface.
Installation (Cont'd)
Figure 40-20-10
Figure 40-20-8
P-4171
P5406A
Press the splined end of the axle free from the bearing
Push the axle out until the ram is at the end of the stroke. [Figure 40-20-10].

Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Remove the sprocket (Item 1) and inner bearing (Item 2)

[Figure 40-20-8].
Installation: Pack the inner and outer bearing with

grease before installing them.
Figure 40-20-9
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed to

do the following procedure:
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-9].


Figure 40-20-11
P4812
Use the tools provided in the MEL1202 Axle Bearing

Service Set. A slide hammer is also needed.
P-4175
Use the long driver handle (Item 1) [Figure 40-20-12]
and the bearing cup removal tool to remove the inner
Installation: Put the spline end of the axle shaft into the bearing cup.

bearing and press the bearing onto the axle.
Figure 40-20-13
NOTE: Hold the axle during installation because it
will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-

20-11] that contacts inner race of the bearing only.
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-11].
P5637
To remove the outer bearing, install a bearing cup

removal tool on the slide hammer.
Install the slide hammer / tool assembly behind the

bearing cup [Figure 40-20-13].


Figure 40-20-14
2
P4811
Install the installation tool (Item 1) [Figure 40-20-16] on

the threaded rod. Install the nut.
P4816
Hold the inside nut (Item 3) [Figure 40-20-15] with a
wrench and tighten the outside nut [Figure 40-20-16].
Use the slide hammer to remove the bearing cup from

the axle tube [Figure 40-20-14]. Tighten the nut until the bearing cup is seated.
Figure 40-20-15 Remove the installation tool and threaded rod.
2
1
P5468A
Use the bearing cup installation tool (Item 1) [Figure 40-

20-15] and (Item 1) [Figure 40-20-16].
Put the inner cup (Item 2) [Figure 40-20-15] in the axle

tube.
Install the long threaded rod (Item 2) [Figure 40-20-16]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-15].
Install the nut (Item 3) [Figure 40-20-15].


Figure 40-20-17
P4813
To install the outer bearing cup, install the bearing cup

installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-17].

DRIVE COMPONENTS (CONT’D) Remove the brake disc. (See Disc Removal And
Chain Removal And Installation
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
DANGER Figure 40-20-18
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic Front Drive
Chain
tubeline, hose, fitting, component or a part failure Rear Drive
Chain
unless supported by an approved lift arm P-68194

D-1009-0409
NOTE: It is necessary to remove the rear axle and
drive chain if the front chain has to be
removed.
WARNING
W-2059-0598



on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover

Remove the fluid from the chaincase. (See Removing


Chain Removal And Installation (Cont’d)
The tools listed are needed for the following procedure:
MEL1269 - Chain Breaker

MEL1246 - Chain Link Press Tool
MEL1364 - Chain Link Installation Tool
Figure 40-20-19

B-13504A
Use the chain breaker MEL1269 to separate the chain.
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use the chain link installation tool MEL1364 to hold both

ends of the chain.
Secure the tool MEL1246 and place the connector link in

the tool as shown [Figure 40-20-19].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-19]. Tighten the
threaded rod of the chain link tool to 339 N•m (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
support device. (See Installing on Page 10-20-1.) 2
Raise the loader operator cab. (See Raising on Page 10-

30-2.) 3
3

on Page 50-100-2.) P-34255
Remove the front chaincase cover mounting screws

DANGER (Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.

NOTE: There are tabs (Item 3) [Figure 40-30-1] on the
side of the cover to help pry the covers off.
Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
P-90328 screw threads to stop fluid leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Disconnect the electrical connector (Item 3) [Figure 40-
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Raising on Page 10- 30-2].
30-2.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
P-90328 W-2059-0598
AVOID DEATH

Figure 40-30-3
3
unless supported by an approved lift arm 1
D-1009-0409
2

on Page 50-100-2.)
Figure 40-30-2 1
P-90048
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
2 1
Remove the center chaincase cover (Item 2) [Figure 40-
3 30-3] from the loader.
NOTE: There are tabs (Item 3) [Figure 40-30-3] on the

P-90047 Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
screw threads to stop fluid leakage. Tighten the mounting
If loader is equipped with SJC, skip to [Figure 40-30-3]. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
1 3
Raise the loader operator cab. (See Installing on Page
10-20-1.) 2
DANGER 1
3
P-90056
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-4].
P-90328 Remove chain case cover (Item 2) [Figure 40-30-4].

AVOID DEATH NOTE: There are tabs (Item 3) [Figure 40-30-4] on the

can cause lift arms to drop. Installation: Apply polyurethane sealer to mating
• Keep out of this area when lift arms are raised surfaces. Polyurethane sealant should be applied to the
unless supported by an approved lift arm screw threads to stop fluid leakage. Tighten the mounting
support. Replace if damaged. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Block Removal And Installation
on Page 30-70-2.)
Remove the drain manifold. (See Drain Manifold Removal

Disconnect the front steering linkage bars from the rear

linkage bars. (See Linkage Removal And Installation on
Page 50-100-5.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.


MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4

3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-6
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Lockable Handle Rear Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2
Clamping Knob Rear Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-3
Slide In Rear Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-4

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-9
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-18
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal And Installation (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
Installation (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-4
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-5
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-5
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1


RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

SEAT BAR Figure 50-10-2
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
The seat bar is located in the operator cab.

1
Figure 50-10-1
P-85652
Remove the seat bar mounting nuts (Item 1) [Figure 50-

1 10-2] (both sides).
Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-

lb) torque.

2 Lower the operator cab. (See Lowering on Page 10-30-
3.)
P-85653 P-85654 Figure 50-10-3
Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
1
Lower the seat bar.
P-90021
Remove the seat bar (Item 1) [Figure 50-10-3] from the

operator cab.
Reverse the above procedure to install the seat bar into

the operator cab.

SEAT BAR (CONT’D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023

4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT’D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)

Bushing (Item 4)
Assembly: Apply Loctite® 518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® 518.


OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
Raise the operator cab (See on Page 10-30-2.)
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without

the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
Figure 50-20-1
2
1
1 3
P-85652
Remove the retaining pin (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D) Removal And Installation
Gas Spring Bracket Disassembly And Assembly Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
Figure 50-20-4 2.)
Figure 50-20-5
3
2
1
1
1
2
P-85661
P100756
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-

20-4]. Unhook the four fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-20-5].
Installation: Apply a small amount of thread-locker on
the threads of the gas spring rod before installing the Installation: (See Installing on Page 80-150-1.)
clevis (Item 1) [Figure 50-20-4].
Figure 50-20-6
WARNING 1
AVOID INJURY 2
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only 1
qualified service personnel can remove the cylinder.
W-2112-0987
1
P100879
Disconnect the expansion / heater unit wiring connectors

(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
NOTE: Cap the heater hoses and the heater valve

with plugs to prevent coolant loss from the
system.

OPERATOR CAB (CONT’D) Earlier Models
Removal And Installation (Cont’d) Figure 50-20-8
Figure 50-20-7
1
1
P-85663
P103082
Disconnect the cab harness connector screw (Item 1)
[Figure 50-20-8].
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].
Installation: Tighten the connector screw to 3,39 - 3,96

Cap and plug the hoses and expansion valve fittings with N•m (30 - 35 in-lb) torque.
proper A/C caps and plugs.
Later Models
Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb)
torque. Figure 50-20-9
1
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
1
Remove the engine speed control cable from the cab. P107406
(See Cable Removal And Installation on Page 70-20-2.)
Remove the operator cab gas spring(s). (See Gas Spring Disconnect the cab harness connectors (Item 1) [Figure
Removal And Installation on Page 50-20-1.) 50-20-9].
NOTE: Use the hoist connected to the operator cab

grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

OPERATOR CAB (CONT’D)
Figure 50-20-10
P-85658
Remove the two cab mount bolts and nuts (Item 1)

[Figure 50-20-10] from both sides of the cab.

Installation: Tighten the cab mount bolts and nuts to
24,4 - 29,8 N•m (18 - 22 ft-lb) torque.
Figure 50-20-11
P-85662
Using a strap and a hoist remove the cab from the loader
[Figure 50-20-11].

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Removal And Installation Figure 50-30-2
Figure 50-30-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure

Remove the four seat mounting nuts (Item 1) [Figure 50- 50-30-2].
30-1] and washers from the operator seat mounting
studs. Figure 50-30-3
Lower the operator cab. (See Lowering on Page 10-30-

3.)
Remove the seat. 2
NOTE: With the seat removed, the cab may raise.
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-30-3].
Remove the slide rail (Item 2) [Figure 50-30-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-30-6
Figure 50-30-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-30-6].
Remove the nut (Item 1) [Figure 50-30-4] from the seat
belt mount.

Figure 50-30-5
P-85772
Remove the nut (Item 1) [Figure 50-30-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-30-9
Figure 50-30-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-30-9] and tilt
30-7]. the seat back to the upright position.

Figure 50-30-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-30-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-30-10
Figure 50-30-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-30-1.) Remove the mounting nut (Item 1) [Figure 50-30-11].

Remove the seat shock clips (Item 1) [Figure 50-30-10]. Remove the end release buckle (Item 2) [Figure 50-30-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-30-10]. Figure 50-30-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-30-12].
Remove the seat belt retractor (Item 2) [Figure 50-30-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-30-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-30-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-30-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-30-15].
13].

Figure 50-30-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-30-14].


BOB-TACH (HAND LEVER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
1
The Bob-Tach is located on the front of the loader
connected to the loader lift arms.
P-85554
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1].

Lower the Bob-Tach onto the blocks.


40 ft-lb) torque.
Figure 50-40-2
P-85649

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-5
Figure 50-40-3
1 P-31405
Replace O-ring (Item 1) [Figure 50-40-5] on the grease

P-31402 plug.
Figure 50-40-6
Bob-Tach pivot pin grease plug (both sides).

Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330 Figure 50-40-10
ft-lb) torque.
Figure 50-40-8
2
P-85665
1
P-31407 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].
With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-40-8]

and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach.
NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.

BOB-TACH (HAND LEVER) (CONT'D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-40-13

(Cont'd)
Figure 50-40-11 4
1
1 2
2
P19287
P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise. Remove the bolt (Item 1) [Figure 50-40-13] and
Use a punch and hammer to remove the roll pin (Item 1) replace the damaged parts as needed.

[Figure 50-40-11] from the Bob-Tach wedge and spring
clevis. Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-40-13], tighten to 125 - 135
Remove the spring clevis assembly (Item 2) [Figure 50- N•m (90 - 100 ft-lb) torque.
40-11].
Later Design
Figure 50-40-12
Figure 50-40-14
3
P-85667 2
P121303
Remove the wedge (Item 1) [Figure 50-40-12] out the

bottom of the Bob-Tach. If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Always replace bent or broken wedges. vise. Remove the bolt (Item 1) [Figure 50-40-14] and
replace the damaged parts as needed.
Assembly: Clean the threads and apply Loctite® 242 to


BOB-TACH (HAND LEVER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-15
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Use a seal pick to remove seal (Item 1) [Figure 50-40-
15] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-15]

with a driver tool and hammer.
Figure 50-40-16
3
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item
3) [Figure 50-40-16].


BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. 2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1].

Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove and cap the hoses from the cylinder.
Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).

40 ft-lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT'D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5

40 ft-lb) torque.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
P-85649

BOB-TACH (POWER) (CONT’D) Figure 50-41-8
Figure 50-41-6
P-31406
1
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer nut and bolt (Item 1)

Replace the O-ring (Item 1) [Figure 50-41-6] on the [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
grease plug. ft-lb) torque.

1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 22,2 mm (7/8 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin retaining bolt (both sides). and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.
Remove the Bob-Tach from the loader.

BOB-TACH (POWER) (CONT'D) Figure 50-41-12
Lever And Wedge Disassembly And Assembly
Figure 50-41-10
1 1 2
P-85665
Remove the washer and spring, (Item 1) and the lever

P-85570 assembly (Item 2) [Figure 50-41-12].
Figure 50-41-13
Remove the washers and bolts (Item 1) [Figure 50-41-
10] from the cylinder (both ends).

Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
lb) torque.
Remove the cylinder from the lever pivots.

1
Figure 50-41-11
P-85666
1 Use a punch and hammer to remove the roll pin (Item 1)

[Figure 50-41-13] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
P-85664
Remove the lever mounting nut (Item 1) [Figure 50-41-

11].
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.

BOB-TACH (POWER) (CONT'D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-41-15

(Cont'd)
Figure 50-41-14 4
2
1
P19287
P-85667 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Remove the wedge (Item 1) [Figure 50-41-14] out the replace the damaged parts as needed.

bottom of the Bob-Tach.
Always replace bent or broken wedges. the bolt (Item 1) [Figure 50-41-15], tighten to 125 - 135
Later Design
Figure 50-41-16
2
P121303
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
replace the damaged parts as needed.


BOB-TACH (POWER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-41-17
2 1
P-85669
Remove the Power Bob-Tach. (See Removal And


Use a seal pick to remove seal (Item 1) [Figure 50-41-
17] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-17]

with a driver tool and hammer.
Figure 50-41-18
1
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3 [Figure 50-41-18].

LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
P-90591
1
2 With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4

P-90592A
Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593

the stabilizer bar rear pivot pin at the lift arm.


LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].

Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT'D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).

P-90600
At the right side upright disconnect and cap the two tilt
Remove the lift arm link from the loader. cylinder hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90599
At the left side upright disconnect and cap the three

auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
1
P-90611

P-85692 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)

Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.

50-13] from the pin on the rod end of the lift cylinder (both
sides).


Figure 50-50-16
1
2
P-90609
2
Remove the retaining bolt and nut (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being

removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.


REAR GRILLE Slide In
Identification Figure 50-60-3
Review the following photographs to identify the rear

grille installed in your machine. Follow the instructions
below the photograph to find the correct rear grille
removal and installation instructions for the rear grille.
Lockable Handle
Figure 50-60-1
P109720
This rear grille [Figure 50-60-3] is identified by the lack of

a handle or a knob. (See Slide In Rear Grille on Page 50-
60-4.)

P100808
This rear grille [Figure 50-60-1] is identified by a lockable

handle. (See Lockable Handle Rear Grille on Page 50-
60-2.)
Clamping Knob
Figure 50-60-2
P100808C
This rear grille [Figure 50-60-2] is identified by a

clamping knob. (See Clamping Knob Rear Grille on Page
50-60-3.)

REAR GRILLE (CONT’D) Installing
Lockable Handle Rear Grille Figure 50-60-6
Removing Front Tab And Slot
Figure 50-60-4
P100807
Rear Tab And Slot
P100808

Flip the lockable handle (Item 1) [Figure 50-60-4] up and P109761
turn the handle 90° counterclockwise. Lift and pull the
rear grille backward to remove from the loader. Align the front tabs of the two side covers into the slots in
the loader frame [Figure 50-60-6].
Figure 50-60-5
Align the rear tabs of the two side covers into the slots in
the loader frame and lower [Figure 50-60-6].
Figure 50-60-7
P100809
Lift and remove the two side covers (Item 1) [Figure 50-
60-5].
P109170
Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-7].
Turn the lockable handle 90° clockwise and fold the

handle down [Figure 50-60-4].

REAR GRILLE (CONT’D) Installing
Clamping Knob Rear Grille Figure 50-60-10
Removing Front Tab And Slot
Figure 50-60-8
P100807
2
Rear Tab And Slot
P100808C

Remove the clamping knob (Item 1). Lift using the handle P109761
(Item 2) [Figure 50-60-8] and pull the rear grille
backward to remove from the loader. Align the front tabs of the two side covers into the slots in
the loader frame [Figure 50-60-10].
Figure 50-60-9
the loader frame and lower [Figure 50-60-10].
Figure 50-60-11
P100809
60-9].
P109170
Install the clamping knob (Item 1) [Figure 50-60-8].

REAR GRILLE (CONT’D)
Slide In Rear Grille
Removing
Figure 50-60-12
P109720

Lift and pull the rear grille backward to remove from the
loader [Figure 50-60-12].
Figure 50-60-13
P109719
60-13].

REAR GRILLE (CONT’D) Figure 50-60-16
Slide In Rear Grille (Cont’d)
Installing
Figure 50-60-14
P109722
P100807
Figure 50-60-17

Align the front tabs of the two side covers into the slots in
the loader frame and lower [Figure 50-60-14]. (Right
side shown.)
Figure 50-60-15
P109721
Align the tabs of the rear grille into the slots in the two
side covers [Figure 50-60-17]. (Left side shown.)

P109718
the loader frame and lower [Figure 50-60-15]. (Left side
shown.)


REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
3
2
P-85695
1
Remove the top and bottom door hinge mounting bolts

P-85697 and nuts (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness.
[Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from
the door. (See Rear Removal And Installation on Page
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
1 1
P-90585
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)
Striker Removal And Installation

1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-85698A
Remove the two striker mount bolts (Item 1) [Figure 50- 1

70-4].

Remove the striker assembly from the loader.
Striker Disassembly And Assembly P-85698A
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
5 50-70-6].
Align the striker assembly in the center of the mounting

3 4 holes.
2 1
NOTE: Tighten the striker assembly, top mount bolt
only, until it will hold the striker assembly in
the center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P106584
Tighten both striker mount bolts (Item 1) [Figure 50-70-
6] to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the locknut (Item 1) [Figure 50-70-5].
Remove the bolt (Item 2), spacer (Item 3) and roller (Item
4) from the bracket (Item 5) [Figure 50-70-5].
Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9
Latch Removal And Installation (Earlier Models)
Figure 50-70-7
1
1
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door from the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-7] from
the latch.
Figure 50-70-8
P-85700
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-12
Latch Removal And Installation (Later Models)
Figure 50-70-10
1
2
1
P109094
Remove the door handle (Item 1) [Figure 50-70-12] from

P109092 the rear door.

Remove the bolt (Item 1) and nut (Item 2) [Figure 50-70-
10] from the latch.

Installation: Tighten the bolt (Item 1) and nut (Item 2) to
34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-70-11
2
1
P109093
Remove the spacer (Item 1) [Figure 50-70-11] from the

latch.

latch.

FUEL TANK Figure 50-80-3

Remove the engine / hydrostatic pump assembly from 1

2
Page 70-10-7.)
Figure 50-80-1
P-85707
Disconnect the fuel vent hose (Item 1) and remove the

two bolts (Item 2) [Figure 50-80-3].
1 Figure 50-80-4
1 4

P-85714
2 3
Remove the three mount bolts (Item 1) [Figure 50-80-1]
from the access cover at the rear of the loader frame.
Remove the access cover.
Figure 50-80-2
1
P-85708
Disconnect the two fuel lines (Item 1) [Figure 50-80-4].

1
50-80-4] from the fuel level sender.
Remove the two mounting bolts (Item 3) and remove the

bracket (Item 4) [Figure 50-80-4].
P-85713
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.

FUEL TANK (CONT'D) Figure 50-80-7
Figure 50-80-5
1
1
1 1
P-85711
At the right side of the loader, remove the two main frame
P-85710 mount bolts and nuts (Item 1) [Figure 50-80-7].
Installation: Tighten the main frame mount bolts to 542 -

Remove the bolts (Item 1) [Figure 50-80-5] from the 583 N•m (400 - 430 ft-lb) torque.
battery hold down plate.

Figure 50-80-8
Remove the hold down plate from the loader.
Figure 50-80-6
1 1 1
P-85712
2
P-85709 At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-7].
Remove the two mounting bolts (Item 1) and the bracket Installation: Tighten the main frame mount bolts to 542 -
(Item 2) [Figure 50-80-6]. 583 N•m (400 - 430 ft-lb) torque.
Lift the fuel tank and remove it from the loader frame.
NOTE: When installing the fuel tank, avoid striking

the tank with heavy objects to prevent
damage.

FUEL TANK (CONT'D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-11
Figure 50-80-9
1
1
P-85707
P-85708
Remove the two bolts (Item 1) and disconnect the fuel fill
hose (Item 2) [Figure 50-80-11].
50-80-9] from the fuel level sender. Figure 50-80-12

Remove the fuel level sender.
Figure 50-80-10
P-85715
Remove the fuel fill screen (Item 1) [Figure 50-80-12].

P-85716
Inspect and replace as needed.
Inspect the fuel level sender [Figure 50-80-9] and

replace if worn or damaged.


CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
WARNING P-85675
Never work on a machine with the lift arms up unless Inspect the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598

Figure 50-90-2
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P-85678 5].
Remove the crossbar from the pivot (Item 2) [Figure 50-

Remove the bolt and nut (Item 1) [Figure 50-90-3] to 90-6].
disconnect the lift pedal linkage from the crossbar.

Figure 50-90-6
Figure 50-90-4
2
1
P-85681
P-85680
Installation: Inspect the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation (Cont’d) After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-7 spool must travel full stroke without the pedal hitting the
floor panel.
1 The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
2
Figure 50-90-9
P-85675
Remove the bolt (Item 1) [Figure 50-90-7] and nut from

the pedal linkage.

Remove the linkage (Item 2) [Figure 50-90-7].
P-85676
Figure 50-90-8
Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.
1 Figure 50-90-10
2
2
P-85675A
Remove the bolt (Item 1) [Figure 50-90-8] and nut from

P-85675
the pedal linkage.
Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
Remove the linkage (Item 2) [Figure 50-90-8]. the pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable

“NEUTRAL” angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-90-10] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-90-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11

1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
the lift arms are secured by an approved lift arm Inspect the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.

to fall and cause injury or death. Figure 50-91-2
W-2059-0598

DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-91-3 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.

Figure 50-91-4 P-85676
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]

from the pedal mounting bracket.
Figure 50-91-6
1
1
2
P-90981
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot.
P-85675
Repeat for other side.

Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable

“NEUTRAL” angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-91-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7

1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].


CONTROL PANEL
Description
Figure 50-100-1

NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the NEUTRAL or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT'D) Figure 50-100-2
2
DANGER
1
P-85846
P-90328
AVOID DEATH Figure 50-100-3

• Keep out of this area when lift arms are raised 2

D-1009-0409
1
WARNING
P-85847
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598
the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286



CONTROL PANEL (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Figure 50-100-4
Figure 50-100-6
2
1
1 1
2
2 2
P-90612
1 1
P-85864
Scribe a mark across the top of the steering linkage bars

(Item 1) [Figure 50-100-4] which are connected to the Remove the nuts (Item 1) and the steering stabilizers

steering shaft on the control panel. (Item 2) [Figure 50-100-6].
Remove the four steering linkage mounting bolts, nuts

and rubber isolators (Item 2) [Figure 50-100-4].
Inspect and replace any damaged parts.
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-100-5
3 2 3
3 3 P-85848
Remove the two bracket mounting bolts (Item 1) and the

knob (Item 2) [Figure 50-100-5] from the lift arm bypass
valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Disassembly And Assembly (Cont’d)
Figure 50-100-7 2
2 2
1
3 1 3 3 P-85867
3
Remove the four bolts (Item 1) [Figure 50-100-9] from

P-85865 the control panel.
Remove the control handle assembly (Item 2) [Figure

Figure 50-100-8 50-100-9].

Figure 50-100-10
4
3
2
1
1
P-85861
P-85868
Remove the bolt and nut (Item 1) [Figure 50-100-7] and
[Figure 50-100-8], steering link (Item 2), and washers
(Item 3) [Figure 50-100-7]. Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8]. Remove the control handle (Item 4) [Figure 50-100-10].

CONTROL PANEL (CONT'D) Linkage Removal And Installation

W-2059-0598
1 2 1
WARNING
P-85872
Remove the two bolts (Item 1) from the bellcrank (Item 2) fall or move and cause injury or death.
[Figure 50-100-11]. W-2017-0286

Remove the bellcrank from the bracket [Figure 50-100- Lift and block the loader. (See LIFTING AND BLOCKING
11]. THE LOADER on Page 10-10-1.)
Figure 50-100-12 Raise the lift arms and install an approved lift arm

2
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-11] for wear and
replace as need.
Repeat the procedure for the other control handle

assembly.

Linkage Removal And Installation (Cont’d)

1
Figure 50-100-13
2
1
2
P-48631
2
Remove the nut (Item 1) from the end of the centering

P-90612 spring shoulder bolt (Item 2) [Figure 50-100-14].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-13] which are connected to the Installation: Tighten the centering spring bolt and a

steering shaft on the control panel. NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage mounting bolts, nuts Figure 50-100-15
and rubber isolators (Item 2) [Figure 50-100-13].

1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the Linkage Neutral Adjusting procedure
must be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-10.)
P-48632
Slide the centering plate (Item 1) [Figure 50-100-15] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator’s seat.

Figure 50-100-16
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Inspect for wear on the centering blocks (Item 1) [Figure
P-48630 50-100-17].
If the centering blocks need replacement, remove the

The centering plate / centering spring assembly consists bolts (Item 2) [Figure 50-100-17]. Remove the centering
of the following parts: blocks.

ITEM DESCRIPTION Installation: Tighten the centering block bolts to 47,5 -
54,2 N•m (35 - 40 ft-lb) torque.
1 Bolt
2 Bushings NOTE: The washers go between the bolts and the
3 Washer centering plate.
4 Bushing Spacer NOTE: If the centering blocks are worn, they can be
5 Spring removed and rotated 180 degrees and
6 Locknut reinstalled.
7 Centering Plate
8 Guide Bushings

Figure 50-100-18
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-20].

P-54617
Remove the pintle base (Item 2) [Figure 50-100-20].
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-21
18] from the pintle.

Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-18].
Figure 50-100-19 2
1 3
1
2 P-48659
4
3 NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-100-21].
1 Installation: Install the pintle base (Item 1) onto the

P-48624 pump shaft (Item 2) [Figure 50-100-21]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the bolt and nut (Item 1) [Figure 50-100-19].
NOTE: After installing the linkage onto the
Inspect the washers (Item 2), pintle arm (Item 3) and the hydrostatic pumps the Linkage Neutral
steering control lever (Item 4) for damage and replace as Adjusting procedure must be performed. (See
needed [Figure 50-100-19]. Linkage Neutral (Adjusting) on Page 50-100-
10.)
NOTE: The washers (Item 2) [Figure 50-100-19] are
hardened, and should only be replaced
through Bobcat Parts.

CONTROL PANEL (CONT'D) NOTE: Anti-seize should be used on the adjusting
screw to prevent corrosion and allow free
Pintle Arm Disassembly And Assembly movement while adjusting.
Figure 50-100-22 Figure 50-100-24
2
4
3 1
2
3
1 P-48619
P-54624
Using a bushing driver (Item 1) remove the torsion

Remove the nut (Item 1) from the pintle roller cams (Item bushing (Item 2) by pressing the bushing through the
2) and inspect the pintle roller cams and washers (Item 3) pintle arm into an oversized socket (Item 3) [Figure 50-
100-24] to catch the torsion bushing.

[Figure 50-100-22] for damage.
Inspect the torsion bushing (Item 4) [Figure 50-100-22] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-24] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-100-23 arm should be the same.
4
2
P-54626
Remove the base pintle (Item 1) [Figure 50-100-23] from

the pump shaft.
Remove the retaining bolt (Item 2), adjusting screw (Item

3) and neoprene dampener (Item 4) [Figure 50-100-23]
from the base pintle.
Inspect parts for wear and damage, replace as needed.

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
MEL1563 or 7217666 Remote Start Tool Kit. 1
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)

THE LOADER on Page 10-10-1.) P-85845
Figure 50-100-25
Loosen the bolt / nut (Item 1) [Figure 50-100-26] only
until the tension is released from the torsion bushing.
3
Figure 50-100-27

2
1
P-48450A
Tool that may assist in the Neutral adjustment [Figure

50-100-25]. P-54613
To make this tool use a locking grip C-clamp and grind

one edge flat (Item 1) and grind the other edge (Item 2) Loosen the nut (Item 1) only until the tension is released
[Figure 50-100-25] to a small rounded edge. from the torsion bushing (Item 2) [Figure 50-100-27].
A steering centering block (Item 3) [Figure 50-100-25] is NOTE: The bolt must be loose enough to allow the
also needed. The centering block can be placed as torsion bushing (Item 2) [Figure 50-100-27] to
shown and welded to the C-clamp if desired. turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-28
W-2017-0286
1
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.

[Figure 50-100-28] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-29
Tighten bolts (Item 3) [Figure 50-100-29] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-100-28] and
[Figure 50-100-29].
1
P-48451
A modified locking grip C-clamp and steering block

shown in [Figure 50-100-25] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-clamp (Item 2) [Figure 50-100-29]
around both centering blocks.
Lock the C-clamp in place.

CONTROL PANEL (CONT'D) NOTE: This procedure is shown for Neutral
Adjustment on the left side of the loader. The
Linkage Neutral (Adjusting) (Cont’d) procedure is the same for the right side
Neutral Adjustment.
Start the Neutral Adjustment procedure with the left
pump first and complete the Neutral Adjustment for Turn the adjustment screw (Item 1) [Figure 50-100-31]
the left pump before adjusting the right pump. counterclockwise until forward creep is seen.
Figure 50-100-30 Turn the adjustment screw (Item 1) [Figure 50-100-31] to

a point between forward and reverse where there is zero
creep.
Stroke the left steering lever to forward and allow the

2 1 lever to return to NEUTRAL. Stroke the left steering lever
to reverse and allow the lever to return to NEUTRAL.
Verify that there is zero creep when the lever returns from
either direction, on the left side. Turn the adjustment
screw (if necessary) until zero creep is obtained.
P-48632

Loosen the left pump pintle adjustment lock bolts
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-30].) Loosen the bolts enough to
allow free movement between the pintle arm and the
pintle base.
NOTE: If the bolts are too loose or too tight, the

Neutral Adjustment may be affected.
Figure 50-100-31
P-54610
Move the engine speed control to high idle.
NOTE: The NEUTRAL range (dead-band) will vary

between the hydrostatic pumps.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-32
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to NEUTRAL by the return spring
force.
If the levers do not return to NEUTRAL and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-32] at a time and apply Loctite® 242 or equivalent
thread locker to the bolt and reinstall the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with preapplied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the Neutral Adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-14.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader Neutral
Adjusting procedure, inspect the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
WARNING
P-85845
support device. Failure to use an approved lift arm Loosen the bolt / nut (Item 1) [Figure 50-100-33] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-34

WARNING
of the frame before running the engine for service. 2
W-2017-0286

P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-100-34].
Preload tension in the torsion bushings must be removed The bolts must be loose enough to allow the torsion
before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-34] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-35
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-37].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-35] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-36 Figure 50-100-38
3 2
2
4
1
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-100-36]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-100-38].
Verify the cam mounting nuts (Item 4) [Figure 50-100-36]

are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-39
1
1
1
P-51132
Remove the spacer (Item 1) [Figure 50-100-41].

P-85844
Figure 50-100-42
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
39] on each steering linkage bar. 2

Figure 50-100-40
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-42].
P-90615
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-100-
40]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Inspect the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-100-43 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in until it contacts the bellcrank.
1
Repeat steps on the other control lever.

Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,0 m (10

ft) of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P-85845 adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in.
Tighten the two bolts and nuts (Items 1) [Figure 50-100- If the drift is excessive to the right, turn the left
43] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-220-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-100-44 prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-100-46
1 2
P-85845
Remove the mounting nuts (Item 1) [Figure 50-100-46]

from the end of the shocks connected to the steering

linkages.
Remove the mounting nuts (Item 2) [Figure 50-100-46]

from the other end of the shocks connected to the
brackets on the control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-101-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three mount bolts (Item 1) [Figure 50-101-1]

DANGER

that secure the controller.
Figure 50-101-2
1
1
1
2
1
P-90328
AVOID DEATH
1 1
P-85881
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-

101-2].
WARNING Remove the lift arm bypass knob and rubber washer
(Item 2) [Figure 50-101-2].
Never work on a machine with the lift arms up unless Remove the control panel (Item 3) [Figure 50-101-2].
W-2059-0598


CONTROL HANDLE / LEVER Lever Removal And Installation
The control handles / levers are used to control the 2

forward and reverse travel. 3
The control handles / levers are mounted to the control

panel assembly.
P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.

Remove the four nuts (Item 2) and the plate (Item 3)
[Figure 50-110-1] used to mount the control lever.
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.

CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-110-2
P-85883A

Remove the rubber boot (Item 1) [Figure 50-110-2].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Figure 50-111-1 1
P-85882
P-21879
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)

functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector [Figure 50-111-3].

Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.

Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)
torque.
Figure 50-111-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, inspect the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-9] and [Figure 50-
3 111-10] to assure proper return of the control handle to
7 NEUTRAL and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2
P-21882 [Figure 50-111-10] as shown away from stop
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-111-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Inspect the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-13] from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the Allen head screws (Item 2) [Figure
P16534 50-111-14] from the handle assembly.
Installation: Tighten the Allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-111-12]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-3.)

CONTROL HANDLE / LEVER (ACS) (CONT’D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-111-15] from the handle.

Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-111-17] used to mount the control lever.
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Inspect the mounting bolt (Item 1) [Figure 50-111-16]

that connects the handle to the handle sensor unit for
wear, replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A

Remove the rubber boot (Item 1) [Figure 50-111-18].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (SJC) Joystick Testing
Description See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to test function.
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.

CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-112-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-1.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890

Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 47,5 - 54,2 N•m


ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the top mounting screw (Item 1), washer (Item

2), and loosen the two bottom mounting screws (Item 3)
Remove the four mounting screws, (Item 1), washer (Item [Figure 50-120-2] from the front access panel.
2), and remove the left access panel (Item 3) [Figure 50-
120-1]. Remove the front access panel from the loader.
Remove the front access panel from the loader.


ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-121-3
Figure 50-121-1
2 1
2
P-90587
P100731
Remove the two mounting nuts (Item 1), and remove the
footrest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
footrest (Item 2) [Figure 50-121-1]. Figure 50-121-4

Figure 50-121-2
2
3 2
2
1
1
1
2
P-90588
P100732
NOTE: Mark the location of the foot pedal before
removal for correct assembly.
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2]. Loosen the bolt, remove the engine speed control pedal
(Item 1), and remove the mounting screws (Item 2)
[Figure 50-121-4].
Remove the right inside access panel (Item 3) [Figure

50-121-4].


WINDOW (REAR) Removal And Installation (Latches)
Rear Window Identification

Latches Rubber Cord
2 • When fluids are under pressure.
1 • Engine is running.
P-85309B P-64994D W-2019-0907
There are two different procedures for removing the rear Figure 50-130-2
window from the machine:
1. This window is equipped with latches (Item 1) [Figure

50-130-1].
2. This window is equipped with a rubber cord and tag

(Item 2) [Figure 50-130-1]. 1 1

P-85706
Remove the rear window assembly by turning the two

latches (Item 1) [Figure 50-130-2] in until they disengage
from the window frame.
Push the rear window out the rear of the operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
installing a new window.
Clean the area before installing the rear window

assembly.
Reverse the procedure to install the rear window.

WINDOW (REAR) (CONT’D) Figure 50-130-4
Disassembly And Assembly (Latches)

8
Figure 50-130-3 7
1
6
1
2
3
4
5
P-85704

P-85705
The items listed below refer to [Figure 50-130-4].
Remove the screw (Item 1) from the latch [Figure 50- 1. Latch
130-3].
2. Spacer

Installation: Tighten the screw (Item 1) [Figure 50-130- 3. Bushing
3] to 21 - 23 N•m (180 - 200 in-lb) torque.
4. O-ring (factory installed on later models)
5. Washer
6. Screw
7. Rear Window
8. Seal

WINDOW (REAR) (CONT’D)
Removal (Rubber Cord)
WARNING
• When fluids are under pressure.
W-2019-0907
Figure 50-130-5

P-64994
Pull on the tag on the top of the rear window to remove

the rubber cord [Figure 50-130-5].
Push the rear window out of the rear of the operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
installing a new window.

WINDOW (REAR) (CONT’D) Figure 50-130-8
Installation (Rubber Cord)
Figure 50-130-6
1
P109581
Install the rear window assembly from the outside of the

P109560 operator cab into the window frame.
Install a lower corner of the rear window assembly into

Install the rubber molding (Item 1) [Figure 50-130-6] the corner of the window frame (Item 1) [Figure 50-130-
around the edge of the rear window. 8].

Figure 50-130-7 Work the window assembly downward until the window is
fully seated in the lower portion of the window frame.
2 Figure 50-130-9
P-85228
Apply liquid soap to the rubber molding (Item 1) [Figure

P109582
50-130-7] for installation.
NOTE: Install the window assembly with the narrow Apply light pressure to the outside of the window
edge (Item 2) [Figure 50-130-7] towards the assembly holding it tight up against the window frame.
inside of the loader.
Use a multipurpose tool (Item 1) [Figure 50-130-9] under
the molding lip to guide the window assembly into the
window frame.
NOTE: Tapping the window with a rubber hammer will

help seat the window assembly in the window
frame.

WINDOW (REAR) (CONT’D)
Installation (Rubber Cord) (Cont’d)
Figure 50-130-10
P109583A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-

10] with the safety tag into the molding on the outside of
the operator cab.
NOTE: Verify the safety tag is located in the top center

of the window.


WINDOW (TOP) Figure 50-131-3
Figure 50-131-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].

Figure 50-131-4
Figure 50-131-2
1 1
1 1
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONT’D)
Figure 50-131-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-1].

Tighten the nuts (Item 1) [Figure 50-131-1] to 9 - 10 N•m
NOTE: Allow two hours of cure time before exposing

to direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-132-3

1 1
Figure 50-132-1
1
1
1
1
2
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.
P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.

Figure 50-132-2 Remove the window assembly.
NOTE: The window assembly can only be replaced

as a complete unit.
1 3 4 5
2
P-85819
From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2]
from the window assembly.
Installation: Tighten the nut (Item 2) [Figure 50-132-1]

flush to the end of the bolt.


CAB DOOR Removal And Installation
The standard cab door is available as an option or dealer 1

installed kit.
P-85781A
Open the cab door.
Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 50-140-1].

Figure 50-140-2
2
3
P-85588A P-85589A
Rotate and pull the clip (Item 1) out of the gas spring
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2].

CAB DOOR (CONT’D) Installation: Install the hinges (Item 1) on the cab and
use the bolts and nuts (Item 2) [Figure 50-140-4] to
Removal And Installation secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.
Figure 50-140-3
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4

2 1
2 1
P-85837
Remove the four bolts and nuts (Item 2) [Figure 50-140-

4] from the cab.
Remove the hinges (Item 1) [Figure 50-140-4] from the

cab.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].

2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].

9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

Figure 50-140-10
1
1
3
P-85833A P-85838A
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
If adjustment is needed. (See Adjusting on Page 50-140-

5.)
2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-5.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
2
1
1
P-85413F
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.

Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P-85831
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch recheck the alignment

of the door sensor. (See Aligning on Page 50-140-4.)


ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837

Adjustable armrests (Item 1) [Figure 50-150-1].

ARMREST (CONT’D) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.

P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].
Remove the nut (Item 3) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

Remove the joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8

1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

Disassembly And Assembly (Cont’d) Later Models
Figure 50-150-9
Earlier Models
1
3
2
P100825
1
Figure 50-150-12
P-90842
Later Models
Figure 50-150-10
Earlier Models

7 4
6 3
5 2
3
6 1
5 2 P100824
4 1
Remove the nut (Item 1), washer (Item 2), spring (Item 3)
P-90843 [Figure 50-150-11] and [Figure 50-150-12].
Remove the spacer (Item 4), washer (Item 5), plastic

Remove the nut (Item 1), washer (Item 2), and the plastic washer (Item 6) and the bolt (Item 7) [Figure 50-150-12].
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10]. Installation: Tighten the nut to 21 - 23 N•m (80 - 200 in-
lb) torque.
Remove the spacer (Item 4), plastic washer (Item 5), and
the bolt (Item 6) [Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

ARMREST (CONT’D)
Figure 50-150-13
All Models
1 1
2
P-90844
Remove the two nuts and bolts (Item 1) and the slide rail
(Item 2) [Figure 50-150-13] from the armrest mount.

Repeat for the other side.


LEFT SIDE LOWER PANEL Figure 50-160-3
Raise the operator’s cab.
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1
[Figure 50-160-3] from the left side lower panel.
P-90897 Figure 50-160-4

Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (if equipped). (See
3-Point Seat Belt Removal And Installation on Page 50- 1
30-4.)
Lower the operator’s cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].

Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-160-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11

1
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-12
1 1
1
1
P-90866

remove the speaker from the left side lower panel.

Figure 50-160-13
P-90864

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Raise the operator’s cab.

1
Figure 50-170-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
P-90897 Figure 50-170-4

Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
2
1
Lower the operator’s cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lockwasher (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.

NOTE: The power port lockwasher must be replaced
NOTE: Pull the right side lower panel away from the with a new lockwasher when it has been
side of the cab far enough to access the wire removed.
harness.
Figure 50-170-8
Figure 50-170-6
2 1
1
2 P-90877
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove

Disconnect the wire harnesses (Item 1) and the antenna the radio from the right side lower panel.
(Item 2) [Figure 50-170-6] (if equipped with radio).
Installation: Insert a screwdriver into the slot (Item 2)
NOTE: Install the right side lower panel with the radio [Figure 50-170-8] to lock the tab into place.
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.

Remove the input from the right side lower panel.
Figure 50-170-10
1
1
1
1
P-90876

remove the speaker from the right side lower panel.


HEADLINER Figure 50-180-3
Figure 50-180-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if

P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation (Earlier Models) on Page 60-
2) [Figure 50-180-1] (if equipped). 60-2.) or (See Cab Light Removal And Installation (Later

Models) on Page 60-60-3.)
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage. Figure 50-180-4
Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
Figure 50-180-2
1
1
1
1
1 2
P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
P-90894
Installation: Route the cab light wire harness in the
groove on the topside of the headliner (if equipped with
Remove the air duct (Item 1) [Figure 50-180-2] (if HVAC).
equipped).
NOTE: Replace the retainers if needed.


ELECTRICAL SYSTEM
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-4

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-12
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-13
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-13
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2

Cab Light Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-3
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-2
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3

ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-171-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-200-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2

PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-201-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1


Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-3


CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 FC1 FUSE CENTER 1 3
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 FC2 FUSE CENTER 2 3
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 T1 BATT GROUND 4
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 T2 BUZZER GROUND 8
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11 T3 FLASHER 13
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7 T6 BATT GROUND 4
C126 HORN 2 13 C441 TWO SPEED 2 7 T8 BATT GROUND 4
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 T13 BUZZER POWER 8
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5 T14 PRE HEATER 6
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C250 DOOR SENSOR 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T16 RIGHT REAR WORK LIGHT(-) 11
C251 WIPER 5 9 C480 LEFT PANEL(GRAY) 12 8 T17 LEFT REAR WORK LIGHT (+) 11
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 T18 LEFT REAR WORK LIGHT (-) 11
C277 AIR RIDE SEAT 6 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C278 RIGHT SPEAKER 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C279 LEFT SPEAKER 2 9 C489 ACCESSORY 2 3,4
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8
C362 REAR AUX SOLENOID 8 7 C602 LEFT REAR TAIL LIGHT 2 11
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB CONNECTOR 48 3-5, 8-13 C611 BLOWER MOTOR 4
Dealer 12
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12 SW1 BRAKE SWITCH 9
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12 SW2 BEACON SWITCH 13
C411 LEFT HANDLE 5 WAY 5 10,13 C667 DOOR KIT 6 9 SW3 HAZARD SWITCH 13
C412 HANDLE(HORN) 2 10,13 C670 EXTERIOR BEACON 6 13 SW4 HAND/FOOT, H/ISO SWITCH 9
C413 REAR ROD 2 7 C676 RADIO 6 9 SW5 POWER BOBTACH SWITCH 13
C414 REAR BASE 2 7 SW6 BUCKET POSITION SWITCH 13
C415 HIGH FLOW SOLENOID 2 7 SW8 FRONT WIPER SWITCH 9
C416 DIVERTER SOLENOID 2 7 SW9 TRAVEL CONTROL SWITCH 8
C417 REAR AUX RELIEF 2 7 J1A GATEWAY COTROLLER 34 SW10 BLOWER SWITCH 12
C418 FRONT ROD 2 7 J1B GATEWAY CONTOLLER 26 SW11 AC SWITCH 12
C419 FRONT BASE 2 7 J2A AUX CONTROLLER 34
C420 HYD LOCK 2 7 J2B AUX CONTROLLER 26
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 WIRING SCHEMATIC
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 (STANDARD MACHINE)
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 S650 (S/N A3NV11001 - A3NV13098)
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10 (S/N A3NW11001 - A3NW11248)
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 Sheet 1 of 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
(PRINTED MARCH 2011)
7175752
Printed In U.S.A.
679 of 1311
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE)
A-26 SPARE B-26 TWO SPEED COIL A-26 Dealer Copy
HIGH -- Not RETURN
FLOW for Resale B-26 HIGH FLOW
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN
A-32 HYD OIL TEMP A-32
A-33 SPARE ANALOG A-33
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE
HARNESS PART NUMBER

MAIN FRAME 7174782
STD CAB 7165991
DLX CAB 7176098
DLX FUEL 7175293 WIRING SCHEMATIC
STD FUEL 7149219
DOOR 7155024 (STANDARD MACHINE)
S/R 6733370
TAILGATE DOM 7175271 S650 (S/N A3NV1100 1 - A3NV13098)
TAILGATE EUR 7175287
2 SPD ADP 7159366 (S/N A3NW11001 - A3NW11248)
BACKUP ALARM 7175017
BRAKE ADAPTER 7165061 Sheet 2 of 13
7175752
Printed In U.S.A.
680 of 1311
POWER
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
BATTERY MEGAFUSE
FC1 FUSE 2
100.0 Amps 1180 RED/WHT
BATT_CABLE 25 A J2B 2
1025 RED 1160 RED/WHT 1150 RED/WHT
J2B 3
1240 RED/WHT
FC1 FUSE 1 SHEET 8
1400 RED/WHT
25 A C408 17 SHEET 9
1070 RED 1120 RED/WHT 1450 RED/WHT 1450 RED/WHT 1420 RED/WHT
SHEET 8
1110 RED/WHT 1440 RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130 RED/WHT
15 A J1B 3
1290 RED 1370 RED/WHT
SHEET 9
FC2 FUSE 2 1460 RED/WHT
25 A SHEET 13
SHEET 13
FC2 FUSE 1
25 A
SHEET 5
1010 RED
FRC 1 FUSE 6
30 A
SHEET 7
1050 RED FRC1 FUSE 5

30 A
1350 RED/WHT
SHEET 6
FRC1 FUSE 11
25 A
SHEET 12
FRC1 FUSE 10
20 A
SHEET 11
1620 RNG/WHT
FRC1 FUSE 9 SHEET 8
1940 RNG/WHT
15 A SHEET 8
1320 RED/WHT 1930 RNG/WHT
SHEET 11 SHEET 8
1060 RED 1775 RNG/WHT
SHEET 6 SHEET 9
SHEET 6 SHEET 8
1785 RNG/WHT
SHEET 9
1950 RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
5A SHEET 8
1570 RNG/WHT
SHEET 10
FRC1 FUSE 2
25 A
1760 RNG/WHT 1850 RNG/WHT
SHEET 9
FRC1 FUSE 3
15 A
1550 RNG/WHT Printable Version Click Here
SHEET 13
FRC1 FUSE1
25 A 1750 RNG/WHT 1780 RNG/WHT
C489 A
WIRING SCHEMATIC
SWITCHED
POWER
1720 RNG/WHT
C404 B (STANDARD MACHINE)
1050 RED 30
S650 (S/N A3NV11001 - A3NV13098)
87 SHEET 12
SHEET 6
2055 BLK 85 86 FRC1 FUSE 7
25 A
(S/N A3NW11001 - A3NW11248)
2030 BLK 1795 RNG/WHT 1730 RNG/WHT
SHEET 12
FRC1 FUSE 8
SHEET 5
Sheet 3 of 13
25 A
1580 RNG/WHT
SHEET 9
8000 TAN
J1A 4 (PRINTED MARCH 2011)
SHEET 5
C408 6
1830 RNG/WHT
SHEET 5
7175752
Printed In U.S.A.
681 of 1311
GROUND
2080 BLK
SHEET 5
2070 BLK
SHEET 5 C408 32
2940 BLK 2950 BLK 2950 BLK
SHEET 8
2960 BLK 2510 BLK
SHEET 8 J1B 16
2920 BLK 2500 BLK 2110 BLK T6
SHEET 8 J1B 15 BATT GND
2250 BLK 2540 BLK
SHEET 8 J2B 16
2550 BLK 2090 BLK
J2B 15
2765 BLK
SHEET 11
2745 BLK
SHEET 12
2790 BLK T8
SHEET 9 BATT GND
2780 BLK
SHEET 13
2730 BLK
SHEET 9
2620 BLK
SHEET 11
2630 BLK 2720 BLK
SHEET 11 C103 B C489 B
2650 BLK 2600 BLK 2600 BLK
SHEET 10
2640 BLK 2810 BLK 2390 BLK
SHEET 11 SHEET6
2610 BLK
SHEET 11
2200 BLK
SHEET 7
2751/BLK OR 2770/BLK
SHEET 13
2450 BLK
SHEET 7
2741 BLK
SHEET 13
2785 BLK 2710 BLK 2300 BLK T1
SHEET 13 SHEET 5 BATT GND
2930 BLK 2480 BLK
SHEET 9 C408 42 SHEET 7
2830 BLK 2900 BLK 2900 BLK
SHEET 13
2700 BLK 2000 BLK
SHEET 8 SHEET 11

3530 LBL
SHEET 7
SHEET 6
3800 LBL WIRING SCHEMATIC
2370/BRN OR 3910 LBL
SHEET 9
SHEET 7 3310/LBL OR 2180/BRN
3410 LBL
3010 LBL
J1B 17 (STANDARD MACHINE)
SHEET 7
SHEET 6
SHEET 6
3110/LBL OR 2180/BRN
3510 LBL S650 (S/N A3NV11001 - A3NV13098)
3710 LBL
SHEET 6
(S/N A3NW11001 - A3NW11248)
Sheet 4 of 13
Printed In U.S.A. (PRINTED MARCH 2011)
7175752
682 of 1311
CAN BUS
9160 PUR/WHT
C503 2
9260 PUR RH DLX PANEL
C503 4
9200 PUR 9270 PUR 9230 PUR C408 8 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR
GWY CTRLR J1B 8 C479 4
9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
1830 RNG/WHT 1
#
SHEET 3
2070 BLK 2
SHEET 4 RIGHT
9560 PUR/WHT 3
JOYSTICK
9660 PUR 4
9220 PUR
J2B 8 C449
9120 PUR/WHT Dealer
AUX CTRLRCopy -- Not for Resale #
J2B 9 1840 RNG/WHT 1
SHEET 3
2080 BLK 2
SHEET 4
9540 PUR/WHT 3 LEFT
9640 PUR 4 JOYSTICK
C426
9500 PUR/WHT A
J1B 14
9600 PUR B
J1B 20
9400 PUR D
J1B 21
C CAN (Remote Start Tool, ACD)
1730 RNG/WHT E
SHEET 3
1165 RED/WHT F
SHEET 3
SHEET 4
2710 BLK G
# CONNECTOR DOES NOT EXIST IN 7165991
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV1100 1 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 5 of 13
Printed In U.S.A.
7175752
683 of 1311
ENGINE
STARTER
STARTER C109
1030 RED 30 J1A 22

8250 TAN B 8250 TAN R M
B SHEET 3
SHEET 3 87 8200 TAN A 8200 TAN S 1015 RED
C110
2005 BLK 85 86 8210 TAN B
SHEET 12 J1A 7 S 1020 RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800 RNG/WHT 1815 RNG/WHT
SHEET 12
EXCITATION
2015 BLK
FUEL SHUTOFF
FUEL SOLENOID
C101
PULL
8120 TAN
Dealer Copy -- Not
D5 for Resale 8100 TAN B 8100 TAN PULL 24.5 OHM
1350 RED/WHT 30 0.33 OHM
SHEET 3 87 8150 TAN J1B 4 8800 TAN A 8800 TAN HOLD
J1A 30
2810 BLK 2800 BLK C 2800 BLK
85 86 SHEET4
2025 BLK 8110 TAN
SHEET 7 J1A 3
C106 GLOW
3600 LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550 TAN
3610 LBL B GND 1060 RED J1A 14
SHEET 3 87 8500 TAN
3800 LBL T14 PRE HEATER
SHEET 4
3210 LBL B SIG 85 86
ENGINE COOLANT 2016 BLK 8510 TAN
3200 LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055 BLK
SHEET 3
C104

C107
3500 LBL B +5V PWR
SHEET 9
J1A 25
3520 LBL C SIG ENGINE OIL PRESSURE WIRING SCHEMATIC
3510 LBL A GND SENDER (0.5 ~ 4.5V)
SHEET 4
(STANDARD MACHINE)
C355 C
C406 S650 (S/N A3NV11001 - A3NV13098)
3100/LBL OR 3180/LBL 3100/LBL OR 3180/LBL A SIG FUEL
J1B 12
SHEET 4
3110/LBL OR 2180/BRN 3110/LBL OR 2180/BRN B GND
SENDER
(S/N A3NW11001 - A3NW11248)
C355 D
C405
Sheet 6 of 13
3710 LBL B GND
SHEET 4 AIR FILTER
Printed In U.S.A. J1A 16
3700 LBL A SIG
SWITCH
7175752
684 of 1311
HYDRAULICS
TRACTION
LOCK C425 TRACK MACHINES
30 4150 LGN
1360 RED/WHT J1A 13
SHEET 3 87 4100 LGN B C308
BRAKE
2025 BLK 4200 LGN A 4200 RED A SOLENOID
SHEET 6 85 86 J1B 6
2035 BLK 4110 LGN 2200 BLK C 2200 BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C
C362 C414
OPTIONAL REAR AUX
4440 LGN A 4440 LGN 1 SIG DIRECTIONAL SOLENOID
J2B 5
2440 BLK B 2440 BLK 2 GND FEMALE COUPLER
J2A 2
7.5 OHM 12V C420
C413 2410 BLK B
4430 LGN C 4430 LGN 1 SIG OPTIONAL REAR AUX J1A 1 HYD LOCK SOLENOID
J2B 7 4410 LGN A
2430 BLK D 2430 BLK 2 GND DIRECTIONAL SOLENOID J1B 13 9.8 OHM 12V
J2A 10 MALE COUPLER
7.5 OHM 12V C105
HYDRAULIC
C416 Dealer Copy -- Not for Resale 3410 LBL B CHARGE
4450 LGN E 4450 LGN 1 SIG OPTIONAL REAR AUX 3420 LBL C
J2B 4 J1B 1 PRESSURE
2450 BLK F 2450 BLK 2 GND BLEED / LOCK VALVE
SHEET 4 SOLENOID MALE COUPLER 3400 LBL A 0.5-7.5V
J1B 23
7.5 OHM 12 V +8V
C417 C108
4480 LGN G 4480 LGN 1 SIG OPTIONAL REAR AUX HYDRAULIC
J2B 6 3310/LBL OR 2180/BRN B TEMPERATURE
2480 BLK H 2480 BLK 2 GND BLEED / LOCK VALVE SHEET 4
SHEET 4 3300 LBL A SENDER
SOLENOID FEMALE COUPLER J1A 32
500 - 3000 OHM
C112
C415
OPTIONAL HIGH FLOW 3430 LBL A HYDRAULIC
2460 BLK B GND J1A 34
J2A 26 SOLENOID 3530 LBL B FILTER SWITCH
4460 LGN A SIG SHEET 4
J2B 26 7.5 OHM
12 V
C418
2330 BLK 2 GND FRONT ROD SOLENOID (MALE)
J2A 18
4330 LGN 1 SIG 3.3 OHM PWM
J2B 19
C419
2340 BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A 1
J2B 13
4340 LGN 1 SIG 3.3 OHM PWM Printable Version Click Here
C437
J1A 27
2360 BLK 2 GND
TWO SPEED
WIRING SCHEMATIC
4360 LGN 1 SIG MAKEUP SOLENOID
J1B 25
C441
(STANDARD MACHINE)
J1A 26
2350 BLK
4350 LGN
2
1
GND
SIG TWO SPEED SOLENOID
S650 (S/N A3NV11001 - A3NV13098)
J1B 26
C446 (S/N A3NW11001 - A3NW11248)
2910 BLK 2 GND HYDRAULIC
J1A 18
J1B 19
4010 LGN 1 SIG
FAN SOLENOID
7.2 OHM Sheet 7 of 13
12 V
Printed In U.S.A. 7175752
685 of 1311
CAB
DISPLAY
T13
BUZZER (+)
1940 RNG/WHT
SHEET 3
T2
BUZZER (-)
C500
LEFT PANEL (BLACK) C408 4 RH KEY SWITCH
9360/PUR OR 8130/TAN 9360/PUR OR 8130/TAN 2
J1A 24 START
9320/PUR OR 7040/WHT C479 10 9350/PUR OR 3040/LBL 9350/PUR OR 3040/LBL 4
BUZZER J1B 22 RUN/ENTER SW
2920 BLK C479 2 C408 40

SHEET 4 GROUND 1950 RNG/WHT 5
SHEET 3 Switched Power
1440 RED/WHT C479 1 1420 RED/WHT 1
SHEET 3 Dealer
Battery (+) Copy -- Not for Resale SHEET 3
2960 BLK 3
Battery (+)
1960 RNG/WHT 1620 RNG/WHT C479 5 SHEET 4 GROUND

SHEET 3 SHEET 3 Switched Power 6
SW9 6450 PNK C479 11
SHEET 13 Left Blinker Input
TRAVEL CONTROL C479 8
SWITCH (OPTIONAL) 6550 PNK
SHEET 13 Right Blinker Input
5 6 4500/LGN OR 3600/LBL C479 9

SHEET 9 Park Break Input
4 C479 7
2700 BLK 2 3 4730 LGN
SHEET 4 Travel Control Input RH DLX PANEL
1
1590 RNG/WHT C503 5

C480 SHEET 3 Switched Power
LEFT PANEL (GRAY) C503 1
1240 RED/WHT
4750 LGN 12 SHEET 3 Battery (+)
SHEET 9 Reserved Output 5 C503 3
9310/PUR OR 3610/LBL 2 2250 BLK
SHEET 9 Park Break Output SHEET 4 GROUND
PTOL
C499 (Press To Operate Loader)
C408 1
9380/PUR OR 3030/LBL 9380/PUR OR 3030/LBL 2
J1A 20 PTOL OUTPUT
J1A 19
9370/PUR OR 2380/BRN
C408 37
9370/PUR OR 2380/BRN 4
PTOL LED WIRING SCHEMATIC
1930 RNG/WHT 1
SHEET 3
SHEET 4
2940 BLK 3
SWITCH POWER
GROUND
(STANDARD MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Printed In U.S.A. Sheet 8 of 13
7175752
686 of 1311
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550 LGN C408 5
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1 4275 LGN C408 3
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060 BLK 5 6 4235 LGN C408 2
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 4
C212
2795 BLK 1
+ POWER SOCKET
1375 RED/WHT 2
-
C209
2790 BLK C408 24 2790 BLK 2010 BLK B
C408 23 SHEET 4
1370 RED/WHT 1370 RED/WHT 1390 RED/WHT A DOME LIGHT
SHEET 3
4760 LGN C
*
C676
1885 RNG/WHT 1
2885 BLK 2
C129 C279
1210 RED/WHT A
SHEET 3
1580 RNG/WHT C408 16 1580 RNG/WHT * 1865 RNG/WHT B LEFT SPEAKER
1
2
+ 7820 WHT
7830 WHT
3
4 RADIO CONN
2820 BLK C -
ACCESSORY
CONN C278
2 - 7810 WHT 6
RIGHT SPEAKER 1 7800 WHT 5
+
2730 BLK C408 33 2730 BLK
SHEET 4
Dealer Copy -- Not for Resale C277
1510 RNG/WHT 4
2210 BLK 5 AIR RIDE
SEAT SOLENOID
C482 SEATBAR
SENSOR C667 C250 SENSOR SHOWN
2370/BRN OR 3910 LBL C408 45 2370/BRN OR 3910 LBL A GND
SHEET 4 4750 LGN 4740 LGN 4 4740 LGN 1 WITH DOOR OPEN
SHEET 8 DOOR SENSOR
1400 RED/WHT 5 1400 RED/WHT 2 C251
3920/LBL OR 3370/LBL C408 46 3920/LBL OR 3370/LBL B SIG SHEET 3
J1B 11 1860 RNG/WHT D SW PWR
6 7330 WHT C PARK WIPER
3930 LBL 3900/LBL OR 5370/YEL 3900/LBL OR 5370/YEL C PWR
J1B 24 1570 RNG/WHT 7300 WHT A LOW MOTOR
3500 LBL
+5V SHEET 6 C408 44 B GND
1850 RNG/WHT 1850 RNG/WHT 1 1850 RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310 WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN OR 3600/LBL 3 2 FRONT WIPER
SHEET 8 1 2840 BLK 2 2840 BLK SWITCH C252
9310/PUR OR 3610/LBL 4 5
SHEET 8 7310 WHT L
1775 RNG/WHT 6
SHEET 3 WASHER
2930 BLK
SHEET 4 2845 BLK X MOTOR
WIRING SCHEMATIC
(STANDARD MACHINE)
7165991Standard Cab Harness S650 (S/N A3NV1100 1 - A3NV13098)
7176098 Deluxe Cab Harness (S/N A3NW11001 - A3NW11248)
Sheet 9 of 13 Printable Version Click Here
(PRINTEDNOVEMBER 2010)
Printed
687 of 1311 In U.S.A. * SPLICE DOES NOT EXIST IN 7165991 7175752
MANUAL
CONTROLS
C409
K
G RIGHT HANDLE
1590 RNG/WHT A
4940 LGN H
J2A 30
4930 LGN J SKI CTRL
J2A 31
4920 LGN E DETENT FLOW
J2B 21
4910 LGN F
J2A 13 TWO SPD
4310 LGN C -
J2B 17
4320 LGN D
J2B 18 PWM
4300 LGN B +
J2B 23
C410
K
D LEFT HANDLE
4840 LGN C
J2A 28
4830 LGN B SKI CTRL
Dealer J2A 22
4820 LGN G
J2A 12
4810 LGN F SIDE SHIFT
J2A 11
1570 RNG/WHT 1710 RNG/WHT A
SHEET 3
1560 RNG/WHT J
J2B 22
H
E
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A C103 C T19 1
7100 WHT 7100 WHT B
+
BACKUP ALARM
2650 BLK 7001923 A HORN
SHEET 4 -
T20 1
C421 Printable Version Click Here

2370 BLK 3
J1A 10
J1B 7
4370 LGN 1
2
TILT SPOOL LOCK SOLENOID WIRING SCHEMATIC
C422 (STANDARD MACHINE)
2380 BLK 3
J1A 2
J1B 5
4380 LGN 1 LIFT SPOOL LOCK SOLENOID S650 (S/N A3NV11001 - A3NV13098)
2
(S/N A3NW11001 - A3NW11248)
Sheet 10 of 13
688 of 1311
LIGHTS
C434-1
2735 BLK B LEFT FRONT
6100 PNK A WORK LIGHT
37.00 Watts
C434-2
2765 BLK C408 28 2765 BLK 2750 BLK B
SHEET 4 LEFT FRONT
50.00 Watts
C435-1
6000 PNK C408 25 6000 PNK 6120 PNK A RIGHT FRONT
2760 BLK B WORK LIGHT
37.00 Watts
C435-2
6130 PNK A
RIGHT FRONT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610 BLK 2
1330 RED/WHT 30 Dealer Copy -- Not forC103
Resale
A 6310 PNK RIGHT REAR
SHEET 3 87 6340 PNK 6310 PNK 6320 PNK 1 TAIL LIGHT
2000 BLK 85 86 C602

SHEET 4
2045 BLK 6330 PNK 1 LEFT REAR
6320 PNK 2640 BLK 2 TAIL LIGHT
J1A 5 SHEET 4
6330 PNK
J1A 31
2620 BLK T16 1

SHEET 4 RIGHT REAR
6210 PNK WORK LIGHT
REAR
LIGHT T15 1
1320 RED/WHT 30 C103 H
SHEET 3 6200 PNK 6200 PNK T17 1
87
2630 BLK LEFT REAR
85 86 SHEET 4 WORK LIGHT
2045 BLK T18 1
2035 BLK
SHEET 7
6210 PNK
J1A 17
6230 PNK
J1A 28
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Printed In U.S.A. Sheet 11 of 13 Printable Version Click Here
7175752
689 of 1311
HVAC
C630
7021 WHT 7020 WHT C408 34 7020 WHT B
J1A 11
7023 WHT 2570 BLK C
3320 LBL A
THERMOSTAT
C350
B C483
7024 WHT A EVAPORATOR 2560 BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980 RNG/WHT A DBL
C486 7220 WHT B WHT (TEMP CONTROL
C355 A SWITCH)
7024 WHT 7025 WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290 BLK 2280 BLK D SIG
SHEET 13
D4 2130 BLK C GND HEATER
1900 RNG/WHT 1910 RNG/WHT A 12V VALVE
SW10 B
BLOWER E
Dealer Copy -- Not for Resale SWITCH F
HVAC
1140 RED/WHT 30 OFF
SHEET 3 87 1500 RNG/WHT C408 21 1500 RNG/WHT 5 2
1
2030 BLK 85 86 4
SHEET 3 6 C611
2005 BLK
SHEET 6 3 1970 RNG/WHT A 14.00 Amps High
1790 RNG/WHT
SHEET 3 1520 RNG/WHT B 7.50 Amps Med BLOWER
1815 RNG/WHT
SHEET 6 7320 WHT C 5.00 Amps Low MOTOR
8020 TAN
J1A 21 2580 BLK D
2745 BLK 2745 BLK
SHEET 4
C408 22
7040 WHT
SW11
AC SWITCH
1 C
2100 BLK Printable Version Click Here
3
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 12 of 13
Printed In U.S.A. (PRINTEDNOVEMBER 2010)
7175752
690 of 1311
OPTIONS
SW5
POWER
BOBTACH
SWITCH
C411 1410 RED/WHT
C408 26
1410 RED/WHT 1380 RED/WHT 2 1 7000/WHT OR 4480/LGN C408 97000/WHT OR 4480/LGN
C408 15 SHEET 3
B 6010 PNK 6010 PNK 1430 RED/WHT 1200 RED/WHT 3 C408 10
C 6550 PNK 5 4 7010/WHT OR 4470/LGN 7010/WHT OR 4470/LGN
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515 PNK 6500 PNK 6500 PNK 6530 PNK FLASHER CONN SW2
5 PIN E 6540 PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415 PNK 6400 PNK 6400 PNK 6430 PNK 6570 PNK
2725 BLK C607
6450 PNK 6 C355 E
SHEET 8 5 A 7010/WHT OR 4470/LGN
SW3 1 4
C103 E HAZARD SWITCH 2 C670 STROBE 1 2 B 2770 BLK OR 2470/BLK 2751/BLK OR 2770/BLK
6410 PNK (PINS 3 & 6 3 BEACON
4 6700 PNK E 3 2751/BLK OR 2770/BLK
6510 PNK INTERNALLY 5 SHEET 12 2290 BLK SHEET 4
2850 BLK 2420 BLK D C355 B
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK OR 2480/BLK
F
2780 BLK C408 30 2780 BLK A 7000 WHT C355 F
SHEET 4 B
6440 PNK
6540 PNK RIGHT PWR BOB OPEN
Dealer Copy -- Not for ResaleBLINKER
1550 RNG/WHT C408 13

1550 RNG/WHT
SHEET 3
SW6
3 2 BUCKET
7022 WHT 1 POSITION
C126
SHEET 4 SHEET 4 4 SWITCH
C412 2785 BLK B 2830 BLK 5
C408 38 C423
LEFT HANDLE B 7210 WHT 7210 WHT A 6 OPTIONAL
C408 35 D3 A
2 PIN A 1460 RED/WHT 7022 WHT 7030 WHT BUCKET
SHEET 3
POSITION
2741 BLK 2740 BLK B SOLENOID
SHEET 4 9.8 OHM
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 13 of 13
Printed In U.S.A. (PRINTEDNOVEMBER 2010)
7175752
691 of 1311
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C423 BUCKET POSITION 2 13 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C425 BRAKE SOLENOID 3 7 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C434-1 LEFT WORKLIGHT 1 2 11
C106 ENGINE SPEED SENSOR 2 6 C434-2 LEFT WORKLIGHT 2 2 11 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C107 ENGINE OIL PRESSURE 3 6 C435-1 RIGHT WORKLIGHT 1 2 11 J1B GATEWAY CONTOLLER 26 3-10,13
C108 HYD TEMPERATURE SENDER 2 7 C435-2 RIGHT WORKLIGHT 2 2 11 J2A AUX CONTROLLER 34 7,10,13
C109 S/R ADAPTER HARNESS 2 6 C437 TWO SPEED MAKEUP 2 13 J2B AUX CONTROLLER 26 3,4,5,7,10,13
C110 ALTERNATOR 2 6 C441 TWO SPEED 2 13
C112 HYD OIL FILTER SWITCH 2 7 C446 HYDRAULIC FAN 2 7 SW1 BRAKE SWITCH 6 8
C126 HORN 2 13 C449 LEFT JOYSTICK (CAB HARN) 4 5 SW2 BEACON SWITCH 6 13
C129 CAB ACCESSORY 3 9 C450 RIGHT JOYSTICK (CAB HARN) 4 5 SW3 HAZARD SWITCH 6 13
C209 DOME LIGHT 3 9 C479 LEFT PANEL(BLACK) 12 5,8 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C212 POWER SOCKET 2 9 C480 LEFT PANEL(GRAY) 12 8 SW5 POWER BOBTACH SWITCH 6 13
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 SW6 BUCKET POSITION SWITCH 6 13
C277 AIR RIDE SEAT 6 13 C483 TEMP CONTROL SWITCH 3 12 SW9 TRAVEL CONTROL SWITCH 6 8
C278 RIGHT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW10 BLOWER SWITCH 5 12
C279 LEFT SPEAKER 2 13 C489 MFR ACCESSORY 2 3,4 SW11 AC SWITCH 3 12
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8 T1 BATT GROUND 1 4
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8 T2 BUZZER GROUND 1 8
C404 BU ALARM-MFR HARN 2 3,10 C602 LEFT REAR TAIL LIGHT 2 11 T3 FLASHER 2 13
C405 AIR FILTER SWITCH 2 6 C603 RIGHT REAR TAIL LIGHT 2 11 T6 BATT GROUND 1 4
C406 FUEL SENDER 2 6 C606 POWER BOBTACH OPEN 2 13 T8 BATT GROUND 1 4
C408 CAB - MFR HARN CONNECTOR 48 3-5,8,9,11-13 C607 POWER BOBTACH CLOSE 2 13 T13 BUZZER POWER 1 8
C409 RIGHT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 T14 PRE HEATER 1 6
C410 LEFT HANDLE 10 10 C611 BLOWER MOTOR 4 12 T15 RIGHT REAR WORK LIGHT(+) 1 11
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C630 THERMOSTAT 3 12 T16 RIGHT REAR WORK LIGHT(-) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C635 HEATER VALVE 6 12 T17 LEFT REAR WORK LIGHT (+) 1 11
C415 HIGH FLOW SOLENOID 2 13 C667 DOOR 6 9 T18 LEFT REAR WORK LIGHT (-) 1 11
C418 FRONT ROD (MALE) 2 7 C670 EXTERIOR BEACON Dealer
6 Copy --
13 Not for Resale
T19 BACKUP ALARM 1 10
C419 FRONT BASE (FEMALE) 2 7 C676 RADIO 6 13 T20 BACKUP ALARM (GND) 1 10
C420 HYD LOCK 2 7
C421 TILT SPOOL LOCK 3 10
C422 TILT SPOOL LCOK 3 10

BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 Printable Version Click Here
BATTERY GROUND
CONTROLLER GROUND/RETURN
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
ENGINE
HYDRAULICS
PAGE 6
PAGE 7
WIRING SCHEMATIC
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY
CAB
PAGE 8
PAGE 9
(STANDARD MACHINE)
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
S650 (S/N A3NV13099 - A3NV18204)
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
(S/N A3NW11249 - A3NW12733)
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
Sheet 1 of 13
(PRINTED APRIL 2014)
692 of 1311
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 B-5 REAR AUX (F)
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7 REAR AUX (M)
A-9 B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 A-10 REAR AUX (M) RETURN B-10
A-12 B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 B-14
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 B-20
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 B-21 RH TRIGGER
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER (8 VOLT)
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27
A-29 A-29
A-32 HYD OIL TEMP (8 VOLT)
Dealer
A-32
A-33 A-33
A-34 HYD OIL FILTER SW1 A-34
HARNESS PART NUMBER

S630, S650, T630, T650
7199263
MAINFRAME
A770
7196824
MAINFRAME
S750, S770, T750, T770
7196823
MAINFRAME
DLX CAB 7196753
STD CAB 7195991
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
TAILGATE DOM 7175271
TRK BRAKE ADP 7165061
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 2 of 13
693 of 1311
1240 RED/WHT WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
SHEET 8 GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER
C503 RH DLX PANEL
C408 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
1400 RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB-MFR HARN SHEET 9
C667 DOOR HARNESS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
1450 RED/WHT 17 1450 RED/WHT 1420 RED/WHT BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
SHEET 8
C500 RH KEY SWITCH CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
FC1 FUSE CENTER 1440 RED/WHT MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
2 SHEET 8
FUSE 1 25 A 1110 RED/WHT J1B HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C479 LH PANEL
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
+12V 1025 RED
FUSE 2 25 A
1160 RED/WHT 1150 RED/WHT 3
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
100.0 Amps FUSE 3 OPEN COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATT_CABLE
LEGEND
SCHEMATIC INDEX
FUSE 4 OPEN PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
POWER PAGE 3
GROUND PAGE 4
1010 RED
SHEET 6 CAN BUS PAGE 5
STARTER FC2 FUSE CENTER ENGINE PAGE 6
CONNECTOR
FUSE 1 25 A HYDRAULICS PAGE 7
1190 RED 1165 RED/WHT CAB DISPLAY PAGE 8
SHEET 5
C426 REMOTE RUN, ACD CAB PAGE 9
FUSE 2 25 A MANUAL CONTROLS PAGE 10
1040 RED 1490 RED/WHT 1410 RED/WHT WIRE BREAK
SHEET 13
(TWO WIRE BREAKS LIGHTS PAGE 11
C408 CAB-MFR CONN (OPTIONS)
FUSE 3 OPEN JOIN ONE WIRE) HVAC PAGE 12
1460 RED/WHT
SHEET 13 SHEET # OPTIONS PAGE 13
C412 LH HANDLE HORN
FUSE 4 15 A ACS PAGE 14
SHEET 9 SJC PAGE 15
C408 CAB-MFR CONN (ACCESSORIES)
FRC1 FUSE RELAY CENTER
1050 RED
FUSE 5 30 A
1350 RED/WHT
SHEET 6
SHEET 6 1060 RED FRC1 FUEL SHUTOFF RELAY
FUSE 6 30 A
FRC1 PRE HEATER RELAY 1310 RED 1360 RED/WHT
SHEET 7
1030 RED FRC1 TRACTION LOCK RELAY
SHEET 6
FUSE 9 15 A 1320 RED/WHT
FRC1 STARTER RELAY
SHEET 11
FRC1 REAR LIGH RELAY
1340 RED Dealer
SHEET 11
FRC1 FRONT LIGHT RELAY
C404
FUSE 11 25 A BU ALARM-MFR HARN
1620 RNG/WHT
1300 RED 1140 RED/WHT 1720 RNG/WHT B SHEET 8
SHEET 12 (SEE ADDITIONAL C479 LH PANEL
FUSE1 25 A FRC1 HVAC RELAY OPTIONS SHEET)
SHEET 8
A T13 LH PANEL BUZZER
1760 RNG/WHT FUSE 2 25 A 1850 RNG/WHT 1780 RNG/WHT C489
SHEET 9 MFR ACCESSORY 1930 RNG/WHT
C408 CAB-MFR CONN (FR WIPER) SHEET 8
FUSE 3 15 A C499 RH PANEL PTOL
1550 RNG/WHT C408
SHEET 13 1775 RNG/WHT
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN SHEET 8
SW1 BRAKE SWITCH
FUSE4 5 A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
43
SHEET 8
1530 RNG/WHT SHEET 10 C503 RH DELUXE PANEL
C410 LEFT HANDLE
SHEET 10 SHEET 8
C409 RIGHT HANDLE J2B C500 RH PANEL KEY SWITCH
FUSE 7 25 A 1560 RNG/WHT 22
1795 RNG/WHT 1730 RNG/WHT AUX CTRLR
SHEET 9
C426 REMOTE RUN, ACD SW4 H/ISO SWITCH
FUSE 8 25 A
FRC1 1580 RNG/WHT
SWITCHED C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
POWER RELAY FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
SHEET 6
1050 RED 30 J1A C110 ALT EXCITATION
87 GWY CTRLR 1790 RNG/WHT
SHEET 12 WIRING SCHEMATIC
2055 BLK 85 86 3380 LBL 4 C408 FRC1 HVAC RELAY
SHEET 6
SHEET 12
2030 BLK
1920 RNG/WHT
CAB-MFR HARN
6 1840 RNG/WHT
(STANDARD MACHINE)
1920 RNG/WHT
SHEET 5
1830 RNG/WHT
C449 LH JOYSTICK S650 (S/N A3NV13099 - A3NV18204)
SHEET 5
C450 RH JOYSTICK
(S/N A3NW11249 - A3NW12733)
694 of 1311
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUND
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
ACS PAGE 14
SJC PAGE 15
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5
C450 RH JOYSTICK
2920 BLK C408
SHEET 8 CAB-MFR HARN
C479 LH PANEL
2940 BLK 2950 BLK 32 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
SHEET 8 J1B BATT GND
C500 RH PANEL KEY SWITCH GWY CTRLR 15 2500 BLK
2250 BLK
SHEET 8 2765 BLK
C503 RH DELUXE PANEL SHEET 11
16 2540 BLK C408 CAB-MFR CONN (FR LIGHTS) T8
J2B 15 2745 BLK BATT GND
2930 BLK AUX CTRLR 2550 BLK 2090 BLK SHEET 12
SHEET 8 C408 CAB-MFR CONN (HVAC)
SW1 BRAKE SWITCH 2790 BLK
2830 BLK 2900 BLK 42 2900 BLK SHEET 9
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES)
SW6 BKT POSITION SWITCH
2780 BLK
SHEET 8 2700 BLK SHEET 13
SW9 TRAVEL CONTROL SWITCH C408 CAB-MFR CONN (OPTIONS)
SHEET 13 2785 BLK Dealer Copy -- Not for Resale SHEET 9

2730 BLK
C126 HORN C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
SHEET 11 2105 BLK
2620 BLK
SHEET 11 T1
T16 RH REAR LIGHT
C103 BATT GND
2630 BLK C489
SHEET 11 TAILGATE HARN B 2720 BLK
T18 LH REAR LIGHT MFR ACCESSORY
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
T20 BU ALARM 2400 BLK 2390 BLK
SHEET 6
2640 BLK C101 FUEL SHUTOFF SOLENOID
SHEET 11 2200 BLK
C602 LH REAR LIGHT SHEET 7
2610 BLK C425 BRAKE
SHEET 11 2770 BLK
C603 RH REAR LIGHT SHEET 13
C355 FUEL HARN (PWR BOB/AC)
2455 BLK
2170 BRN SHEET 13
SHEET 6 C423 BKT POSITION SOLENOID
C104 ENGINE COOLANT SENSOR 2710 BLK 2300 BLK
2160 BRN SHEET 5
SHEET 6 C426 REMOTE RUN, ACD
C106 ENGINE SPEED SENSOR
2320 BRN
SHEET 7
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 9 Printable Version Click Here
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR
SHEET 7
2220 BRN
C108 HYD TEMP SENDER
2230 BRN 17
WIRING SCHEMATIC
SHEET 7 2190 BRN
C105 HYD CHG PRESSURE SENDER
(STANDARD MACHINE)
SHEET 6
2180 BRN S650 (S/N A3NV13099 - A3NV18204)
C355 FUEL HARN (FUEL SENDER)
SHEET 6
2140 BRN (S/N A3NW11249 - A3NW12733)
C107 ENG OIL PRESS SENDER
2150 BRN
Sheet 4 of 13
SHEET 6
C405 AIR FILTER SWITCH (PRINTED APRIL 2014)
695 of 1311
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 PARTIAL CONNECTOR
CAN BUS
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 7 CONNECTOR
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK
(TWO WIRE BREAKS
* DLX CAB HARN 7196753 ONLY
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13
JOIN ONE WIRE)
SHEET #
(NOT IN STD CAB HARN 7165991)
ACS PAGE 14
SJC PAGE 15
J1B C408
GWY CTRLR CAB-MFR HARN
8 9200 PUR 9270 PUR 9230 PUR 8 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR 4
CAN LO C479
9 9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 7 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426 9260 PUR 4

C503
Remote Run Tool, ACD Dealer Copy -- Not for Resale 9160 PUR/WHT 2 RIGHT DELUXE PANEL
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
21 3090 LBL D REMOTE RUN KEY 1830 RNG/WHT 1
C SHEET 3
SHEET 3
1730 RNG/WHT E SWITCHED POWER SHEET 4
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
1165 RED/WHT F (SJC/AWS ONLY)
SHEET 3 UNSWITCHED POWER 9660 PUR 4
2710 BLK G GROUND 9220 PUR 8
SHEET 4 J2B
9120 PUR/WHT 9 AUX CTRLR
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 5 of 13
696 of 1311
ENGINE
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
ACS PAGE 14
SJC PAGE 15
FRC1
STARTER RELAY C109
30 S/R ADAPTER STARTER
1030 RED A
SHEET 3 87 8200 TAN TAN S M
B SHEET 3
3560 LBL B TAN R
85 86 1015 RED
2005 BLK 8210 TAN
SHEET 12 C110
B S 1020 RED
ALTERNATOR G
L 1800 RNG/WHT
SHEET 3
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
RELAY C101
D5 8100 TAN B
1350 RED/WHT 30 8120 TAN PULL 0.33 OHM
SHEET 3 87 3410 LBL
2400 BLK 2800 BLK C GND
85 86 SHEET 4
2025 BLK 8110 TAN
SHEET 7 8800 TAN A HOLD
24.5 OHM
FRC1 T14
GLOW PLUG PRE HEATER
RELAY 8500 TAN
1060 RED 30 Dealer Copy -- Not for Resale
SHEET 3 87
2016 BLK 85 86
2055 BLK
SHEET 3
6 8510 TAN
14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
GWY CTRLR 25 3140 LBL C SIG ENGINE OIL PRESSURE
2140 BRN A GND SENDER (0.5-4.5V)
SHEET 4
C405
2150 BRN B GND
SHEET 4 AIR FILTER
16 3150 LBL A SIG Printable Version Click Here
SWITCH (NC)
C106
15 3160 LBL A
B
SIG
ENGINE SPEED SENSOR
WIRING SCHEMATIC
SHEET 4 2160 BRN GND
(163 OHM)
C104
(STANDARD MACHINE)
ENGINE COOLANT
18
SHEET 4 2170 BRN
3170 LBL
B
A
GND
SIG
SENSOR (500-3000 OHM)
(8 VOLT)
S650 (S/N A3NV13099 - A3NV18204)
4 8800 TAN
(S/N A3NW11249 - A3NW12733)
J1B C355
GWY CTRLR FUEL HARN
C406
Sheet 6 of 13
12 3180 LBL C 3180 LBL OR 3100, LBL A SIG
2180 BRN D 2180 BRN OR 3110, LBL B GND
FUEL SENDER (PRINTED APRIL 2014)
SHEET 4 (30 - 270 OHM)

697 of 1311
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
HYDRAULICS
GROUND PAGE 4
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CAB PAGE 9
MANUAL CONTROLS PAGE 10
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14 C425
SJC PAGE 15
FRC1 B C308
TRACTION LOCK BRAKE
4100 LGN 4200 LGN A 4200 LGN A SOLENOID
RELAY TRACK 2 SPEED
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
1360 RED/WHT 30 SHEET 4
SHEET 3 3430 LBL 12 V ADDITIONAL
87
2025 BLK WHEEL 2 SPD ADAPTER HARNESS 7159366 OPTIONS SHEET)
SHEET 6 85 86 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061
2035 BLK 4110 LGN
SHEET 11
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
C WHEEL SINGLE SPEED
8
TRACTION LOCK
13
C108
2220 BRN B HYDRAULIC
GND
SHEET 4 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 4
C446
18 2910 BRN 2 GND
HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 4
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A 18 2330 BRN 2 GND FRONT ROD
AUX CTRLR
4330 LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
WIRING SCHEMATIC
1 2340 BRN
C419
2 GND
(STANDARD MACHINE)
FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
19 13
J2B
Sheet 7 of 13
AUX CTRLR
698 of 1311
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PARTIAL CONNECTOR
CAB DISPLAY
POWER PAGE 3
GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
CAN BUS PAGE 5
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CONNECTOR
CAB DISPLAY PAGE 8
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB
MANUAL CONTROLS
PAGE 9
PAGE 10
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
WIRE BREAK
(TWO WIRE BREAKS
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS PAGE 14 SHEET #
SJC PAGE 15
T13
BUZZER (+)
C499
LEFT PANEL
Press To Operate Loader
7040 WHT OR 9320, PUR BUZZER
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 3 SWITCHED POWER
2940 BLK 3
7040 WHT OR 9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920 BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960 RNG/WHT 1440 RED/WHT 1 20 3030 LBL 1 3030 LBL OR 9380, PUR 2
SHEET 3 SHEET 3 UNSWITCHED POWER PTOL OUTPUT
*
SW9
TRAVEL CONTROL
SHEET 3
1620 RNG/WHT 5 SWITCHED POWER
J1A
19 2380 BRN 37 2380 BRN OR 9370, PUR 4
PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
4
SHEET 13 RIGHT BLINKER INPUT Dealer Copy -- Not for Resale RIGHT KEY SWITCH PANEL
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 4 8130 TAN OR 9360, PUR 2
SHEET 4 TRAVEL CONTROL INPUT START
1 9
3600 LBL OR 4500, LGN
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 40 4
3040 LBL OR 9350, PUR RUN/ENTER SWITCH
3610 LBL OR 9310, PUR 4 5 GWY CTRLR
SHEET 3 1775 RNG/WHT 6

2930 BLK 1950 RNG/WHT 5
SHEET 4 C480 SHEET 3 SWITCHED POWER
LEFT PANEL (GRAY) 1420 RED/WHT 1
SHEET 3 UNSWITCHED POWER
3620 LBL 12 2960 BLK 3
SHEET 9 DOOR SIGNAL SHEET 4 GROUND
11
10
9 C503
3610 LBL OR 9310, PUR 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
7 SHEET 3 SWITCHED POWER
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)

699 of 1311
PAGE 1,2 LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3 PARTIAL CONNECTOR
CAB
GROUND PAGE 4
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 CONNECTOR
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
ENGINE 8000 THROUGH 8999 TAN TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
(TWO WIRE BREAKS
JOIN ONE WIRE)
ACS PAGE 14 SHEET #
SJC PAGE 15
*
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
SHEET 9 2060 BLK 5 6
4
C408
CAB-MFR HARN
2
3
4235 LGN
4275 LGN
*C212
POWER
SOCKET
5 4550 LGN 2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
2790 BLK 24 2790 BLK 2790 BLK 2010 BLK

* C209
B GND
SHEET 4
1370 RED/WHT 23 1370 RED/WHT 1390 RED/WHT A +12V PWR DOME
SHEET 3
3640 LBL C DOOR SIG LIGHT
C129
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR
1580 RNG/WHT 16 1580 RNG/WHT B
SHEET 3
1865 RNG/WHT Dealer Copy -- Not for Resale
+12V SW PWR
2820 BLK C GND
1510 RNG/WHT
SHEET 13
1885 RNG/WHT SHEET 13
2210 BLK SHEET 13
2885 BLK SHEET 13
2060 BLK
SHEET 4
2730 BLK 33 2730 BLK
SHEET 9
*C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
3620 LBL 3630 LBL 4

SHEET 8 DOOR SIGNAL
1400 RED/WHT 5 DOOR UNSW PWR
SHEET 3
6
1850 RNG/WHT 27 1850 RNG/WHT 1850 RNG/WHT 1

SHEET 3 WIPER SWITCH, MOTOR SWITCHED POWER
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 45 2370 BRN OR 3910, LBL A GND WASHER SIGNAL
GWY CTRLR SHEET 4
11 3370 LBL 46 3370 LBL OR 3920, LBL B SIG * C252
L SIG
WASHER
+5V
24 5100 YEL 5370 YEL 44 5370 YEL OR 3900, LBL C +5V PWR 2845 BLK X GND MOTOR WIRING SCHEMATIC
SHEET 6 5140 YEL
(STANDARD MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
(PRINTEDAPRIL 2014)
700 of 1311 Printed In U.S.A. 7197683
BATT FEED, GENERAL RED RED PARTIAL CONNECTOR
1000 THROUGH 1499 POWER PAGE 3
MANUAL
CAB DISPLAY PAGE 8
CONTROLS
LIGHTS PAGE 11 WIRE BREAK
HVAC PAGE 12 (TWO WIRE BREAKS
OPTIONS PAGE 13
ACS PAGE 14 SHEET #
SJC PAGE 15
C409
RIGHT HANDLE
J2A
K
AUX CTRLR G
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C404 31 4930 LGN J SKI CTRL
C103
BU ALARM-MFR HARN 4920 LGN E
TAILGATE HARN DETENT FLOW
T19 TERMINAL (+) 13 4910 LGN F
(SEE ADDITIONAL A 7100 WHT C 7100 WHT TWO SPD
OPTIONS SHEET) 4310 LGN C
BACK UP
4320 LGN D PWM
2650 BLK ALARM
SHEET 4 4300 LGN B (8 VOLT)
T20 TERMINAL (-)

21 17 18 23
C410
J2B LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND D
GWY CTRLR 4670 LGN 1 SIG TILT SPOOL LOCK 28 4840 LGN C
2 7.8 OHM 12V 22 4830 LGN B SKI CTRL
12 4820 LGN G
C422 11 4810 LGN F SIDE SHIFT
2 2680 BRN 3 GND 1530 RNG/WHT A
LIFT SPOOL LOCK SHEET 3
4680 LGN 1 SIG J
7.8 OHM 12V
2 H
E
7 5
J1B
GWY CTRLR WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
701 of 1311
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 JOIN ONE WIRE)
ACS PAGE 14
SJC PAGE 15 C434-1
2735 BLK B GND LEFT FRONT
6100 PNK A SIG WORK LIGHT
C408
37.00 Watts
CAB-MFR HARN
C434-2
2765 BLK 28 2765 BLK 2750 BLK B GND LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000 PNK 25 6000 PNK 6120 PNK A SIG RIGHT FRONT
2760 BLK B GND WORK LIGHT
37.00 Watts
C435-2
6130 PNK A SIG RIGHT FRONT
50.00 Watts
FRC1
FRONT WORK C103
LIGHTS RELAY TAILGATE HARN C603
2610 BLK 2
SHEET 3
1330 RED/WHT 30
6340 PNK
Dealer Copy -- Not forA Resale
6310 PNK 6310 PNK
SHEET 4
6320 PNK 1
GND
RIGHT REAR
87 SIG
TAIL LIGHT
2105 BLK 85 86 C602
SHEET 4
2045 BLK 6330 PNK 1 SIG
2640 BLK 2 LEFT REAR
GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
6210 PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
RELAY
1320 RED/WHT 30 T17 TERMINAL (+)
SHEET 3 87 6200 PNK H 6200 PNK SIG LEFT REAR
2630 BLK GND WORK LIGHT
2045 BLK 85 86 SHEET 4
T18 TERMINAL (-)
2035 BLK
SHEET 7
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
702 of 1311
HVAC
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
(TWO WIRE BREAKS
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13
JOIN ONE WIRE)
SHEET #
ACS PAGE 14
SJC PAGE 15
2440 BLK *
C610
2 GND
#
DLX FUEL HARN 7184255 ONLY
HVAC DUCT
7440 WHT 1 SIG FAN (NOT IN STD FUEL HARN 7149219)
C483
2560 BLK * C BLK
7420 WHT A DBL POTENTIOMETER
7425 WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
B
E
F
FRC1 C408
*BLOWER
SW10
HVAC RELAY SWITCH

CAB-MFR HARN
30 Dealer Copy -- Not for Resale OFF
1140 RED/WHT
SHEET 3 87 1500 RNG/WHT 21 1500 RNG/WHT 5 2
1
2030 BLK 85 86 4
SHEET 3 6
SHEET 6
2005 BLK
1790 RNG/WHT 3 7530 WHT * C611
1 14.00 Amps High
SHEET 3 7410 WHT 7520 WHT 2 7.50 Amps Med BLOWER
SW11 7510 WHT 3 5.00 Amps Low MOTOR
21 3450 LBL
SHEET 4
2745 BLK 22 2745 BLK *
AC SWITCH 2580 BLK 4
J1A 7015 WHT 1 C 7400 WHT

GWY CTRLR 2100 BLK
3
11 7021 WHT 7020 WHT 34
* C630
3
THERMOSTAT
AC EVAPORATOR C350 2570 BLK 2

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT Printable Version Click Here
C355
#
FUEL HARN
A 7024 WHT 7025 WHT
C486
1 SIG
WIRING SCHEMATIC
2 MAGNET CLUTCH
GND
SHEET 13
2290 BLK 2280 BLK
(COMPRESSOR)
(STANDARD MACHINE)
D4
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 12 of 13
703 of 1311
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11 WIRE BREAK * DLX CAB HARN 7196753 ONLY
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
SJC PAGE 15
# C607
C355
FUEL HARN C408
#
POWER 10 CAB-MFR HARN
BOB-TACH
SIG
GND
1
2
4470 LGN OR 7010, WHT
2470 OR 2770, BLK 2770 OR 2751, BLK
E
B
4470 LGN
2770 BLK
4470 LGN
4480 LGN
(NOT IN STD FUEL HARN 7149219)
CLOSE SHEET 4
SHEET 12 2290 BLK
#
*POWER
SW5 2 1
3
C606 BOBTACH
POWER 5 4
SIG 2 2480 OR 2775, BLK SWITCH 6
BOB-TACH 1 4480 LGN OR 7000, WHT F 4480 LGN 9
GND
OPEN
1380 RED/WHT
1410 RED/WHT 26 1410 RED/WHT 1200 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 15
1430 RED/WHT
6010 PNK L
* FLASHER CONN
C 3500 LBL
SHEET 8 D1
LEFT HANDLE A 6515 PNK 6500 PNK 36 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(BLINKER / FLASHER) E 6540 PNK
5 PIN D2 SWITCH
D 6415 PNK 6400 PNK 29 6400 PNK 6430 PNK
3400 LBL 2725 BLK 6
C103
SHEET 8
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
2
(PINS 3 & 6 3
TAILGATE HARN
INTERNALLY 5 4 3
2850 BLK
INSULATED) 6
E 6410 PNK
EURO TAIL LIGHTS
(SEE ADDITIONAL D 6510 PNK Dealer Copy -- Not for Resale * C670
E
OPTIONS SHEET) 2780 BLK 30 D
2780 BLK 2420 BLK BEACON/FLASHER
SHEET 4
6440 PNK F EXTERIOR HARNESS
6540 PNK B (SEE ADDITIONAL
1550 RNG/WHT 13 1550 RNG/WHT C OPTIONS SHEET)
C423
SHEET 3
LEFT +
C279
1 7820 WHT
* C676
3
A
3
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 35 4455 LGN 1
4
2 *BUCKET
SW6 SPEAKER
-
2 7830 WHT 4
2830 BLK 5 POSITION C278 RADIO CONN
SOLENOID GND B 2450 BLK 2455 BLK SWITCH
9.8 OHM SHEET 4 SHEET 4 6 2 7810 WHT 6
RIGHT -
C126 SPEAKER 1 7800 WHT 5
SHEET 4 2785 BLK + 1885 RNG/WHT 1
C412 B GND SHEET 9 PWR
FRONT 2885 BLK 2
LEFT HANDLE B 7210 WHT 38 7210 WHT A SIG SHEET 9 GND
HORN
(HORN) A 1460 RED/WHT
2 PIN
SHEET 3 C277
* 1
2
3
C415 1510 RNG/WHT 4 PWR
J2A HIGH FLOW SHEET 9 AIR RIDE
26 2460 BRN B GND 2210 BLK 5 GND
AUX CTRLR SOLENOID SHEET 9 SEAT
4460 LGN A SIG 6
7.5 OHM 12 V
J2B
26
AUX CTRLR
C437 WIRING SCHEMATIC

27 2360 BRN 2 GND TWO SPEED
J1A
4360 LGN 1 SIG
MAKEUP SOLENOID
8.8 OHM 12V TRACK 2 SPEED
(STANDARD MACHINE)
ADAPTER (SEE
GWY CTRLR
26 2350 BRN
C441
2 GND TWO SPEED
ADDITIONAL
OPTIONS SHEET)
S650 (S/N A3NV13099 - A3NV18204)
SOLENOID
4350 LGN 1 SIG
5.1 OHM 12 V (S/N A3NW11249 - A3NW12733)
25 26
J1B
GWY CTRLR
704 of 1311
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C425 BRAKE SOLENOID 3 7 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C426 CAN (Remote Start Tool, ACD) 7 5 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C428 CAB-MFR HARN CONN (LT GRY) 14 3,4,9,13 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C106 ENGINE SPEED SENSOR 2 6 C434-2 LEFT WORKLIGHT 2 2 11
C107 ENGINE OIL PRESSURE 3 6 C435-1 RIGHT WORKLIGHT 1 2 11 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C108 HYD TEMPERATURE SENDER 2 7 C435-2 RIGHT WORKLIGHT 2 2 11 J1B GATEWAY CONTOLLER 26 3-10,13
C109 S/R ADAPTER HARNESS 2 6 C437 TWO SPEED MAKEUP 2 13 J2A AUX CONTROLLER 34 7,10,13
C110 ALTERNATOR 2 6 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13 J2B AUX CONTROLLER 26 3,4,5,7,10,13
C112 HYD OIL FILTER SWITCH 2 7 C441 TWO SPEED 2 13
C126 HORN 2 13 C446 HYDRAULIC FAN 2 7 SW1 BRAKE SWITCH 6 8
C129 CAB ACCESSORY 3 9 C449 LEFT JOYSTICK (CAB HARN) 4 5 SW2 BEACON SWITCH 6 13
C209 DOME LIGHT 3 9 C450 RIGHT JOYSTICK (CAB HARN) 4 5 SW3 HAZARD SWITCH 6 13
C212 POWER SOCKET 2 9 C479 LEFT PANEL(BLACK) 12 5,8 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C252 WASHER 2 9 C480 LEFT PANEL(GRAY) 12 8 SW5 POWER BOBTACH SWITCH 6 13
C277 AIR RIDE SEAT 6 13 C482 SEATBAR SENSOR 3 9 SW6 BUCKET POSITION SWITCH 6 13
C278 RIGHT SPEAKER 2 13 C483 TEMP CONTROL SWITCH 3 12 SW9 TRAVEL CONTROL SWITCH 6 8
C279 LEFT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW10 BLOWER SWITCH 5 12
C308 BRAKE SOLENOID 2 7 C489 MFR ACCESSORY 2 3,4 SW11 AC SWITCH 3 12
C350 AC EVAPORATOR SWITCH 2 12 C499 PTOL 4 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C500 RH KEY SWITCH 6 8 T1 BATT GROUND 1 4
C404 BU ALARM-MFR HARN 2 3,10 C503 RH DLX PANEL 6 5,8 T2 BUZZER GROUND 1 8
C405 AIR FILTER SWITCH 2 6 C602 LEFT REAR TAIL LIGHT 2 11 T3 FLASHER 2 13
C406 FUEL SENDER 2 6 C603 RIGHT REAR TAIL LIGHT 2 11 T6 BATT GROUND 1 4
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C606 POWER BOBTACH OPEN 2 13 T8 BATT GROUND 1 4
C409 RIGHT HANDLE 10 10 C607 POWER BOBTACH CLOSE 2 13 T13 BUZZER POWER 1 8
C410 LEFT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 T14 PRE HEATER 1 6
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C611 BLOWER MOTOR 4 12 T15 RIGHT REAR WORK LIGHT(+) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C630 THERMOSTAT 3 12 T16 RIGHT REAR WORK LIGHT(-) 1 11
C415 HIGH FLOW SOLENOID 2 13 C635 HEATER VALVE 6
Dealer 12
Copy -- Not for ResaleLEFT REAR WORK LIGHT (+)
T17 1 11
C418 FRONT ROD 2 7 C667 DOOR 6 9 T18 LEFT REAR WORK LIGHT (-) 1 11
C419 FRONT BASE 2 7 C670 EXTERIOR BEACON 6 13 T19 BACKUP ALARM 1 10
C420 HYD LOCK 2 7 C676 RADIO 6 13 T20 BACKUP ALARM (GND) 1 10
C421 TILT SPOOL LOCK 3 10
C423 BUCKET POSITION 2 13

BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 Printable Version Click Here
BATTERY GROUND
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
ENGINE
HYDRAULICS
PAGE 6
PAGE 7
WIRING SCHEMATIC
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY
CAB
PAGE 8
PAGE 9
(STANDARD MACHINE)
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
S650 (S/N A3NV18205 - A3NV21746)
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
(S/N A3NW12734 - A3NW13097)
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
Sheet 1 of 13
Printed In U.S.A. 7210766 (A)

705 of 1311
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER
A-27 SPARE A-27
A-29 A-29
A-31 LIGHT 1 RELAY FDBK Dealer
A-31
RH LEFT DOWN
A-32 HYD OIL TEMP (8 VOLT) A-32
A-33 A-33
HARNESS PART NUMBER

S630, S650, T630, T650
7210764
MAINFRAME
A770
7210768
MAINFRAME
S750, S770, T750, T770
7210768
MAINFRAME
DLX CAB 7210556
STD CAB 7210577
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
TAILGATE DOM 7217484 Printable Version Click Here
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
Sheet 2 of 13
706 of 1311
C408
POWER
C503 RH DLX PANEL
(BLACK) BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
CAB-MFR HARN CONN 1 SHEET 9
SHEET 8
2 SHEET 8
C479 LH PANEL
+12V 1025 RED
FUSE 2 25 A
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATT_CABLE
LEGEND
SCHEMATIC INDEX
OVERVIEW PAGE 1,2
POWER PAGE 3
GROUND PAGE 4
1010 RED
CONNECTOR
SHEET 5
SHEET 13
1460 RED/WHT
C412 LH HANDLE HORN
FUSE 4 15 A
SHEET 9
1050 RED
FUSE 5 30 A
1350 RED/WHT
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FRC1 STARTER RELAY
Dealer
SHEET 11Copy -- Not for Resale
1340 RED SHEET 11
C404
FUSE 11 25 A BU ALARM-MFR HARN 1620 RNG/WHT
SHEET 8
FUSE 3 15 A C428 C499 RH PANEL PTOL
1550 RNG/WHT
SHEET 13 (LT GRAY) 1775 RNG/WHT
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN CONN 2 SHEET 8
SW1 BRAKE SWITCH
2
SHEET 8
C410 LEFT HANDLE
SHEET 10 SHEET 8
SHEET 9
FRC1 FUSE 8 25 A
1580 RNG/WHT
SWITCHED SHEET 9 1960 RNG/WHT
POWER RELAY C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
+12V
PWR
FUSE 12 15 A
1800 RNG/WHT
SHEET 6
WIRING SCHEMATIC SW9 TRAVEL CONTROL SWITCH
85
87
86
GWY CTRLR
C428
1790 RNG/WHT
SHEET 12
FRC1 HVAC RELAY
(STANDARD MACHINE)
2055 BLK GND 3450 LBL 21
SHEET 4 (LT GRAY)
3380 LBL 4 CAB-MFR HARN CONN 2 S650 (S/N A3NV18205 - A3NV21746)
1920 RNG/WHT 6 1920 RNG/WHT 1840 RNG/WHT
SHEET 5
C449 LH JOYSTICK
(S/N A3NW12734 - A3NW13097)
1830 RNG/WHT
SHEET 5
C450 RH JOYSTICK
707 of 1311
LEGEND
GROUND
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5
C450 RH JOYSTICK C408
2920 BLK (BLACK)
SHEET 8 CAB-MFR HARN CONN 1
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
C503 RH DELUXE PANEL
16 2540 BLK
C428 2765 BLK
J2B 15 SHEET 11
2930 BLK
(LT GRAY)
AUX CTRLR 2550 BLK 2090 BLK
SHEET 8 CAB-MFR HARN CONN 2 C408 CAB-MFR CONN (FR LIGHTS) T8
SW1 BRAKE SWITCH 2745 BLK BATT GND
2830 BLK 2900 BLK 1 2900 BLK SHEET 12
SW6 BKT POSITION SWITCH 2790 BLK
2455 BLK SHEET 9
C423 BKT POSITION SOLENOID C408 CAB-MFR CONN (ACCESSORIES)
SW9 TRAVEL CONTROL SWITCH
2710 BLK 2300 BLK 2780 BLK
SHEET 13 2785 BLK SHEET 5 SHEET 13
C126 HORN C426 REMOTE RUN, ACD Dealer Copy -- Not for Resale C408 CAB-MFR CONN (OPTIONS)
2770 BLK 2730 BLK
2620 BLK SHEET 13 SHEET 9
SHEET 11 C355 FUEL HARN (PWR BOB/AC) C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
T16 RH REAR LIGHT T1
2630 BLK C103 BATT GND
SHEET 11 C489 B
TAILGATE HARN 2720 BLK
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
T20 BU ALARM 2390 BLK
2400 BLK
2640 BLK SHEET 6
SHEET 11 C101 FUEL SHUTOFF SOLENOID
C602 LH REAR LIGHT 2200 BLK
2610 BLK SHEET 7
SHEET 11 C425 BRAKE
C603 RH REAR LIGHT
2025 BLK
SHEET 6
FRC1 FUEL PULL RELAY
2035 BLK
2170 BRN SHEET 7
SHEET 6 FRC1 TRACTION LOCK RELAY
C104 ENGINE COOLANT SENSOR SHEET 11 2045 BLK
2160 BRN FRC1 REAR LIGHT RELAY
SHEET 6 2115 BLK 2105 BLK
C106 ENGINE SPEED SENSOR SHEET 11
2320 BRN 2016 BLK
SHEET 7 SHEET 6
C112 HYD OIL FILTER SWITCH FRC1 GLOW PLUG RELAY
2370 BRN J1B 2055 BLK
SHEET 9 SHEET 3
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR FRC1 SWITCHED PWR RELAY
2220 BRN 2230 BRN 17 SHEET 12
2030 BLK WIRING SCHEMATIC
SHEET 7 FRC1 HVAC RELAY
SHEET 7 2190 BRN

SHEET 6
FRC1 STARTER RELAY
2005 BLK
(STANDARD MACHINE)
2180 BRN
S650 (S/N A3NV18205 - A3NV21746)
SHEET 6
C355 FUEL HARN (FUEL SENDER) (S/N A3NW12734 - A3NW13097)
2140 BRN
SHEET 6
C107 ENG OIL PRESS SENDER Sheet 4 of 13
2150 BRN
SHEET 6 (PRINTED APRIL 2014)
C405 AIR FILTER SWITCH

708 of 1311
LEGEND
CAN BUS
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 (TWO WIRE BREAKS
JOIN ONE WIRE)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13 SHEET # (NOT IN STD CAB HARN 7210557)
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1
CAN LO C479
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR

C426 9260 PUR 4
Remote Run Tool, ACD C503
9160 PUR/WHT 2 RIGHT DELUXE PANEL
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
C SHEET 3
SHEET 3
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
9120 PUR/WHT 9
AUX CTRLR
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
709 of 1311
LEGEND
ENGINE
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
FRC1
+12V STARTER RELAY C109
1030 RED PWR
SHEET 3 87 8200 TAN A TAN S B
M SHEET 3
3560 LBL B TAN R
GND 85 86 8210 TAN 1015 RED
SHEET 4 2005 BLK
C110
B S 1020 RED
ALTERNATOR G
L 1800 RNG/WHT
SHEET 3
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
+12V RELAY C101
D5 8100 TAN B
1350 RED/WHT PWR 30 8120 TAN PULL 0.33 OHM
SHEET 3 87 3410 LBL
GND 85 86 SHEET 4
2025 BLK 8110 TAN
24.5 OHM
FRC1 T14
+12V RELAY 8500 TAN Dealer Copy -- Not for Resale
1060 RED PWR 30
SHEET 3 87
2016 BLK GND 85 86

SHEET 4
6 8510 TAN
14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
SHEET 4
2150 BRN B GND
SHEET 4 AIR FILTER
16 3150 LBL A SIG
SWITCH (NC) WIRING SCHEMATIC
C106
15 3160 LBL
2160 BRN
A
B
SIG
GND
ENGINE SPEED SENSOR (STANDARD MACHINE)
SHEET 4 (163 OHM)
C104
S650 (S/N A3NV18205 - A3NV21746)
B ENGINE COOLANT
18
SHEET 4 2170 BRN
3170 LBL A
GND
SIG
(8 VOLT)
(S/N A3NW12734 - A3NW13097)
4 8800 TAN
Sheet 6 of 13
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C A
Printed In U.S.A. 2180 BRN
3180 LBL
B
SIG
FUEL SENDER 7210766 (A)
D 2180 BRN GND (30 - 270 OHM)
SHEET 4
710 of 1311
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
GROUND PAGE 4
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 7
CAB PAGE 9
MANUAL CONTROLS PAGE 10 WIRE BREAK
LIGHTS PAGE 11 (TWO WIRE BREAKS
HVAC PAGE 12
OPTIONS PAGE 13 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT C425
FRC1 4100 LGN B C308
TRACTION LOCK BRAKE
4200 LGN A 4200 LGN A SOLENOID
+12V RELAY TRACK 2 SPEED
2200 BLK C 2200 BLK B 9.8 OHM
1360 RED/WHT PWR 30 SHEET 4
12 V
ADAPTER (SEE
SHEET 3 87 3430 LBL ADDITIONAL
WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS SHEET)
GND 85 86 TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
2035 BLK 4110 LGN
SHEET 4
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
8
TRACTION LOCK
13
C108 HYDRAULIC
TEMPERATURE
2220 BRN B GND
SHEET 4 SENDER
32 3220 LBL A SIG 500 - 3000 OHM
(8 VOLT)
C112
SHEET 4
C446
18 2910 BRN 2 GND HYDRAULIC
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR Printable Version Click Here

AUX CTRLR
3.3 OHM PWM
(STANDARD MACHINE)
1 2340 BRN
C419
2 GND FRONT BASE
S650 (S/N A3NV18205 - A3NV21746)
1
4340 LGN SIG SOLENOID (FEMALE)
3.3 OHM PWM (S/N A3NW12734 - A3NW13097)
Sheet 7 of 13
19 13
J2B
AUX CTRLR
711 of 1311
LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
CAB DISPLAY
POWER PAGE 3
GROUND PAGE 4
CAN BUS PAGE 5
ENGINE PAGE 6 CONNECTOR
HYDRAULICS PAGE 7
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
CAB DISPLAY PAGE 8
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
JOIN ONE WIRE) (NOT IN STD CAB HARN 7210557)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 SHEET #
T13
BUZZER (+)
1940 RNG/WHT
SHEET 3 C499
LEFT PANEL
7040 WHT BUZZER
(PTOL)
C479
T2
C408
2940 BLK 3
7040 WHT 10 SHEET 4 GROUND
BUZZER (BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 4 GROUND
1960 RNG/WHT 1440 RED/WHT 1 20 3030 LBL 1 3030 LBL 2
*
SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 12 2380 BRN 4
PTOL LED
SHEET 13 GWY CTRLR
5 6
SHEET 13
3500 LBL 8
RIGHT BLINKER INPUT
Dealer Copy -- Not for Resale C500
RIGHT KEY SWITCH PANEL
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 14 4
3040 LBL RUN/ENTER SWITCH
3610 LBL 4 5 GWY CTRLR

2930 BLK 1950 RNG/WHT 5
3620 LBL 12 2960 BLK 3
11
10
9 C503
3610 LBL 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
712 of 1311
LEGEND
PARTIAL CONNECTOR
CAB
GROUND PAGE 4
HYDRAULICS PAGE 7
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
HVAC
OPTIONS
PAGE 12
PAGE 13
JOIN ONE WIRE)
SHEET #
*
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
C438 SHEET 9
(DK GRAY) 4
CAB-MFR HARN CONN 3
4 4235 LGN
5 4275 LGN
6 4550 LGN
*C212
POWER
SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK
* C209
B GND
SHEET 3
C129
CAB ACCESSORY
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B Dealer Copy -- Not for Resale
+12V SW PWR
SHEET 3
2820 BLK C GND
1510 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
SHEET 4
2885 BLK SHEET 13
2060 BLK SHEET 9
C428
(LT GRAY) *C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS SHEET)
2790 BLK 11 2790 BLK 2790 BLK
SHEET 4
3620 LBL 3630 LBL 4
SHEET 8 DOOR SIGNAL
SHEET 3
6
WIPER MOTOR GROUND
J1B SENSOR 7310 WHT 3
2370 BRN 4 2370 BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 4
11 3370 LBL 5 3370 LBL B SIG * C252
L SIG
24 5100 YEL 5370 YEL 5370 YEL C

WASHER
MOTOR
WIRING SCHEMATIC
3 +5V PWR 2845 BLK X GND
+5V
SHEET 6 5140 YEL
(STANDARD MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
(PRINTEDMARCH 2011)
713 of 1311
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
C409
RIGHT HANDLE
J2A K
AUX CTRLR G
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET) 4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B
T20 TERMINAL (-)
21 17 18 23
C410
J2B LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND D
12 4820 LGN G
4680 LGN 1 SIG J
7.8 OHM 12V
2 H
E
7 5 WIRING SCHEMATIC
J1B
GWY CTRLR (STANDARD MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
714 of 1311
LEGEND
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 SHEET #
C434-1
C408
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK
C103
LIGHTS RELAY
+12V Dealer Copy -- NotTAILGATE
for Resale
HARN C603
2610 BLK 2 GND
1330 RED/WHT PWR 30 SHEET 4 RIGHT REAR
SHEET 3 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
2115 BLK GND 85 86 C602
SHEET 4
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
+12V RELAY
1320 RED/WHT PWR 30 T17 TERMINAL (+)
SHEET 3 87 6200 PNK H 6200 PNK 6220 PNK SIG LEFT REAR
2045 BLK GND 85 86 SHEET 4
SHEET 4 T18 TERMINAL (-)
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
715 of 1311
LEGEND
PARTIAL CONNECTOR
HVAC
HYDRAULICS PAGE 7
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11 (TWO WIRE BREAKS * DLX CAB HARN 7210556 ONLY
HVAC PAGE 12 JOIN ONE WIRE)
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
2440 BLK * C610

2 GND
#
HVAC DUCT
C483
2560 BLK * C BLK
WHT SWITCH)
C635
* D SIG
B
E
F
C438
FRC1
(DK GRAY)
CAB-MFR HARN CONN 3 Dealer Copy -- Not for Resale
*BLOWER
SW10
HVAC RELAY SWITCH

+12V
1140 RED/WHT PWR 30 OFF
1
2030 BLK GND 85 86 4
SHEET 4 6
1790 RNG/WHT 3 *
7530 WHT
C611
1 14.00 Amps High
SHEET 4
2745 BLK 8 2745 BLK *AC SWITCH 2580 BLK 4
2100 BLK 3
C 7400 WHT
7015 WHT 1
J1A
GWY CTRLR 11 7021 WHT 7020 WHT 9
* C630
3
THERMOSTAT

A 7024 WHT
C355
WIRING SCHEMATIC
FUEL HARN #
A 7024 WHT 7025 WHT
C486
1 SIG
(STANDARD MACHINE)
2 MAGNET CLUTCH
GND
SHEET 13
2290 BLK 2280 BLK
(COMPRESSOR)
S650 (S/N A3NV18205 - A3NV21746)
D4
(S/N A3NW12734 - A3NW13097)
716 of 1311
LEGEND
OVERVIEW PAGE 1,2
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 SHEET # (NOT IN STD CAB HARN 7210557)
C428
C355
# C607
FUEL HARN
(LT GRAY)
CAB-MFR HARN CONN 2
#
POWER BOB
SIG
GND
1
2
4470 LGN
2470 BLK 2770 BLK
E
B
4470 LGN
2770 BLK
8 4470 LGN
4480 LGN
CLOSE SHEET 4
SHEET 12 2290 BLK
#
*POWER
SW5 2 1
3
C606 BOBTACH
5 4
GND 2 2480 BLK SWITCH 6
POWER BOB 1 4480 LGN 4480 LGN
SIG F 7
OPEN
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
C
D2
LEFT HANDLE D 6415 PNK 6400 PNK 14 6400 PNK 6430 PNK
*BEACON
SW2
6570 PNK
(BLINKER / FLASHER) E
SHEET 8 3400 LBL
5 PIN SWITCH
A 1550 RNG/WHT 9
6515 PNK
SHEET 3
1550 RNG/WHT
* SW3
HAZARD SWITCH
2
1 2725 BLK 6
5
(PINS 3 & 6 3 4
INTERNALLY 5 4 6700 PNK 1 2
C103
TAILGATE HARN INSULATED) 6 2850 BLK
C438
3
E 6410 PNK (DK GRAY)
EURO TAIL LIGHTS
(SEE ADDITIONAL
CAB-MFR HARN CONN 3
SHEET 8
Dealer3500
CopyLBL -- Not for Resale
* C670E
OPTIONS SHEET) D 6500 PNK 3 D1 6530 PNK D
6510 PNK 6500 PNK 2420 BLK BEACON/FLASHER
C423 OPTIONS SHEET)
3 C
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6
A
2830 BLK 5 POSITION
9.8 OHM SHEET 4 SHEET 4 6
2780 BLK 1 2780 BLK
SHEET 4
C408
(BLACK) C279
* C676
RADIO CONN
C126
CAB-MFR HARN CONN 1 SHEET 4 LEFT + 1 7820 WHT 3
C412 2785 BLK B
LEFT HANDLE B 7210 WHT 13 7210 WHT A
GND
SIG
FRONT
HORN
SPEAKER
-
2 7830 WHT 4
* C2771
(HORN) A 1460 RED/WHT C278 2
SHEET 3 AIR RIDE
2 PIN 3
RIGHT - 2 7810 WHT 6 SEAT
C415 SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
J2A HIGH FLOW SHEET 9
26 2460 BRN B GND + 1 2210 BLK 5 GND
AUX CTRLR SOLENOID SHEET 9 1885 RNG/WHT SHEET 9
4460 LGN A SIG
2885 BLK 2 6
7.5 OHM 12 V SHEET 9
J2B
26
AUX CTRLR
WIRING SCHEMATIC
C437
TWO SPEED
27 2360 BRN
4360 LGN
2
1
GND
SIG MAKEUP SOLENOID (STANDARD MACHINE)
J1A
GWY CTRLR C441
ADAPTER (SEE
ADDITIONAL
S650 (S/N A3NV18205 - A3NV21746)
26 2350 BRN 2 GND TWO SPEED OPTIONS SHEET)
4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V
(S/N A3NW12734 - A3NW13097)
25 26 Sheet 13 of 13 Printable Version Click Here
J1B
GWY CTRLR (PRINTED APRIL 2014)
Printed In U.S.A.
7210766 (A)
717 of 1311
PINS PINS PINS
C110 ALTERNATOR 2 6 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13 J2B AUX CONTROLLER 26 3,4,5,7,10,13
C212 POWER SOCKET 2 9 C479 LEFT PANEL(BLACK) 12 5,8 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C252 WASHER 2 9 C480 LEFT PANEL(GRAY) 12 8 SW5 POWER BOBTACH SWITCH 6 13
C350 AC EVAPORATOR SWITCH 2 12 C499 PTOL 4 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C500 RH KEY SWITCH 6 8 T1 BATT GROUND 1 4
C404 BU ALARM-MFR HARN 2 3,10 C503 RH DLX PANEL 6 5,8 T2 BUZZER GROUND 1 8
C405 AIR FILTER SWITCH 2 6 C602 LEFT REAR TAIL LIGHT 2 11 T3 FLASHER 2 13
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C606 POWER BOBTACH OPEN 2 13 T8 BATT GROUND 1 4
C409 RIGHT HANDLE 10 10 C607 POWER BOBTACH CLOSE 2 13 T13 BUZZER POWER 1 8
C410 LEFT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 T14 PRE HEATER 1 6
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C611 BLOWER MOTOR 4 12 T15 RIGHT REAR WORK LIGHT(+) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C630 THERMOSTAT 3 12 T16 RIGHT REAR WORK LIGHT(-) 1 11
C415 HIGH FLOW SOLENOID 2 13 C635 HEATER VALVE 6 12 T17 LEFT REAR WORK LIGHT (+) 1 11
C418 FRONT ROD 2 7 C667 DOOR 6 9 T18 LEFT REAR WORK LIGHT (-) 1 11
C419 FRONT BASE 2 7 C670 EXTERIOR BEACON 6 13 T19 BACKUP ALARM 1 10
C420 HYD LOCK 2 7 C676 RADIO 6 13 T20 BACKUP ALARM (GND) 1 10
C421 TILT SPOOL LOCK 3 10 T36 DOMELIGHT (-) 9
C422 TILT SPOOL LCOK 3 10 T37 DOMELIGHT (+) 9
C423 BUCKET POSITION 2 13

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 WIRING SCHEMATIC
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 (STANDARD MACHINE)
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 S650 (S/N A3NV21747 - A3NV25155)
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 (S/N A3NW13098 - A3NW13766)
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 (S/N 1MLS11001 AND ABOVE)
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 Sheet 1 of 13 Printable Version Click Here
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT (PRINTED JANUARY 2017)
7210766 (C)
Printed In U.S.A.
718 of 1311
A-27 SPARE A-27
A-29 A-29
A-33 A-33

HARNESS PART NUMBER
MAINFRAME
EXMF 7210764
LF 7210768
WIRING SCHEMATIC
DLX CAB 7234737
STD CAB 7210557 (STANDARD MACHINE)
DLX FUEL 7184255
STD FUEL 7149219 S650 (S/N A3NV21747 - A3NV25155)
S/R 6733370
(S/N A3NW13098 - A3NW13766)
TRK BRAKE ADP
WHL 2 SPD ADP
7165061
7159366
(PRINTED JANUARY 2017)
7210766 (C)
719 of 1311
SHEET 8
POWER
C408 GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
C503 RH DLX PANEL
1400 RED/WHT
CAB-MFR HARN CONN 1 SHEET 9 BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
SHEET 8
2 SHEET 8
C479 LH PANEL
+12V 1025 RED
FUSE 2 25 A
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATT_CABLE
LEGEND
SCHEMATIC INDEX
OVERVIEW PAGE 1,2
POWER PAGE 3
GROUND PAGE 4
1010 RED
CONNECTOR
SHEET 5
SHEET 13
C408 CAB-MFR CONN (OPTIONS) (TWO WIRE BREAKS LIGHTS PAGE 11
1460 RED/WHT
C412 LH HANDLE HORN
FUSE 4 15 A
SHEET 9

1050 RED
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FUSE 9 15 A
FRC1 STARTER RELAY 1320 RED/WHT
SHEET 11
1340 RED
FUSE 10 20 A 1330 RED/WHT Dealer Copy -- Not for Resale
SHEET 11
C404
SHEET 8
FUSE 2 25 A 1780 RNG/WHT C489
1760 RNG/WHT 1850 RNG/WHT SHEET 9 1930 RNG/WHT
MFR ACCESSORY SHEET 8
C408 CAB-MFR CONN (FR WIPER) C499 RH PANEL PTOL
SW1 BRAKE SWITCH
2
SHEET 8
C410 LEFT HANDLE
SHEET 10 SHEET 8
SHEET 9
FRC1 FUSE 8 25 A
1580 RNG/WHT
FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
+12V 1765 RNG/WHT 1815 RNG/WHT 1800 RNG/WHT
PWR SHEET 6
1050 RED 30
87
J1A
GWY CTRLR 1790 RNG/WHT
C110 ALT EXCITATION
SHEET 12
WIRING SCHEMATIC
85 86 C428 FRC1 HVAC RELAY
2055 BLK GND
SHEET 4
3450 LBL
3380 LBL
21
4
(LT GRAY)
CAB-MFR HARN CONN 2
(STANDARD MACHINE)
SHEET 5
S650 (S/N A3NV21747 - A3NV25155)
C449 LH JOYSTICK
1830 RNG/WHT
SHEET 5 (S/N A3NW13098 - A3NW13766)
C450 RH JOYSTICK
Printed In U.S.A. (PRINTED JANUARY 2017)
7210766 (C)
720 of 1311
LEGEND
GROUND
CAN BUS PAGE 5
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL PAGE 10 WIRE BREAK
MANUAL CONTROLS
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
SHEET 5
2920 BLK (BLACK)
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428 2765 BLK
J2B 15 SHEET 11
(LT GRAY) 2550 BLK 2090 BLK
2930 BLK AUX CTRLR C408 CAB-MFR CONN (FR LIGHTS)
SHEET 8 CAB-MFR HARN CONN 2 T8
2830 BLK 2900 BLK 1 2900 BLK SHEET 12
2455 BLK SHEET 9
2700 BLK SHEET 13
SHEET 8 C423 BKT POSITION SOLENOID C408 CAB-MFR CONN (ACCESSORIES)
2710 BLK 2300 BLK 2780 BLK
C126 HORN C426 REMOTE RUN, ACD Dealer Copy -- Not for Resale C408 CAB-MFR CONN (OPTIONS)
2770 BLK 2730 BLK
SHEET 11 C489 B
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
SHEET 6 2400 BLK
2640 BLK
SHEET 11 C101 FUEL SHUTOFF SOLENOID
2610 BLK SHEET 7
SHEET 11 C425 BRAKE
C603 RH REAR LIGHT
2025 BLK
SHEET 6
2035 BLK
2170 BRN SHEET 7
C106 ENGINE SPEED SENSOR SHEET 11 Printable Version Click Here
SHEET 7 2320 BRN 2016 BLK
SHEET 6
SHEET 9
2370 BRN J1B
FRC1 GLOW PLUG RELAY
SHEET 3 2055 BLK
WIRING SCHEMATIC
C408 CAB-MFR CONN (SEATBAR SENSOR) GWY CTRLR FRC1 SWITCHED PWR RELAY
2220 BRN 2230 BRN 17 SHEET 12
2030 BLK (STANDARD MACHINE)
SHEET 7 FRC1 HVAC RELAY
2190 BRN
SHEET 6
FRC1 STARTER RELAY
2005 BLK S650 (S/N A3NV21747 - A3NV25155)
SHEET 7
2180 BRN
(S/N A3NW13098 - A3NW13766)
SHEET 6
C355 FUEL HARN (FUEL SENDER) (S/N 1MLS11001 AND ABOVE)
2140 BRN
SHEET 6
C107 ENG OIL PRESS SENDER Sheet 4 of 13
2150 BRN
SHEET 6
C405 AIR FILTER SWITCH (PRINTED JANUARY 2017)
Printed In U.S.A. 7210766 (C)
721 of 1311
LEGEND
CAN BUS
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
JOIN ONE WIRE)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
C408
J1B (BLACK)
CAN LO C479
CAN HI 9 9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 3 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT 3 LEFT PANEL (BLACK)
120 OHM 120 OHM
RESISTOR RESISTOR
C426 9260 PUR 4

Remote Run Tool, ACD C503
9160 PUR/WHT 2 RIGHT DELUXE PANEL
14 9500 PUR/WHT A
CAN HI Dealer Copy -- Not for Resale
20 9600 PUR B
CAN LO
C SHEET 3
SHEET 3
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
Printed In U.S.A.
7210766 (C)
722 of 1311
LEGEND
BATTERY GROUND
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
LIGHTS
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
6000 THROUGH 6999
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
PINK
BLK
BRN
LBL
LGN
YEL
PNK
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 10
PAGE 11
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
ENGINE
HVAC PAGE 12
OPTIONS PAGE 13
FRC1
1030 RED PWR
M SHEET 3
3560 LBL B TAN R
GND 85 86 8210 TAN 1015 RED
2005 BLK
SHEET 4 C110
B S 1020 RED
ALTERNATOR G
L 1800 RNG/WHT
SHEET 3
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
+12V RELAY C101
D5 8100 TAN B
1350 RED/WHT PWR
30 8120 TAN PULL 0.33 OHM
SHEET 3 87 3410 LBL
GND 85 86 SHEET 4
2025 BLK 8110 TAN
SHEET 4 8800 TAN A HOLD 24.5 OHM
FRC1 T14
RELAY 8500 TAN
+12V Dealer Copy -- Not for Resale
1060 RED PWR 30
SHEET 3 87
2016 BLK GND 85 86

SHEET 4
6 8510 TAN
14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
GWY CTRLR 25 3140 LBL C SIG ENGINE OIL PRESSURE Printable Version Click Here
SHEET 4
2150 BRN B GND
SHEET 4
16 3150 LBL A SIG
AIR FILTER
SWITCH (NC) (STANDARD MACHINE)
15 3160 LBL
C106
A SIG
S650 (S/N A3NV21747 - A3NV25155)
B ENGINE SPEED SENSOR
2160 BRN GND
SHEET 4 (163 OHM)
(S/N A3NW13098 - A3NW13766)
C104
SHEET 4 2170 BRN B GND ENGINE COOLANT
18 3170 LBL A SIG
(8 VOLT)
4 8800 TAN Sheet 6 of 13
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
7210766 (C)
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
SHEET 4
Printed In U.S.A.
723 of 1311
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
GROUND PAGE 4
HYDRAULICS PAGE 7
CAB PAGE 9
HVAC PAGE 12
TRACTION LOCK BRAKE
2200 BLK C 2200 BLK B 9.8 OHM
12 V
ADAPTER (SEE
2035 BLK GND 85 86 TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
4110 LGN
SHEET 4
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
8
TRACTION LOCK
13
C108 HYDRAULIC
TEMPERATURE
2220 BRN B GND
SHEET 4 SENDER
32 3220 LBL A SIG 500 - 3000 OHM
(8 VOLT)
C112
J1A
34 3320 LBL A SIG
HYDRAULIC OIL
GWY CTRLR SHEET 4
2320 BRN B GND Dealer Copy -- Not for Resale
FILTER SWITCH (NC)
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN Printable Version Click Here
WIRING SCHEMATIC
19 13 1 23 6
J1B +8V (STANDARD MACHINE)
GWY CTRLR
S650 (S/N A3NV21747 - A3NV25155)
C418
J2A
AUX CTRLR
18 2330 BRN 2 GND FRONT ROD (S/N A3NW13098 - A3NW13766)
C419
3.3 OHM PWM
1 2340 BRN
4340 LGN
2
1
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
Sheet 7 of 13
3.3 OHM PWM
7210766 (C)
19 13
Printed
724 of 1311 In U.S.A. J2B
AUX CTRLR
LEGEND
OVERVIEW PAGE 1,2
CAB DISPLAY
POWER PAGE 3
GROUND PAGE 4
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
T13
BUZZER (+)
C499
LEFT PANEL
7040 WHT BUZZER
(PTOL)
C479
T2
C408
2940 BLK 3
BUZZER (BLACK)
SHEET 4 GROUND
*
SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 12 2380 BRN 4
PTOL LED
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
4 SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 14 4

2930 BLK 1950 RNG/WHT 5
3630 LBL 12 2960 BLK 3
11
10
9 C503
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
7210766 (C)
725 of 1311
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RNG/WHT
BLK
BRN
LBL
LGN
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 5
PAGE 6
PAGE 7
PAGE 8
PAGE 9
CONNECTOR
CAB
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
HVAC
OPTIONS
PAGE 12
PAGE 13
JOIN ONE WIRE)
SHEET #
*
SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
2060 BLK 5 6
C438 SHEET 9
(DK GRAY) 4
CAB-MFR HARN CONN 3
4 4235 LGN
5 4275 LGN
6 4550 LGN
*C212
POWER
SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
SHEET 3
* T37
DOME LIGHT (+)
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
T38
SHEET 3
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B
+12V SW PWR * DOME LIGHT (-)
2820 BLK C GND

1510 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
SHEET 4
2885 BLK SHEET 13
2060 BLK SHEET 9
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS SHEET)
2790 BLK 11 2790 BLK 2790 BLK
SHEET 4
3630 LBL 4 DOOR SIGNAL
SHEET 8
SHEET 3
6
WIPER MOTOR GROUND
J1B
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
GWY CTRLR SHEET 4
11 3370 LBL 5 3370 LBL B SIG * C252

L SIG WIRING SCHEMATIC
WASHER
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR X MOTOR
+5V
SHEET 6 5140 YEL
2845 BLK GND
(STANDARD MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
7210766 (C)
726 of 1311
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
C409
RIGHT HANDLE
J2A
K
AUX CTRLR G
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET)
4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B
T20 TERMINAL (-)
21 17 18 23
C410
J2B LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND D
12 4820 LGN G
4680 LGN 1 SIG J
7.8 OHM 12V
2 H
E
WIRING SCHEMATIC
7 5
(STANDARD MACHINE)
J1B
GWY CTRLR
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
7210766 (C)
727 of 1311
LEGEND
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
C434-1
C408
(BLACK)
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK
C103
LIGHTS RELAY C603
TAILGATE HARN
+12V Dealer Copy -- Not for Resale SHEET 4
2610 BLK 2 GND
1330 RED/WHT PWR 30 RIGHT REAR
TAIL LIGHT
2115 BLK GND 85 86 C602
SHEET 4
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
+12V RELAY
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
Printed In U.S.A.
7210766 (C)
728 of 1311
HVAC
LEGEND
PARTIAL CONNECTOR
MONITORING
2000 THROUGH 2999
3000 THROUGH 3999
BROWN
LIGHT BLUE
BRN
LBL
HYDRAULICS PAGE 7
CONNECTOR
CAB DISPLAY PAGE 8
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10
WIRE BREAK
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
#
2440 BLK * C610
2 GND HVAC DUCT
7440 WHT 1 SIG FAN
C483
2560 BLK * C BLK
WHT SWITCH)
C635
* D SIG
B
E
F
C438
FRC1
(DK GRAY)
CAB-MFR HARN CONN 3
Dealer Copy -- Not for Resale *BLOWER
SW10
HVAC RELAY SWITCH

+12V
1
2030 BLK GND 85 86 4
SHEET 4 6 C611
1790 RNG/WHT 3 7530 WHT * 1 14.00 Amps High
SHEET 4
2100 BLK 3
C 7400 WHT
7015 WHT 1
J1A
* C630
3
THERMOSTAT
AC EVAPORATOR C350 2570 BLK 2 WIRING SCHEMATIC

A 7024 WHT
C355
(STANDARD MACHINE)
FUEL HARN #
A 7024 WHT 7025 WHT
C486
1 SIG
S650 (S/N A3NV21747 - A3NV25155)
2 MAGNET CLUTCH
SHEET 13
2290 BLK 2280 BLK
GND
(COMPRESSOR) (S/N A3NW13098 - A3NW13766)
D4
7210766 (C)
729 of 1311
LEGEND
OVERVIEW PAGE 1,2
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 SHEET # (NOT IN STD CAB HARN 7210557)
C428
C355 #
# C607
FUEL HARN
(LT GRAY)
CAB-MFR HARN CONN 2 DLX FUEL HARN 7184255 ONLY
POWER BOB
SIG
GND
1
2
4470 LGN
2470 BLK 2770 BLK
E
B
4470 LGN
2770 BLK
8 4470 LGN
4480 LGN
CLOSE SHEET 4
2290 BLK
SHEET 12
#
*POWER
SW5 2 1
3
C606 BOBTACH
5 4
POWER BOB 1 4480 LGN F 4480 LGN 7
SIG
OPEN
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
C
D2
*BEACON
SW2
6570 PNK
SHEET 8 3400 LBL
5 PIN SWITCH
A 1550 RNG/WHT 9
6515 PNK
SHEET 3
1550 RNG/WHT
* SW3
HAZARD SWITCH
2
1 2725 BLK 6
5
(PINS 3 & 6 3 4
C103 INTERNALLY 5 4 6700 PNK 1 2
INSULATED) 2850 BLK
TAILGATE HARN 6 3
C438
EURO TAIL LIGHTS
(SEE ADDITIONAL
CAB-MFR HARN CONN 3
SHEET 8
3500 LBL
Dealer Copy -- NotD1for Resale
* C670
E
OPTIONS SHEET) D 6500 PNK 3 6530 PNK D
C423 OPTIONS SHEET)
3 C
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6
A
2830 BLK 5 POSITION
2780 BLK 1 2780 BLK

SHEET 4
C408
(BLACK) C279
*C676
RADIO CONN
C126
4 LEFT + 1 7820 WHT 3
C412 BLK B GND C277
LEFT HANDLE B 7210 WHT 13 7210 WHT A SIG
FRONT
HORN
SPEAKER
-
2 7830 WHT 4
* 1
SHEET 3 AIR RIDE
2 PIN 3
26 2460 BRN B GND + 1 2210 BLK 5 GND
AUX CTRLR SOLENOID 1885 RNG/WHT SHEET 9
4460 LGN A SIG SHEET 9 6
7.5 OHM 12 V 2885 BLK 2
SHEET 9
J2B
26
AUX CTRLR
WIRING SCHEMATIC
C437
MAKEUP SOLENOID
(STANDARD MACHINE)
4360 LGN 1 SIG
8.8 OHM 12V
J1A
GWY CTRLR C441
TRACK 2 SPEED
ADAPTER (SEE S650 (S/N A3NV21747 - A3NV25155)
ADDITIONAL
26 2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
OPTIONS SHEET) (S/N A3NW13098 - A3NW13766)
5.1 OHM 12 V
25 26
J1B
GWY CTRLR
7210766 (C)
730 of 1311
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C423 BUCKET POSITION 2 13 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C425 BRAKE SOLENOID 3 7 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C428 CAB-MFR HARN CONN (LT GRY) 14 3,4,9,13
C107 ENGINE OIL PRESSURE 3 6 C434-2 LEFT WORKLIGHT 2 2 11 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C109 S/R ADAPTER HARNESS 2 6 C435-2 RIGHT WORKLIGHT 2 2 11 J2A AUX CONTROLLER 34 7,10,13
C110 ALTERNATOR 2 6 C437 TWO SPEED MAKEUP 2 13 J2B AUX CONTROLLER 26 3,4,5,7,10,13
C112 HYD OIL FILTER SWITCH 2 7 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13
C126 HORN 2 13 C441 TWO SPEED 2 13 SW1 BRAKE SWITCH 6 8
C129 CAB ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 SW2 BEACON SWITCH 6 13
C212 POWER SOCKET 2 9 C449 LEFT JOYSTICK (CAB HARN) 4 5 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C252 WASHER ADAPTER INTMD 2 9 C479 LEFT PANEL(BLACK) 12 5,8 SW5 POWER BOBTACH SWITCH 6 13
C253 WASHER PUMP 2 9 C480 LEFT PANEL(GRAY) 12 8 SW6 BUCKET POSITION SWITCH 6 13
C277 AIR RIDE SEAT 6 13 C482 SEATBAR SENSOR 3 9 SW9 TRAVEL CONTROL SWITCH 6 8
C278 RIGHT SPEAKER 2 13 C483 TEMP CONTROL SWITCH 3 12 SW10 BLOWER SWITCH 5 12
C279 LEFT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW11 AC SWITCH 3 12
C308 BRAKE SOLENOID 2 7 C489 MFR ACCESSORY 2 3,4
C350 AC EVAPORATOR SWITCH 2 12 C499 PTOL 4 8 T1 BATT GROUND 1 4
C355 DLX or STD FUEL HARNESS 6 6,12,13 C500 RH KEY SWITCH 6 8 T2 BUZZER GROUND 1 8
C404 BU ALARM-MFR HARN 2 3,10 C503 RH DLX PANEL 6 5,8 T3 FLASHER 2 13
C405 AIR FILTER SWITCH 2 6 C602 LEFT REAR TAIL LIGHT 2 11 T6 BATT GROUND 1 4
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C606 POWER BOBTACH Dealer
OPEN Copy 2-- Not 13
for Resale T13 BUZZER POWER 1 8
C409 RIGHT HANDLE 10 10 C607 POWER BOBTACH CLOSE 2 13 T14 PRE HEATER 1 6
C410 LEFT HANDLE 10 10 C610 HVAC DUCT FAN 2 12 T15 RIGHT REAR WORK LIGHT(+) 1 11
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C611 BLOWER MOTOR 4 12 T16 RIGHT REAR WORK LIGHT(-) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C630 THERMOSTAT 3 12 T17 LEFT REAR WORK LIGHT (+) 1 11
C415 HIGH FLOW SOLENOID 2 13 C635 HEATER VALVE 6 12 T18 LEFT REAR WORK LIGHT (-) 1 11
C418 FRONT ROD 2 7 C667 DOOR 6 9 T19 BACKUP ALARM 1 10
C419 FRONT BASE 2 7 C670 EXTERIOR BEACON 6 13 T20 BACKUP ALARM (GND) 1 10
C420 HYD LOCK 2 7 C676 RADIO 6 13 T37 DOMELIGHT (+) 1 9
C421 TILT SPOOL LOCK 3 10 T38 DOMELIGHT (-) 1 9
GROUP DESCRIPTION
BATT FEED, GENERAL
GROUP NUMBER RANGE
1000 THROUGH 1499
WIRE COLOR
RED
COLOR CODE
RED
OVERVIEW
POWER
PAGE 1,2
PAGE 3
PARTIAL CONNECTOR WIRING SCHEMATIC
GROUND
CAN BUS
PAGE 4
PAGE 5 (STANDARD MACHINE)
MONITORING
2000 THROUGH 2999
3000 THROUGH 3999
BROWN
LIGHT BLUE
BRN
LBL
HYDRAULICS
CAB DISPLAY
PAGE 7
PAGE 8
CONNECTOR S650 (S/N A3NV25156 - A3NV25639)
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10
(S/N A3NW13767 - A3NW13930)
LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS Printable Version Click Here
OPTIONS PAGE 13
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
SHEET #
Sheet 1 OF 13
Printed In U.S.A. 7254943 (0)
731 of 1311
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 B-4
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 B-5
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7
A-10 TILT SPOOL LOCK RETURN B-10 A-10 B-10
A-18 HYD FAN RETURN B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL
A-19 PTOL LED B-19 HYD FAN OUTPUT A-19 B-19 FRONT AUX (M)
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP Dealer Copy -- Not for Resale
A-25 B-25
A-26 TWO SPEED MAKE UP GROUND B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED GROUND A-27
A-28 LIGHT 2 RELAY FDBK A-28
A-29 A-29
A-33 A-33
HARNESS PART NUMBER

MAINFRAME
EXMF 7265252
LF 7210768 WIRING SCHEMATIC
EXMF 7265252
MAINFRAME
LF 7210768 (STANDARD MACHINE)
DLX CAB 7253409
STD CAB 7210557 S650 (S/N A3NV25156 - A3NV25639)
DLX FUEL 7266824
STD FUEL 7149219 (S/N A3NW13767 - A3NW13930)
S/R (STARTER) 6733370
WHL 2 SPD ADP 7159366 Sheet 2 OF 13
Printed In U.S.A. TRK 2 SPD 7214626
(1PC) TRK 2 SPD 7243409 (PRINTED JANUARY 2017)
7254943 (0)
732 of 1311
1240 RED/WHT
SHEET 8
POWER
C408 C503 RH DLX PANEL
(BLACK)
1400 RED/WHT
C667 DOOR HARNESS
SHEET 8
C500 RH KEY SWITCH
FC1 FUSE CENTER 1440 RED/WHT
2 SHEET 8
FUSE 1 25 A 1110 RED/WHT J1B C479 LH PANEL
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR
+12V 1025 RED

FUSE 2 25 A
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps FUSE 3 OPEN
BATT_CABLE
FUSE 4 OPEN
1010 RED
SHEET 6
STARTER FC2 FUSE CENTER
1190 RED SHEET 5
C426 REMOTE RUN, ACD
FUSE 2 25 A
SHEET 13
FUSE 3 OPEN
1460 RED/WHT
SHEET 13
C412 LH HANDLE HORN
FUSE 4 15 A
SHEET 9

1050 RED
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FRC1 STARTER RELAY
SHEET 11
1340 RED
SHEET 11
C404
1620 RNG/WHT
FUSE1 25 A FRC1 HVAC RELAY OPTIONS DWG)
SHEET 8
SW1 BRAKE SWITCH
2
SHEET 8
C410 LEFT HANDLE
SHEET 10 SHEET 8
SHEET 9
FRC1 FUSE 8 25 A
1580 RNG/WHT
FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
+12V 1765 RNG/WHT 1815 RNG/WHT 1800 RNG/WHT
PWR SHEET 6
SHEET 12
WIRING SCHEMATIC
85 86 C428 FRC1 HVAC RELAY
2055 BLK GND 3450 LBL 21
SHEET 4
3380 LBL 4
(LT GRAY)
CAB-MFR HARN CONN 2 (STANDARD MACHINE)
SHEET 5 S650 (S/N A3NV25156 - A3NV25639)
C449 LH JOYSTICK
1830 RNG/WHT
SHEET 5
C450 RH JOYSTICK
(S/N A3NW13767 - A3NW13930)
Sheet 3 OF 13
Printed In U.S.A.
7254943 (0)
733 of 1311
2080 BLK
SHEET 5
C449 LH JOYSTICK
2070 BLK
GROUND
SHEET 5
2920 BLK (BLACK)
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
16 2540 BLK
C428 2765 BLK
J2B 15 SHEET 11
(LT GRAY) 2550 BLK 2090 BLK
2930 BLK AUX CTRLR C408 CAB-MFR CONN (FR LIGHTS)
SHEET 8 CAB-MFR HARN CONN 2 T8
2830 BLK 2900 BLK 1 2900 BLK SHEET 12
2455 BLK SHEET 9
C423 BKT POSITION SOLENOID C408 CAB-MFR CONN (ACCESSORIES)
2710 BLK 2300 BLK 2780 BLK
C126 HORN C426 REMOTE RUN, ACD C408 CAB-MFR CONN (OPTIONS)
2770 BLK 2730 BLK
SHEET 11 C489 B
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
2400 BLK
2640 BLK SHEET 6
SHEET 11 Dealer Copy
C101 FUEL SHUTOFF SOLENOID -- Not for Resale
2610 BLK SHEET 7
SHEET 11 C425 BRAKE
C603 RH REAR LIGHT
2025 BLK
SHEET 6
2035 BLK
2170 BRN SHEET 7
C106 ENGINE SPEED SENSOR SHEET 11
SHEET 7
2320 BRN
SHEET 6 2016 BLK WIRING SCHEMATIC
C112 HYD OIL FILTER SWITCH FRC1 GLOW PLUG RELAY
SHEET 9
2370 BRN
C408 CAB-MFR CONN (SEATBAR SENSOR)
J1B
GWY CTRLR
SHEET 3
FRC1 SWITCHED PWR RELAY
2055 BLK (STANDARD MACHINE)
SHEET 7
2220 BRN 2230 BRN 17 SHEET 12
FRC1 HVAC RELAY
2030 BLK
S650 (S/N A3NV25156 - A3NV25639)
C108 HYD TEMP SENDER 2005 BLK
SHEET 7 2190 BRN
SHEET 6
FRC1 STARTER RELAY (S/N A3NW13767 - A3NW13930)
2180 BRN
SHEET 6
2140 BRN
Sheet 4 OF 13
SHEET 6
2150 BRN
SHEET 6
7254943 (0)
Printed In U.S.A.
734 of 1311
CAN BUS
J1B
C408
(BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
RESISTOR RESISTOR
C426 9260 PUR 4

C503
Remote Run Tool, ACD 9160 PUR/WHT 2 RIGHT DELUXE PANEL
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
C SHEET 3
SHEET 3
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
9120 PUR/WHT 9 AUXDealer
CTRLR Copy -- Not for Resale
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 5 OF 13
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FRC1
1030 RED PWR
M SHEET 3
3560 LBL B TAN R
GND 85 86 8210 TAN 1015 RED
2005 BLK
SHEET 4 C110
B S 1020 RED
ALTERNATOR G
L 1800 RNG/WHT SHEET 3
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
+12V RELAY C101
D5 8100 TAN B
1350 RED/WHT PWR 30 8120 TAN PULL 0.33 OHM
SHEET 3 87 3410 LBL
GND 85 86 SHEET 4
2025 BLK 8110 TAN
24.5 OHM
FRC1 T14
ENGINE
+12V RELAY 8500 TAN
1060 RED PWR 30
SHEET 3 87
2016 BLK GND 85 86

SHEET 4
6 8510 TAN
14 3420 LBL Dealer Copy -- Not for Resale
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
SHEET 4
C405
2150 BRN B GND
SHEET 4
16 3150 LBL A SIG
AIR FILTER
SWITCH (NC) WIRING SCHEMATIC
C106
15 3160 LBL A SIG
ENGINE SPEED SENSOR
(STANDARD MACHINE)
SHEET 4 2160 BRN B GND
(163 OHM)
S650 (S/N A3NV25156 - A3NV25639)
C104
18
SHEET 4 2170 BRN B
A
GND ENGINE COOLANT
(S/N A3NW13767 - A3NW13930)
3170 LBL SIG
(8 VOLT)
4 8800 TAN Printable Version Click Here
J1B
GWY CTRLR
C355
FUEL HARN
Sheet 6 OF 13
C406
12 3180 LBL C 3180 LBL A SIG (PRINTED JANUARY 2017)
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
SHEET 4 7254943 (0)
Printed In U.S.A.
736 of 1311
FRC1
TRACTION LOCK
HYDRAULICS
4100 LGN
C425
B C308
BRAKE
2200 BLK C 2200 BLK B 9.8 OHM
12 V
ADAPTER (SEE
WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS DWG)
2035 BLK 4110 LGN
SHEET 4
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
8
TRACTION LOCK
13
C108 HYDRAULIC
TEMPERATURE
2220 BRN B GND
SHEET 4 SENDER
32 3220 LBL A SIG 500 - 3000 OHM
(8 VOLT)
C112
J1A
34 3320 LBL A SIG HYDRAULIC OIL
SHEET 4
C446
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULICDealer
LOCK
4410 LGN A SIG
SOLENOID
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

AUX CTRLR
3.3 OHM PWM (STANDARD MACHINE)
1 2340 BRN
C419
2 GND FRONT BASE
S650 (S/N A3NV25156 - A3NV25639)
3.3 OHM PWM (S/N A3NW13767 - A3NW13930)
19 13
J2B
Sheet 7 OF 13
AUX CTRLR
7254943 (0)
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T13
BUZZER (+)
CAB DISPLAY
LEFT PANEL
* DLX CAB HARN 7253409 ONLY C499
7040 WHT
T2
BUZZER
C479 (NOT IN STD CAB HARN 7210557) (PTOL)

C408
2940 BLK 3
BUZZER (BLACK)
SHEET 4 GROUND
*SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 12 2380 BRN 4
PTOL LED
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 14 4

2930 BLK 1950 RNG/WHT 5
C480 SHEET 3 SWITCHED POWER
SHEET 4 LEFT PANEL (GRAY) 1420 RED/WHT 1
SHEET 9
3630 LBL 12
DOOR SIGNAL
Dealer Copy -- Not for Resale SHEET 4
2960 BLK 3
GROUND
11
10
9 C503
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 8 OF 13
Printed In U.S.A.
738 of 1311
SW4
*
HAND/FOOT
SHEET 3
1785 RNG/WHT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
2 1
3
CAB
C438
(DK GRAY)
4
CAB-MFR HARN CONN 3
4 4235 LGN
5 4275 LGN
6 4550 LGN
* C212
POWER
SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
SHEET 3
* T37
DOME LIGHT (+)
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
T38
SHEET 3
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B +12V SW PWR * DOME LIGHT (-)
2820 BLK C GND

1510 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
SHEET 4
2885 BLK SHEET 13
2060Dealer
BLK Copy --SHEET
Not for
9 Resale
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 11 2790 BLK 2790 BLK
SHEET 4
3630 LBL 4 DOOR SIGNAL
SHEET 8
SHEET 3
6
WIPER MOTOR GROUND
J1B 7310 WHT
GWY CTRLR SHEET 4
2370 BRN 4 2370 BRN A GND SENSOR 3
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG

WIRING SCHEMATIC
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR
+5V
SHEET 6 5140 YEL
(STANDARD MACHINE)
HARNESS WASHER PUMP
7253378 S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
* C252
A
C253
1
PWR
WASHER
7310 WHT
2845 BLK B 2845 BLK 2 GND

MOTOR
Sheet 9 OF 13
Printed In U.S.A.
7254943 (0)
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MANUAL CONTROLS J2A
AUX CTRLR
C409
RIGHT HANDLE
K
G
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET)
4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B
T20 TERMINAL (-)
21 17 18 23
C410
J2B LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND D
12 4820 LGN G
4680 LGN 1 SIG J
7.8 OHM 12V
2 H
E
7 5 WIRING SCHEMATIC
J1B
GWY CTRLR
(STANDARD MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 10 OF 13
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C434-1
C408
(BLACK)
C434-2
SHEET 4
50.00 Watts
LIGHTS 6000 PNK 8 6000 PNK 6120 PNK

2760 BLK
C435-1
A
B
SIG
GND
RIGHT FRONT
WORK LIGHT
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK
C103
LIGHTS RELAY C603
TAILGATE HARN
+12V
2610 BLK 2 GND
1330 RED/WHT PWR 30 SHEET 4 RIGHT REAR
TAIL LIGHT
2115 BLK GND 85 86 C602

SHEET 4
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
+12V RELAY
WIRING SCHEMATIC
(STANDARD MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Printed In U.S.A. Sheet 11 OF 13

7254943 (0)
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HVAC 2440 BLK
7440 WHT
* C610
C483
2
1
GND
SIG
HVAC DUCT
FAN
* DLX CAB HARN 7253409 ONLY 2560 BLK* C BLK

(TEMP CONTROL
(NOT IN STD CAB HARN 7210557) 7425 WHT B WHT SWITCH)
C635
# DLX FUEL HARN 7266824 ONLY * D SIG

(NOT IN STD FUEL HARN 7149219) B
E
F
C438
FRC1
(DK GRAY)
CAB-MFR HARN CONN 3
*BLOWER
SW10
HVAC RELAY SWITCH

+12V
1
2030 BLK GND 85 86 4
SHEET 4 6
1790 RNG/WHT 3 7530 WHT * C611
1 14.00 Amps High
SHEET 3 BLOWER
Dealer Copy -- Not for Resale 7410 WHT 7520 WHT 2 7.50 Amps Med
SHEET 4
2100 BLK 3
C 7400 WHT
7015 WHT 1
J1A
* C630
3
THERMOSTAT

A 7024 WHT
C355
WIRING SCHEMATIC
FUEL HARN #
A 7024 WHT 7025 WHT
C486
1 SIG
(STANDARD MACHINE)
2 MAGNET CLUTCH
GND
SHEET 13
2290 BLK 2280 BLK
(COMPRESSOR)
S650 (S/N A3NV25156 - A3NV25639)
D4
(S/N A3NW13767 - A3NW13930)
Sheet 12 OF 13
7254943 (0)
742 of 1311
C355
C428
(LT GRAY)
OPTIONS
# C607
FUEL HARN CAB-MFR HARN CONN 2
SIG 1 4470 LGN E 4470 LGN 8 4470 LGN
POWER BOB
CLOSE GND 2 2470 BLK 2770 BLK B 2770 BLK
SHEET 4 4480 LGN (NOT IN STD CAB HARN 7210557)
2290 BLK
SHEET 12
#
*POWER
SW5 2 1
3
#
C606 BOBTACH
5 4
2 2480 BLK SWITCH
POWER BOB
OPEN
GND
SIG 1 4480 LGN F 4480 LGN 7
6
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
C
D2
*BEACON
SW2
6570 PNK
SHEET 8 3400 LBL
5 PIN SWITCH
A 1550 RNG/WHT 9
6515 PNK
SHEET 3
1550 RNG/WHT
* SW3
HAZARD SWITCH
2
1 2725 BLK 6
5
(PINS 3 & 6 3 4
INTERNALLY 5 4 6700 PNK 1 2
C103
TAILGATE HARN INSULATED) 6 2850 BLK
C438
3
EURO TAIL LIGHTS
(SEE ADDITIONAL
CAB-MFR HARN CONN 3
SHEET 8 3500 LBL
* C670
E
OPTIONS DWG) D 6500 PNK 3 D1 6530 PNK D
C423 OPTIONS DWG)
3 C
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN Dealer Copy
1 2
4
*BUCKET
-- Not SW6
for Resale A
2830 BLK 5 POSITION
2780 BLK 1 2780 BLK

SHEET 4
C408
(BLACK) C279
* C676
RADIO CONN
C126
4 LEFT + 1 7820 WHT 3
C412 BLK B GND C277
LEFT HANDLE B 7210 WHT 13 7210 WHT A SIG
FRONT
HORN
SPEAKER
-
2 7830 WHT 4
* 1
SHEET 3 AIR RIDE
2 PIN 3
26 2460 BRN B GND + 1885 RNG/WHT 1 2210 BLK 5 GND
AUX CTRLR SOLENOID SHEET 9 SHEET 9
4460 LGN A SIG 2 6
7.5 OHM 12 V SHEET 9 2885 BLK
J2B
26
AUX CTRLR
WIRING SCHEMATIC
C437
TWO SPEED
27 2360 BRN
4360 LGN
2
1
GND
SIG
MAKEUP SOLENOID (STANDARD MACHINE)
J1A
GWY CTRLR C441
ADAPTER (SEE
ADDITIONAL
S650 (S/N A3NV25156 - A3NV25639)
26 2350 BRN 2 GND TWO SPEED OPTIONS DWG)
5.1 OHM 12 V
(S/N A3NW13767 - A3NW13930)
25 26 Printable Version Click Here
J1B
Printed In U.S.A.
GWY CTRLR Sheet 13 OF 13
7254943 (0)
743 of 1311
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
4 SH04 - GROUND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
5 SH05 - CAN BUS
6 SH06 - ENGINE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
7 SH07 - HYDRAULICS BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
8 SH08 - CAB DISPLAY
9 SH09 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
10 SH10 - MANUAL CONTROLS
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT LEGEND
11 SH11 - LIGHTS
12 SH12 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK CONNECTOR
13 SH13 - OPTIONS 1
14 SH14 - OPTIONS 2 CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN 1 1

HARNESS PART NUMBER LGN
PARTIAL CONNECTOR
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN
EXMF MAN 7305441
LF MAN MFR 7304757 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL 1 1
DLX CAB 7304511 LIGHTS 6000 THROUGH 6999 PINK PNK

STD CAB 7210557 1 1
STD FUEL 7149219
ENGINE 8000 THROUGH 8999 TAN TAN WIRE BREAK
S/R (STARTER) 6733370 WIRE BREAK
SHT1/E2 SHT1/E2
7217484 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
TAILGATE DOM
WIRE BREAK
SHT1/F2 SHT1/F2
WHL 2 SPD ADP 7159366 COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
(1 PC) TRK 2 SPD 7243409

SUSP JSTK 7163706
WARNING PROPRIETARY NOTICE ECN 102712

Wiring Schematic S630
S650 S/N A3NT18589 through A3NT19199
A3NV25640 A3NV26199 TOLERANCES:
Printed On December 2018
csf
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT WEST FARGO, NORTH DAKOTA, USA
CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
Standard Machine S/N A3NW13931

A3NU13060 through
through A3NU13299
A3NW14199
TO U.S. EXPORT ADMINISTRATION REGULATIONS
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS
OR REGULATIONS.
DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
UNLESS OTHERWISE SPECIFIED
TITLE
7305440_0
SCHEM ELEC MAN
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
DWG. NO. Sheet 1 of 14

Click Here for Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
0
REV DESCRIPTION
102712 MSE
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
14
7305440
SHT 1 /Printable Version Click Here
744 of 1311
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT8/E3
1400 RED/WHT
SHT9/D3
C408
1450 RED/WHT 1450 RED/WHT SP7 1420 RED/WHT
6 6 SHT8/E3
1440 RED/WHT
SHT8/G8

2
FUSE 1 25 A GWY CTRLR
1 2 SP2 3
J1B
1025 RED
FUSE 2 25 A 1160 RED/WHT SP36 1150 RED/WHT
3 4 3
+12V BATTERY MEGAFUSE AUX CTRLR
HW11 1 1 2
T5 T4 J2B
FUSE 3 25 A
7 8
FUSE 4 25 A
5 6
SHT6/G1
FC1 FC1
1010 RED
FC2 FUSE CENTER
1190 RED FUSE 1 25 A 1165 RED/WHT

1 2 SHT5/C8
1040 RED FUSE 2 25 A 1490 RED/WHT SP24 1410 RED/WHT

3 4 SHT13/G7
1460 RED/WHT
SP26 1290 RED FUSE 4 15 A

Dealer 1370
RED/WHT
SHT13/B7
5 6 SHT9/F8
FC2 FC2
FUSE RELAY CENTER
FUSE 5 30 A
1350 RED/WHT
5A 5B SHT6/D1
BUS BAR
1310 RED
FUSE 6 30 A
1360 RED/WHT
6A 6B SHT7/H8
FUSE 9 15 A
1320 RED/WHT
9A 9B SHT11/B8
BUS BAR
1340 RED
10A 10B SHT11/D8
1300 RED
11A 11B SHT12/F8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/E8
1060 RED
SHT6/E1

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN

COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712 MSE
SHT 2 /Printable
14
7305440
Version Click Here
745 of 1311
SWITCHED
POWER
C404
1720 RNG/WHT BU ALARM-MFR HARN
FUSE RELAY CENTER B B (SEE ADDITIONAL
OPTION DWG)
FUSE 1 25 A 1750 RNG/WHT SP52
1A 1B
BUS BAR
1780 RNG/WHT C489
A A MFR ACCESSORY
1760 RNG/WHT
FUSE 2 25 A 1850 RNG/WHT
2A 2B SHT9/D8
BUS BAR
1575 RNG/WHT
SHT14/G4
3A 3B SHT13/F7
1620 RNG/WHT
SHT8/G8
1940 RNG/WHT
SHT8/H8
BUS BAR
C428
MFR HARN CONN 2 1930 RNG/WHT
SHT8/H3
(LT GRAY) 1775 RNG/WHT
FUSE 4 5 A 1660 RNG/WHT 1660 RNG/WHT SHT8/D8
4A 4B 2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT
SHT9/H6
1960 RNG/WHT
SHT8/E8
1565 RNG/WHT
FRC1 SHT14/E4
SWITCHED 1520 RNG/WHT
SHT10/G3
POWER
1570 RNG/WHT SP11 1530 RNG/WHT
RELAY - A SHT10/D3
1560 RNG/WHT
22 AUX CTRLR
1050 RED 30
SHT2/B1 G4 87
G1
7A
Dealer
FUSE 7Copy
25 A -- Not 7B
for Resale 1730 RNG/WHT J2B
SHT5/C8
SP25
BUS BAR
2055 BLK 86 85
SHT4/B8 G5 G2
FRC1 FRC1 8A 8B SHT9/F8
1815 RNG/WHT
12A 12B SHT6/G4
FRC1 FRC1
1790 RNG/WHT
SHT12/E8
GWY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428 1830 RNG/WHT

MFR HARN CONN 2 (LT GRAY) SHT5/E3
1920 RNG/WHT 1920 RNG/WHT SP37
6 6
1840 RNG/WHT
SHT5/D3

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
7305440_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712 MSE
14
7305440
746 of 1311
GROUND
2140 BRN
SHT6/E7
2150 BRN
SHT6/G7
2160 BRN
2080 BLK SHT6/F7 GWY CTRLR
SHT5/D3
2170 BRN
SHT6/B7
2070 BLK 2180 BRN SP12 2230 BRN
SHT5/E3 SHT6/B7 17 SENSOR GND
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
MFR HARN CONN 1 (BLACK) SHT7/F7
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

SHT8/D3 16 BATTERY GROUND
GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
SHT14/D4 2550 BLK SP28 2090 BLK 2730 BLK
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
2830 BLK MFR HARN CONN 2 (LT GRAY) SHT11/H8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK
2700 BLK 1 1 SHT13/D8
SHT8/F8 SP47 2790 BLK
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/B8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

SHT11/C4 MFR ACCESSORY B B Dealer Copy -- Not for Resale
2650 BLK
SHT10/F8 C103
TAILGATE HARN 2015 BLK 1
2600 BLK SP6 2390 BLK 1 T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2400 BLK
SHT6/C7 2185 BRN
SHT14/E7 SP58 2995 BRN
2195 BRN 17 SENSOR GND
SHT10/G3
2005 BLK J2B
SHT6/G8
2016 BLK
SHT6/E1
2025 BLK
SHT6/D1
2030 BLK
SHT12/E8 SP1 2105 BLK
2035 BLK
SHT7/H5
2045 BLK
SHT11/B8
2055 BLK
SHT3/D8
2115 BLK
SHT11/D8
2505 BLK
SHT14/G4
2155 BLK
SHT14/F5

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
14
7305440
747 of 1311
CAN BUS
RE016 RE019 C479

C408
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
GWY CTRLR R3-1 SP18 R1-1 (BLACK)
TP-09 TP-09 TP-10 TP-10 SP31 TP-16 TP-16 TP-01 9230 PUR TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 TP-08 9630 PUR TP-08
9200 PUR 9270 PUR 9230 PUR 9240 PUR 9250 PUR 9650 PUR
CAN LO 8 4 4 4 CAN LO
SP30 SP17 SP38 SP34

CAN HI 9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
9 3 3 3 CAN HI
R3-2 TP-04
R1-2
TP-11 TP-02 TP-06
C479
C503
RH DLX PANEL
9260 PUR TP-06
4 CAN LO
9160 PUR/WHT
2 CAN HI
C503
AUX CTRLR * C450 C460

RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
9220 PUR TP-11 1830 RNG/WHT +12V PWR
1830 RNG/WHT
8 CAN LO SHT3/C1 1 1 1 1
2070 BLK 2070 BLK GND
9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
J2B 9660 PUR 9660 PUR CAN LO
4 4 4 4
C426
Remote Run Tool, ACD
CAN HI 14
TP-17 9500 PUR/WHT TP-17
Dealer
A A CAN HICopy -- Not for Resale * C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
1840 RNG/WHT 1840 RNG/WHT +12V PWR
9600 PUR SHT3/B1 1 1 1 1
CAN LO 20 B B CAN LO
SHT4/H8 2 2 2 2
9540 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
9640 PUR 9640 PUR CAN LO
4 4 4 4
SUSP SEAT JOYSTICK HARNESS
3090 LBL SP93 3085 LBL

REMOTE RUN KEY 21 D D REMOTE RUN KEY
J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A
1730 RNG/WHT
SHT3/D1 E E SWITCHED POWER
1165 RED/WHT
SHT2/E1 F F UNSWITCHED POWER
2710 BLK
SHT4/E8 G G GROUND

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
7305440_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 5 /Printable
14
7305440
Version Click Here
748 of 1311
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C109
STARTER CONNECTOR T21 S
1030 RED
SHT2/B1 J4 87 8200 TAN 8220 TAN
30 J1 A A
8210 TAN 85 3560 LBL

J2 J5 B B T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
C110 ALTERNATOR
1015 RED 1020 RED
GWY CTRLR S
1800 RNG/WHT
SHT3/D1 L
STARTER RELAY SIGNAL 7 2015 BLK 1
SHT4/D3
3560 LBL T11
STARTER RELAY FEEDBACK 22
2150 BRN GND GND 1
SHT4/H3 B AIR FILTER T12
3150 LBL SWITCH (NC)
AIR FILTER SENDER SIGNAL 16 A SIG
C405
3160 LBL
ENGINE SPEED SENDER SIGNAL 15 A
ENGINE SPEED
2160 BRN SENSOR (163 OHMS)
SHT4/H3 B
C106
5140 YEL
SHT9/B8 B
3140 LBL
ENGINE OIL PRESS SENDER SIGNAL 25 C
ENGINE OIL PRESSURE
2140 BRN SENDER (0.5-4.5V) FRC1 GLOW PLUG
SHT4/H3 A
RELAY - F
C107
1 8500 TAN
1060 RED
T14 3420 LBL F4 SHT2/B1
GLOW PLUG RELAY FEEDBACK 14 F1
8510 TAN 2016 BLK

GLOW PLUG RELAY SIGNAL 6 F2 F5 SHT4/C8
FRC1 Dealer Copy -- Not for Resale

FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL E1 SHT2/D1
FUEL RELAY FEEDBACK 30 E4
8110 TAN 2025 BLK
FUEL RELAY SIGNAL 3 E5 E2 SHT4/C8
J1A FRC1 FRC1

C101
FUEL SHUTOFF SOLENOID
8120 TAN 8100 TAN PULL
B B 0.33 OHM
D1
SHT4/C8 C C
8800 TAN HOLD
FUEL SHUTOFF SOLENOID HOLD 4 A A 24.5 OHM
C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER SIGNAL 12 C C A
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
ENGINE COOLANT SENSOR SIGNAL 18 A
ENGINE COOLANT SENSOR
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 6 /Printable
14
7305440
Version Click Here
749 of 1311
FRC1
TRACTION LOCK RELAY - D
C425 HYDRAULICS
4100 LGN
1360 RED/WHT +12V PWR B B
SHT2/C1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND 2035 BLK SOLENOID 9.8
D5 D2 SHT4/C8 2200 BLK 2200 BLK
86 SHT4/D8 C C B OHM 12 V TRACK 2 SPEED ADAPTER
FRC1 FRC1 (SEE ADDITIONAL OPTIONS DWG)
C308
WHEEL 2 SPD ADP HARNESS 7159366

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
TRACTION LOCK 13 C425
RELAY FEEDBACK
PULL 0.3 OHMS
B B
2220 BRN GND
SHT4/G3 B 10.9 OHMS
HYDRAULIC TEMPERATURE SENDER HOLD
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
HYD TEMP SIGNAL 32 A
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
HYD FILTER DIFF PRESS 34 A
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1
HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446
HYD LOCK VALVE 2410 BRN GND

1 2
SOL GROUND
HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
J1A
C420 Dealer Copy -- Not for Resale
2190 BRN GND
SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
6
HYD LOCK
SOLENOID SIGNAL
HYD CHARGE PRESS

SENDER POWER
HYD CHARGE PRESS
SENDER SIGNAL
TRACTION SOLENOID
OUTPUT
HYDRAULIC FAN
SIGNAL
4330 LGN GND

AUX CTRLR 1
FRONT ROD SOLENOID (MALE)
2330 BRN SIG 3.3 OHM PWM
FRONT ROD SOLENOID GROUND 18 2
C418
4340 LGN GND
GWY CTRLR 1
FRONT BASE SOLENOID (FEMALE)
FRONT BASE SOLENOID GROUND 1 2
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
7305440_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 7 /Printable
14
7305440
Version Click Here
750 of 1311
1940 RNG/WHT
T13 LEFT PANEL BUZZER CAB DISPLAY
SHT3/F1 1
7040 WHT
1 C499
T2 PTOL CONN
C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/F1 1
2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
MFR HARN CONN 1 (BLACK)
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
1620 RNG/WHT SWITCHED POWER
SHT3/F1 5 C499
C500
3400 LBL LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT13/F5 11
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT13/F5 8 START ENGINE 24 2 2 2
J1A
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/F1 5
6
1
1420 RED/WHT UNSWITCHED POWER
5 4 SHT2/G1 1
3600 LBL PARK BRAKE INPUT
SW9 SW9 9
1960 RNG/WHT 2960 BLK GROUND
SHT3/E1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/F1 5
5 6
4
3
Dealer Copy -- Not for Resale SHT2/H1 1
SW1 C480 2250 BLK GROUND
SW1 SHT4/G8 3
1775 RNG/WHT LEFT PANEL CONN (GRAY)
SHT3/F1
3630 LBL DOOR SIGNAL
6
SHT9/D3 12
C503 SHT5/F1
3610 LBL PARK BRAKE OUTPUT

2
C480

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 8 /Printable
14
7305440
Version Click Here
751 of 1311
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
2060 BLK (NOT IN STD CAB HARN 7210557)
SHT9/E3 5
4
SW4 3
SW4
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
HAND CONTROL LIGHT 4 4
4275 LGN
FOOT CONTROL LIGHT 5 5
FOOT CONTROL SIGNAL 6 6

4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
1375 RED/WHT +12V PWR
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
SHT2/D1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT SP41 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT SP8 1865 RNG/WHT
SHT3/D1 5 5 B B +12V SW PWR
* T38
2820 BLK
C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/B3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
Dealer Copy -- Not for
2885Resale
BLK
C428
SHT13/B3
* C667
MFR HARN CONN 2 (LT GRAY) DOOR HARNESS
2790 BLK 2790 BLK
SHT4/E3 11 11 (SEE ADDITIONAL
OPTIONS DWG)
3630 LBL
SHT8/D8 4 4 DOOR SIGNAL
1400 RED/WHT
SHT2/G1 5 5 DOOR UNSW PWR
2840 BLK
2 2 WIPER MOTOR GROUND
SHT3/F1 13 13 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
2370 BRN 2370 BRN 7310 WHT

SHT4/G3 4 4 SEATBAR 3 3 WASHER SIGNAL
SENSOR
GWY CTRLR GND

A
3370 LBL 3370 LBL SIG
SEATBAR SENSOR SIGNAL 11 5 5 B
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
5V CTRLR POWER 24 3 3 HARNESS WASHER PUMP
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/F7 A A PWR 1
WASHER
2845 BLK 2845 BLK
MOTOR
B B GND 2

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
7305440_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
14
7305440
752 of 1311
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/E1 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT ROCKER UP 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
GWY CTRLR AUX CTRLR
TILT SPOOL LOCK 2670 BRN GND

10 3
SOLENOID GROUND LEFT HANDLE
TILT SPOOL LOCK
4670 LGN SIG
1
7.8 OHM 12V
Dealer Copy -- Not for Resale LIFT (ACS/AHC ONLY)
C421
HANDLE LOCK (ACS ONLY)

H
LIFT SPOOL LOCK 2680 BRN GND
2 3 E
SOLENOID GROUND
LIFT SPOOL LOCK
J1A D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/E1 A
LEFT HANDLE RIGHT ROCKER
C422 4830 LGN
DOWN 22 B
RIGHT POSTION SWITCH
LEFT HANDLE RIGHT ROCKER UP 4840 LGN
28 C
4810 LGN
LEFT HANDLE PADDEL RIGHT 11 F PADDLE
J1B
4820 LGN
7
LEFT HANDLE PADDEL LEFT 12 G

C410
TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
J2A LEFT POSITION SWITCH
TRIGGER
GWY CTRLR

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN
DWG. NO.Sheet 10 of 14
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 10Printable
/ 14
7305440
Version Click Here
753 of 1311
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2
FRC1
2610 BLK GND
FRONT WORK
LIGHTS RELAY - B
Dealer Copy -- Not SHT4/D8
for Resale 2
C103 RIGHT REAR

TAIL LIGHT
1330 RED/WHT TAILGATE HARN
SHT2/C1 B1 6340 PNK SP10 6310 PNK 6310 PNK SP49 6320 PNK SIG
B4 A A 1
6320 PNK
C603
2115 BLK
SHT4/B8 B2 B5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
GWY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR SHT4/D8 2
RELAY SIGNAL 5
C602
MRKR LIGHT PWR 3460 LBL
RELAY FEEDBACK
31
REAR LIGHT 6210 PNK

RELAY SIGNAL 17 T16 TERMINAL (-)
2620 BLK
3440 LBL SHT4/E8
REAR LIGHT GND 1
RELAY FEEDBACK
28
RIGHT REAR
FRC1 WORK LIGHT
J1A
REAR LIGHT 6210 PNK SIG 1
RELAY - C T15 TERMINAL (+)
1320 RED/WHT T17 TERMINAL (+)

SHT2/C1 C1 87 6200 PNK 6200 PNK SP96 6220 PNK
30 C4 H H SIG 1
SHT4/C8 C2 C5 WORK LIGHT
86
FRC1 FRC1 2630 BLK GND 1
SHT4/D8
T18 TERMINAL (-)

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 11Printable
/ 14
7305440
Version Click Here
754 of 1311
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
M (NOT IN STD CAB HARN 7210557)
7440 WHT SIG
C610
1
* DLX FUEL HARN 7266824 ONLY
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
2130 BLK HEATER VALVE
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
1140 RED/WHT (DK GRAY) 1
SHT2/C1 H4 87 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT
MED
30 H1 7 7 5 1 2
4 7510 WHT
LOW
2030 BLK 85 SW10 3

SHT4/C8 H5 H2 7400 WHT
86 3
FRC1 FRC1 M
SW10
1790 RNG/WHT 7410 WHT
SHT3/D1 4
C611
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
9 9
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT C355

B FUEL HARN
AC EVAPORATOR
SWITCH 7024 WHT 7024 WHT 7025 WHT SIG
A A A 1
D4
C350 MAGNET CLUTCH

2290 BLK (COMPRESSOR)
2280 BLK GND
2
C486

csf


A3NU13060 through
through A3NU13299
A3NW14199
OR REGULATIONS.
TITLE
7305440_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 12Printable
/ 14
7305440
Version Click Here
755 of 1311
C428
# C355
FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
8 8
4470 LGN
4480 LGN
OPTIONS 1
CLOSE SP33
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
B B SHT4/E8
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
# 1380 RED/WHT 1
4480 LGN 4480 LGN
1 SIG F F 7 7 2
3 DLX CAB HARN 7304511 ONLY
POWER BOB
OPEN SW5
* (NOT IN STD CAB HARN 7210557)
GND 2480 BLK
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
10 10
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
1405 RED/WHT
SHT14/D6
(SEE ADDITIONAL OPTIONS DWG)
1410 RED/WHT 1410 RED/WHT 1430 RED/WHT
SHT2/E1 12 12 X T3
SP43 * FLASHER
1200 RED/WHT L
3400 LBL
T3
SHT8/G8
SP22 D5
6400 PNK 6400 PNK 6430 PNK
14 14
FLOAT (ACS/AHC ONLY)
SHT3/F1
1550 RNG/WHT
9 9
1550 RNG/WHT * SW2
BEACON SWITCH
3500 LBL
SHT8/F8
D2 1
RIGHT POSTION SWITCH 6500 PNK 6530 PNK
2
SW3
PADDLE
* HAZARD SWITCH
6
1
B C438 2 SW2 SW2
6415 PNK MFR HARN CONN 3 (DK GRAY)
D 6500 PNK 3
LEFT POSITION SWITCH
6515 PNK SP21 3 3
6410 PNK
6510 PNK
A 4
C103 5 6
C411 TAILGATE HARN
TRIGGER
SW3 (PINS 3 & 6 SW3
E E INTERNALLY INSULATED)
EURO TAIL LIGHTS
(SEE ADDITIONAL
OPTIONS DWG) D D * SW6
BUCKET POSITION SWITCH
2850 BLK
SP46 2725 BLK
BUCKET
POSITION
A SIG
4450 LGN 4455 LGN
2 2
4455 LGN
1
2
6570 PNK
*
D3
2905 BLK
SOLENOID
2450 BLK
3 Dealer Copy -- Not for Resale SHT14/F6
2455 BLK 2970 BLK
9.8 OHM B GND SHT4/E8 4 SHT14/F4 6700 PNK
2830 BLK 2810 BLK E E
C423 SHT4/E8 6 5 SHT14/D5 2420 BLK
D D C670
SW6 SW6 6540 PNK BEACON/FLASHER
2780 BLK 2780 BLK B B EXTERIOR HARNESS
SHT4/E3 1 1 6440 PNK
F F (SEE ADDITIONAL
LEFT HANDLE
OPTIONS DWG)
LIFT (ACS/AHC ONLY)
C C
LEFT HANDLE (HORN) 2 WAY A A

(SEE ADDITIONAL OPTIONS DWG) C676
LEFT SPEAKER
* * RADIO CONN
*
GWY CTRLR 7820 WHT LEFT 1
HANDLE LOCK (ACS ONLY) 1 3 SPEAKER (+)
TWO SPEED 2
MAKEUP GROUND 2360 BRN
27 2 7830 WHT LEFT L010
TWO SPEED 2 4 3
SPEAKER (-) AIR RIDE SEAT
TWO SPEED 26 MAKEUP SOLENOID 1510 RNG/WHT PWR
FLOAT (ACS/AHC ONLY) GROUND C279 SHT9/E3 4
4360 LGN 8.8 OHM 12V PWR
J1A 1 RIGHT SPEAKER
C437 * 7810 WHT RIGHT 2210 BLK GND GND
2350 BRN GND
2 6 SPEAKER (-)
SHT9/E3 5
2
TWO SPEED TWO SPEED TRACK 2 SPEED 7800 WHT RIGHT 6
PADDLE MAKEUP 25 SOLENOID (SEE ADDITIONAL 1 5 SPEAKER (+)
OPTIONS DWG) C277
4350 LGN SIG 5.1 OHM 12 V C278
TWO SPEED SIGNAL 26 1 1885 RNG/WHT
SHT9/E3 1
J1B C441 AUX CTRLR
2885 BLK
LEFT POSITION SWITCH HIGH FLOW 2460 BRN
SHT9/D3 2
C408 26
SOLENOID GROUND C676
MFR HARN CONN 1 C126
1460 RED/WHT J2A GND
A SHT2/E1 (BLACK) HORN CONNECTOR B
TRIGGER
SIG
HIGH FLOW
7210 WHT 7210 WHT
B 13 13 A A _ SOLENOID
C412 SIG
A 7.5 OHM 12 V
HORN
GND + C415
2785 BLK HIGH FLOW 4460 LGN
SHT4/E8 B B SOLENOID SIGNAL
26
J2B

csf


A3NU13060 through
OR REGULATIONS.
through A3NU13299
A3NW14199 DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
TITLE
7305440_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 13Printable
/ 14
7305440
Version Click Here
756 of 1311
AUX CTRLR
C438
*SW7
RIDE CONTROL
OPTIONS 1
RIDE CONTROL SW AUTO 23
3700 LBL
10 10
3700 LBL
1 2
2915 BLK
SHT4/F8
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIGNAL 7
RIDE CONTROL
RELAY - RC1
SP9 1575 RNG/WHT

3415 LBL 3425 LBL 30 SHT3/F1
RIDE CONTROL COIL SIGNAL 21 87
3435 LBL 3445 LBL 2505 BLK
1 1 85 86 SHT4/B8
RIDE CONTROL RIDE CONTROL RC1 RC1
COIL COIL
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK
SHT4/B8
C438 *
SW13
REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIGNAL 16 12 12 3
2905 BLK 2970 BLK

SHT13/E3 1 2 SHT13/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIGNAL 29 11 11 6
1565 RNG/WHT
5 SHT3/E1
C443 4
2175 BRN 2 SW13 SW13
REVERSING FAN RETURN SIGNAL 27
J2A REVERSING
FAN COIL
REVERSING FAN SIGNAL 3485 LBL 1
25
C442
RIDE CONTROL PRESSURE

SHT4/C3
2185 BRN
A
RIDE CONTROL
3455 LBL
SENSOR SIGNAL 10 C PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 24 B
+5V SUPPLY
J2B
*SIDELIGHT
SW8 C672
SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT13/G3 2
2810 BLK
SHT13/D3 2 2
2860 BLK
6 SHT4/F8
SW8 SW8
PROPRIETARY NOTICE
A3NV25640
WARNING
A3NV26199 TOLERANCES: ECN 102712
csf

PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT DATE WEST FARGO, NORTH DAKOTA, USA

A3NU13060 through
through A3NU13299
A3NW14199 7305440_0
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
DRAWN MSE SCHEM ELEC MAN
X ± 13 MAT
0
REV DESCRIPTION
102712 MSE
SHT 14 / 14
7305440
757 of 1311
Index Diagram
1 SH01 - INDEX
3 SH03 - SWITCHED POWER
4 SH04 - GROUND WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
5 SH05 - CAN BUS
6 SH06 - ENGINE
9 SH09 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT LEGEND
11 SH11 - LIGHTS
12 SH12 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK CONNECTOR
13 SH13 - OPTIONS 1
14 SH14 - OPTIONS 2 CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN 1 1

HARNESS PART NUMBER LGN
PARTIAL CONNECTOR
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN
EXMF MAN 7322221
LF MAN MFR 7322218 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL 1 1
DLX CAB 7304511 LIGHTS 6000 THROUGH 6999 PINK PNK

STD CAB 7210557 1 1
STD FUEL 7149219
ENGINE 8000 THROUGH 8999 TAN TAN WIRE BREAK
S/R (STARTER) 6733370 WIRE BREAK
SHT1/E2 SHT1/E2
7217484 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
TAILGATE DOM
WIRE BREAK
SHT1/F2 SHT1/F2
WHL 2 SPD ADP 7159366 COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
(1 PC) TRK 2 SPD 7243409

SUSP JSTK 7163706

S650 S/N A3NT19200 & Above
A3NV26200 TOLERANCES:
csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV DESCRIPTION
108481 MMM
14
7322217
758 of 1311
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT8/E3
1400 RED/WHT
SHT9/D3
C408
6 6 SHT8/E3
1440 RED/WHT
SHT8/G8

2
1 2 SP2 3
J1B
1025 RED
3 4 3
HW11 1 1 2
T5 T4 J2B
FUSE 3 25 A
7 8
FUSE 4 25 A
5 6
SHT6/G1
FC1 FC1
1010 RED
FC2 FUSE CENTER

1 2 SHT5/C8

3 4 SHT13/G7
1460 RED/WHT
SP26
1290 RED FUSE 4 15 A
Dealer 1370
RED/WHT
SHT13/B7
5 6 SHT9/F8
FC2 FC2
1325 RED FUSE RELAY CENTER
FUSE 5 30 A
1350 RED/WHT
SP1 5A 5B SHT6/D1
BUS BAR
1310 RED
FUSE 6 30 A
1360 RED/WHT
6A 6B SHT7/H8
1055 RED
FUSE 9 15 A
1320 RED/WHT
9A 9B SHT11/B8
BUS BAR
1340 RED
10A 10B SHT11/D8
1300 RED
11A 11B SHT12/F8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/E8
SP60
1060 RED
SHT6/E1
1205 RED
SHT3/D8

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 2 /Printable
14
7322217
Version Click Here
759 of 1311
SWITCHED
POWER
C404
1720 RNG/WHT BU ALARM-MFR HARN
FUSE RELAY CENTER B B (SEE ADDITIONAL
OPTION DWG)
FUSE 1 25 A 1750 RNG/WHT SP52
1A 1B
BUS BAR
1780 RNG/WHT C489
A A MFR ACCESSORY
1760 RNG/WHT
2A 2B SHT9/D8
BUS BAR
1575 RNG/WHT
SHT14/G4
3A 3B SHT13/F7
1620 RNG/WHT
SHT8/G8
1940 RNG/WHT
SHT8/H8
BUS BAR
C428
SHT8/H3
4A 4B 2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT
SHT9/H6
1960 RNG/WHT
SHT8/E8
1565 RNG/WHT
SHT14/E4
SWITCHED POWER
1520 RNG/WHT
RELAY-RC2 SHT10/G3
SHT10/D3
1050 RED
SHT2/B1 30 1765 RNG/WHT 1560 RNG/WHT
87 22 AUX CTRLR
SP25
3390 LBL 2055 BLK
86 85 SHT4/B8 1795 RNG/WHT
7A
Dealer
FUSE 7Copy
25 A -- Not 7B
for Resale 1730 RNG/WHT J2B
SHT5/C8
RC2 RC2
1820 RNG/WHT FUSE 8 25 A 1580 RNG/WHT

8A 8B SHT9/F8
SWITCHED POWER FUSE 12 15 A

RELAY-RC1 12A 12B SHT6/G4
FRC1 FRC1
1205 RED
SHT2/B1 30 1820 RNG/WHT
87
SP100 3385 LBL 2065 BLK
86 85 SHT4/C8
RC1 RC1
1790 RNG/WHT
SHT12/E8
GWY CTRLR
3450 LBL
3380 LBL
J1A
1830 RNG/WHT
SHT5/E3
C428
MFR HARN CONN 2 (LT GRAY)
6 6
1840 RNG/WHT
SHT5/D3

csf


A3NU13300 && Above
Above
OR REGULATIONS.
7322217_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 3 /Printable
14
7322217
Version Click Here
760 of 1311
GROUND
2140 BRN
SHT6/E7
2150 BRN
SHT6/G7
2160 BRN
2080 BLK SHT6/F7 GWY CTRLR
SHT5/D3
2170 BRN
SHT6/B7
2070 BLK 2180 BRN SP12 2230 BRN
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK
2700 BLK 1 1 SHT13/D8
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/B8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

2650 BLK
SHT10/F8 C103
2600 BLK SP6 2390 BLK 1 T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2400 BLK
SHT6/C7 2185 BRN
2065 BLK 2195 BRN 17 SENSOR GND
SHT3/C1 SHT10/G3
2005 BLK
SHT6/G8 J2B
2016 BLK
SHT6/E1
2025 BLK
SHT6/D1
2030 BLK
SHT12/E8 SP55 2105 BLK
2035 BLK
SHT7/H5
2045 BLK
SHT11/B8
2055 BLK
SHT3/E6
2115 BLK
SHT11/D8
2505 BLK
SHT14/G4
2155 BLK
SHT14/F4

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
14
7322217
761 of 1311
CAN BUS
GWY CTRLR C479

Z3 C408
MFR HARN CONN 1 (BLACK) Z1 LEFT PANEL
120 OHM 0.5 W RESISTOR SP18 120 OHM 0.5 W RESISTOR (BLACK)
SP31 SP39 SP35
9200 PUR 9270 PUR 9230 PUR 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR
CAN LO 8 4 4 4 CAN LO
SP30 SP17 SP38 SP34

CAN HI 9100 PUR/WHT 9170 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
9 3 3 3 CAN HI
C479
C503
RH DLX PANEL
9260 PUR
4 CAN LO
9160 PUR/WHT
2 CAN HI
C503
AUX CTRLR * C450 C460

RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
9220 PUR 1830 RNG/WHT 1830 RNG/WHT +12V PWR
8 CAN LO SHT3/B1 1 1 1 1
9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT 9560 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
C426
CAN HI 14
9500 PUR/WHT
Dealer
A A CAN HICopy -- Not for Resale * C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK LEFT JOYSTICK
9600 PUR SHT3/B1 1 1 1 1
CAN LO 20 B B CAN LO
SHT4/H8 2 2 2 2
9540 PUR/WHT 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
3090 LBL SP93 3085 LBL

J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A
1730 RNG/WHT
SHT3/D1 E E SWITCHED POWER
1165 RED/WHT
SHT2/E1 F F UNSWITCHED POWER
2710 BLK
SHT4/E8 G G GROUND

csf


A3NU13300 && Above
Above
OR REGULATIONS.
7322217_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481 MMM
SHT 5 /Printable
14
7322217
Version Click Here
762 of 1311
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C109
1030 RED
SHT2/B1 J4 87 8200 TAN 8220 TAN
30 J1 A A
8210 TAN 85 3560 LBL

J2 J5 B B T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
C110 ALTERNATOR
1015 RED 1020 RED
GWY CTRLR S
1800 RNG/WHT
SHT3/D1 L
SHT4/D3
3560 LBL T11
2150 BRN GND GND 1
C405
3160 LBL
ENGINE SPEED
SHT4/H3 B
C106
5140 YEL
SHT9/B8 B
3140 LBL
ENGINE OIL PRESSURE
SHT4/H3 A
RELAY - F
C107
1 8500 TAN
1060 RED
T14 3420 LBL F4 SHT2/B1
8510 TAN 2016 BLK


FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL E1 SHT2/D1
8110 TAN 2025 BLK
J1A FRC1 FRC1

C101
B B 0.33 OHM
D1
SHT4/C8 C C
8800 TAN HOLD
C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 6 /Printable
14
7322217
Version Click Here
763 of 1311
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/C1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
D5 D2 SHT4/C8 2200 BLK 2200 BLK
C308

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
RELAY FEEDBACK
PULL 0.3 OHMS
B B
2220 BRN GND
SHT4/G3 B 10.9 OHMS
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1
C446
HYD LOCK VALVE 2410 BRN GND

1 2
SOL GROUND
1
J1A
2190 BRN GND
SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT9/B8 B
C105
4200 LGN
J1B
19
13
6
HYD LOCK
SOLENOID SIGNAL
HYD CHARGE PRESS

SENDER SIGNAL
TRACTION SOLENOID
OUTPUT
HYDRAULIC FAN
SIGNAL
4330 LGN GND

AUX CTRLR 1
FRONT ROD SOLENOID GROUND 18 2
C418
4340 LGN GND
GWY CTRLR 1
FRONT BASE SOLENOID GROUND 1 2
J2A C419
J2B
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

csf


A3NU13300 && Above
Above
OR REGULATIONS.
7322217_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 7 /Printable
14
7322217
Version Click Here
764 of 1311
1940 RNG/WHT
T13 LEFT PANEL BUZZER CAB DISPLAY
SHT3/F1 1
7040 WHT
1 C499
T2 PTOL CONN

2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
SHT2/G1 1 PTOL LED 19 12 12 4
SHT3/F1 5 C499
C500
SHT13/F5 11
J1A
SW9

SHT3/F1 5
6
1
5 4 SHT2/G1 1
SW9 SW9 9
SHT3/E1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/F1 5
5 6
4
3
SW1 SHT4/G8 3
SHT3/F1
6
SHT9/D3 12
C503 SHT5/F1

2
C480

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN

X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 8 /Printable
14
7322217
Version Click Here
765 of 1311
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT9/E3 5
4
SW4 3
SW4
C438
4235 LGN
HAND CONTROL LIGHT 4 4
4275 LGN
FOOT CONTROL LIGHT 5 5

4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
2
C212
C408
SHT2/D1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
* T38
2820 BLK
C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/B3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
Dealer Copy -- Not for
2885Resale
BLK
C428
SHT13/B3
* C667
MFR HARN CONN 2 (LT GRAY) DOOR HARNESS
2790 BLK 2790 BLK
OPTIONS DWG)
3630 LBL
1400 RED/WHT
2840 BLK
2370 BRN 2370 BRN 7310 WHT

SENSOR
GWY CTRLR GND

A
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/F7 A A PWR 1
WASHER
5190 YEL
SHT7/D7 2845 BLK 2845 BLK
MOTOR
B B GND 2

csf


A3NU13300 && Above
Above
OR REGULATIONS.
7322217_0
TITLE
SCHEM ELEC MAN


X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
14
7322217
766 of 1311
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/E1 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT ROCKER UP 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
GWY CTRLR AUX CTRLR

10 3
SOLENOID GROUND LEFT HANDLE
TILT SPOOL LOCK
4670 LGN SIG
1
7.8 OHM 12V
Dealer Copy -- Not for Resale LIFT (ACS/AHC ONLY)
C421

H
LIFT SPOOL LOCK 2680 BRN GND
2 3 E
SOLENOID GROUND
LIFT SPOOL LOCK
J1A D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/E1 A
LEFT HANDLE RIGHT ROCKER
C422 4830 LGN
DOWN 22 B
LEFT HANDLE RIGHT ROCKER UP 4840 LGN
28 C
4810 LGN
J1B
4820 LGN
7

C410
TILT SPOOL LOCK
SOLENOID SIGNAL
LIFT SPOOL LOCK

SOLENOID SIGNAL
TRIGGER
GWY CTRLR

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 10Printable
/ 14
7322217
Version Click Here
767 of 1311
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2
FRC1
2610 BLK GND
FRONT WORK
LIGHTS RELAY - B
Dealer Copy -- Not SHT4/D8
for Resale 2
C103 RIGHT REAR

TAIL LIGHT
B4 A A 1
6320 PNK
C603
2115 BLK
SHT4/B8 B2 B5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
2640 BLK GND
MRKR LIGHT PWR SHT4/D8 2
RELAY SIGNAL 5
C602
RELAY FEEDBACK
31
REAR LIGHT 6210 PNK

RELAY SIGNAL 17 T16 TERMINAL (-)
2620 BLK
3440 LBL SHT4/E8
REAR LIGHT GND 1
RELAY FEEDBACK
28
RIGHT REAR
FRC1 WORK LIGHT
J1A

30 C4 H H SIG 1
86
SHT4/D8
T18 TERMINAL (-)

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 11Printable
/ 14
7322217
Version Click Here
768 of 1311
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
7440 WHT SIG
C610
1
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
MED
30 H1 7 7 5 1 2
4 7510 WHT
LOW
2030 BLK 85 SW10 3

86 3
FRC1 FRC1 M
SW10
SHT3/C1 4
C611
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
7021 WHT 7020 WHT
9 9
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT C355

B FUEL HARN
AC EVAPORATOR
A A A 1
D4
C350 MAGNET CLUTCH

2280 BLK GND
2
C486

csf


A3NU13300 && Above
Above
OR REGULATIONS.
TITLE
7322217_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 12Printable
/ 14
7322217
Version Click Here
769 of 1311
C428
# C355
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
8 8
4470 LGN
4480 LGN
OPTIONS 1
CLOSE SP33
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
B B SHT4/E8
# 1380 RED/WHT 1
4480 LGN 4480 LGN
1 SIG F F 7 7 2
POWER BOB
OPEN SW5
GND 2480 BLK
2 SW5
C606
10 10
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
1405 RED/WHT
SHT14/D6
SHT2/E1 12 12 X T3
SP43 * FLASHER
1200 RED/WHT L
3400 LBL
T3
SHT8/G8
SP22 D5
6400 PNK 6400 PNK 6430 PNK
14 14
SHT3/F1
1550 RNG/WHT
9 9
1550 RNG/WHT * SW2
BEACON SWITCH
3500 LBL
SHT8/F8
D2 1
2
SW3
PADDLE
* HAZARD SWITCH
6
1
B C438 2 SW2 SW2
D 6500 PNK 3
6515 PNK SP21 3 3
6410 PNK
6510 PNK
A 4
C103 5 6
C411 TAILGATE HARN
TRIGGER
SW3 (PINS 3 & 6 SW3
EURO TAIL LIGHTS
(SEE ADDITIONAL
2850 BLK
SP46 2725 BLK
BUCKET
POSITION
A SIG
4450 LGN 4455 LGN
2 2
4455 LGN
1
2
6570 PNK
*
D3
2905 BLK
SOLENOID
2450 BLK
3 Dealer Copy -- Not for Resale SHT14/F6
2455 BLK 2970 BLK
9.8 OHM B GND SHT4/E8 4 SHT14/F4 6700 PNK
2830 BLK 2810 BLK E E
C423 SHT4/E8 6 5 SHT14/D5 2420 BLK
D D C670
SHT4/E3 1 1 6440 PNK
F F (SEE ADDITIONAL
LEFT HANDLE
OPTIONS DWG)
LIFT (ACS/AHC ONLY)
LEFT HANDLE (HORN) 2 WAY

(SEE ADDITIONAL OPTIONS DWG) C676
LEFT SPEAKER
* * RADIO CONN
* L010
HEATED SEAT
GWY CTRLR 7820 WHT LEFT 1510 RNG/WHT
HANDLE LOCK (ACS ONLY) 1 3 SPEAKER (+) SHT9/E3 4 PWR
TWO SPEED PWR
MAKEUP GROUND 2360 BRN
27 2 7830 WHT LEFT
TWO SPEED 2 4 SPEAKER (-)
TWO SPEED 26 MAKEUP SOLENOID 2210 BLK GND GND
FLOAT (ACS/AHC ONLY) GROUND C279 SHT9/E3 5
4360 LGN 8.8 OHM 12V
J1A 1 RIGHT SPEAKER C277
C437 * 7810 WHT RIGHT
SEE OPTION PAGES FOR HARNESSES
2350 BRN GND
2 6 SPEAKER (-)
2
TWO SPEED TWO SPEED TRACK 2 SPEED 7800 WHT RIGHT
PADDLE MAKEUP 25 SOLENOID (SEE ADDITIONAL 1 5 SPEAKER (+)
4350 LGN OPTIONS DWG)
TWO SPEED SIGNAL 26 SIG
1 5.1 OHM 12 V C278 1885 RNG/WHT
SHT9/E3 1
J1B C441 AUX CTRLR
2885 BLK
LEFT POSITION SWITCH HIGH FLOW 2460 BRN
SHT9/D3 2
C408 26
SOLENOID GROUND C676
MFR HARN CONN 1 C126
1460 RED/WHT J2A GND
A SHT2/E1 (BLACK) HORN CONNECTOR B
TRIGGER
SIG
HIGH FLOW
7210 WHT 7210 WHT
B 13 13 A A SOLENOID
+
C412 SIG
A 7.5 OHM 12 V
HORN
GND
_ C415
2785 BLK HIGH FLOW 4460 LGN
SHT4/E8 B B SOLENOID SIGNAL
26
J2B

csf


A3NU13300 && Above
OR REGULATIONS.
Above DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
TITLE
7322217_0
SCHEM ELEC MAN
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
108481
CHG NOTICE DWN
MMM
SHEET
SHT 13Printable
/ 14
7322217
Version Click Here
770 of 1311
AUX CTRLR
C438
*SW7
RIDE CONTROL
OPTIONS 1
3700 LBL
10 10
3700 LBL
1 2
2915 BLK
SHT4/F8
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIGNAL 7 RIDE CONTROL
RELAY - G
FUSE RELAY CENTER
SP9 1575 RNG/WHT

3415 LBL 3425 LBL G4 G1 SHT3/F1
RIDE CONTROL COIL SIGNAL 21
3435 LBL 3445 LBL 2505 BLK
1 1 G5 G2 SHT4/B8
RIDE CONTROL RIDE CONTROL FRC1 FRC1
COIL COIL
2040 BLK 2020 BLK
2 2
SP32
C439 C440 2155 BLK
SHT4/B8
C438 *
SW13
REVERSING FAN
3475 LBL 3475 LBL
2905 BLK 2970 BLK

SHT13/E3 1 2 SHT13/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/E1
C443 4
2175 BRN 2 SW13 SW13
REVERSING FAN RETURN SIGNAL 27
J2A REVERSING
FAN COIL
REVERSING FAN SIGNAL 3485 LBL 1
25
C442
2185 BRN
RIDE CONTROL PRESSURE
SHT4/C3 A
RIDE CONTROL
3455 LBL
SENSOR SIGNAL 10 C PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 24 B
+5V SUPPLY
J2B
*SIDELIGHT
SW8 C672
SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT13/G3 2
2810 BLK
SHT13/D3 2 2
2860 BLK
6 SHT4/F8
SW8 SW8

csf

PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE DATE WEST FARGO, NORTH DAKOTA, USA

A3NU13300 && Above
Above
OR REGULATIONS.
DRAWN MMM
TITLE
SCHEM ELEC7322217_0
MAN
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT Sheet 14 of 14
DWG. NO.
0
REV DESCRIPTION
108481 MMM
SHT Printable
14 / 14
7322217
Version Click Here
771 of 1311
CONNECTOR ASSIGNMENTS CONNECTOR ASSIGNMENTS (ACS)
NUM OF NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 J1A GATEWAY COTROLLER 34 C428 TILT ACTUATOR 8 14
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26 C429 LIFT ACTUATOR 8 14
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 J2A AUX CONTROLLER 34 C467 LIFT PEDAL LOCK 3 14
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7 J2B AUX CONTROLLER 26 C468 TILT PEDAL LOCK 3 14
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 J1-ACS ACS CONTROLLER 8 C469 TILT HANDLE 3 14
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11 J2-ACS ACS CONTROLLER 10 C470 TILT PEDAL 3 14
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 J3-ACS ACS CONTROLLER 10 C471 LIFT PEDAL 3 14
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 J5 DRIVE CONTROLLER 50 C472 LIFT HANDLE 3 14
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7
C126 HORN 2 13 C441 TWO SPEED 2 7 FC1 FUSE CENTER 1 3
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 FC2 FUSE CENTER 2 3
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5,15 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5,15
C250 DOOR SENSOR 2 9 C459 LEFT JOYSTICK 4 15
C251 WIPER 5 9 C460 RIGHT JOYSTICK 4 15 T1 BATT GROUND 4
C252 WASHER 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T2 BUZZER GROUND 8
C277 AIR RIDE SEAT 6 9 C480 LEFT PANEL(GRAY) 12 8 T3 FLASHER 13
C278 RIGHT SPEAKER 2 9 C482 SEATBAR SENSOR 3 9 T6 BATT GROUND 4
C279 LEFT SPEAKER 2 9 C483 TEMP CONTROL SWITCH 3 12 T8 BATT GROUND 4 CONNECTOR ASSIGNMENTS (SJC)
C308 BRAKE SOLENOID 2 7 C486 AC COMPRESSOR 2 12 T13 BUZZER POWER 8 NUM OF
CONN DESCRIPTION SHEET
C350 AC EVAPORATOR SWITCH 2 12 C489 ACCESSORY 2 3,4 T14 PRE HEATER 6 PINS
C355 DLX or STD FUEL HARNESS 6 6,12,13 C492 ACS/SJC/AWS 1 8 3,5,9,14,15 T15 RIGHT REAR WORK LIGHT(+) C536 RIGHT SWASHPLATE 4 15
11
C362 REAR AUX SOLENOID 8 7 C493 ACS/SJC/AWS 2 4 3,4,14,15 T16 RIGHT REAR WORK LIGHT(-) 11 C537 LEFT SWASHPLATE 4 15
C404 BACKUP ALARM 2 3,10 C497 SJC HORN/BLINKER 3 13 LEFT REAR WORK LIGHT (+) 11 C428 TILT ACTUATOR 8 15
T17
C405 AIR FILTER SWITCH 2 6 C499 PTOL 4 8 T18 LEFT REAR WORK LIGHT (-) 11 C429 LIFT ACTUATOR 8 15
C406 FUEL SENDER 2 6 C500 RH KEY SWITCH 6 8 T19 10 C453 RIGHT QUAD A DRIVE 4 15
BACKUP ALARM
C408 CAB CONNECTOR 48 3-5, 8-13 C503 RH DLX PANEL 6 5,8 T20 BACKUP ALARM (GND) 10 C454 LEFT QUAD DIRVE 4 15
C409 RIGHT HANDLE 10 10 C602 LEFT REAR TAIL LIGHT 2
Dealer Copy
11
-- Not for Resale C474 BRAKE LIGHT 1 15
C410 LEFT HANDLE 10 10 C603 RIGHT REAR TAIL LIGHT 2 11
C411 LEFT HANDLE 5 WAY 5 10,13 C606 POWER BOBTACH OPEN 2 13 SW1 BRAKE SWITCH 9 C501 A22 PUMP HARNESS 8 15
C412 HANDLE(HORN) 2 10,13 C607 POWER BOBTACH CLOSE 2 13 SW2 BEACON SWITCH 13 C544 LEFT FORWARD DRIVE 2 15
C413 REAR ROD 2 7 C611 BLOWER MOTOR 4 12 SW3 HAZARD SWITCH 13 C545 LEFT REVERSE DRIVE 2 15
C414 REAR BASE 2 7 C630 THERMOSTAT 3 12 SW4 HAND/FOOT, H/ISO SWITCH 9 C546 RIGHT FORWARD DRIVE 2 15
C415 HIGH FLOW SOLENOID 2 7 C635 HEATER VALVE 6 12 SW5 POWER BOBTACH SWITCH 13 C547 RIGHT REVERSE DRIVE 2 15
C416 DIVERTER SOLENOID 2 7 C667 DOOR KIT 6 9 SW6 BUCKET POSITION SWITCH 13 C542 LEFT SWASHPLATE 3 15
C417 REAR AUX RELIEF 2 7 C670 EXTERIOR BEACON 6 13 SW8 FRONT WIPER SWITCH 9 C543 RIGHT SWASHPLATE 3 15
C418 FRONT ROD 2 7 C676 RADIO 6 9 SW9 TRAVEL CONTROL SWITCH 8 C707 OBW STOP BRAKE LIGHT 3 15
C419 FRONT BASE 2 7 SW10 BLOWER SWITCH 12
C420 HYD LOCK 2 7 SW11 AC SWITCH 12

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 Printable Version Click Here
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 WIRING SCHEMATIC
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 (ACS & SJC MACHINE)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 S650 (S/N A3NV11001 - A3NV13098)
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10 (S/N A3NW11001 - A3NW11248)
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 Sheet 1 of 15
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14 (PRINTED DECEMBER 2011)
SJC CONTROL PAGE 15
772 of 1311
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) J5 DRIVE CONTROLLER
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1 1 SAFETY IN
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT 2 TWO SPEED SWITCH
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT 3 SPARE DIGITAL INPUT 2
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID 4 H PAT SWITCH
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F) 5 ISO PAT SWITCH
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID 6 ISO LITE
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M) 7 L SWASH PLATE ANGLE
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1 8 R SWASH PLATE ANGLE
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1 9 SPARE ANALOG 4
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10 10 SPARE ANALOG 5
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11 11 L FWD RETURN
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12 12 CAN HIGH
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F) 13 LF ANGLE
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2 14 RF ANGLE
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND 15 LR ANGLE
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND 16 H PAT LITE
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND 17 RR ANGLE
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL 18 L JOYSTICK X
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M) 19 L JOYSTICK Y
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2 20 R JOYSTICK X
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER 21 L FWD DRIVE
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER 22 CAN LOW
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER 23 R QUAD A DRIVE
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24 24 R QUAD B DRIVE
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE) 25 TWO SPEED 1
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW 26 BRAKE LIGHT OUTPUT
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN 27 GROUND
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON 28 GROUND
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN 29 SENSOR GROUND
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP 30 SENSOR SUPPLY 2 +5V
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN 31 L REV DRIVE
A-32 HYD OIL TEMP A-32 32 CAN SHIELD
A-33 SPARE ANALOG A-33 33 L QUAD A DRIVE
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE 34 L QUAD B DRIVE
35 SAFETY OUT
36 BACKUP ALARM
ACS CONTROLLER HARNESS PART NUMBER HARNESS PART NUMBER 37 R JOYSTICK Y
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS MAINFRAME 7175625 A22 PUMP 7169309
PIN FUNCTION PIN FUNCTION PIN FUNCTION 38 SPARE ANALOG 1
STD CAB 7165991 SUSP JSTK 7163706
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 39 SPARE PWM COIL 7
DLX CAB 7176098 BACKUP ALARM 7175017
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 40 SENSOR SUPPLY 1 +5V
DLX FUEL 7175293 BRAKE ADAPTER 7165061
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 41 L REV RETURN
STD FUEL 7149219
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 42 R FWD RETURN
DOOR 7155024
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 43 R FWD DRIVE
S/R 6733370
F F LIFT HANDLE F LIFT MOTOR 1 44 R REV DRIVE
G GROUND G TILT HANDLE G PEDAL ENABLE 45 R REV RETURN
TAILGATE EUR 7175287
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 46 TWO SPEED 2
2 SPD ADP 7159366
J LIFT PEDAL J GROUND 47 UNSWITCHED BATTERY
ACS 7164144
K TILT PEDAL K TILT MOTOR 2 48 UNSWITCHED BATTERY
7159325 S630, S650, WITH SPEED SENSORS
SJC WHEEL 49 SPARE PWN COIL 6
7210503 S750, S770 WITHOUT SPEED SENSORS 50 SWITCHED BATTERY
7159458 T630, T650, WITH SPEED SENSORS
SJC TRACK
7210504 T750, T770 WITHOUT SPEED SENSORS
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
(PRINTED DECEMBER 2011)
Printed In U.S.A.
7171253
773 of 1311
POWER
FC1 FUSE 3 ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
25 A COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
C493 1 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
FC1 FUSE 4
25 A
C493 2
BATTERY MEGAFUSE
FC1 FUSE 2
BATT_CABLE 25 A J2B 2
J2B 3
1240 RED/WHT
FC1 FUSE 1 SHEET 8
1400 RED/WHT
25 A C408 17 SHEET 9
1070 RED 1120 RED/WHT 1450 RED/WHT 1450 RED/WHT 1420 RED/WHT
SHEET 8
1110 RED/WHT 1440 RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130 RED/WHT
15 A J1B 3
SHEET 9
FC2 FUSE 2 1460 RED/WHT
25 A SHEET 13
SHEET 13
FC2 FUSE 1
1190 RED 25 A 1165 RED/WHT
SHEET 5
1010 RED
FRC 1 FUSE 6
1310 RED 30 A 1360 RED/WHT
SHEET 7
1050 RED FRC1 FUSE 5
30 A 1350 RED/WHT
SHEET 6
FRC1 FUSE 11 Dealer Copy -- Not for Resale
1300 RED 25 A 1140 RED/WHT
SHEET 12
FRC1 FUSE 10
1340 RED 20 A 1330 RED/WHT
SHEET 11
1620 RNG/WHT
FRC1 FUSE 9 SHEET 8
1940 RNG/WHT
15 A SHEET 8
1320 RED/WHT 1930 RNG/WHT
SHEET 11 SHEET 8
SHEET 6 SHEET 9
SHEET 6 SHEET 8
1785 RNG/WHT
SHEET 9
1950 RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
5A SHEET 8
1570 RNG/WHT
SHEET 10
FRC1 FUSE 2
1760 RNG/WHT 25 A 1850 RNG/WHT
SHEET 9
FRC1 FUSE 3 Printable Version Click Here
15 A 1550 RNG/WHT
FRC1 FUSE1
SHEET 13
WIRING SCHEMATIC
25 A
C489 A (ACS & SJC MACHINE)
POWER
C404 B
S650 (S/N A3NV1100 1 - A3NV13098)
1050 RED 30
87
SHEET 12 (S/N A3NW11001 - A3NW11248)
SHEET 6
2055 BLK
2030 BLK
85 86
1795 RNG/WHT
FRC1 FUSE 7
25 A 1730 RNG/WHT
Sheet 3 of 15
SHEET 12 SHEET 5
FRC1 FUSE 8 (PRINTED DECEMBER 2011)
25 A
1740 RNG/WHT 1580 RNG/WHT 7171253
C492 6 SHEET 9
8000 TAN
J1A 4
SHEET 5
Printed In U.S.A. 1830 RNG/WHT
C408 6 SHEET 5
774 of 1311
GROUND
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
2080 BLK 2235 BLK

SHEET 5 C493 3
2070 BLK 2240 BLK
SHEET 5 C408 32 C493 4
2940 BLK 2950 BLK 2950 BLK
SHEET 8
2960 BLK 2510 BLK
SHEET 8 J1B 16
2920 BLK 2500 BLK 2110 BLK T6
SHEET 8 J1B 15 BATT GND
2250 BLK 2540 BLK
SHEET 8 J2B 16
2550 BLK 2090 BLK
J2B 15
2765 BLK
SHEET 11
2745 BLK
SHEET 12
2790 BLK T8
Dealer
SHEET 9 Copy -- Not
2780 BLK for Resale BATT GND
SHEET 13
2730 BLK
SHEET 9
2620 BLK
SHEET 11
2630 BLK 2720 BLK
SHEET 11 C103 B C489 B
2650 BLK 2600 BLK 2600 BLK
SHEET 10
2640 BLK 2810 BLK 2390 BLK
SHEET 11 SHEET 6
2610 BLK
SHEET 11
2200 BLK
SHEET 7
SHEET 13
2450 BLK
SHEET 7
2741 BLK
SHEET 13
2785 BLK 2710 BLK 2300 BLK T1
SHEET 13 SHEET 5 BATT GND
2930 BLK 2480 BLK
SHEET 9 C408 42 SHEET 7
2830 BLK 2900 BLK 2900 BLK
SHEET 13
2700 BLK 2105 BLK
SHEET 8 SHEET 11
2530 BLK 2000 BLK
SHEET 10
2520 BLK Printable Version Click Here
SHEET 10
SHEET 7
3530 LBL
3800 LBL
WIRING SCHEMATIC
SHEET 6
2370/BRN OR 3910 LBL
SHEET 9
SHEET 7
3310 LBL 3010 LBL
J1B 17
(ACS & SJC MACHINE)
3410 LBL
SHEET 7
SHEET 6
3110/LBL OR 2189/BRN S650 (S/N A3NV11001 - A3NV13098)
3510 LBL
SHEET 6
SHEET 6
3710 LBL
(S/N A3NW11001 - A3NW11248)
Sheet 4 of 15
Printed In U.S.A.
775 of 1311
CAN BUS
SJC CONTROL PAGE 15
9160 PUR/WHT
C503 2
9260 PUR RH DLX PANEL
C503 4
9200 PUR 9270 PUR 9210 PUR 9280 PUR 9230 PUR C408 8 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR
J1B 8 C479 4
GWY CTRLR 9100 PUR/WHT 9170 PUR/WHT 9110 PUR/WHT 9180 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
SHEET 3
1830 RNG/WHT 1 #
2070 BLK 2
SHEET 4 RIGHT
9560 PUR/WHT 3 JOYSTICK
9660 PUR 4
9240 PUR
C492 1
9140 PUR/WHT ACS CTRLR C449
C492 4
9290 PUR 1840 RNG/WHT 1 #
C492Copy
Dealer 7 -- Not for Resale SHEET 3
9190 PUR/WHT DRIVE CTRLR 2080 BLK 2
C492 8 SHEET 4 LEFT
9540 PUR/WHT 3
JOYSTICK
9640 PUR 4
9220 PUR
J2B 8 AUX CTRLR
9120 PUR/WHT
J2B 9
C426
9500 PUR/WHT A
J1B 14
J1B 20
J1B 21
9600 PUR
9400 PUR
B
D # CONNECTOR DOES NOT EXIST IN 7165991
C CAN (Remote Start Tool, ACD)
1730 RNG/WHT E Printable Version Click Here
SHEET 3
1165 RED/WHT F
SHEET 3
SHEET 4
2710 BLK G
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 5 of 15
Printed In U.S.A. (PRINTED DECEMBER 2011)
7171253
776 of 1311
ENGINE
SJC CONTROL PAGE 15
STARTER C109 STARTER
30 J1A 22
8250 TAN B 8250 TAN R M
B SHEET 3
1030 RED A
SHEET 3 87 8200 TAN 8200 TAN S 1015 RED
C110
2005 BLK 85 86 8210 TAN B
SHEET 12 J1A 7 S 1020 RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800 RNG/WHT 1815 RNG/WHT
SHEET 12
EXCITATION
2015 BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120 TAN D5
1350 RED/WHT 30 Dealer Copy -- Not for Resale8100 TAN B 8100 TAN PULL 24.5 OHM
SHEET 3 87 8150 TAN J1B 4 8800 TAN A 8800 TAN HOLD 0.33 OHM
J1A 30
2810 BLK 2800 BLK C 2800 BLK
85 86 SHEET 4
2025 BLK 8110 TAN
SHEET 7 J1A 3
C106 GLOW
3600 LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550 TAN
3610 LBL B GND 1060 RED J1A 14
SHEET 3 87 8500 TAN
3800 LBL T14 PRE HEATER
SHEET 4
3210 LBL B SIG 85 86
ENGINE COOLANT 2016 BLK 8510 TAN
3200 LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055 BLK
SHEET 3
C104
C107
3500 LBL B +5V PWR
3520 LBL C SIG ENGINE OIL PRESSURE
J1A 25
3510 LBL A GND SENDER (0.5-4.5V)
SHEET 4
WIRING SCHEMATIC
C355 C
3100/LBL OR 3180/LBL
C406
A
(ACS & SJC MACHINE)
3100/LBL OR 3180/LBL SIG
J1B 12 FUEL
SHEET 4
3110/LBL OR 2189/BRN 3110/LBL OR 2180/BRN B GND SENDER S650 (S/N A3NV11001 - A3NV13098)
C355 D
C405 (S/N A3NW11001 - A3NW11248)
3710 LBL B GND
SHEET 4
J1A 16
3700 LBL A SIG AIR FILTER
SWITCH
Sheet 6 of 15
Printed In U.S.A.
777 of 1311
HYDRAULIC
SJC CONTROL PAGE 15
TRACTION
LOCK C425 TRACK MACHINES
30 4150 LGN
1360 RED/WHT J1A 13
SHEET 3 87 4100 LGN B C308
BRAKE
2025 BLK 4200 LGN A 4200 RED A SOLENOID
SHEET 6 85 86 J1B 6
2035 BLK 4110 LGN 2200 BLK C 2200 BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C SOLENOID
C362 C414
OPTIONAL REAR AUX
4440 LGN A 4440 LGN 1 SIG DIRECTIONAL SOLENOID
J2B 5
2440 BLK B 2440 BLK 2 GND FEMALE COUPLER
J2A 2
7.5 OHM 12V C420
C413 2410 BLK B HYD LOCK
4430 LGN C 4430 LGN 1 SIG OPTIONAL REAR AUX J1A 1 SOLENOID
J2B 7 4410 LGN A
2430 BLK D 2430 BLK 2 GND
DIRECIONAL SOLENOID J1B 13 9.8 OHM 12V
J2A 10 MALE COUPLER Dealer Copy -- Not for Resale C105
7.5 OHM 12V HYDRAULIC
C416 3410 LBL B CHARGE
4450 LGN E 4450 LGN 1 SIG OPTIONAL REAR AUX 3420 LBL C
J2B 4 J1B 1 PRESSURE
2450 BLK F 2450 BLK 2 GND BLEED / LOCK VALVE 3400 LBL A 0.5-7.5V
SHEET 4 SOLENOID MALE COUPLER J1B 23
7.5 OHM 12 V +8V
C417 C108 HYDRAULIC
4480 LGN G 4480 LGN 1 SIG OPTIONAL REAR AUX 3310 LBL B TEMPERATURE
J2B 6 BLEED / LOCK VALVE SHEET 4
2480 BLK H 2480 BLK 2 GND 3300 LBL A SENDER
SHEET 4 SOLENOID FEMALE COUPLER J1A 32 500 - 3000 OHM
9.8 OHM 12 V
C112
C415 3430 LBL A HYDRAULIC OIL
2460 BLK B GND J1A 34
J2A 26 OPTIONAL HIGH FLOW 3530 LBL B FILTER SWITCH
4460 LGN A SIG SOLENOID SHEET 4
J2B 26 7.5 OHM 12 V
C418
2330 BLK 2 GND
J2A 18 FRONT ROD SOLENOID (MALE)
J2B 19
C419
2340 BLK 2 GND Printable Version Click Here
J2A 1 FRONT BASE SOLENOID (FEMALE)
J2B 13
C437
WIRING SCHEMATIC
2360 BLK 2 GND
J1A 27
J1B 25
4360 LGN 1 SIG
OPTIONAL TWO SPEED
MAKEUP SOLENOID
(ACS & SJC MACHINE)
2350 BLK
C441
2 GND
S650 (S/N A3NV11001 - A3NV13098)
J1A 26 TWO SPEED
J1B 26
(S/N A3NW11001 - A3NW11248)
C446
J1A 18
2910 BLK 2 GND HYDRAULIC
FAN SOLENOID
Sheet 7 of 15
4010 LGN 1 SIG
J1B 19 7.2 OHM
12 V
Printed In U.S.A.
7171253
778 of 1311
CAB
YEL
DISPLAY
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW CABIN PAGE 9
SJC CONTROL PAGE 15
C500 RH KEY SWITCH

T13 C408 4
BUZZER (+) 9360/PUR OR 8130/TAN 9360/PUR OR 8130/TAN 2
J1A 24
SHEET 3 1940 RNG/WHT 9350/PUR OR 3040/LBL 9350/PUR OR 3040/LBL 4
J1B 22
C408 40
1950 RNG/WHT 5
SHEET 3
T2 1420 RED/WHT 1
SHEET 3
BUZZER (-) 2960 BLK 3
SHEET 4
6
LEFT PANEL (BLACK)
C479 10
9320/PUR OR 7040/WHT
RH DLX PANEL
2920 BLK C479 2
SHEET 4 1590 RNG/WHT C503 5
1440 RED/WHT C479 1 SHEET 3
SHEET 3 Dealer Copy -- Not for Resale 1240 RED/WHT C503 1
1620 RNG/WHT C479 5 SHEET 3
1960 RNG/WHT SHEET 3 C503 3
SHEET 3 2250 BLK
SW9 6450 PNK C479 11 SHEET 4
SHEET 13
TRAVEL CONTROL C479 8
SWITCH OPTIONAL 6550 PNK
SHEET 13
5 6 4500/LGN OR 3600/LBL C479 9
SHEET 9
4
4730 LGN C479 7
2700 BLK 2 3
SHEET 4 1
C480 LEFT PANEL (GRAY)

4750 LGN 12
SHEET 9
9310/PUR OR 3610/LBL 2
SHEET 9

PTOL
C408 1 C499 (Press To Operate Loader)
J1A 20
9380/PUR OR 3030/LBL 9380/PUR OR 3030/LBL 2 WIRING SCHEMATIC
9370/PUR OR 2380/BRN 9370/PUR OR 2380/BRN 4
J1A 19
C408 37
1930 RNG/WHT 1
(ACS & SJC MACHINE)
SHEET 3
2940 BLK 3
SHEET 4 S650 (S/N A3NV1100 1 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 8 of 15
Printed In U.S.A.
7171253
779 of 1311
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550 LGN C408 5 4550 LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS) C492 2
SWITCH
1785 RNG/WHT 2 1 4275 LGN C408 3 4275 LGN
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 C492 3
3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060 BLK 5 6 4235 LGN C408 2 4235 LGN 4230 LGN
4 SHEET 10
4220 LGN 4240 LGN
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14 C492 5 SHEET 10
SJC CONTROL PAGE 15
C212
2795 BLK 1
+
1375 RED/WHT 2 POWER SOCKET
-
C209
C408 24
2790 BLK 2790 BLK 2010 BLK B
C408 23 SHEET 4
1370 RED/WHT 1370 RED/WHT 1390 RED/WHT A DOME LIGHT
SHEET 3
4760 LGN C
*
C676
1885 RNG/WHT 1
2885 BLK 2
C129 C279
1210 RED/WHT A
SHEET 3
1580 RNG/WHT
C408 16
1580 RNG/WHT * 1865 RNG/WHT B LEFT SPEAKER
1
2
+ 7820 WHT
7830 WHT
3
4 RADIO CONN
2820 BLK C -
ACCESSORY
CONN C278
2 - 7810 WHT 6
RIGHT SPEAKER 1 7800 WHT 5
+
2730 BLK C408 33 2730 BLK
SHEET 4
C277
Dealer Copy -- Not1510
forRNG/WHT
Resale 4
AIR RIDE
2210 BLK 5 SEAT SOLENOID
C482
SEATBAR
SENSOR C667 C250 SENSOR SHOWN
2370/BRN OR 3910 LBL C408 45 2370/BRN OR 3910 LBL A GND
SHEET 4 4750 LGN 4740 LGN 4 4740 LGN 1 WITH DOOR OPEN
SHEET 8
3920/LBL OR 3370/LBL 3920/LBL OR 3370/LBL 1400 RED/WHT 5 1400 RED/WHT 2 DOOR SENSOR C251
C408 46 B SIG SHEET 3
J1B 11 1860 RNG/WHT D SW PWR
3900/LBL OR 5370/YEL 3900/LBL OR 5370/YEL 6 7330 WHT C PARK
3930 LBL C PWR WIPER
J1B 24 1570 RNG/WHT 7300 WHT A LOW MOTOR
+5V 3500 LBL C408 44
SHEET 6 B GND
1850 RNG/WHT 1850 RNG/WHT 1 1850 RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310 WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN OR 3600/LBL 3 2 FRONT WIPER
SHEET 8 1 2840 BLK 2 2840 BLK SWITCH C252
9310/PUR OR 3610/LBL 4 5
SHEET 8 7310 WHT L
1775 RNG/WHT 6
SHEET 3 WASHER
2930 BLK
SHEET 4 2845 BLK X MOTOR
WIRING SCHEMATIC
(ACS & SJC MACHINE)
7165991 Standard Cab
S650 (S/N A3NV11001 - A3NV13098)
7176098 Deluxe Cab (S/N A3NW11001 - A3NW11248)
Printed In U.S.A. * SPLICE DOES NOT EXIST IN 7165991 7171253
780 of 1311
MANUAL
CONTROLS
SJC CONTROL PAGE 15
C409
RIGHT HANDLE
2530 BLK K
SHEET 4
4230 LGN G
SHEET 9
1590 RNG/WHT A
4940 LGN H
J2A 30
4930 LGN J SKI CTRL
J2A 31
4920 LGN E DETENT FLOW
J2B 21
4910 LGN F
J2A 13 TWO SPD
4310 LGN C -
J2B 17
4320 LGN D
J2B 18 PWM
4300 LGN B +
J2B 23
C410
LEFT HANDLE
K
4640 LGN D
J2A 20
4840 LGN C
J2A 28
4830 LGN B SKI CTRL
Dealer Copy --J2A
Not22 for Resale
4820 LGN G
J2A 12
4810 LGN F SIDE SHIFT
J2A 11
1570 RNG/WHT 1710 RNG/WHT A
SHEET 3
1560 RNG/WHT J
J2B 22
4240 LGN H
SHEET 9
2520 BLK E
SHEET 4
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A C103 C T19 1
7100 WHT 7100 WHT B
+ BACKUP ALARM
2650 BLK 7001923 A HORN
SHEET 4 -
T20 1

2370 BLK 3
J1A 10 TILT SPOOL LOCK SOLENOID
J1B 7
4370 LGN 1
2
(NOT USED WITH ACS) WIRING SCHEMATIC
C422 (ACS & SJC MACHINE)
2380 BLK 3
J1A 2 LIFT SPOOL LOCK SOLENOID
J1B 5
4380 LGN 1
2
(NOT USED WITH ACS) S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 10 of 15
Printed In U.S.A. (PRINTED DECEMBER 2011)
7171253
781 of 1311
LIGHTS
SJC CONTROL PAGE 15 C434-1
2735 BLK B LEFT FRONT
37.00 Watts
C434-2
C408 28
2765 BLK 2765 BLK 2750 BLK B LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000 PNK C408 25 6000 PNK 6120 PNK A RIGHT FRONT
37.00 Watts
C435-2
6130 PNK A
RIGHT FRONT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610 BLK 2
1330 RED/WHT 30 C103 A 6310 PNK RIGHT REAR
SHEET 3 87 6340 PNK 6310 PNK 6320 PNK 1
Dealer Copy -- Not for Resale TAIL LIGHT
2105 BLK 85 86 C602
SHEET 4
2045 BLK 6330 PNK 1
6320 PNK 2640 BLK LEFT REAR
2
J1A 5 SHEET 4 TAIL LIGHT
6330 PNK
J1A 31
2620 BLK T16 1 RIGHT REAR

SHEET 4
6210 PNK WORK LIGHT
REAR
LIGHT T15 1
1320 RED/WHT 30 C103 H
SHEET 3 6200 PNK 6200 PNK T17 1
87 LEFT REAR
2630 BLK WORK LIGHT
85 86 SHEET 4
2045 BLK T18 1
2035 BLK
SHEET 7
6210 PNK
J1A 17
6230 PNK Printable Version Click Here
J1A 28
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
782 of 1311
HVAC
SJC CONTROL PAGE 15
C630
7021 WHT 7020 WHT C408 34 7020 WHT B
J1A 11
7023 WHT 2570 BLK C
3320 LBL A
THERMOSTAT
C350
B C483
7024 WHT A EVAPORATOR 2560 BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980 RNG/WHT A DBL
C486 7220 WHT B WHT (TEMP CONTROL
C355 A 7024 WHT SWITCH)
7025 WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290 BLK 2280 BLK D SIG
SHEET 13
D4 2130 BLK C GND HEATER
1900 RNG/WHT 1910 RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140 RED/WHT 30 Dealer Copy -- Not for Resale OFF
SHEET 3 87 1500 RNG/WHT C408 211500 RNG/WHT 5 2
1
2030 BLK 85 86 4
SHEET 3 6 C611
2005 BLK
SHEET 6 3 1970 RNG/WHT A 14.00 Amps High
1790 RNG/WHT
SHEET 3 1520 RNG/WHT B 7.50 Amps Med BLOWER
1815 RNG/WHT
SHEET 6 7320 WHT C 5.00 Amps Low MOTOR
8020 TAN
J1A 21 2580 BLK D
2745 BLK 2745 BLK
SHEET 4
7040 WHT
C408 22
SW11
AC SWITCH
1 C
2100 BLK
3
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 12 of 15
Printed In U.S.A.
7171253
783 of 1311
OPTIONS
SJC CONTROL PAGE 15
SW5
POWER
BOBTACH
SWITCH C408 9
C408 26 1 7000/WHT OR 4480/LGN 7000/WHT OR 4480/LGN
C411 1410 RED/WHT 1410 RED/WHT 1380 RED/WHT 2
C408 15 SHEET 3
B 6010 PNK 6010 PNK 1430 RED/WHT 3 C408 10
1200 RED/WHT 4 7010/WHT OR 4470/LGN 7010/WHT OR 4470/LGN
C 6550 PNK 5
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515 PNK 6500 PNK 6500 PNK 6530 PNK FLASHER CONN
5 PIN E 6540 PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415 PNK 6400 PNK 6400 PNK 6430 PNK 6570 PNK
C607
6450 PNK 2725 BLK 6 C355 E
SHEET 8 SW3 5 A 7010/WHT OR 4470/LGN WHT
1 4
C103 E HAZARD SWITCH 2 C670 STROBE B 2770/BLK OR 2470/BLK BLK 2751/BLK OR 2770/BLK
6410 PNK 3 1 2
(PINS 3 & 6 6700 PNK E BEACON 2751/BLK OR 2770/BLK
6510 PNK 4 3 2290 BLK SHEET 4
INTERNALLY SHEET 12 C355 B
5 2850 BLK 2420 BLK D
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK OR 2480/BLK
F
2780 BLK C408 302780 BLK A 7000 WHT C355 F
SHEET 4 B
6440 PNK
Dealer Copy
6540 PNK
-- Not for Resale RIGHT PWR BOB OPEN
BLINKER
SW6
BUCKET
POSITION
1550 RNG/WHT C408 13 1550 RNG/WHT SWITCH
SHEET 3
3 2
7022 WHT 1
C126
SHEET 4 SHEET 4 4
C412 2785 BLK B 2830 BLK 5
B 7210 WHT C408 38 7210 WHT A 6 C423
LEFT HANDLE C408 35 D3
2 PIN A 1460 RED/WHT 7022 WHT 7030 WHT A
SHEET 3
2741 BLK 2740 BLK B

SHEET 4
C497
7200 WHT C
J2A 5 SJC
6420 PNK A HORN/BLINKER
J2A 4
6520 PNK B Printable Version Click Here
J2A 3
WIRING SCHEMATIC
(ACS & SJC MACHINE)
S650 (S/N A3NV11001 - A3NV13098)
(S/N A3NW11001 - A3NW11248)
Sheet 13 of 15
Printed In U.S.A.
7171253
784 of 1311
ACS
CONTROLS
SJC CONTROL PAGE 15
J1-ACS
H 2280 BLK
2670 BLK See manual controls for harness
2240 BLK
connection
HANDLE TILT
MAINFRAME HARNESS 1170 RED/WHT HALL SENSOR C409
C492 K A
G 2250 BLK 8 J3-ACS HANDLE
G B
7 B 1190 RED/WHT LOCK
A
C 4450 LGN 2 C 1180 RED/WHT H
4220 LGN 5 J SKI CTRL
4275 LGN 3 C429 LIFT ACTUATOR E DETENT
9240 PUR 1 D 4690 LGN 8 F FLOW
9140 PUR/WHT 4 7 C TWO SPD
1740 RNG/WHT 6 6 D
F 4680 LGN 5 PWM
B
C493 J 2260 BLK 4
A 4 H 2270 BLK 1 GND C410
E 3 4670 LGN 2 SIG
2 K
D 1530 RNG/WHT 3 PWR
1 D
B FLOAT
C
C428 TILT ACTUATOR
C472 B SKI CTRL
K 4790 LGN 8
J2-ACS G
2650 BLK B B GND 7 SIDE
F 4650 LGN C C SIG HANDLE LIFT Dealer Copy -- Not for Resale 6
F
SHIFT
A
1510 RNG/WHT A A PWR HALL SENSOR A 4780 LGN 5
J
4
H A
1630 RNG/WHT 3 PWR HANDLE
E B
4770 LGN 2 SIG LOCK
H 2770/BLK OR 2470/BLK 1 GND
C411
E
C467 E
A 2 C
B 4280 LGN 1 A
C 2510 BLK 3 LIFT D TURN SIGNAL
D SOLENOID B
C468
2 C412
C469 G 4260 LGN 4270 LGN 1 B
2750 BLK B B GND E 4220 LGN 2500 BLK 3 TILT A HORN
SOLENOID
G 4750 LGN C C SIG HANDLE TILT
1610 RNG/WHT A A PWR HALL SENSOR
C471
1520 RNG/WHT 1 PWR
J 4660 LGN 3 SIG LIFT PEDAL
2660 BLK 2 GND HALL SENSOR Printable Version Click Here
1620 RNG/WHT
C470
1 PWR
WIRING SCHEMATIC
K 4760 LGN 3 SIG TILT PEDAL
2760 BLK 2 GND HALL SENSOR (ACS & SJC MACHINE)
1610 RNG/WHT
1510 RNG/WHT
1500 RNG/WHT
1530 RNG/WHT
1630 RNG/WHT
S650 (S/N A3NV11001 - A3NV13098)
4275 LGN
4220 LGN
(S/N A3NW11001 - A3NW11248)
4670 LGN
4770 LGN Sheet 14 of 15
785 of 1311
HARNESS PART NUMBER
7159325 WITH SPEED SENSORS
SJC WHEEL S630, S650, S750, S770
SJC
7210503 WITHOUT SPEED SENSORS
J5 - DRIVE CONTROLLER C454

SJC TRACK
7159458
7210504
T630, T650, T750, T770
WITH SPEED SENSORS
WITHOUT SPEED SENSORS
LIFT
SUSP JSTK 7163706
S630, S650,S750, S770, C429 ACTUATOR
29 2510 BLK 2580 BLK 3 GND T630, T650, T750, T770
4680 LGN 5
1540 RNG/WHT 1 PWR 6
LEFT SPEED
33 3020 LBL 2 SIG SENSOR 4690 LGN 8
34 3080 LBL 4
CONTROLS
SIG 2630 BLK 1 GND
NOTE: SPEED SENSORS NO LONGER
40 1640 RNG/WHT C453 FACTORY INSTALLED. SEE SERVICE 4
1530 RNG/WHT 1 PWR LETTER SL5323 OR BTI 410 4670 LGN 2 SIG
2570 BLK 3 GND 7
23 3000 LBL 2 SIG
RIGHT SPEED 1610 RNG/WHT 3 PWR
SENSOR
24 3070 LBL 4 SIG
1500 RNG/WHT
C428 TILT ACTUATOR
2250 BLK
C536 1630 RNG/WHT 3 PWR SCHEMATIC INDEX
1810 RNG/WHT 2 C543 HARNESS, A22 PUMP 7169309 OVERVIEW PAGE 1,2
4
2810 BLK 4 2810 BLK 1 GND POWER PAGE 3
4770 LGN 2 SIG
8 4720 LGN 3 4720 LGN 3 SIG RIGHT GROUND PAGE 4
6
1710 RNG/WHT 1 1770 RNG/WHT 2 PWR
SWASHPLATE CAN BUS PAGE 5
1 GND
ENGINE PAGE 6
C537
4780 LGN 5
HYDRAULICS PAGE 7
1820 RNG/WHT 2 C542 7
CAB DISPLAY PAGE 8
2860 BLK 4 2860 BLK 1 GND 4790 LGN 8
CABIN PAGE 9
7 4950 LGN 3 4950 LGN 3 LEFT
SIG MANUAL CONTROLS PAGE 10
SWASHPLATE
1770 RNG/WHT 1 1770 RNG/WHT 2 PWR K LIGHTS PAGE 11
HVAC PAGE 12
J2-ACS
C501 C546 J
E OPTIONS PAGE 13
43 4260 LGN 1 4260 LGN 1
RIGHT FORWARD DRIVE H ACS CONTROL PAGE 14
42 2660 BLK 2 2660 BLK 2
SJC CONTROL PAGE 15
F
C547
G
C WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
44 4250 LGN 3 4250 LGN 1
45 2650 BLK 4 2650 BLK 2 RIGHT REVERSE DRIVE D
B
C545 A
ACS CONTROLLER
31 4280 LGN 5 4280 LGN 1 GROUNDING 2000 THROUGH 2999 BLACK BLK
41 2680 BLK 6 2680 BLK 2 LEFT REVERSE DRIVE
C544 G ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
J1-ACS
21 4270 LGN 7 4270 LGN 1 A LIGHTS 6000 THROUGH 6999 PINK PNK
LEFT FORWARD DRIVE
11 2670 BLK 8 2670 BLK 2 Dealer Copy -- Not for Resale F ACCESSORIES 7000 THROUGH 7999 WHITE WHT
E ENGINE 8000 THROUGH 8999 TAN TAN
D COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
C474 HARNESS, OBW STOP LTS 7151696 C707 B COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
26 4210 LGN A 1730 RNG/WHT A H
6600 PNK B C C460
87A 2730 BLK C
30 1 1830 RNG/WHT 1
C492
4210 LGN 85 86 SEE OPTIONS 2 2070 BLK 2
12 9190 PUR/WHT 8 RIGHT
HARNESS 7151691 4 9660 PUR 4
22 9290 PUR 7 BRAKE LIGHT RELAY JOYSTICK
4 4550 LGN 2
K 3 9560 PUR/WHT 3
6 4220 LGN 5
16 4275 LGN 3 A
D C459
J3-ACS
9140 PUR/WHT 4
9240 PUR 1 F 1 1840 RNG/WHT +12V PWR 1
MAINFRAME H
1740 RNG/WHT 6 2 2080 BLK GND 2
50 1750 RNG/WHT HARNESS J LEFT
47 1250 RED/WHT C 4 9640 PUR CAN LOW 4
C493 JOYSTICK
48 1260 RED/WHT 1235 RED/WHT 2 B
3 9540 PUR/WHT CAN HIGH 3
27 2470 BLK 2235 BLK 3 E
28 2490 BLK 1170 RED/WHT 1 G
2240 BLK 4
1760 RNG/WHT WIRING SCHEMATIC

2280 BLK
2270 BLK
2260 BLK
(ACS & SJC MACHINE)
1180 RED/WHT
1190 RED/WHT S650 (S/N A3NV11001 - A3NV13098)
C404
C103 C
(S/N A3NW11001 - A3NW11248)
36 7100 WHT A 7100 WHT +
B
SHEET4 - Sheet 15 of 15
BACKUP
(CONNECTS TO BACKUP ALARM
ALARM C404 ON MFR (PRINTED DECEMBER 2011)
HARNESS)
786 of 1311
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C446 HYDRAULIC FAN 2 7 FC1 FUSE CENTER 1 8 3
C103 TAILGATE 8 4,10,11,13 C449 LEFT JOYSTICK (CAB HARN) 4 5 FC2 FUSE CENTER 2 8 3
C104 ENGINE COOLANT SENSOR 2 6 C450 RIGHT JOYSTICK (CAB HARN) 4 5 FRC1 FUSE RELAY CENTER 64 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C453 RIGHT QUAD A DRIVE 4 15
C106 ENGINE SPEED SENSOR 2 6 C454 LEFT QUAD DRIVE 4 15 J1A GATEWAY CONTROLLER 34 3,6-8,10-13
C107 ENGINE OIL PRESSURE 3 6 C467 LIFT PEDAL LOCK 3 14 J1B GATEWAY CONTOLLER 26 3-10,13
C108 HYD TEMPERATURE SENDER 2 7 C468 TILT PEDAL LOCK 3 14 J2A AUX CONTROLLER 34 7,10,13
C109 S/R ADAPTER HARNESS 2 6 C469 TILT HANDLE 3 14 J2B AUX CONTROLLER 26 3-5,7,10,13
C110 ALTERNATOR 2 6 C470 TILT PEDAL 3 14
C112 HYD OIL FILTER SWITCH 2 7 C471 LIFT PEDAL 3 14 J1-ACS ACS CONTROLLER 8 14, 15
C126 HORN 2 13 C472 LIFT HANDLE 3 14 J2-ACS ACS CONTROLLER 10 14, 15
C129 CAB ACCESSORY 3 9 C474 BRAKE LIGHT 1 15 J3-ACS ACS CONTROLLER 10 14, 15
C209 DOME LIGHT 3 9 C479 LEFT PANEL(BLACK) 12 5,8 J5 DRIVE CONTROLLER 50 15
C212 POWER SOCKET 2 9 C480 LEFT PANEL(GRAY) 12 8
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 SW1 BRAKE SWITCH 6 8
C277 AIR RIDE SEAT 6 13 C483 TEMP CONTROL SWITCH 3 12 SW2 BEACON SWITCH 6 13
C278 RIGHT SPEAKER 2 13 C486 AC COMPRESSOR 2 12 SW3 HAZARD SWITCH 6 13
C279 LEFT SPEAKER 2 13 C489 MFR ACCESSORY 2 3,4 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C308 BRAKE SOLENOID 2 7 C492 ACS/SJC/AWS-MFR HARN 8 3,5,9 SW5 POWER BOBTACH SWITCH 6 13
C350 AC EVAPORATOR SWITCH 2 12 C493 ACS/SJC/AWS-MFR HARN 4, 15 3,4 SW6 BUCKET POSITION SWITCH 6 13
C355 DLX or STD FUEL HARNESS 6 6,12,13 C497 SJC HORN/BLINKER 3 13 SW9 TRAVEL CONTROL SWITCH 6 8
C404 BU ALARM-MFR HARN 2 3,10 C499 PTOL 4 8 SW10 BLOWER SWITCH 5 12
C405 AIR FILTER SWITCH 2 6 C500 RH KEY SWITCH 6 8 SW11 AC SWITCH 3 12
C406 FUEL SENDER 2 6 C501 A22 PUMP HARNESS 8 15
C408 CAB - MFR HARN CONNECTOR 48 3-5,8-9,11-13 C503 RH DLX PANEL 6 5,8 T1 BATT GROUND 1 4
C409 RIGHT HANDLE 10 10 C542 LEFT SWASHPLATE 3 15 T2 BUZZER GROUND 1 8
C410 LEFT HANDLE 10 10 C543 RIGHT SWASHPLATE 3 15 T3 FLASHER 2 13
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C544 LEFT FORWARD DRIVE 2 15 T6 BATT GROUND 1 4
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C545 LEFT REVERSE DRIVE 2 15 T8 BATT GROUND 1 4
C415 HIGH FLOW SOLENOID 2 13 C546 RIGHT FORWARD DRIVE 2 15 T13 BUZZER POWER 1 8
C418 FRONT ROD (MALE) 2 7 C547 RIGHT REVERSE DRIVE 2
Dealer 15 --
Copy Not forT14
Resale PRE HEATER 1 6
C419 FRONT BASE (FEMALE) 2 7 T15 RIGHT REAR WORK LIGHT(+) 1 11
C420 HYD LOCK 2 7 T16 RIGHT REAR WORK LIGHT(-) 1 11
C440 RF BASE 2 14 C602 LEFT REAR TAIL LIGHT 2 11 T17 LEFT REAR WORK LIGHT (+) 1 11
C422 TILT SPOOL LCOK 3 10 C603 RIGHT REAR TAIL LIGHT 2 11 T18 LEFT REAR WORK LIGHT (-) 1 11
C423 BUCKET POSITION 2 13 C606 POWER BOBTACH OPEN 2 13 T19 BACKUP ALARM 1 10
C425 BRAKE SOLENOID 3 7 C607 POWER BOBTACH CLOSE 2 13 T20 BACKUP ALARM (GND) 1 10
C426 CAN (Remote Start Tool, ACD) 7 5 C610 HVAC DUCT FAN 2 12
C428 TILT ACTUATOR 8 14, 15 C611 BLOWER MOTOR 4 12
C429 LIFT ACTUATOR 8 14,15 C630 THERMOSTAT 3 12
C434-1 LEFT WORKLIGHT 1 2 11 C635 HEATER VALVE 6 12
C434-2 LEFT WORKLIGHT 2 2 11 C667 DOOR 6 9
C435-1 RIGHT WORKLIGHT 1 2 11 C670 EXTERIOR BEACON 6 13
C435-2 RIGHT WORKLIGHT 2 2 11 C676 RADIO 6 13
C437 TWO SPEED MAKEUP 2 13
C441 TWO SPEED 2 13 C707 OBW STOP BRAKE LIGHT 3 15

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 Printable Version Click Here
BATT FEED, FUSED
BATT FEED, SWITCHED
1000 THROUGH 1499
1500 THROUGH 1999
RED/WHITE
ORANGE/WHITE
RED/WHT
RNG/WHT
GROUND
CAN BUS
PAGE 4
PAGE 5
WIRING SCHEMATIC
BATTERY GROUND
move
2000 THROUGH 2999
2000 THROUGH 2999
BLACK
BROWN
BLK
BRN
ENGINE
HYDRAULICS
PAGE 6
PAGE 7
(ACS / SJC MACHINE)
MONITORING
HYDRAULIC
3000 THROUGH 3999
4000 THROUGH 4999
LIGHT BLUE
LIGHT GREEN
LBL
LGN
CAB DISPLAY
CAB
PAGE 8
PAGE 9
S650 (S/N A3NV13099 - A3NV18204)
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
(S/N A3NW11249 - A3NW12733)
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC
OPTIONS
PAGE 12
PAGE 13
Sheet 1 of 15
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14 (PRINTED APRIL 2014)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT SJC PAGE 15

787 of 1311
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PWM POT SIGNAL
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20
A-23 B-23 SENSOR SUPPLY 8V A-23 B-23 HANDLE POT POWER (8 VOLT)
A-27 SPARE A-27
A-29 A-29
A-32 HYD OIL TEMP (8 VOLT) Dealer
A-32 Copy -- Not for Resale
A-33 A-33
HARNESS PART NUMBER

S630, S650, T630, T650
7199263
MAINFRAME
A770
7196824
MAINFRAME
S750, S770, T750, T770
7196823
MAINFRAME
DLX CAB 7196753
STD CAB 7195991
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 2 of 15

788 of 1311
POWER
C503 RH DLX PANEL
C408 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
CAB-MFR HARN SHEET 9
SHEET 8
2 SHEET 8
C479 LH PANEL
+12V 1025 RED
FUSE 2 25 A
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
100.0 Amps
BATT_CABLE FUSE 3 25 A 1
1270 RED 1170 RED/WHT LEGEND
SCHEMATIC INDEX
C493 PARTIAL CONNECTOR
OVERVIEW PAGE 1,2
SJC/ACS/AWS-MFR HARN
FUSE 4 25 A POWER PAGE 3
1280 RED 1235 RED/WHT 2 (4 PIN)
GROUND PAGE 4
1010 RED
CONNECTOR
SHEET 5
SHEET 13
1460 RED/WHT
C412 LH HANDLE HORN
FUSE 4 15 A ACS PAGE 14
SHEET 9 SJC PAGE 15

1050 RED
FUSE 5 30 A
1350 RED/WHT
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FRC1 STARTER RELAY
SHEET 11
Dealer
FRC1 REARCopy -- Not
LIGH RELAY for Resale
1340 RED SHEET 11
C404
SHEET 8
FUSE 3 15 A C499 RH PANEL PTOL
1550 RNG/WHT C408
C408 CAB-MFR CONN (BKT POSITION) CAB-MFR HARN SHEET 8
SW1 BRAKE SWITCH
43
SHEET 8
C410 LEFT HANDLE
SHEET 10 SHEET 8
SHEET 9
FUSE 8 25 A
FRC1 1580 RNG/WHT
SWITCHED C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) SHEET 8
POWER RELAY FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
SHEET 6
1050 RED 30
87
J1A
C110 ALT EXCITATION WIRING SCHEMATIC
SHEET 12
85 86 FRC1 HVAC RELAY
SHEET 6
2055 BLK
2030 BLK
3380 LBL 4 C408
CAB-MFR HARN (ACS / SJC MACHINE)
SHEET 12
1920 RNG/WHT 6 1840 RNG/WHT
1920 RNG/WHT
SHEET 5
C449 LH JOYSTICK
S650 (S/N A3NV13099 - A3NV18204)
C492 1830 RNG/WHT
1740 RNG/WHT 6
SHEET 5
C450 RH JOYSTICK (S/N A3NW11249 - A3NW12733)
(8 PIN)
789 of 1311 Printed In U.S.A. 7197682

GROUND
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
ACS PAGE 14
SJC PAGE 15
C493
2080 BLK
SHEET 5 SJC/ACS/AWS-MFR HARN
C449 LH JOYSTICK (4 PIN)
2070 BLK
SHEET 5
C450 RH JOYSTICK 3 2235 BLK
2920 BLK C408 4 2240 BLK
SHEET 8 CAB-MFR HARN
C479 LH PANEL
2940 BLK 2950 BLK 32 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8 2765 BLK
C503 RH DELUXE PANEL SHEET 11
16 2540 BLK C408 CAB-MFR CONN (FR LIGHTS) T8
J2B 15 2745 BLK BATT GND
2550 BLK 2090 BLK SHEET 12
2930 BLK AUX CTRLR
SW1 BRAKE SWITCH 2790 BLK
2830 BLK 2900 BLK 42 2900 BLK SHEET 9
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES)
SHEET 11 2780 BLK
SHEET 8 2700 BLK FRC1 FRONT LIGHT RELAY SHEET 13
2785 BLK
SHEET 10 Dealer Copy -- Not 2000
2530 BLK
for Resale 2730 BLK
SHEET 13 C409 RIGHT HANDLE SHEET 9
C126 HORN C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
2520 BLK
SHEET 10
2620 BLK C410 LEFT HANDLE
SHEET 11 T1
T16 RH REAR LIGHT
C103 BATT GND
2630 BLK C489
SHEET 11 TAILGATE HARN B 2720 BLK
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
T20 BU ALARM 2400 BLK 2390 BLK
SHEET 6
2640 BLK C101 FUEL SHUTOFF SOLENOID
SHEET 11 2200 BLK
C602 LH REAR LIGHT SHEET 7
2610 BLK C425 BRAKE
SHEET 11 2770 BLK
C603 RH REAR LIGHT SHEET 13
C355 FUEL HARN (PWR BOB/AC)
2455 BLK
2170 BRN SHEET 13
SHEET 6 C423 BKT POSITION SOLENOID
C104 ENGINE COOLANT SENSOR 2710 BLK 2300 BLK
2160 BRN SHEET 5
SHEET 6 C426 REMOTE RUN, ACD
C106 ENGINE SPEED SENSOR
2320 BRN
SHEET 7
2370 BRN J1B Printable Version Click Here
SHEET 9
SHEET 7
2220 BRN 2230 BRN 17 WIRING SCHEMATIC
SHEET 7 2190 BRN (ACS / SJC MACHINE)

SHEET 6
2180 BRN S650 (S/N A3NV13099 - A3NV18204)
2140 BRN
(S/N A3NW11249 - A3NW12733)
SHEET 6
Sheet 4 of 15
2150 BRN
SHEET 6
C405 AIR FILTER SWITCH (PRINTED APRIL 2014)
790 of 1311
CAN BUS
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK * DLX CAB HARN 7196753 ONLY
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 13
JOIN ONE WIRE)
SHEET #
ACS PAGE 14
SJC PAGE 15
J1B C408
GWY CTRLR CAB-MFR HARN
8 9200 PUR 9270 PUR 9210 PUR 9280 PUR 9230 PUR 8 9230 PUR 9240 PUR 9250 PUR 9650 PUR 9630 PUR 4
CAN LO C479
9 9100 PUR/WHT 9170 PUR/WHT 9110 PUR/WHT 9180 PUR/WHT 9130 PUR/WHT 7 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
120 OHM 120 OHM
RESISTOR C492 RESISTOR
(8 PIN)
C426 1 9260 PUR 4
9240 PUR C503
Remote Run Tool, ACD Dealer4Copy
9140 PUR/WHT ACS -- Not
CTRLR for Resale 9160 PUR/WHT 2 RIGHT DELUXE PANEL
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
21 3090 LBL D REMOTE RUN KEY 9290 PUR 7
1830 RNG/WHT 1
C 9190 PUR/WHT 8 SHEET 3
SHEET 3
1730 RNG/WHT E SWITCHED POWER
DRIVE CTRLR
SHEET 4
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
9120 PUR/WHT 9
AUX CTRLR
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 5 of 15
791 of 1311
PARTIAL CONNECTOR
ENGINE
CONNECTOR
CAB DISPLAY PAGE 8
OPTIONS PAGE 13
ACS PAGE 14 SHEET #
SJC PAGE 15
FRC1
STARTER RELAY C109
1030 RED A
B SHEET 3
3560 LBL B TAN R
85 86 8210 TAN 1015 RED
2005 BLK
SHEET 12 C110
B S 1020 RED
ALTERNATOR G
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
RELAY C101
D5 8100 TAN B
1350 RED/WHT 30 8120 TAN PULL 0.33 OHM
SHEET 3 87 3410 LBL
85 86 SHEET 4
2025 BLK 8110 TAN
24.5 OHM
FRC1 T14
RELAY 8500 TAN
SHEET 3
1060 RED 30 Dealer Copy -- Not for Resale
87
2016 BLK 85 86
2055 BLK
SHEET 3
6 8510 TAN
14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
SHEET 4
C405
2150 BRN B GND
SHEET 4 AIR FILTER
16 3150 LBL A SIG
SWITCH (NC) Printable Version Click Here
C106
15
SHEET 4
3160 LBL
2160 BRN
A
B
SIG
GND
ENGINE SPEED SENSOR WIRING SCHEMATIC
(163 OHM)
C104
(ACS / SJC MACHINE)
2170 BRN B GND ENGINE COOLANT
18
SHEET 4
3170 LBL A SIG
(8 VOLT)
S650 (S/N A3NV13099 - A3NV18204)
4 8800 TAN
J1B
(S/N A3NW11249 - A3NW12733)
C355
GWY CTRLR FUEL HARN
C406 Sheet 6 of 15
12 3180 LBL C 3180 LBL OR 3100 LBL A SIG
FUEL SENDER
SHEET 4
2180 BRN D 2180 BRN OR 3110 LBL B GND (30 - 270 OHM) (PRINTED APRIL 2014)
792 of 1311
HYDRAULICS
GROUND PAGE 4
CAB DISPLAY PAGE 8
CAB PAGE 9
OPTIONS PAGE 13 JOIN ONE WIRE)
ACS PAGE 14 SHEET # C425
SJC PAGE 15
FRC1 B C308
TRACTION LOCK BRAKE
4100 LGN 4200 LGN A 4200 LGN A SOLENOID
RELAY TRACK 2 SPEED
1360 RED/WHT 30 SHEET 4
87
2025 BLK WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS SHEET)
SHEET 6 85 86 TRACK SINGLE SPD BRAKE ADAPTER HARNESS 7165061
2035 BLK 4110 LGN
SHEET 11
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
8
TRACTION LOCK
13
C108
2220 BRN B HYDRAULIC
GND
SHEET 4 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
SHEET 4
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330 BRN 2 GND FRONT ROD WIRING SCHEMATIC
C419
3.3 OHM PWM
(ACS / SJC MACHINE)
1 2340 BRN
4340 LGN
2
1
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
S650 (S/N A3NV13099 - A3NV18204)
3.3 OHM PWM
(S/N A3NW11249 - A3NW12733)
19 13 Sheet 7 of 15
J2B
AUX CTRLR
793 of 1311
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE LEGEND
OVERVIEW PAGE 1,2
CAB DISPLAY
POWER PAGE 3 PARTIAL CONNECTOR
GROUND PAGE 4
CAN BUS PAGE 5
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
MANUAL CONTROLS
PAGE 9
PAGE 10
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
WIRE BREAK
(TWO WIRE BREAKS
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 JOIN ONE WIRE)
SJC PAGE 15
T13
BUZZER (+)
1940 RNG/WHT
SHEET 3 C499
LEFT PANEL
7040 WHT OR 9320, PUR BUZZER
(PTOL)
C479
T2
2940 BLK 3
7040 WHT OR 9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920 BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960 RNG/WHT 1440 RED/WHT 1 20 3030 LBL 1 3030 LBL OR 9380, PUR 2
*
SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 37 2380 BRN OR 9370, PUR 4
PTOL LED
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
SHEET 13 RIGHT BLINKER INPUT Dealer Copy -- Not for Resale RIGHT KEY SWITCH PANEL
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 4 8130 TAN OR 9360, PUR 2
1 9
3600 LBL OR 4500, LGN
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 40 4
3040 LBL OR 9350, PUR RUN/ENTER SWITCH
3610 LBL OR 9310, PUR 4 5 GWY CTRLR

1950 RNG/WHT 5
SHEET 4 2930 BLK C480 SHEET 3 SWITCHED POWER
3620 LBL 12 2960 BLK 3
11
10
9 C503
3610 LBL OR 9310, PUR 2 RIGHT DELUXE PANEL
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
794 of 1311
PARTIAL CONNECTOR
CAB
GROUND PAGE 4
CAB DISPLAY PAGE 8
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11 WIRE BREAK
HVAC
OPTIONS
PAGE 12
PAGE 13
(TWO WIRE BREAKS
ACS PAGE 14 SHEET #
SJC PAGE 15
SW4
*
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 3 3
4
C492
SHEET 10 4230 LGN C408
(8 PIN) CAB-MFR HARN
SHEET 10 4240 LGN
5
3
4220 LGN
4275 LGN
4235 LGN 2
3
4235 LGN
4275 LGN
*C212
POWER
SOCKET
2 4550 LGN 5 4550 LGN 2795 BLK 1 GND
2790 BLK 24 2790 BLK 2790 BLK 2010 BLK

* C209
B GND
SHEET 4
SHEET 3
C129
CAB ACCESSORY
1580 RNG/WHT 16 1580 RNG/WHT 1865 RNG/WHT B +12V SW PWR
SHEET 3
2820 BLK C GND Dealer Copy -- Not for Resale
1510 RNG/WHT
SHEET 13
2210 BLK SHEET 13
2885 BLK SHEET 13
2060 BLK
SHEET 4
2730 BLK 33 2730 BLK
SHEET 9
*C667
DOOR HARNESS
(SEE ADDITIONAL
OPTIONS SHEET)
3620 LBL 3630 LBL 4

SHEET 8 DOOR SIGNAL
SHEET 3
6

WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 4
2370 BRN 45 2370 BRN OR 3910, LBL A GND SENSOR 7310 WHT 3
WASHER SIGNAL
11 3370 LBL 46 3370 LBL OR 3920, LBL B SIG * C252

L SIG
WASHER
24 5100 YEL 5370 YEL 44 5370 YEL OR 3900, LBL C +5V PWR X MOTOR
2845 BLK GND
+5V
SHEET 6 5140 YEL WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
795 of 1311
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
ACS PAGE 14
SJC PAGE 15
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 4
AUX CTRLR 4230 LGN G
SHEET 9
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET)
4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B (8 VOLT)
T20 TERMINAL (-)
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND 20 4640 LGN D
12 4820 LGN G
4680 LGN 1 SIG J
7.8 OHM 12V
2 4240 LGN H
SHEET 9
2520 BLK E
SHEET 4
7 5 Printable Version Click Here
J1B
GWY CTRLR WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 10 of 15
796 of 1311
LEGEND
LIGHTS
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 CONNECTOR
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT PAGE 15
SJC C434-1
C408
37.00 Watts
CAB-MFR HARN
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK C103
LIGHTS RELAY TAILGATE HARN C603
Dealer Copy -- Not for ResaleSHEET 4 2610 BLK 2 GND
1330 RED/WHT 30 RIGHT REAR
TAIL LIGHT
2105 BLK 85 86 C602
SHEET 4
2045 BLK 6330 PNK 1 SIG
GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
RELAY
1320 RED/WHT 30 T17 TERMINAL (+)
SHEET 3 87 6200 PNK H 6200 PNK SIG LEFT REAR
2045 BLK 85 86 SHEET 4
2035 BLK T18 TERMINAL (-)
SHEET 7
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
797 of 1311
HVAC
CAB DISPLAY PAGE 8
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS
ACS
PAGE 13 JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
PAGE 14 SHEET #
SJC PAGE 15
2440 BLK *
C610
2
#
GND HVAC DUCT
C483
2560 BLK * C BLK
WHT SWITCH)
C635
* D SIG
B
E
F
FRC1 C408
*BLOWER
SW10
HVAC RELAY SWITCH

CAB-MFR HARN
1140 RED/WHT 30 Dealer Copy -- Not for Resale OFF
1
2030 BLK 85 86 4
SHEET 3
SHEET 6
2005 BLK
1790 RNG/WHT
6
3 7530 WHT
* C611
1 14.00 Amps High
21 3450 LBL
SHEET 4
2745 BLK 22 2745 BLK *
J1A 7015 WHT 1 C 7400 WHT

GWY CTRLR 2100 BLK 3
11 7021 WHT 7020 WHT 34
* C630
3
THERMOSTAT

A 7024 WHT
C355
FUEL HARN # C486 Printable Version Click Here
A 7024 WHT 7025 WHT 1 SIG
2290 BLK 2280 BLK

2 GND
MAGNET CLUTCH
(COMPRESSOR) WIRING SCHEMATIC
SHEET 13
D4
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
Sheet 12 of 15
798 of 1311
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED PARTIAL CONNECTOR
POWER PAGE 3
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR OPTIONS PAGE 13 JOIN ONE WIRE) (NOT IN STD CAB HARN 7165991)
SJC PAGE 15
C355
POWER
# C607
1
FUEL HARN
E
C408
10 CAB-MFR HARN
#
SIG 4470 LGN OR 7010, WHT 4470 LGN 4470 LGN
BOB-TACH
CLOSE
GND 2 2470 OR 2770, BLK 2770 OR 2751, BLK B 2770 BLK
SHEET 4 4480 LGN (NOT IN STD FUEL HARN 7149219)
2290 BLK
SHEET 12
*POWER
SW5 2 1
# C606 BOBTACH 3
POWER 5 4
SIG 2 2480 OR 2775, BLK SWITCH 6
BOB-TACH 1 4480 LGN OR 7000, WHT F 4480 LGN 9
GND
OPEN
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 15
1430 RED/WHT
6010 PNK L
* FLASHER CONN
C 3500 LBL
SHEET 8 D1
LEFT HANDLE A 6515 PNK 6500 PNK 36 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(BLINKER / FLASHER) E 6540 PNK
5 PIN D2 SWITCH
D 6415 PNK 6400 PNK 29 6400 PNK 6430 PNK
3400 LBL 2725 BLK 6
C103
SHEET 8
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
2
(PINS 3 & 6 3
TAILGATE HARN
INTERNALLY 5 4 3
INSULATED)
2850 BLK
E 6410 PNK 6
EURO TAIL LIGHTS C670
(SEE ADDITIONAL D 6510 PNK * E
OPTIONS SHEET) 2780 BLK 30 D
2780 BLK 2420 BLK
SHEET 4 Dealer Copy -- Not for Resale 6440 PNK F
BEACON/FLASHER
EXTERIOR HARNESS
1550 RNG/WHT 13 1550 RNG/WHT C OPTIONS SHEET)
C423
SHEET 3
LEFT +
C279
1 7820 WHT
* C676
3
A
3
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 35 4455 LGN 1
4
2 *BUCKET
SW6 SPEAKER
-
2 7830 WHT 4
2830 BLK 5 POSITION C278 RADIO CONN
9.8 OHM SHEET 4 SHEET 4 6 2 7810 WHT 6
RIGHT -
C126 SPEAKER 1 7800 WHT 5
SHEET 4 2785 BLK + 1885 RNG/WHT 1
C412 B GND SHEET 9 PWR
FRONT 2885 BLK 2
LEFT HANDLE B 7210 WHT 38 7210 WHT A SIG SHEET 9 GND
HORN
(HORN) A 1460 RED/WHT
2 PIN
SHEET 3 C277
* 1
2
C497 3
5 7200 WHT C SJC 4 PWR
HORN/BLINKER AIR RIDE
4 6420 PNK A 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 9 SEAT
J2A 3 6520 PNK B OPTIONS SHEET) 6
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW
A SOLENOID
4460 LGN SIG
7.5 OHM 12 V Printable Version Click Here
J2B
26
AUX CTRLR
WIRING SCHEMATIC
27 2360 BRN
C437
2 GND TWO SPEED (ACS / SJC MACHINE)
4360 LGN 1 SIG
MAKEUP SOLENOID
J1A
GWY CTRLR
ADAPTER (SEE
S650 (S/N A3NV13099 - A3NV18204)
C441
26 2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
ADDITIONAL
OPTIONS SHEET) (S/N A3NW11249 - A3NW12733)
5.1 OHM 12 V
Sheet 13 of 15
25 26
J1B (PRINTED APRIL 2014)
GWY CTRLR

799 of 1311
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
K TILT PEDAL K TILT MOTOR 2
ACS AND AHC HARNESS 7164144

J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170 RED/WHT C409 C466
C492 C493 J3-ACS K A
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
B 1740 RNG/WHT 6 2 SOLENOID D
A 2250 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
Dealer Copy -- Not for Resale 4270 LGN 1 TILT D
FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GRD LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C 5980 YEL 3 +5V PWR
SIG TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GND
3980 LBL 2 SIG
A C471
B 2660 BRN 2 GND C428 TILT ACTUATOR
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2980 BRN
2990 BRN
6
C470 A 4645 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 SIG 5990 YEL 3 +5V PWR
TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
2250 YEL 5990 YEL
WIRING SCHEMATIC
H
E
3980 LBL
3990 LBL
(ACS / SJC MACHINE)
S650 (S/N A3NV13099 - A3NV18204)
(S/N A3NW11249 - A3NW12733)
800 of 1311 Printed In U.S.A. 7197682
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
SJC PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN

A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
6 ISO LITE
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
HARNESS PART NUMBER 13 LF ANGLE
7159325 WITH SPEED SENSORS LIFT 14 RF ANGLE
SJC WHEEL S630, S650, S750, S770 C429
7210503 WITHOUT SPEED SENSORS ACTUATOR 15 LR ANGLE
4600 LGN 5
7159458 WITH SPEED SENSORS 16 H PAT LITE
J5 - DRIVE SJC TRACK
7210504
T630, T650, T750, T770
WITHOUT SPEED SENSORS 4610 LGN
6
8 17 RR ANGLE
S630, S650,S750, S770,
CONTROLLER SUSP JSTK 7163706
T630, T650, T750, T770
2980 BRN 1
4
GND 18
19
L JOYSTICK X
L JOYSTICK Y
C454 3980 LBL 2 SIG 20 R JOYSTICK X
29 2890 BRN 2880 BRN 3 7
GND 21 L FWD DRIVE
5880 YEL 1 +5V PWR 5980 YEL 3 +5V PWR
LEFT SPEED 22 CAN LOW
33 3880 LBL 2 SIG SENSOR
C428 23 R QUAD A DRIVE
34 3885 LBL 4 SIG TILT ACTUATOR
NOTE: SPEED SENSORS NO LONGER 5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL C453 FACTORY INSTALLED. SEE SERVICE 4 25 TWO SPEED 1
+5V
5970 YEL
5870 YEL 1 +5V PWR LETTER SL5323 OR BTI 410 3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870 BRN 3 GND 6
23 3870 LBL 2 RIGHT SPEED 27 GROUND
SIG 2990 BRN 1 GND
SENSOR 28 GROUND
24 3875 LBL 4 SIG 4640 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN OR BLK 4 2810 BRN or BLK 1 GND
31 L REV DRIVE
8 3810/LBL OR 4720/LGN 3 3810/LBL OR 4720/LGN 3 SIG 32 CAN SHIELD
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860 YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860/BRN OR BLK BRN 4 2860 BRN or BLK 1 GND 36 BACKUP ALARM
F
7 3860/LBL OR 4950/LGN 3 3860 LBL or 4950/LGN 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
42 2660/BRN OR BLK 2 2660 BRN or BLK 2
RIGHT FORWARD DRIVE Dealer Copy -- Not for Resale A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
RIGHT REVERSE DRIVE +5V 44 R REV DRIVE
45 2650/BRN OR BLK 4 2650 BRN or BLK 2 G
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN OR BLK 6 2680 BRN or BLK 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H 49 SPARE PWN COIL 6
C544 C
21 4270 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670/BRN OR BLK 8 2670 BRN or BLK 2 LEFT FORWARD DRIVE
K
C460
TO SJC BRAKE A 1 1
C474 1830 RNG/WHT +12V PWR
HARNESS D 2 2
26 4210 LGN A C450 2070 BLK GND
J3-ACS
(SEE ADDITIONAL OPTIONS F RIGHT
RIGHT JOYSTICK 4 9660 PUR 4 CAN LO
SHEET)
2270 BLK H (CONNECTS TO JOYSTICK
2260 BLK J DLX CAB HARNESS)
3 3
C492 9560 PUR/WHT CAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7 C459
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
C449 2 2080 BLK 2 GND
16 4275 LGN 3 LEFT JOYSTICK
9140 PUR/WHT 4
LEFT
(CONNECTS TO 4 9640 PUR 4 CAN LO
9240 PUR 1 DLX CAB HARNESS) JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6
MAINFRAME 3 9540 PUR/WHT 3 CAN HI
HARNESS
27 2470 BLK C493
28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2
2240 BLK 4 WIRING SCHEMATIC
(ACS / SJC MACHINE)
1760 RNG/WHT
2280 BLK
S650 (S/N A3NV13099 - A3NV18204)
2270 BLK
2260 BLK (S/N A3NW11249 - A3NW12733)
1180 RED/WHT
1190 RED/WHT Sheet 15 of 15 Printable Version Click Here
C404
36 7100 WHT A (CONNECTS TO BACKUP (PRINTED APRIL 2014)
B ALARM C404 ON MFR
HARNESS)
7197682
801 of 1311 Printed In U.S.A.
PINS PINS PINS
C418 FRONT ROD (MALE) 2 7 C547 RIGHT REVERSE DRIVE 2 15 T14 PRE HEATER 1 6
C419 FRONT BASE (FEMALE) 2 7 T15 RIGHT REAR WORK LIGHT(+) 1 11
C440 RF BASE 2 14 C602 LEFT REAR TAIL LIGHT Dealer
2 Copy11 -- Not forT17
Resale
LEFT REAR WORK LIGHT (+) 1 11

HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 9 Printable Version Click Here
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11 WIRING SCHEMATIC
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13 (ACS / SJC MACHINE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
Sheet 1 of 15
802 of 1311
A-27 SPARE A-27
A-29 A-29
A-32 HYD OIL TEMP (8 VOLT) Dealer
A-32 Copy -- Not for Resale
A-33 A-33
HARNESS PART NUMBER

S630, S650, T630, T650
7210765
MAINFRAME
A770, S750, S770, T750, T770
7210769
MAINFRAME
DLX CAB 7210556
STD CAB 7210557
DLX FUEL 7184255
STD FUEL 7149219
S/R 6733370
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
803 of 1311
C408
POWER
C503 RH DLX PANEL
CAB-MFR HARN CONN 1 1400 RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
SHEET 9
SHEET 8
2 SHEET 8
C479 LH PANEL
+12V 1025 RED
FUSE 2 25 A
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
100.0 Amps COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
SCHEMATIC INDEX
OVERVIEW PAGE 1,2
1280 RED 1235 RED/WHT 2 (4 PIN)
GROUND PAGE 4
1010 RED
CONNECTOR
SHEET 5
SHEET 13
1460 RED/WHT
C412 LH HANDLE HORN
FUSE 4 15 A
SHEET 9
1050 RED
FUSE 5 30 A
1350 RED/WHT
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FRC1 STARTER RELAY
SHEET 11
1340 RED
SHEET 11
C404
1620 RNG/WHT
SHEET 8
1550 RNG/WHT
SW1 BRAKE SWITCH
2
SHEET 8
C410 LEFT HANDLE 1950 RNG/WHT
1570 RNG/WHT 1520 RNG/WHT SHEET 10 SHEET 8
SHEET 9
FRC1 FUSE 8 25 A
1580 RNG/WHT
+12V FUSE 12 15 A SW9 TRAVEL CONTROL SWITCH
PWR SHEET 6
SHEET 4
2055 BLK
GND 85 86
3450 LBL 21 C428
SHEET 12
FRC1 HVAC RELAY WIRING SCHEMATIC
(LT GRAY)
3380 LBL 4 CAB-MFR HARN CONN 2
(ACS / SJC MACHINE)
1830 RNG/WHT
SHEET 5
C449 LH JOYSTICK S650 (S/N A3NV18205 - A3NV21746)
6 C492 SHEET 5
1740 RNG/WHT
(8 PIN)
C450 RH JOYSTICK (S/N A3NW12734 - A3NW13097)
804 of 1311 Printed In U.S.A. 7210767
LEGEND
GROUND
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
2080 BLK C493

2070 BLK
SHEET 5
C450 RH JOYSTICK C408 3 2235 BLK
2920 BLK (BLACK) 4 2240 BLK
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
C503 RH DELUXE PANEL C428
(LT GRAY) 16 2540 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 2765 BLK
SHEET 8 AUX CTRLR 2550 BLK 2090 BLK SHEET 11
SW1 BRAKE SWITCH C408 CAB-MFR CONN (FR LIGHTS)
2830 BLK 2900 BLK 1 2900 BLK T8
SHEET 13 2745 BLK BATT GND
SW6 BKT POSITION SWITCH SHEET 12
2455 BLK C408 CAB-MFR CONN (HVAC)
SHEET 8 2700 BLK SHEET 13 2790 BLK
SW9 TRAVEL CONTROL SWITCH C423 BKT POSITION SOLENOID SHEET 9
2785 BLK 2710 BLK 2300 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 13 SHEET 5
C126 HORN C426 REMOTE RUN, ACD 2780 BLK
SHEET 13
2770 BLK C408 CAB-MFR CONN (OPTIONS)
2620 BLK SHEET 13 2730 BLK
SHEET 11
T16 RH REAR LIGHT Dealer Copy -- Not for Resale
C355 FUEL HARN (PWR BOB/AC) SHEET 9
C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
2630 BLK C103 T1
SHEET 11 C489 B
TAILGATE HARN 2720 BLK BATT GND
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
T20 BU ALARM
2640 BLK 2400 BLK 2390 BLK
C602 LH REAR LIGHT SHEET 6 C101 FUEL SHUTOFF SOLENOID
FRC1 GLOW PLUG RELAY 2200 BLK
2610 BLK 2025 BLK SHEET 7
SHEET 11 SHEET 6
C603 RH REAR LIGHT FRC1 FUEL PULL RELAY C425 BRAKE
SHEET 7 2035 BLK
FRC1 TRACTION LOCK RELAY 2520 BLK
2045 BLK SHEET 10
SHEET 11 C410 LEFT HANDLE
FRC1 REAR LIGHT RELAY
2115 BLK 2105 BLK 2000
SHEET 11
2170 BRN FRC1 FRONT LIGHT RELAY
C104 ENGINE COOLANT SENSOR SHEET 3 SHEET 10
2160 BRN 2030 BLK C409 RIGHT HANDLE
SHEET 6 SHEET 12
C106 ENGINE SPEED SENSOR FRC1 HVAC RELAY
SHEET 6 2005 BLK
2320 BRN
SHEET 7 FRC1 STARTER RELAY
2370 BRN J1B
SHEET 9
2220 BRN 2230 BRN 17 Printable Version Click Here

SHEET 7
SHEET 7 2190 BRN

WIRING SCHEMATIC
SHEET 6
2180 BRN (ACS / SJC MACHINE)
SHEET 6
2140 BRN S650 (S/N A3NV18205 - A3NV21746)
2150 BRN
(S/N A3NW12734 - A3NW13097)
SHEET 6
C405 AIR FILTER SWITCH Sheet 4 of 15
805 of 1311 Printed In U.S.A. 7210767
LEGEND
CAN BUS
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
JOIN ONE WIRE)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
C408
J1B (BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
(8 PIN)
C426 1 9260 PUR 4
9240 PUR C503
Remote Run Tool, ACD 9160 PUR/WHT 2
9140 PUR/WHT 4 ACS CTRLR RIGHT DELUXE PANEL
14 9500 PUR/WHT A Dealer Copy -- Not for Resale
CAN HI
20 9600 PUR B
CAN LO
1830 RNG/WHT 1
SHEET 3
DRIVE CTRLR
SHEET 4
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
9120 PUR/WHT 9
AUX CTRLR
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
Sheet 5 of 15
806 of 1311
LEGEND
ENGINE
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
FRC1
PWR 30 S/R ADAPTER STARTER
1030 RED A
B SHEET 3
3560 LBL B TAN R
GND 85 86 8210 TAN 1015 RED
SHEET 4 2005 BLK
C110
B S 1020 RED
ALTERNATOR G
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
+12V RELAY C101
D5 8100 TAN B
1350 RED/WHT
PWR
SHEET 3 87 3410 LBL
GND 85 86 SHEET 4
2025 BLK 8110 TAN
24.5 OHM
FRC1 T14
+12V RELAY 8500 TAN
PWR 30
1060 RED
SHEET 3 87 Dealer Copy -- Not for Resale
GND 85 86
SHEET 4 2016 BLK
6 8510 TAN
14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
SHEET 4
C405
2150 BRN B GND
SHEET 4 AIR FILTER
16 3150 LBL A SIG
SWITCH (NC)
C106
15
3160 LBL A SIG
B ENGINE SPEED SENSOR
SHEET 4 2160 BRN GND
(163 OHM)
WIRING SCHEMATIC
C104
18
SHEET 4 2170 BRN
3170 LBL
B
A
GND
SIG
ENGINE COOLANT
(ACS / SJC MACHINE)
(8 VOLT)
4 8800 TAN S650 (S/N A3NV18205 - A3NV21746)
J1B
GWY CTRLR
C355
FUEL HARN
C406
(S/N A3NW12734 - A3NW13097)
12 3180 LBL
2180 BRN
C
D
3180 LBL
2180 BRN
A
B
SIG
GND
FUEL SENDER Sheet 6 of 15
SHEET 4 (30 - 270 OHM)
807 of 1311 Printed In U.S.A. 7210767
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
GROUND PAGE 4
HYDRAULICS PAGE 7
CAB PAGE 9
HVAC PAGE 12
FRC1 C425 C308
TRACTION LOCK
+12V RELAY 4100 LGN B
BRAKE
PWR 30 4200 LGN A 4200 LGN A
1360 RED/WHT SOLENOID TRACK 2 SPEED
SHEET 3 87 3430 LBL 2200 BLK C 2200 BLK B 9.8 OHM
SHEET 4 ADAPTER (SEE
12 V ADDITIONAL
GND 85 86
2035 BLK 4110 LGN WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS SHEET)
SHEET 4
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
C425 PULL 0.3 OHM

B HOLD 10.9 OHM
8 A WHEEL SINGLE SPEED
C TRACTION LOCK
13
C108 HYDRAULIC
2220 BRN B GND TEMPERATURE
SHEET 4 SENDER
32 3220 LBL A SIG
500 - 3000 OHM
(8 VOLT)
C112
SHEET 4
C446
18 2910 BRN 2 GND
HYDRAULIC
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

AUX CTRLR SOLENOID (MALE)
4330 LGN 1 SIG
3.3 OHM PWM WIRING SCHEMATIC
C419
1 2340 BRN 2 GND FRONT BASE (ACS / SJC MACHINE)
3.3 OHM PWM S650 (S/N A3NV18205 - A3NV21746)
19 13
(S/N A3NW12734 - A3NW13097)
J2B Sheet 7 of 15
AUX CTRLR
808 of 1311
LEGEND
OVERVIEW PAGE 1,2
RED RED
CAB DISPLAY
BATT FEED, GENERAL 1000 THROUGH 1499
POWER PAGE 3
GROUND PAGE 4
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
T13
BUZZER (+)
C499
LEFT PANEL
7040 WHT BUZZER
(PTOL)
C479
T2
2940 BLK 3
7040 WHT 10 C408 SHEET 4 GROUND
BUZZER
(BLACK)
SHEET 4 GROUND
*
SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 12 2380 BRN 4
PTOL LED
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
4
2700 BLK 2 3 3650 LBL 7 Dealer Copy --24 Not for Resale8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 14 4

1950 RNG/WHT 5
3620 LBL 12 2960 BLK 3
11
10
9 C503
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
809 of 1311 Printed In U.S.A. 7210767
LEGEND
PARTIAL CONNECTOR
CAB
HYDRAULICS PAGE 7
CONTROLLER SUPPLY
LIGHTS
5000 THROUGH 5999
6000 THROUGH 6999
YELLOW
PINK
YEL
PNK
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRE BREAK
(TWO WIRE BREAKS
HVAC
OPTIONS
PAGE 12
PAGE 13
JOIN ONE WIRE)
SHEET #
* SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS) SWITCH
C438 1785 RNG/WHT 2 1

C492 SHEET 3 3
SJC/ACS/AWS-MFR HARN 4230 LGN (DK GRAY) 6
SHEET 10 2060 BLK 5
(8 PIN) CAB-MFR HARN CONN 3 SHEET 9
SHEET 10 4240 LGN 4
5 4220 LGN 4235 LGN 4 4235 LGN
3 4275 LGN 5 4275 LGN
2 4550 LGN 6 4550 LGN
*C212
POWER
SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK
* C209
B GND
SHEET 3
C129
CAB ACCESSORY
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B +12V SW PWR
2790 BLK
SHEET 3
2820 BLK C GND
1510 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
SHEET 4
2885 BLK SHEET 13
2060 BLK SHEET 9
C428
(LT GRAY)
CAB-MFR HARN CONN 2
*C667
DOOR HARNESS
2790 BLK 11 2790 BLK (SEE ADDITIONAL
SHEET 4 OPTIONS SHEET)
3620 LBL 3630 LBL 4

SHEET 8 DOOR SIGNAL
1400 RED/WHT 5
SHEET 3 DOOR UNSW PWR
6
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 4
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG * C252

L SIG
WASHER
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR X MOTOR Printable Version Click Here
+5V 2845 BLK GND
SHEET 6 5140 YEL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
Sheet 9 of 15
810 of 1311
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 4
SHEET 9
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET)
4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B
T20 TERMINAL (-)
Dealer Copy -- Not for Resale 21 17 18 23

C410
LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND 20 4640 LGN D
12 4820 LGN G
4680 LGN 1 SIG J
7.8 OHM 12V
2 4240 LGN H
SHEET 9
2520 BLK E
SHEET 4
7 5
J1B Printable Version Click Here
GWY CTRLR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
Sheet 10 of 15

811 of 1311
LEGEND
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
C434-1
C408 2735 BLK B GND LEFT FRONT
(BLACK) 6100 PNK A SIG WORK LIGHT
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK
LIGHTS RELAY C103
TAILGATE HARN C603
+12V
PWR 30 2610 BLK 2 GND
Dealer Copy -- Not for SHEET 4
6310 Resale
1330 RED/WHT RIGHT REAR
SHEET 3 87 6340 PNK 6310 PNK A PNK 6320 PNK 1 SIG
TAIL LIGHT
2115 BLK GND 85 86 C602
SHEET 4
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
+12V RELAY
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
812 of 1311 Printed In U.S.A. 7210767
LEGEND
PARTIAL CONNECTOR
HVAC
HYDRAULICS PAGE 7
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
LIGHTS PAGE 11 (TWO WIRE BREAKS * DLX CAB HARN 7210556 ONLY
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
#
2440 BLK * C610
2
GND HVAC DUCT
C483
2560 BLK * C BLK
WHT SWITCH)
C635
* D SIG
B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY CAB-MFR HARN CONN 3

SWITCH
PWR 30 OFF
1140 RED/WHT
SHEET 3 87 1500 RNG/WHT 7 Dealer
1500 RNG/WHT Copy -- Not for Resale 5 2
1
GND 85 86 4
2030 BLK
SHEET 4
1790 RNG/WHT
6
3 7530 WHT
* C611
1 14.00 Amps High
7510 WHT 3 5.00 Amps Low MOTOR
SHEET 4
2745 BLK 8 2745 BLK * SW11
2100 BLK 3
C 7400 WHT
7015 WHT 1
J1A 11 7021 WHT 7020 WHT 9
GWY CTRLR
* C630
3
THERMOSTAT

A 7024 WHT
C355
FUEL HARN # C486
2 MAGNET CLUTCH Printable Version Click Here
GND
(COMPRESSOR)
2290 BLK 2280 BLK
SHEET 13
D4 WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
Sheet 12 of 15
813 of 1311
LEGEND
OVERVIEW PAGE 1,2
ENGINE PAGE 6
OPTIONS
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
C428
C355 (LT GRAY)
CAB-MFR HARN CONN 2
# C607
1
FUEL HARN
E 8 4470 LGN
#
SIG 4470 LGN 4470 LGN
POWER BOB
CLOSE
GND 2 2470 BLK 2770 BLK B 2770 BLK
2290 BLK
SHEET 12
#
*POWER
SW5 2 1
3
C606 BOBTACH
5 4
SIG
OPEN
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10
1430 RED/WHT
6010 PNK L
* FLASHER CONN
C
D2
6530 PNK
*BEACON
SW2
6570 PNK
SHEET 8 3400 LBL
5 PIN SWITCH
A 6515 PNK 1550 RNG/WHT 9 1550 RNG/WHT
2725 BLK 6
SHEET 3
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
2
(PINS 3 & 6 3
C103 C438 5 4 3
INTERNALLY
TAILGATE HARN (DK GRAY) 2850 BLK
INSULATED) 6
CAB-MFR HARN CONN 3 C670
EURO TAIL LIGHTS
(SEE ADDITIONAL
E
D
6410 PNK
6510 PNK 6500 PNK 3
SHEET 8
6500 PNK
3500 LBL
D1
* E
OPTIONS SHEET) Dealer Copy -- Not for Resale 2420 BLK D BEACON/FLASHER
C423 6540 PNK B (SEE ADDITIONAL
3 6540 PNK
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6 C
A
OPTIONS SHEET)
2830 BLK 5 POSITION

2780 BLK 1 2780 BLK
SHEET 4
C408
(BLACK) C126
C412
B 7210 WHT
CAB-MFR HARN CONN 1
13
SHEET 4 2785 BLK B
A
GND
FRONT C279 * C676
RADIO CONN
LEFT HANDLE 7210 WHT SIG HORN 1 7820 WHT 3
LEFT C277
(HORN)
2 PIN
A 1460 RED/WHT
SHEET 3 SPEAKER
+
-
2 7830 WHT 4 * 1
2 AIR RIDE
C497 C278 3 SEAT
5 7200 WHT C SJC RIGHT - 2 7810 WHT 6 1510 RNG/WHT 4 PWR
HORN/BLINKER SPEAKER 1 7800 WHT 5 SHEET 9
4 6420 PNK A 2210 BLK 5 GND
(SEE ADDITIONAL + 1 SHEET 9
3 6520 PNK B SHEET 9 1885 RNG/WHT 6
J2A OPTIONS SHEET)
2885 BLK 2
AUX CTRLR SHEET 9
C415
A SIG
SOLENOID
4460 LGN
7.5 OHM 12 V
J2B
26
AUX CTRLR

J1A
4360 LGN 1 SIG
MAKEUP SOLENOID
(ACS / SJC MACHINE)
GWY CTRLR ADAPTER (SEE
26 2350 BRN
C441
2 GND TWO SPEED
ADDITIONAL
OPTIONS SHEET)
S650 (S/N A3NV18205 - A3NV21746)
5.1 OHM 12 V (S/N A3NW12734 - A3NW13097)
25 26
J1B
Sheet 13 of 15
GWY CTRLR

814 of 1311
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS

J1-ACS
CONTROLLER
H 14 BLK
SEE MANUAL CONTROL
14 BLK
12 BLK
12 BLK CONTROLLER HANDLE
16 LGN
15 LGN 5 4 G B
A
C 9 LGN 2 2 C 7 RED/WHT H
15 LGN
8 J 190 BLK C467 E DETENT
191 BLK 1 BLK
D 11 PUR/WHT 4 G 187 LGN 1 LIFT C TWO SPD
189 LGN
A 5 YEL PWM
+5V 13 OHM B
G 13 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2 BLK
Dealer Copy -- Not for Resale 188 LGN 1 TILT D
FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
3 BRN B B GRD LIFT ACTUATOR SIDE
D 184 LGN 8 F
F 180 LGN C C TRAK131 LIFT HANDLE SHIFT
7 A
5650 YEL A A TRAK132 HALL SENSOR
6 J
F 183 LGN 5 H A
C469 HANDLE
4 E B
18 BRN B B TRAK147 LOCK
G 4750 LGN C C TRAK137 176 YEL 3 TRAK148
TILT HANDLE
5750 YEL A A HALL SENSOR 177 BRN 1 TRAK152
TRAK133
181 LBL 2 TRAK151
A C471
B 2 C428 TILT ACTUATOR
179 BRN TRAK130
C
J 3 TRAK129 K 186 LGN 8
4660 LGN LIFT PEDAL
D 1 TRAK128 HALL SENSOR 7
5660 YEL
6
177 BRN
178 BRN
C470 A 185 LGN 5

4 BRN 2 4
TRAK108
K 4760 LGN 3 TRAK107 175 YEL 3 TRAK99
TILT PEDAL
5760 YEL 1 TRAK246 HALL SENSOR 178 BRN 1 TRAK245
5750 YEL 182 LBL 2 TRAK100
5650 YEL 176 YEL
5 YEL 175 YEL
WIRING SCHEMATIC
H
E
181 LBL
182 LBL
(ACS / SJC MACHINE)
S650 (S/N A3NV18205 - A3NV21746)
(S/N A3NW12734 - A3NW13097)
815 of 1311

6 ISO LITE
CONTROLS
12 CAN HIGH
SJC WHEEL S630, S650, S750, S770 C429
153 LGN 5
7210504
T630, T650, T750, T770
6
8 17 RR ANGLE
S630, S650,S750, S770,
T630, T650, T750, T770
157 BRN 1
4
GND 18
19
L JOYSTICK X
L JOYSTICK Y
29 174 BRN 171 BRN 3 7
GND 21 L FWD DRIVE
172 YEL 1 +5V PWR 161 YEL 3 +5V PWR
+5V
160 YEL
167 BRN 3 GND 6
SIG 156 BRN 1 GND
SENSOR 28 GROUND
24 165 LBL 4 SIG 25 LGN 5
7 29 SENSOR GROUND .
C536 A22 PUMP HARNESS (7169309 or 7188448) 151 LGN 8 30 SENSOR SUPPLY 2 +5V ..
159 BRN
112 YEL 2 C543
31 L REV DRIVE
8 113 3 123 3 SIG 32 CAN SHIELD
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
H
F
G
128 RNG/WHT 1 121 RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
J1-ACS
F 45 R REV RETURN
31 108 LGN 5 118 LGN 1
C544 C
K
C460
TO SJC BRAKE A 1 1
HARNESS D 2 2
26 111 LGN A C450 49 BLK GND
J3-ACS
(SEE ADDITIONAL OPTIONS F RIGHT
RIGHT JOYSTICK 4 47 PUR 4 CAN LO
SHEET) H
154 BLK (CONNECTS TO JOYSTICK
C492 3 48 PUR/WHT 3 CAN HI
26 RED/WHT C
12 41 PUR/WHT 8
27 RED/WHT B
22 40 PUR 7 C459
E
4 22 LGN 2 1 42 RNG/WHT 1 +12V PWR
G
6 20 LGN 5
C449 2 45 BLK 2 GND
32 PUR/WHT 4
LEFT
33 PUR 1 DLX CAB HARNESS)
JOYSTICK
HARNESS
27 30 BLK C493
28 162 BLK 29 BLK 3
24 BLK 4 WIRING SCHEMATIC
(ACS / SJC MACHINE)
38 RNG/WHT
28 BLK
S650 (S/N A3NV18205 - A3NV21746)
154 BLK
155 BLK (S/N A3NW12734 - A3NW13097)
26 RED/WHT
27 RED/WHT Sheet 15 of 15 Printable Version Click Here
C404
36 31 WHT A (CONNECTS TO BACKUP (PRINTED APRIL 2014)
B ALARM C404 ON MFR
HARNESS)
7210767
PINS PINS PINS
C418 FRONT ROD (MALE) 2 7 C547 RIGHT REVERSE DRIVE 2 15 T14 PRE HEATER 1 6
C419 FRONT BASE (FEMALE) 2 7
Dealer Copy -- Not for Resale RIGHT REAR WORK LIGHT(+)
T15 1 11
C440 RF BASE 2 14 C602 LEFT REAR TAIL LIGHT 2 11 T17 LEFT REAR WORK LIGHT (+) 1 11

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2 WIRING SCHEMATIC
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4 (ACS / SJC MACHINE)
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 S650 (S/N A3NV21747 - A3NV25155)
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 8 (S/N A3NW13098 - A3NW13766)
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 10 (S/N 1MLS11001 AND ABOVE)
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 11
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 12 Sheet 1 OF 15 Printable Version Click Here
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR ACS PAGE 14 (PRINTED JANUARY 2017)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT SJC PAGE 15
7210767 (C)
Printed In U.S.A.
817 of 1311
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 Dealer Copy -- Not for Resale B-25
A-27 SPARE A-27
A-29 A-29
A-33 A-33
HARNESS PART NUMBER

S630, S650, T630, T650, 7210765
WIRING SCHEMATIC
MAINFRAME
S750, S770, T750, T770, 7210769 (ACS / SJC MACHINE)
MAINFRAME
DLX CAB 7234737 S650 (S/N A3NV21747 - A3NV25155)
STD CAB 7210557
DLX FUEL 7184255 (S/N A3NW13098 - A3NW13766)
STD FUEL 7149219
S/R 6733370 (S/N 1MLS11001 AND ABOVE)
TRK BRAKE ADP 7165061 Sheet 2 OF 15 Printable Version Click Here
Printed In U.S.A. WHL 2 SPD ADP 7159366
7210767 (C)
818 of 1311
C408
POWER
C503 RH DLX PANEL
CAB-MFR HARN CONN 1 1400 RED/WHT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
SHEET 9
SHEET 8
2 SHEET 8
C479 LH PANEL
+12V 1025 RED
FUSE 2 25 A
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
100.0 Amps
SCHEMATIC INDEX
OVERVIEW PAGE 1,2
1280 RED 1235 RED/WHT 2 (4 PIN)
GROUND PAGE 4
1010 RED
CONNECTOR
SHEET 5
SHEET 13
1460 RED/WHT
C412 LH HANDLE HORN
FUSE 4 15 A
SHEET 9

1050 RED
FUSE 5 30 A
1350 RED/WHT
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FRC1 STARTER RELAY
SHEET 11
1340 RED
FUSE 10 20 A 1330 RED/WHT Dealer
SHEET 11
C404
FRC1 HVAC RELAY
FUSE1 25 A OPTIONS SHEET) 1940 RNG/WHT
SW1 BRAKE SWITCH
FUSE4 5 A
SHEET 8
C410 LEFT HANDLE
SHEET 10 SHEET 8
SHEET 9
FRC1 FUSE 8 25 A
1580 RNG/WHT
PWR SHEET 6
1050 RED 30
87
J1A
C110 ALT EXCITATION
SHEET 12
WIRING SCHEMATIC
GND 85 86 C428 FRC1 HVAC RELAY
21
SHEET 4
2055 BLK 3450 LBL
3380 LBL 4
(LT GRAY)
CAB-MFR HARN CONN 2
(ACS / SJC MACHINE)
SHEET 5
S650 (S/N A3NV21747 - A3NV25155)
C449 LH JOYSTICK
1740 RNG/WHT 6 C492 1830 RNG/WHT
SHEET 5
(S/N A3NW13098 - A3NW13766)
SJC/ACS/AWS-MFR HARN C450 RH JOYSTICK
(8 PIN) (S/N 1MLS11001 AND ABOVE)
Sheet 3 OF 15 Printable Version Click Here
Printed In U.S.A.
7210767 (C)
819 of 1311
LEGEND
BATTERY GROUND
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
LIGHTS
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
6000 THROUGH 6999
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
PINK
BLK
BRN
LBL
LGN
YEL
PNK
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
LIGHTS
PAGE 6
PAGE 7
PAGE 8
PAGE 9
PAGE 10
PAGE 11
CONNECTOR
WIRE BREAK
(TWO WIRE BREAKS
GROUND
HVAC PAGE 12
OPTIONS PAGE 13
2080 BLK C493

2070 BLK
SHEET 5
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
AUX CTRLR SHEET 11
2830 BLK 2900 BLK 1 2900 BLK T8
2700 BLK
SHEET 8 SHEET 13 2790 BLK
SW9 TRAVEL CONTROL SWITCH C423 BKT POSITION SOLENOID SHEET 9
SHEET 13 SHEET 5
SHEET 13
SHEET 11
2620 BLK SHEET 13 Dealer Copy -- Not for Resale 2730 BLK
C355 FUEL HARN (PWR BOB/AC) SHEET 9
T16 RH REAR LIGHT C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
2630 BLK C103 T1
SHEET 11 C489 B
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
T20 BU ALARM
2640 BLK 2400 BLK 2390 BLK
C602 LH REAR LIGHT SHEET 6 C101 FUEL SHUTOFF SOLENOID
2610 BLK FRC1 GLOW PLUG RELAY 2200 BLK
SHEET 11 SHEET 6 2025 BLK SHEET 7
2035 BLK
SHEET 7
2045 BLK SHEET 10
2115 BLK 2105 BLK 2000
SHEET 11
SHEET 6 2055 BLK
C104 ENGINE COOLANT SENSOR SHEET 3 SHEET 10 2530 BLK Printable Version Click Here
SHEET 6 SHEET 12
2005 BLK
WIRING SCHEMATIC
2320 BRN SHEET 6
SHEET 7 FRC1 STARTER RELAY
2370 BRN
(ACS / SJC MACHINE)
SHEET 9 J1B
S650 (S/N A3NV21747 - A3NV25155)
2220 BRN 2230 BRN 17
SHEET 7
C108 HYD TEMP SENDER (S/N A3NW13098 - A3NW13766)
SHEET 7 2190 BRN
C105 HYD CHG PRESSURE SENDER (S/N 1MLS11001 AND ABOVE)
2180 BRN
SHEET 6
Sheet 4 OF 15
2140 BRN
SHEET 6 (PRINTED JANUARY 2017)
2150 BRN
7210767 (C)
SHEET 6
Printed In U.S.A.
820 of 1311
LEGEND
CAN BUS
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
JOIN ONE WIRE)
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
C408
J1B (BLACK)
CAN LO C479
CAN HI
120 OHM 120 OHM
(8 PIN)
C426 1 9260 PUR 4
9240 PUR C503
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
21 3090 LBL D REMOTE RUN KEY 9290 PUR 7 Copy -- Not for Resale
Dealer 1830 RNG/WHT 1
SHEET 3
DRIVE CTRLR
SHEET 4
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
9120 PUR/WHT 9
AUX CTRLR
1840 RNG/WHT 1
SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
7210767 (C)
821 of 1311
LEGEND
ENGINE
LIGHTS PAGE 11
HVAC PAGE 12
OPTIONS PAGE 13
FRC1
PWR 30 S/R ADAPTER STARTER
1030 RED A
B SHEET 3
3560 LBL B TAN R
GND 85 86 8210 TAN 1015 RED
SHEET 4 2005 BLK C110
B S 1020 RED
ALTERNATOR G
L 1800 RNG/WHT
SHEET 3
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
+12V RELAY C101
D5 8100 TAN B
1350 RED/WHT
PWR
SHEET 3 87 3410 LBL
GND 85 86 SHEET 4
2025 BLK 8110 TAN
24.5 OHM
FRC1 T14
+12V RELAY 8500 TAN
1060 RED PWR 30 Dealer Copy -- Not for Resale
SHEET 3 87
GND 85 86
SHEET 4 2016 BLK
6 8510 TAN
14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
SHEET 4
C405
2150 BRN B
16
SHEET 4
3150 LBL A
GND
SIG
AIR FILTER
SWITCH (NC)
WIRING SCHEMATIC
15 3160 LBL
C106
A SIG
(ACS / SJC MACHINE)
ENGINE SPEED SENSOR
SHEET 4 2160 BRN B GND
(163 OHM) S650 (S/N A3NV21747 - A3NV25155)
SHEET 4 2170 BRN
C104
B GND ENGINE COOLANT
(S/N A3NW13098 - A3NW13766)
18 3170 LBL A SIG SENSOR (500-3000 OHM)
4 8800 TAN
(8 VOLT) (S/N 1MLS11001 AND ABOVE)
J1B
GWY CTRLR
C355 Sheet 6 OF 15
FUEL HARN
C406 (PRINTED JANUARY 2017)
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
SHEET 4
2180 BRN D 2180 BRN B GND (30 - 270 OHM) 7210767 (C)
822 of 1311
LEGEND
PARTIAL CONNECTOR
HYDRAULICS
GROUND PAGE 4
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
HVAC PAGE 12
TRACTION LOCK BRAKE
PWR 30
1360 RED/WHT SHEET 4
87
2035 BLK 4110 LGN
SHEET 4
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
8
TRACTION LOCK
13
C108 HYDRAULIC
SHEET 4 SENDER
32 3220 LBL A SIG
500 - 3000 OHM
(8 VOLT)
C112
J1A 34 3320 LBL A SIG
HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND
SHEET 4 Dealer Copy -- Not for Resale
FILTER SWITCH (NC)
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN

19 13 1 23 6
J1B
GWY CTRLR
+8V WIRING SCHEMATIC
(ACS / SJC MACHINE)
C418
J2A
AUX CTRLR
18 2330 BRN 2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
S650 (S/N A3NV21747 - A3NV25155)
4330 LGN
3.3 OHM PWM
C419
(S/N A3NW13098 - A3NW13766)
1 2340 BRN
4340 LGN
2
1
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
3.3 OHM PWM
Sheet 7 OF 15
19 13 (PRINTED JANUARY 2017)
Printed In U.S.A. J2B 7210767 (C)
AUX CTRLR
823 of 1311
LEGEND
OVERVIEW PAGE 1,2
CAB DISPLAY
POWER PAGE 3
GROUND PAGE 4
CAN BUS PAGE 5
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
T13
BUZZER (+)
1940 RNG/WHT
SHEET 3 C499
LEFT PANEL
7040 WHT BUZZER
(PTOL)
C479
T2
2940 BLK 3
BUZZER
(BLACK)
SHEET 4 GROUND
*
SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 12 2380 BRN 4
PTOL LED
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
4 SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 14 4

1950 RNG/WHT 5
3630 LBL 12 2960 BLK 3
11
10
9 C503
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
Printed In U.S.A.
7210767 (C)
824 of 1311
LEGEND
PARTIAL CONNECTOR
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
RED/WHITE
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
PAGE 4
PAGE 5
PAGE 6
PAGE 7
PAGE 8
CONNECTOR CAB
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
LIGHTS
HVAC
PAGE 11
PAGE 12
(TWO WIRE BREAKS
*SW4
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
C438 1785 RNG/WHT 2 1
C492 SHEET 3 3
SJC/ACS/AWS-MFR HARN 4230 LGN (DK GRAY) 6
SHEET 10 SHEET 9 2060 BLK 5
(8 PIN) CAB-MFR HARN CONN 3
SHEET 10 4240 LGN 4
5 4220 LGN 4235 LGN 4 4235 LGN
3 4275 LGN 5 4275 LGN
2 4550 LGN 6 4550 LGN
*C212
POWER
SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1

* T37
DOME LIGHT (+)
SHEET 3
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
T38
1210 RED/WHT A
+12V BATT PWR
+12V SW PWR
* DOME LIGHT (-)
2790 BLK
SHEET 3
2820 BLK C GND
1510 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
SHEET 4
2885 BLK SHEET 13
2060 BLK SHEET 9
C428
(LT GRAY)
CAB-MFR HARN CONN 2
* C667
DOOR HARNESS
SHEET 4 OPTIONS SHEET)
3630 LBL 4
SHEET 8 DOOR SIGNAL
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B
SHEET 4
WASHER SIGNAL
GWY CTRLR
11 3370 LBL 5 3370 LBL B SIG * C252

L SIG WIRING SCHEMATIC
WASHER
24 5100 YEL 5370 YEL 3 5370 YEL C MOTOR
+5V
SHEET 6 5140 YEL
+5V PWR 2845 BLK X GND
(ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
7210767 (C)
825 of 1311
LEGEND
PARTIAL CONNECTOR
MANUAL
HYDRAULICS PAGE 7
CONTROLS
HVAC PAGE 12
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 4
SHEET 9
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET)
4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B
T20 TERMINAL (-)
C410
21 17 18 23
LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND 20 4640 LGN D
12 4820 LGN G
4680 LGN 1 SIG J
7.8 OHM 12V
2 4240 LGN H
SHEET 9
2520 BLK E
SHEET 4
7 5
WIRING SCHEMATIC
J1B
GWY CTRLR
(ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
7210767 (C)
826 of 1311
LEGEND
PARTIAL CONNECTOR
LIGHTS
CONNECTOR
C434-1
C434-2
SHEET 4
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK
LIGHTS RELAY C103
TAILGATE HARN C603
+12V
2610 BLK 2 GND
SHEET 3
1330 RED/WHT PWR 30
6340 PNK
6310 PNK A 6310 PNK
SHEET 4
6320 PNK 1 SIG
RIGHT REAR
87 TAIL LIGHT
2115 BLK GND 85 86 C602

SHEET 4
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
+12V RELAY
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
(S/N A3NW13098 - A3NW13766)
Printed In U.S.A. Sheet 11 OF 15 Printable Version Click Here
7210767 (C)
827 of 1311
LEGEND
PARTIAL CONNECTOR
HVAC
CONNECTOR
MONITORING
2000 THROUGH 2999
3000 THROUGH 3999
BROWN
LIGHT BLUE
BRN
LBL
HYDRAULICS
CAB DISPLAY
PAGE 7
PAGE 8
CAB
MANUAL CONTROLS
PAGE 9
PAGE 10 WIRE BREAK
HVAC PAGE 12
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
#
2440 BLK * C610
2 GND HVAC DUCT
7440 WHT 1 SIG FAN
C483
2560 BLK * C BLK
WHT
SWITCH)
C635
* D SIG
B
E
F
FRC1
C438
(DK GRAY)
Dealer Copy -- Not for Resale *BLOWER
SW10

SWITCH
PWR 30 OFF
1140 RED/WHT
1
GND 85 86 4
2030 BLK
SHEET 4
1790 RNG/WHT
6
3 7530 WHT
* C611
1 14.00 Amps High
7510 WHT 3 5.00 Amps Low MOTOR
SW11
SHEET 4
2745 BLK 8 2745 BLK *
2100 BLK 3
C 7400 WHT
7015 WHT 1
J1A 11 7021 WHT 7020 WHT 9 Printable Version Click Here
GWY CTRLR
* C630
3
THERMOSTAT
WIRING SCHEMATIC
SWITCH B
A
7023 WHT
7024 WHT
7020 WHT 1
(ACS / SJC MACHINE)
C355
FUEL HARN # C486 S650 (S/N A3NV21747 - A3NV25155)
2290 BLK 2280 BLK

2 GND
MAGNET CLUTCH
(COMPRESSOR) (S/N A3NW13098 - A3NW13766)
SHEET 13
D4 (S/N 1MLS11001 AND ABOVE)
Sheet 12 OF 15
7210767 (C)
828 of 1311
LEGEND
OVERVIEW PAGE 1,2
OPTIONS
ENGINE PAGE 6
HYDRAULICS PAGE 7
CAB DISPLAY PAGE 8
CAB PAGE 9
OTHER FUNCTIONS
ENGINE
7000 THROUGH 7999
8000 THROUGH 8999
WHITE
TAN
WHT
TAN
HVAC PAGE 12 JOIN ONE WIRE) * DLX CAB HARN 7234737 ONLY
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT (NOT IN STD CAB HARN 7210557)
C428
C355 (LT GRAY)
CAB-MFR HARN CONN 2
# C607
1 4470 LGN
FUEL HARN
E 8 4470 LGN
#
SIG 4470 LGN
POWER BOB
CLOSE
GND 2 2470 BLK 2770 BLK B 2770 BLK
2290 BLK
SHEET 12
*POWER
SW5 2 1
# C606 BOBTACH 3
5 4
SIG
OPEN
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10 6010 PNK
1430 RED/WHT
L
* FLASHER CONN
C
D2
6530 PNK
*BEACON
SW2
6570 PNK
SHEET 8 3400 LBL
5 PIN SWITCH
2725 BLK 6
SHEET 3
*SW3
HAZARD SWITCH
2
1
6700 PNK
4
1
5
2
(PINS 3 & 6 3
C103 C438 5 4 3
INTERNALLY
INSULATED) 6
EURO TAIL LIGHTS
E 6410 PNK
SHEET 8
3500 LBL
D1
* E
(SEE ADDITIONAL D 6510 PNK 6500 PNK 3 6500 PNK Dealer Copy -- Not for Resale 2420 BLK D BEACON/FLASHER
OPTIONS SHEET)
3 6540 PNK
BUCKET
POSITION
SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1
4
2 *BUCKET
SW6 C
A
OPTIONS SHEET)
2830 BLK 5 POSITION

2780 BLK 1 2780 BLK

SHEET 4
C408
(BLACK)
C126
C412
B 7210 WHT
CAB-MFR HARN CONN 1
13
SHEET 4 2785 BLK B
A
GND
FRONT C279 * C676
RADIO CONN
LEFT C277
(HORN)
2 PIN
A 1460 RED/WHT
SHEET 3 SPEAKER
+
-
2 7830 WHT 4 * 1
2 AIR RIDE
C497 C278 3 SEAT
4 6420 PNK A 2210 BLK 5 GND
3 6520 PNK B SHEET 9 1885 RNG/WHT 6
J2A OPTIONS SHEET)
2885 BLK 2
AUX CTRLR SHEET 9
C415
26 2460 BRN
4460 LGN
B
A
GND
SIG
HIGH FLOW
SOLENOID WIRING SCHEMATIC
7.5 OHM 12 V
J2B
AUX CTRLR
26 (ACS / SJC MACHINE)
C437
S650 (S/N A3NV21747 - A3NV25155)
4360 LGN 1 SIG
MAKEUP SOLENOID
8.8 OHM 12V
(S/N A3NW13098 - A3NW13766)
J1A TRACK 2 SPEED
GWY CTRLR C441
ADAPTER (SEE
ADDITIONAL (S/N 1MLS11001 AND ABOVE)
26 2350 BRN 2 GND TWO SPEED OPTIONS SHEET)
5.1 OHM 12 V Sheet 13 OF 15 Printable Version Click Here
25 26
Printed In U.S.A.
J1B 7210767 (C)
GWY CTRLR
829 of 1311
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS

J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
4275 LGN
G B HANDLE
3 3 B 1190 RED/WHT LOCK
4275 LGN A
C 4550 LGN 2 2 C 1180 RED/WHT H
4220 LGN
8 J C467 E DETENT
2260 BLK
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
A PWM
+5V
5970 YEL 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
TILT D
Dealer Copy -- Not for Resale 4270 LGN 1
SOLENOID C
FLOAT
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GND LIFT ACTUATOR SIDE
D 4610 LGN 8 F
7 A
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
5750 YEL A A HALL SENSOR 2980 BRN 1 GND
+5V PWR
3980 LBL 2 SIG
A C471
2660 BRN GND
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2980 BRN
2990 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 5990 YEL 3 +5V PWR
SIG TILT PEDAL
1 HALL SENSOR 2990 BRN 1 GND
5760 YEL +5V PWR
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
WIRING SCHEMATIC
H
E
3980 LBL
3990 LBL
(ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
Printed In U.S.A. (S/N A3NW13098 - A3NW13766)
830 of 1311 7210767 (C)

6 ISO LITE
CONTROLS
12 CAN HIGH
SJC WHEEL S630, S650, S750, S770 C429
4600 LGN 5
7210504
T630, T650, T750, T770
6
8 17 RR ANGLE
S630, S650,S750, S770,
T630, T650, T750, T770
2980 BRN 1
4
GND 18
19
L JOYSTICK X
L JOYSTICK Y
29 2890 BRN 2880 BRN 3 7
GND 21 L FWD DRIVE
5880 YEL 1 +5V PWR 5980 YEL 3 +5V PWR
+5V
5970 YEL
2870 BRN 3 GND 6
SIG 2990 BRN 1 GND
SENSOR 28 GROUND
24 3875 LBL 4 SIG 4640 LGN 5
7 29 SENSOR GROUND
2970 BRN
5810 YEL 2 C543 4650 LGN 8
31 L REV DRIVE
8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
H
F
G
C 38 SPARE ANALOG 1
LEFT
43 4260 LGN 1 4260 LGN 1 B
40 SENSOR SUPPLY 1 +5V
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
J1-ACS
F 45 R REV RETURN
31 4280 LGN 5 4280 LGN 1
C544 C
K
C460
TO SJC BRAKE A 1 1
HARNESS D 2 2
26 4210 LGN A C450 2070 BLK GND
J3-ACS
(SEE ADDITIONAL OPTIONS
SHEET)
F RIGHT JOYSTICK 4 9660 PUR 4 CAN LO RIGHT
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7 C459
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
C449 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
9240 PUR 1 DLX CAB HARNESS) JOYSTICK
HARNESS SUSP SEAT JOYSTICK HARNESS
27 2470 BLK C493
28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2 WIRING SCHEMATIC
2240 BLK 4 (ACS / SJC MACHINE)
S650 (S/N A3NV21747 - A3NV25155)
1760 RNG/WHT
2280 BLK
(S/N A3NW13098 - A3NW13766)
2270 BLK
2260 BLK (S/N 1MLS11001 AND ABOVE)
1180 RED/WHT
1190 RED/WHT Sheet 15 OF 15 Printable Version Click Here
C404
36 7100 WHT A (CONNECTS TO BACKUP (PRINTED JANUARY 2017)
B ALARM C404 ON MFR
HARNESS)
7210767 (C)
PINS PINS PINS
C110 ALTERNATOR 2 6 C438 CAB-MFR HARN CONN (DK GRY) 14 9,12,13 J2B AUX CONTROLLER 26 3-5,7,10,13
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK (CAB HARN) 4 5 SW3 HAZARD SWITCH 6 13
C252 WASHER ADAPTER INTMD 2 9 C479 LEFT PANEL(BLACK) 12 5,8 SW4 HAND/FOOT, H/ISO SWITCH 6 9
C253 WASHER PUMP 2 9 C480 LEFT PANEL(GRAY) 12 8 SW5 POWER BOBTACH SWITCH 6 13
C350 AC EVAPORATOR SWITCH 2 12 C492 ACS/SJC/AWS-MFR HARN 8 3,5,9
C355 DLX or STD FUEL HARNESS 6 6,12,13 C493 ACS/SJC/AWS-MFR HARN 4 3,4 T1 BATT GROUND 1 4
C404 BU ALARM-MFR HARN 2 3,10 C497 SJC HORN/BLINKER 3 13 T2 BUZZER GROUND 1 8
C405 AIR FILTER SWITCH 2 6 C499 PTOL 4 8 T3 FLASHER 2 13
C406 FUEL SENDER 2 6 C500 RH KEY SWITCH 6 8 T6 BATT GROUND 1 4
C408 CAB-MFR HARN CONN (BLK) 14 3-5,8,9,11,13 C503 RH DLX PANEL 6 5,8 T8 BATT GROUND 1 4
C409 RIGHT HANDLE 10 10 C602 Dealer
LEFT REAR TAIL LIGHT Copy --
2 Not for11Resale T13 BUZZER POWER 1 8
C410 LEFT HANDLE 10 10 C603 RIGHT REAR TAIL LIGHT 2 11 T14 PRE HEATER 1 6
C411 LEFT HANDLE 5 WAY (FLSHR) 5 13 C606 POWER BOBTACH OPEN 2 13 T15 RIGHT REAR WORK LIGHT(+) 1 11
C412 LEFT HANDLE 2 WAY (HORN) 2 13 C607 POWER BOBTACH CLOSE 2 13 T16 RIGHT REAR WORK LIGHT(-) 1 11
C415 HIGH FLOW SOLENOID 2 13 C610 HVAC DUCT FAN 2 12 T17 LEFT REAR WORK LIGHT (+) 1 11
C418 FRONT ROD 2 7 C611 BLOWER MOTOR 4 12 T18 LEFT REAR WORK LIGHT (-) 1 11
C419 FRONT BASE 2 7 C630 THERMOSTAT 3 12 T19 BACKUP ALARM 1 10
C420 HYD LOCK 2 7 C635 HEATER VALVE 6 12 T20 BACKUP ALARM (GND) 1 10
C421 TILT SPOOL LOCK 3 10 C667 DOOR 6 9 T37 DOMELIGHT (+) 1 9
C422 TILT SPOOL LCOK 3 10 C670 EXTERIOR BEACON 6 13 T38 DOMELIGHT (-) 1 9
C423 BUCKET POSITION 2 13 C676 RADIO 6 13
SCHEMATIC INDEX LEGEND

WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION
BATT FEED, GENERAL
GROUP NUMBER RANGE
1000 THROUGH 1499
WIRE COLOR
RED
COLOR CODE
RED
OVERVIEW
POWER
PAGE 1,2
PAGE 3
PARTIAL CONNECTOR WIRING SCHEMATIC
GROUND PAGE 4
BATT FEED, FUSED
BATT FEED, SWITCHED
1000 THROUGH 1499
1500 THROUGH 1999
RED/WHITE
ORANGE/WHITE
RED/WHT
RNG/WHT CAN BUS PAGE 5 (ACS / SJC MACHINE)
MONITORING
2000 THROUGH 2999
3000 THROUGH 3999
BROWN
LIGHT BLUE
BRN
LBL
HYDRAULICS
CAB DISPLAY
PAGE 7
PAGE 8
CONNECTOR S650 (S/N A3NV25156 - A3NV25639)
HYDRAULIC
CONTROLLER SUPPLY
4000 THROUGH 4999
5000 THROUGH 5999
LIGHT GREEN
YELLOW
LGN
YEL
CAB
MANUAL
PAGE 9
PAGE 10 (S/N A3NW13767 - A3NW13930)
LIGHTS 6000 THROUGH 6999 PINK PNK CONTROLS WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 (TWO WIRE BREAKS Printable Version Click Here
SHEET #
COMMUNICATION
COMMUNICATION
9000 THROUGH 9999
9000 THROUGH 9999
PURPLE
PURPLE/WHITE
PUR
PUR/WHT
OPTIONS
ACS
PAGE 13
PAGE 14 Sheet 1 OF 15
SJC PAGE15
7253421 (0)
Printed In U.S.A.
832 of 1311
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 B-2 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 B-7
A-10 TILT SPOOL LOCK RETURN B-10 A-10 B-10
A-18 HYD FAN B-18 ENGINE COOLANT TEMP (8 VOLT) A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL
A-19 PTOL LED B-19 HYD FAN OUTPUT A-19 B-19 FRONT AUX (M)
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP Dealer
A-25 Copy -- Not for Resale B-25
A-26 TWO SPEED MAKE UP GROUND B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 TWO SPEED GROUND A-27
A-29 A-29
A-33 A-33
HARNESS PART NUMBER

EXMF7265253
WIRING SCHEMATIC
MAINFRAME
LF 7210769
DLX CAB 7253409 (ACS / SJC MACHINE)
STD CAB 7210557
DLX FUEL 7266824
S650 (S/N A3NV25156 - A3NV25639)
STD FUEL 7149219
S/R (STARTER) 6733370
(S/N A3NW13767 - A3NW13930)
TAILGATE DOM 7217484 Printable Version Click Here
WHL 2 SPD ADP
TRK 2 SPD
7159366
7214626
Sheet 2 OF 15
Printed In U.S.A. (1PC) TRK 2 SPD 7243409
7253421 (0)
833 of 1311
1240 RED/WHT
POWER
C408
SHEET 8
C503 RH DLX PANEL
(BLACK)
CAB-MFR HARN CONN 1 1400 RED/WHT
SHEET 9
C667 DOOR HARNESS
SHEET 8
C500 RH KEY SWITCH
2 SHEET 8
FUSE 1 25 A 1110 RED/WHT J1B C479 LH PANEL
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR
+12V 1025 RED

FUSE 2 25 A
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps
C493
FUSE 4 25 A 2 (4 PIN)
1010 RED
SHEET 6
STARTER FC2 FUSE CENTER
1190 RED SHEET 5
C426 REMOTE RUN, ACD
FUSE 2 25 A
SHEET 13
FUSE 3 OPEN
1460 RED/WHT
SHEET 13
C412 LH HANDLE HORN
FUSE 4 15 A
SHEET 9
1050 RED
FUSE 5 30 A
1350 RED/WHT
SHEET 6
FUSE 6 30 A
SHEET 7
SHEET 6
FRC1 STARTER RELAY
SHEET 11
1340 RED
SHEET 11
C404
1620 RNG/WHT
FUSE1 25 A FRC1 HVAC RELAY OPTIONS DWG)
SHEET 8
1550 RNG/WHT
SW1 BRAKE SWITCH
FUSE4 5 A
SHEET 8
C410 LEFT HANDLE 1950 RNG/WHT
1570 RNG/WHT 1520 RNG/WHT SHEET 10 SHEET 8
SHEET 9
FRC1 FUSE 8 25 A
1580 RNG/WHT
1050 RED
PWR
30 J1A
SHEET 6
C110 ALT EXCITATION WIRING SCHEMATIC
SHEET 12
SHEET 4
2055 BLK
GND 85 86
3450 LBL 21 C428
(LT GRAY)
FRC1 HVAC RELAY (ACS / SJC MACHINE)
3380 LBL 4 CAB-MFR HARN CONN 2
S650 (S/N A3NV25156 - A3NV25639)
SHEET 5
1830 RNG/WHT
C449 LH JOYSTICK (S/N A3NW13767 - A3NW13930)
6 C492 SHEET 5
1740 RNG/WHT
SJC/ACS/AWS-MFR HARN C450 RH JOYSTICK Printable Version Click Here
(8 PIN)
Sheet 3 OF 15
7253421 (0)
834 of 1311
2080 BLK C493
GROUND
2070 BLK
SHEET 5
C479 LH PANEL
2940 BLK 2950 BLK 10 2950 BLK
SHEET 8
C499 PTOL
2960 BLK 16 2510 BLK 2110 BLK T6
2250 BLK
SHEET 8
AUX CTRLR SHEET 11
2830 BLK 2900 BLK 1 2900 BLK T8
C423 BKT POSITION SOLENOID 2790 BLK
SW9 TRAVEL CONTROL SWITCH SHEET 9
SHEET 13 SHEET 5
SHEET 13
2620 BLK SHEET 13 2730 BLK
SHEET 11 C355 FUEL HARN (PWR BOB/AC) SHEET 9
T16 RH REAR LIGHT C408 CAB-MFR CONN (ACCESSORIES,OPTIONS)
2630 BLK C103 T1
SHEET 11 C489 B
2650 BLK 2600 BLK B 2600 BLK
SHEET 10
T20 BU ALARM
2640 BLK 2400 BLK 2390 BLK
SHEET 11 SHEET 6
SHEET 6 2016 BLK C101 FUEL SHUTOFF SOLENOID
C602 LH REAR LIGHT
2610 BLK FRC1 GLOW PLUG RELAY
2025 BLK SHEET 7
Dealer Copy
2200 BLK -- Not for Resale
SHEET 11 SHEET 6
SHEET 7 2035 BLK
2045 BLK SHEET 10
2115 BLK 2105 BLK 2000
SHEET 11
C104 ENGINE COOLANT SENSOR SHEET 3 SHEET 10
SHEET 6 SHEET 12
SHEET 7
2320 BRN SHEET 6 2005 BLK WIRING SCHEMATIC
FRC1 STARTER RELAY
SHEET 9
2370 BRN J1B (ACS / SJC MACHINE)
SHEET 7
2220 BRN 2230 BRN 17 S650 (S/N A3NV25156 - A3NV25639)
SHEET 7 2190 BRN

(S/N A3NW13767 - A3NW13930)
2180 BRN
SHEET 6
C355 FUEL HARN (FUEL SENDER) Sheet 4 OF 15
2140 BRN
SHEET 6
C107 ENG OIL PRESS SENDER (PRINTED JANUARY 2017)
SHEET 6
2150 BRN 7253421 (0)
Printed In U.S.A.
835 of 1311
CAN BUS
C408
J1B
GWY CTRLR
(BLACK)
CAB-MFR HARN CONN 1 (NOT IN STD CAB HARN 7210557)
CAN LO C479
CAN HI
120 OHM 120 OHM
(8 PIN)
C426 1 9260 PUR 4
9240 PUR C503
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
1830 RNG/WHT 1
SHEET 3
DRIVE CTRLR
SHEET 4
2070 BLK
9560 PUR/WHT
2
3
* C450
RIGHT JOYSTICK
SHEET 4 J2B
1840 RNG/WHT 1
Dealer Copy -- Not for Resale SHEET 3
SHEET 4
2080 BLK
9540 PUR/WHT
2
3
* C449
LEFT JOYSTICK
(SJC/AWS ONLY)
9640 PUR 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 5 OF 15
Printed In U.S.A.
7253421 (0)
836 of 1311
SHEET 3
1030 RED
PWR 30
FRC1
+12V STARTER RELAY
87 8200 TAN
C109
S/R ADAPTER
A
B
TAN S
STARTER
M
B
ENGINE SHEET 3
GND 85 86
3560 LBL TAN R 1015 RED
2005 BLK 8210 TAN
SHEET 4 C110
B S 1020 RED
ALTERNATOR G
EXCITATION
2015 BLK
FRC1 FUEL SHUTOFF

FUEL PULL SOLENOID
+12V RELAY C101
D5 8100 TAN B
1350 RED/WHT
PWR
SHEET 3 87 3410 LBL
GND 85 86 SHEET 4
2025 BLK 8110 TAN
SHEET 4 8800 TAN A HOLD 24.5 OHM
FRC1 T14
+12V RELAY 8500 TAN
PWR 30
1060 RED
SHEET 3 87
GND 85 86
SHEET 4 2016 BLK
6 8510 TAN Dealer Copy -- Not for Resale

14 3420 LBL
3 8110 TAN
30 3410 LBL
7 8210 TAN
22 3560 LBL
C107
5140 YEL B +5V PWR
J1A SHEET 9
SHEET 4
2150 BRN
C405
B GND
WIRING SCHEMATIC
SHEET 4 AIR FILTER
16 3150 LBL A SIG
C106
SWITCH (NC)
(ACS / SJC MACHINE)
15
SHEET 4
3160 LBL
2160 BRN
A
B
SIG
GND
ENGINE SPEED SENSOR S650 (S/N A3NV25156 - A3NV25639)
(163 OHM)
C104
(S/N A3NW13767 - A3NW13930)
2170 BRN B GND ENGINE COOLANT
18 3170 LBL A SIG SENSOR (500-3000 OHM)
(8 VOLT)
4 8800 TAN
Sheet 6 OF 15
J1B C355
GWY CTRLR FUEL HARN (PRINTED JANUARY 2017)
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER 7253421 (0)
2180 BRN D 2180 BRN B GND
SHEET 4 (30 - 270 OHM)
Printed In U.S.A.
837 of 1311
FRC1
HYDRAULICS
4100 LGN
C425
B C308
TRACTION LOCK BRAKE
PWR 30
1360 RED/WHT SHEET 4
87
WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS DWG)
2035 BLK 4110 LGN
SHEET 4
C425
B PULL 0.3 OHM

A HOLD 10.9 OHM
8
TRACTION LOCK
13
C108 HYDRAULIC
SHEET 4 SENDER
32 3220 LBL A SIG
500 - 3000 OHM
(8 VOLT)
C112
SHEET 4
C446
7.2 OHM 12 V
9.8 OHM 12 V
C105
SHEET 4
0.5-7.5V
4200 LGN
WIRING SCHEMATIC
19 13 1 23 6
J1B +8V (ACS / SJC MACHINE)
GWY CTRLR
S650 (S/N A3NV25156 - A3NV25639)
J2A 18 2330 BRN
C418
2 GND FRONT ROD (S/N A3NW13767 - A3NW13930)
AUX CTRLR 1 SIG SOLENOID (MALE)
4330 LGN
3.3 OHM PWM Printable Version Click Here
C419
1 2340 BRN
4340 LGN
2
1
GND
SIG
FRONT BASE Sheet 7 OF 15
SOLENOID (FEMALE)
3.3 OHM PWM
7253421 (0)
19 13
J2B
AUX CTRLR
Printed In U.S.A.
838 of 1311
T13
BUZZER (+)
CAB DISPLAY
LEFT PANEL
* DLX CAB HARN 7253409 ONLY C499
7040 WHT
T2
BUZZER
C479 (NOT IN STD CAB HARN 7210557) (PTOL)

2940 BLK 3
BUZZER
(BLACK)
SHEET 4 GROUND
*SW9
TRAVEL CONTROL
SHEET 3
J1A
19 2380 BRN 12 2380 BRN 4
PTOL LED
SHEET 13 GWY CTRLR
C500
5 6 3500 LBL 8
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT 6
SW1 6
3 2 BRAKE SWITCH 12
1 J1B 22 3040 LBL 14 4

1950 RNG/WHT 5
3630 LBL 12 2960 BLK 3
SHEET 9 DOOR SIGNAL Dealer Copy -- Not for Resale SHEET 4 GROUND
11
10
9 C503
PARK BRAKE OUTPUT
8 1590 RNG/WHT 5
6 1240 RED/WHT 1
5 2250 BLK 3
4 SHEET 4 GROUND
6
3
1
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 8 OF 15
Printed In U.S.A.
7253421 (0)
839 of 1311
SW4
*
HAND/FOOT
(ACS)
C492
SHEET 10 4230 LGN
C438
(DK GRAY)
SHEET 3
2060 BLK
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
5 6
3
CAB
(8 PIN)
SHEET 10 4240 LGN
4 * DLX CAB HARN 7253409 ONLY
5 4220 LGN 4235 LGN 4 4235 LGN
3 4275 LGN 5 4275 LGN (NOT IN STD CAB HARN 7210557)
2 4550 LGN 6 4550 LGN
*C212
POWER
SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1

* T37
DOME LIGHT (+)
SHEET 3
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
T38
1210 RED/WHT A
+12V BATT PWR
+12V SW PWR * DOME LIGHT (-)
2790 BLK
SHEET 3
2820 BLK C GND
1510 RNG/WHT
SHEET 13
2730 BLK 11 2730 BLK 2210 BLK SHEET 13
SHEET 4
2885 BLK SHEET 13
2060 BLK SHEET 9
C428
(LT GRAY)
CAB-MFR HARN CONN 2
* C667
DOOR HARNESS
SHEET 4 OPTIONS DWG)
3630 LBL 4
SHEET 8 DOOR SIGNAL
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 4
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

+5V
SHEET 6 5140 YEL WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378 (ACS / SJC MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
* C252 C253
PWR (S/N A3NW13767 - A3NW13930)
A 7310 WHT 1 WASHER
MOTOR Printable Version Click Here
2845 BLK B 2845 BLK 2 GND
Sheet 9 OF 15
7253421 (0)
840 of 1311
MANUAL CONTROLS 2530 BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
K
J2A SHEET 4
SHEET 9
1520 RNG/WHT A
SHEET 3
30 4940 LGN H
C103
OPTIONS SHEET)
4310 LGN C
BACK UP
4320 LGN D
2650 BLK ALARM PWM
SHEET 4 4300 LGN B
T20 TERMINAL (-)
C410
21 17 18 23
LEFT HANDLE
C421 AUX CTRLR K
J1A 10 2670 BRN 3 GND 20 4640 LGN D
12 4820 LGN G
C422 Dealer Copy -- Not for Resale 11 4810 LGN F SIDE SHIFT
4680 LGN 1 SIG J
7.8 OHM 12V
2 4240 LGN H
SHEET 9
2520 BLK E
SHEET 4
7 5
J1B WIRING SCHEMATIC
GWY CTRLR
(ACS / SJC MACHINE)

S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 10 OF 15
Printed In U.S.A.
7253421 (0)
841 of 1311
C434-1
LIGHTS SHEET 4
2765 BLK 9 2765 BLK 2750 BLK
6110 PNK
C434-2
B
A
GND
SIG
LEFT FRONT
WORK LIGHT
50.00 Watts
C435-1
37.00 Watts
C435-2
50.00 Watts
FRC1
FRONT WORK
LIGHTS RELAY C103
+12V TAILGATE HARN C603
PWR 30 2610 BLK 2 GND
1330 RED/WHT SHEET 4 RIGHT REAR
TAIL LIGHT
2115 BLK GND 85 86 C602

SHEET 4
6330 PNK 1 SIG
GND
SHEET 4 TAIL LIGHT
5 6320 PNK
31 3460 LBL Dealer Copy -- Not for Resale
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 4 RIGHT REAR
FRC1
+12V RELAY
GND 85 86 SHEET 4
2045 BLK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Printed In U.S.A.
Sheet 11 OF 15
7253421 (0)
842 of 1311
2440 BLK * C610
2
HVAC
GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK * C483C BLK

WHT
* DLX CAB HARN 7253409 ONLY SWITCH)
(NOT IN STD CAB HARN 7210557) * C635D SIG

# DLX FUEL HARN 7266824 ONLY B
E
(NOT IN STD FUEL HARN 7149219) F
FRC1
C438
(DK GRAY)
*BLOWER
SW10

SWITCH
PWR 30 OFF
1140 RED/WHT
1
GND 85 86 4
2030 BLK
SHEET 4
1790 RNG/WHT
6
3 7530 WHT
* C6111 14.00 Amps High
Dealer Copy -- Not for Resale MOTOR
7510 WHT 3 5.00 Amps Low
SHEET 4
2745 BLK 8 2745 BLK *ACSW11
SWITCH 2580 BLK 4
2100 BLK 3
C 7400 WHT
7015 WHT 1
J1A 11 7021 WHT 7020 WHT 9
GWY CTRLR
* C6303 THERMOSTAT
2
AC EVAPORATOR
SWITCH
C350
B 7023 WHT
2570 BLK
7020 WHT 1 WIRING SCHEMATIC
A 7024 WHT
C355
FUEL HARN # C486
(ACS / SJC MACHINE)
A 7024 WHT 7025 WHT 1
2
SIG
GND
MAGNET CLUTCH S650 (S/N A3NV25156 - A3NV25639)
(COMPRESSOR)
2290 BLK 2280 BLK
SHEET 13
D4
(S/N A3NW13767 - A3NW13930)
Sheet 12 OF 15
7253421 (0)
843 of 1311
C428
OPTIONS
C355 (LT GRAY)
# C607
FUEL HARN CAB-MFR HARN CONN 2
SIG 1 4470 LGN E 4470 LGN 8 4470 LGN
POWER BOB 2
GND 2470 BLK 2770 BLK B 2770 BLK 4480 LGN
CLOSE SHEET 4
SHEET 12 2290 BLK
*POWER
SW5 2 1
#
GND
# C606
2 2480 BLK
BOBTACH
SWITCH 5
3
4 (NOT IN STD FUEL HARN 7149219)
POWER BOB 6
SIG 1 4480 LGN F 4480 LGN 7
OPEN
1380 RED/WHT
SHEET 3
X T3
C411
B 6010 PNK 10 6010 PNK
1430 RED/WHT
L
* FLASHER CONN
C
D2
*BEACON
SW2
6570 PNK
SHEET 8 3400 LBL
5 PIN SWITCH
2725 BLK 6
SHEET 3
* SW3SWITCH
HAZARD
2
1
6700 PNK
4
1
5
2
(PINS 3 & 6 3
C103 C438 5 4 3
INTERNALLY
INSULATED) 6
EURO TAIL LIGHTS
(SEE ADDITIONAL
E
D
6410 PNK
6510 PNK 6500 PNK 3
SHEET 8
6500 PNK
3500 LBL
D1 6530 PNK
* E
2420 BLK D BEACON/FLASHER
OPTIONS DWG)
3 6540 PNK
BUCKET SIG A 4450 LGN D3 4455 LGN 2 4455 LGN 1 2 * SW6
BUCKET
C OPTIONS DWG)
2830Dealer Copy -- Not for Resale

POSITION 4 A
BLK 5 POSITION
SHEET 4 SHEET 4 6
9.8 OHM
2780 BLK 1 2780 BLK
SHEET 4
C408
(BLACK) C126
C412
B 7210 WHT
CAB-MFR HARN CONN 1
13
SHEET 4 2785 BLK B
A
GND
FRONT C279 * C676
RADIO CONN
LEFT C277
(HORN)
2 PIN
A 1460 RED/WHT
SHEET 3 SPEAKER
+
-
2 7830 WHT 4 * 1
2 AIR RIDE
C497 C278 3 SEAT
4 6420 PNK A 2210 BLK 5 GND
3 6520 PNK B 1885 RNG/WHT 6
J2A OPTIONS DWG) SHEET 9
2885 BLK 2
AUX CTRLR SHEET 9
C415
4460 LGN A SIG
SOLENOID
7.5 OHM 12 V WIRING SCHEMATIC
J2B
26
AUX CTRLR
(ACS / SJC MACHINE)
27 2360 BRN
C437
2 GND TWO SPEED S650 (S/N A3NV25156 - A3NV25639)
4360 LGN 1 SIG
MAKEUP SOLENOID
J1A
ADAPTER (SEE
(S/N A3NW13767 - A3NW13930)
GWY CTRLR C441
ADDITIONAL
26 2350 BRN 2 GND TWO SPEED OPTIONS DWG) Printable Version Click Here
5.1 OHM 12 V
Sheet 13 OF 15
25 26
J1B
GWY CTRLR 7253421 (0)
844 of 1311
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS

J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
4275 LGN
G B HANDLE
A
C 4550 LGN 2 2 C 1180 RED/WHT H
4220 LGN
8 J C467 E DETENT
2260 BLK
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4280 LGN 1 LIFT C TWO SPD
4260 LGN
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
Dealer Copy -- Not for Resale B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GND LIFT ACTUATOR SIDE
D 4610 LGN 8 F
7 A
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GND
3980 LBL 2 SIG
A C471
2760 BRN GND
C
J 3 SIG K 4645 LGN 8
4660 LGN LIFT PEDAL
D 1 HALL SENSOR 7
5660 YEL +5V PWR
2980 BRN
2990 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 SIG 5990 YEL 3 +5V PWR
TILT PEDAL
5760 YEL 1 HALL SENSOR 2990 BRN 1 GND
+5V PWR
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
WIRING SCHEMATIC
H
E
3980 LBL
3990 LBL (ACS / SJC MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
(S/N A3NW13767 - A3NW13930)
Sheet 14 OF 15
7253421 (0)
845 of 1311

6 ISO LITE
CONTROLS
12 CAN HIGH
LIFT 14 RF ANGLE
SJC TRACK 7210504 C429 ACTUATOR 15 LR ANGLE
4600 LGN 5
16 H PAT LITE
J5 - DRIVE SUSP JSTK 7163706
4610 LGN
6
8 17 RR ANGLE
CONTROLLER 2980 BRN 1

4
GND 18
19
L JOYSTICK X
L JOYSTICK Y
29 2890 BRN 2880 BRN 3 7
21 L FWD DRIVE
5880 YEL 1 5980 YEL 3 +5V PWR
22 CAN LOW
33 3880 LBL 2
34 3885 LBL 4 TILT ACTUATOR
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL C453 4 25 TWO SPEED 1
+5V
5970 YEL
5870 YEL 1 3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
2870 BRN 3 6
23 3870 LBL 2
27 GROUND
2990 BRN 1 GND
24 3875 LBL 4 28 GROUND
4640 LGN 5
7 29 SENSOR GROUND
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN OR BLK 4 2810 BRNor BLK 1 GND
31 L REV DRIVE
8 3810/LBL OR 4720/LGN 3 3810/LBL OR 4270/LGN 3 SIG 32 CAN SHIELD
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E 35
5860 YEL 2 C542 SWASHPLATE SAFETY OUT
H
F
G
C 38 SPARE ANALOG 1
LEFT
RIGHT FORWARD DRIVE
Dealer Copy -- Not for Resale A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
J1-ACS
F 45 R REV RETURN
31 4280 LGN 5 4280 LGN 1
C544 C
K
C460
TO SJC BRAKE A 1 1
HARNESS D
26 4210 LGN A C450 2 2070 BLK 2 GND
J3-ACS
(SEE ADDITIONAL OPTIONS F RIGHT JOYSTICK 4 9660 PUR 4 CAN LO RIGHT
SHEET)
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7 C459
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
C449 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
9240 PUR 1 DLX CAB HARNESS)
JOYSTICK
HARNESS
27 2470 BLK C493
28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2 WIRING SCHEMATIC
2240 BLK 4
(ACS / SJC MACHINE)
S650 (S/N A3NV25156 - A3NV25639)
1760 RNG/WHT
2280 BLK
(S/N A3NW13767 - A3NW13930)
2270 BLK
2260 BLK
1180 RED/WHT
1190 RED/WHT Sheet 15 OF 15
C404
36 7100 WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR
HARNESS)
7253421 (0)
Printed In U.S.A.
846 of 1311
Index Diagram
1 SH01 - INDEX
3 SH03 - SWITCHED POWER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND
5 SH05 - CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
6 SH06 - ENGINE
9 SH09 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT LEGEND
11 SH11 - LIGHTS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CONNECTOR
12 SH12 - HVAC
BATTERY GROUND 2000 THROUGH 2999 1 1
13 SH13 - OPTIONS 1 BLACK BLK
14 SH14 - OPTIONS 2
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN PARTIAL CONNECTOR
HARNESS PART NUMBER MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
1 1
EXMF 7305834
LF MFR 7304712
1 1
DLX CAB 7304511 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
STD CAB 7210557 WIRE BREAK
STD FUEL LIGHTS 6000 THROUGH 6999 PINK PNK
7149219 WIRE BREAK
SHT1/F2 SHT1/F2
S/R (STARTER) 6733370 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
WIRE BREAK
TAILGATE DOM 7217484 SHT1/F2 SHT1/F2
(1 PC) TRK 2 SPD 7243409 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
SUSP JSTK 7163706 COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT

S650 S/N A3NV25640
A3NT18589 through A3NT19199
WARNING A3NV26199
PROPRIETARY NOTICE TOLERANCES: ECN 102712 Printed On December 2018
csf

WEST FARGO, NORTH DAKOTA, USA
ACS / SJC Machine S/N A3NW13931
A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
SCHEM ELEC CTRL
Sheet 1 of 16
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV DESCRIPTION
102712 MSE
SHT 1 / 14
7305835
847 of 1311
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT8/E3
1400 RED/WHT
SHT9/D3
C408
6 6 SHT8/E3
1440 RED/WHT
SHT8/G8

2
1 2 SP2 3
J1B
1025 RED
3 4 3
HW11 1 1 2
T5 T4 J2B
C493
1270 RED
7 8 1 1
1280 RED
5 6 2 2
SHT6/G1
FC1 FC1
1010 RED
FC2 FUSE CENTER

1 2 SHT5/C8

3 4 SHT13/G7
1460 RED/WHT
SP26 1290 RED FUSE 4 15 A

Dealer 1370
RED/WHT
SHT13/B7
5 6 SHT9/F8
FC2 FC2
FUSE RELAY CENTER
FUSE 5 30 A
1350 RED/WHT
5A 5B SHT6/D1
BUS BAR
1310 RED
FUSE 6 30 A
1360 RED/WHT
6A 6B SHT7/H8
FUSE 9 15 A
1320 RED/WHT
9A 9B SHT11/B8
BUS BAR
1340 RED
10A 10B SHT11/D8
1300 RED
11A 11B SHT12/F8
FRC1 FRC1
1030 RED
SHT6/H8
1050 RED
SHT3/E8
1060 RED
SHT6/E1

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 2 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712 MSE
SHT 2 / 14
7305835
848 of 1311
SWITCHED
POWER
C404
1720 RNG/WHT
FUSE RELAY CENTER B B BU ALARM-MFR HARN
(SEE ADDITIONAL
FUSE 1 25 A 1750 RNG/WHT SP52 OPTION DWG)
1A 1B
BUS BAR
1780 RNG/WHT C489
A A MFR ACCESSORY
1760 RNG/WHT
2A 2B SHT9/D8
BUS BAR
1575 RNG/WHT
SHT14/G4
3A 3B SHT13/F7
1620 RNG/WHT
SHT8/G8
1940 RNG/WHT
SHT8/H8
BUS BAR
C428
SHT8/H3
4A 4B 2 2 1590 RNG/WHT
SP42 SHT8/E3
1950 RNG/WHT
SHT8/F3
1785 RNG/WHT
SHT9/H6
1960 RNG/WHT
SHT8/E8
1565 RNG/WHT
FRC1 SHT14/E4
SHT10/G3
POWER
RELAY - A SHT10/D3
1560 RNG/WHT
22 AUX CTRLR
1050 RED 30
SHT2/B1 G4 87
G1
7A
Dealer
FUSE 7Copy
25 A -- Not for
7B
Resale 1730 RNG/WHT J2B
SHT5/C8
SP25
BUS BAR
2055 BLK 86 85
SHT4/B8 G5 G2
FRC1 FRC1 8A 8B SHT9/F8
1815 RNG/WHT
12A 12B SHT6/G4
FRC1 FRC1
1790 RNG/WHT
SHT12/E8
GWY CTRLR
3450 LBL
3380 LBL
J1A
C428 1830 RNG/WHT

MFR HARN CONN 2 (LT GRAY) SHT5/E3
6 6
1840 RNG/WHT
C492 SHT5/E3
ACS/SJC/AWS-MFR HARN (8 PIN)
1740 RNG/WHT
6 6

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 3 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712 MSE
SHT 3 / 14
7305835
849 of 1311
GROUND
2140 BRN
SHT6/E7
C493
2150 BRN
ACS/SJC/AWS CONN 2 SHT6/G7
2235 BLK 2160 BRN
2080 BLK 3 3 SHT6/F7 GWY CTRLR
SHT5/D3
2170 BRN
2240 BLK SHT6/B7
2070 BLK 4 4 2180 BRN SP12 2230 BRN
C493
2190 BRN
2920 BLK SHT7/D7
SHT8/G8 C408 J1B
2220 BRN
2940 BLK SP4 2950 BLK 2950 BLK 2320 BRN
SHT8/G3 10 10 SHT7/F7
2370 BRN
2960 BLK SHT9/C8
SHT8/E3
2250 BLK 2510 BLK SP3 2110 BLK 1 T6

GWY CTRLR 2500 BLK

15
J1B
2540 BLK
16
2860 BLK AUX CTRLR
2915 BLK 15 SHT9/E8
SHT14/H4 2745 BLK
J2B SHT12/D8
2930 BLK
SHT8/E8 C428 2765 BLK 1 T8
BATTERY GROUND
SHT13/D5 2900 BLK 2900 BLK 2780 BLK
2700 BLK 1 1 SHT13/D8
SHT9/D8
2785 BLK
SHT13/B7
2455 BLK
SP27 2300 BLK
SHT13/D6
2710 BLK
SHT5/C8
2770 BLK
SHT13/H6
2620 BLK C489 2720 BLK

2650 BLK
SHT10/F8 C103
2600 BLK SP6 2390 BLK 1 T1 SHT6/G4
2640 BLK 2600 BLK
SHT11/C4 B B T10
BATTERY GROUND
SP51 ENGINE GROUND
2610 BLK
SHT11/E4
2630 BLK
SHT11/B4
2200 BLK
SHT7/H4 AUX CTRLR
2400 BLK
SHT6/C7 2185 BRN
2520 BLK 2195 BRN 17 SENSOR GND
SHT10/D3 SHT10/G3
2005 BLK J2B
SHT6/G8
2016 BLK
SHT6/E1
2025 BLK
SHT6/D1
2030 BLK
SHT12/E8 SP1 2105 BLK SP5 2000 BLK
2035 BLK
SHT7/H5
2045 BLK
SHT11/B8
2055 BLK
SHT3/D8
2115 BLK
SHT11/D8
2505 BLK
SHT14/G4
2530 BLK
SHT10/F3
2155 BLK
SHT14/F4

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 4 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 4 / 14
7305835
850 of 1311
CAN BUS
RE016 RE019 C479

C408
GWY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
R3-1 SP19 SP18 R1-1 (BLACK)
TP-09 9200 PUR TP-09 SP31 TP-12 TP-12 SP79 SP39 SP35 TP-07 TP-07
TP-10 9270 PUR TP-10 9210 PUR TP-14 9280 PUR TP-14 TP-16 9230 PUR TP-16 TP-01 9230 PUR TP-01 TP-03 9240 PUR TP-03 TP-05 9250 PUR TP-05 9650 PUR TP-08 9630 PUR TP-08
CAN LO 8 4 4 4
SP30 SP80 SP17 SP38 SP34

9100 PUR/WHT 9170 PUR/WHT 9110 PUR/WHT 9180 PUR/WHT 9130 PUR/WHT 9130 PUR/WHT 9140 PUR/WHT 9150 PUR/WHT 9550 PUR/WHT 9530 PUR/WHT
CAN HI 9 3 3 3
R3-2 TP-11 TP-13 SP20 TP-15 R1-2
TP-02 TP-04 TP-06
C479
C492
ACS/SJC/AWS-MFR HARN (8 PIN)
9240 PUR TP-15
1 1 CAN LO C503
RH DLX PANEL
9140 PUR/WHT
4 4 CAN HI 9260 PUR TP-06
4
9290 PUR TP-13
7 7 CAN LO 9160 PUR/WHT
2
9190 PUR/WHT
8 8 CAN HI
C503
AUX CTRLR *C450

RIGHT JOYSTICK CONN
C460
RIGHT JOYSTICK RIGHT JOYSTICK
TP-11 1830 RNG/WHT
9220 PUR 1830 RNG/WHT +12V PWR
8 CAN LO SHT3/C1 1 1 1 1
9120 PUR/WHT SHT4/G8 2 2 2 2
9 CAN HI 9560 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
C426
CAN HI 14
TP-17 9500 PUR/WHT TP-17
A A CAN HI *C449
LEFT JOYSTICK CONN
C459
LEFT JOYSTICK
C449
LEFT JOYSTICK
CAN LO 20
9600 PUR Dealer
B B CAN LO
Copy -- Not for Resale SHT3/B1
2080 BLK
1 1
2080 BLK
1 1
GND
SHT4/H8 2 2 2 2
9540 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
3090 LBL SP93 3085 LBL

J1B
AUX CTRLR
3095 LBL
REMOTE RUN KEY 24
J2A

SHT3/D1 E E

SHT2/E1 F F
2710 BLK GROUND

SHT4/E8 G G

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 5 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712 MSE
SHT 5 / 14
7305835
851 of 1311
T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C109
1030 RED
SHT2/B1 J4 87 8200 TAN 8220 TAN
30 J1 A A
8210 TAN 85 3560 LBL

J2 J5 B B T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/C8
SHT2/E6
C110 ALTERNATOR
1015 RED 1020 RED
GWY CTRLR S
1800 RNG/WHT
SHT3/D1 L
SHT4/D3
3560 LBL T11
2150 BRN GND GND 1
C405
3160 LBL
ENGINE SPEED
SHT4/H3 B
C106
5140 YEL
SHT9/B8 B
3140 LBL
ENGINE OIL PRESSURE
SHT4/H3 A
RELAY - F
C107
1 8500 TAN
1060 RED
T14 3420 LBL F4 SHT2/B1
8510 TAN 2016 BLK


FRC1
FRC1 FUEL PULL

RELAY - E
1350 RED/WHT
3410 LBL E1 SHT2/D1
8110 TAN 2025 BLK
J1A FRC1 FRC1

C101
B B 0.33 OHM
D1
SHT4/C8 C C
8800 TAN HOLD
C355
FUEL HARN
3180 LBL 3180 LBL
FUEL SENDER
(30 - 270 OHM)
2180 BRN 2180 BRN
SHT4/G3 D D B
C406
3170 LBL
(500 - 3000 OHM) (8 VOLT)
2170 BRN
SHT4/G3 B
J1B C104

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 6 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 6 / 14
7305835
852 of 1311
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/C1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
D5 D2 SHT4/C8 2200 BLK 2200 BLK
C308

GWY CTRLR
TRACTION LOCK
4110 LGN
RELAY SIGNAL 8
3430 LBL
RELAY FEEDBACK
PULL 0.3 OHMS
B B
2220 BRN GND
SHT4/G3 B 10.9 OHMS
T A A
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108 C C
WHEEL SINGLE SPEED
TRACTION LOCK
3320 LBL SIG
2320 BRN GND
SHT4/G3 B (NC)
C112
4010 LGN SIG

1
C446
2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
1
J1A
2190 BRN GND
SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
4330 LGN GND

AUX CTRLR 1
TRACTION
SOLENOID OUTPUT
HYD CHARGE PRESS
SENDER SIGNAL
HYD CHARGE PRESS

SENDER POWER
HYD LOCK
SOLENOID SIGNAL
HYDRAULIC FAN
SIGNAL

FRONT ROD SIG 3.3 OHM PWM
2330 BRN
SOLENOID GROUND 18 2
C418
4340 LGN GND
1
GWY CTRLR 3.3 OHM PWM
2340 BRN SIG
FRONT BASE 1 2
SOLENOID GROUND
J2A J2B C419
19
13
FRONT ROD
SOLENOID SIGNAL
FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 7 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 7 / 14
7305835
853 of 1311
1940 RNG/WHT
LEFT PANEL BUZZER CAB DISPLAY
SHT3/F1 1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND
SHT4/G8 3
BUZZER GWY CTRLR
10 C408
SHT2/G1 1 PTOL LED 19 12 12 4
SHT3/F1 5 C499
C500
SHT13/F5 11
J1A
SW9

SHT3/F1 5
6
1
5 4 SHT2/G1 1
SW9 SW9 9
SHT3/E1 SHT4/G8 3
SW1 C500
BRAKE SWITCH C503
RH DLX PANEL
2930 BLK C479 SHT5/G1
SHT4/F8 2 1
SHT3/F1 5
5 6
4
3
SW1 SHT4/G8 3
SHT3/F1
6
SHT9/D3 12
C503 SHT5/F1

2
C480

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 8 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 8 / 14
7305835
854 of 1311
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT9/E3 5
4230 LGN 4
SHT10/F3
4240 LGN SW4 3
SHT10/D3
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
4220 LGN SP29 4235 LGN 4235 LGN
HAND CONTROL LIGHT 5 5 4 4
FOOT CONTROL LIGHT 4275 LGN 4275 LGN

3 3 5 5

4550 LGN
6 6
4550 LGN *
C212
POWER SOCKET
2795 BLK GND
1
2
C212
C408
SHT2/D1
1370 RED/WHT
7 7
C129 T37
CAB ACCESSORY
A A +12V BATT PWR 1
* T38
2820 BLK
C C GND
1510 RNG/WHT
SHT13/C2
1885 RNG/WHT
SHT13/C3
2730 BLK 2730 BLK SP44 2060 BLK

SHT4/F3 11 11 SHT9/H6
2210 BLK
SHT13/C2
2885 BLK
C428
MFR HARN CONN 2 (LT GRAY)
SHT13/B3
* C667
DOOR HARNESS
2790 BLK 2790 BLK
OPTIONS DWG)
3630 LBL
1400 RED/WHT
2840 BLK
6 6
2370 BRN 2370 BRN 7310 WHT
SENSOR
GWY CTRLR GND

A
+5V PWR
SP13 C
5100 YEL 5370 YEL 5370 YEL
C482
J1B * C252 C253

7253378
5140 YEL 7310 WHT
SHT6/F7 A A PWR 1
WASHER
2845 BLK 2845 BLK
MOTOR
B B GND 2

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 9 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 9 / 14
7305835
855 of 1311
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1520 RNG/WHT
SHT3/E1 A
RIGHT HANDLE LEFT
4930 LGN
ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE 30 H LEFT POSITION SWITCH
LEFT ROCKER UP 2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN ROCKER UP 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B8 K
SHT4/D8 4230 LGN
T20 SHT9/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
PWM SIGNAL
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM HIGH
GWY CTRLR

SOLENOID GROUND 10 3
LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V
4670 LGN SIG
1
Dealer Copy -- Not for Resale AUX CTRLR
LIFT (ACS/AHC ONLY)
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT9/G8 H
LIFT SPOOL LOCK 2680 BRN GND 2520 BLK
SOLENOID GROUND
2 3 SHT4/C8 E
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4680 LGN
7.8 OHM 12V
SIG 1530 RNG/WHT
1 SHT3/E1 A
LEFT HANDLE RIGHT
C422 ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
LEFT HANDLE RIGHT 4840 LGN
ROCKER UP
28 C
4810 LGN
J1B
4820 LGN
7

SOLENOID SIGNAL
C410
TILT SPOOL LOCK
LIFT SPOOL LOCK

SOLENOID SIGNAL
TRIGGER
GWY CTRLR

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 10 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 10 / 14
7305835
856 of 1311
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/E3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK SP15 6120 PNK
8 8 SIG
A
37 WATT
2760 BLK GND

B RIGHT FRONT
6130 PNK WORK LIGHT
A
SIG
50 WATT
2705 BLK GND

B
C435-2
FRC1
2610 BLK GND
FRONT WORK
LIGHTS RELAY - B
SHT4/D8 2
C103 RIGHT REAR

TAIL LIGHT
B4 A A 1
6320 PNK
C603
2115 BLK
SHT4/B8 B2 B5
FRC1 FRC1
6330 PNK SIG
1
LEFT REAR
MRKR LIGHT PWR 2640 BLK GND
SHT4/D8 2
RELAY SIGNAL 5
C602
RELAY FEEDBACK 31
REAR LIGHT RELAY 6210 PNK

SIGNAL
17 T16 TERMINAL (-)
2620 BLK
3440 LBL SHT4/E8
GND 1
REAR LIGHT 28
RELAY FEEDBACK RIGHT REAR
FRC1 WORK LIGHT
J1A

30 C4 H H SIG 1
86
SHT4/D8
T18 TERMINAL (-)

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 11 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 11 / 14
7305835
857 of 1311
2440 BLK GND
* HVAC
2
HVAC DUCT FAN
7440 WHT SIG
C610
1
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
7425 WHT
D
C
SP48 7430 WHT
A
C635
BLOWER MOTOR
FRC1
HVAC RELAY-B C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
MED
30 H1 7 7 5 1 2
4 7510 WHT
LOW
2030 BLK 85 SW10 3

86 3
FRC1 FRC1 M
SW10
SHT3/D1 4
C611
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 8 8
SP16
2100 BLK
SW11
1
3
C
GWY CTRLR
SP40 * THERMOSTAT
7021 WHT 7020 WHT
9 9
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT C355

B FUEL HARN
AC EVAPORATOR
A A A 1
D4
C350 MAGNET CLUTCH

SHT13/H7 2280 BLK GND
2
C486

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 12 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 12 / 14
7305835
858 of 1311
C428
# C355
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
8 8
4470 LGN
4480 LGN
OPTIONS 1
CLOSE SP33
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
B B SHT4/E8
# SHT12/B8
2290 BLK
1380 RED/WHT 1
4480 LGN 4480 LGN
1 SIG F F 7 7 2
POWER BOB
OPEN SW5
GND 2480 BLK
2 SW5
C606
10 10
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY 1405 RED/WHT
SHT14/D6
SHT2/E1 12 12 X T3
SP43 * FLASHER
1200 RED/WHT L
3400 LBL
T3
SHT8/G8
SP22 D5
6400 PNK 6400 PNK 6430 PNK
14 14
SHT3/F1
1550 RNG/WHT
9 9
1550 RNG/WHT *SW2
BEACON SWITCH
3500 LBL
SHT8/F8
D2 1
2
SW3
PADDLE
* HAZARD SWITCH
6
1
B C438 2 SW2 SW2
D 6500 PNK 3
6515 PNK SP21 3 3
6410 PNK
6510 PNK
A 4
C103 5 6
C411 TAILGATE HARN
TRIGGER
SW3 (PINS 3 & 6 SW3
EURO TAIL LIGHTS
(SEE ADDITIONAL
2850 BLK
SP46 2725 BLK
SIG 4450 LGN 4455 LGN 4455 LGN 6570 PNK 6700 PNK
BUCKET A 2 2 1
POSITION 2
D3
2905 BLK
SOLENOID
2450 BLK
3 Dealer Copy -- Not for Resale SHT14/F6 *
GND 2455 BLK 2970 BLK
9.8 OHM B SHT4/E8 4 SHT14/F4
2830 BLK 2810 BLK E E
C423 SHT4/E8 6 5 SHT14/D5 2420 BLK
D D C670
SHT4/E3 1 1 6440 PNK
AUX CTRLR F F (SEE ADDITIONAL
LEFT HANDLE C676 OPTIONS DWG)
C C
LIFT (ACS/AHC ONLY)
7200 WHT
C497
LEFT SPEAKER
* * RADIO CONN
A A
LEFT HANDLE (HORN) 2 WAY
(SEE ADDITIONAL OPTIONS DWG) HORN SIGNAL 5 C C 7820 WHT
SJC HORN/BLINKER 1 3
RIGHT BLINKER
SIGNAL 4
6420 PNK
A A (SEE ADDITIONAL
7830 WHT
*
OPTIONS DWG) 2 4 1
HANDLE LOCK (ACS ONLY) LEFT BLINKER 6520 PNK
3 B B C279 2
SIGNAL
RIGHT SPEAKER L010
3
HIGH FLOW
SOLENOID GROUND
26
2460 BRN
* 7810 WHT SHT9/E3
1510 RNG/WHT PWR
4
AIR RIDE SEAT
PWR
J2A GND
2 6
B
HIGH FLOW
7800 WHT
SOLENOID 1 5 2210 BLK GND GND
SIG 7.5 OHM 12 V
SHT9/E3 5
A C278 1885 RNG/WHT
SHT9/E3 1 6
PADDLE C415
HIGH FLOW 4460 LGN C277
SOLENOID SIGNAL
26 GWY CTRLR 2885 BLK
SHT9/D3 2
J2B TWO SPEED
2360 BRN C676
MAKEUP GROUND 27 2
TWO SPEED
TWO SPEED GROUND 26 MAKEUP SOLENOID
C408 4360 LGN 8.8 OHM 12V
MFR HARN CONN 1 C126 J1A 1
1460 RED/WHT HORN CONNECTOR
A SHT2/E1 (BLACK) C437
TRIGGER
7210 WHT 7210 WHT SIG
B 13 13 A A _ 2350 BRN GND
2
C412 TWO SPEED TRACK 2 SPEED
HORN
TWO SPEED MAKEUP 25 SOLENOID (SEE ADDITIONAL
2785 BLK GND + 4350 LGN SIG 5.1 OHM 12 V OPTIONS DWG)
SHT4/E8 B B TWO SPEED SIGNAL 26 1
J1B C441

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 13 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 13 / 14
7305835
859 of 1311
* SW7
AUX CTRLR C438
RIDE CONTROL
OPTIONS 2
3700 LBL
10 10
3700 LBL
1 2
2915 BLK
SHT4/F8 * DLX CAB HARN 7304511 ONLY
SW7 SW7
3480 LBL
RIDE CONTROL RELAY SIGNAL 7
RIDE CONTROL
RELAY - RC1
1575 RNG/WHT
3415 LBL SP9 3425 LBL 30 SHT3/F1
RIDE CONTROL COIL SIGNAL 21 87
3445 LBL 2505 BLK
1 3435 LBL
1 85 86 SHT4/B8
RIDE CONTROL RIDE CONTROL RC1 RC1
COIL COIL
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK
SHT4/B8
C438
* SW13
REVERSING FAN
3475 LBL 3475 LBL
2905 BLK 2970 BLK

SHT13/E3 1 2 SHT13/D3
3470 LBL 3470 LBL
1565 RNG/WHT
5 SHT3/E1
C443 4
2175 BRN
REVERSING FAN RETURN SIGNAL 27 2 SW13 SW13
J2A REVERSING
FAN COIL
3485 LBL
REVERSING FAN SIGNAL 25 1
C442
2185 BRN
SHT4/C3 A
RIDE CONTROL PRESSURE 3455 LBL RIDE CONTROL
SENSOR SIGNAL 10
5105 YEL
C
PRESSURE SENSOR Dealer Copy -- Not for Resale
RIDE CONTROL SENSOR +5V SUPPLY 24 B
J2B
SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT13/G3 2
2810 BLK
SHT13/D3 2 2
2860 BLK
6 SHT4/F8
SW8 SW8

S650 S/N A3NV25640
WARNING A3NV26199
csf

A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
SCHEM ELEC CTRL
Sheet 14 of 16
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
102712
CHG NOTICE DWN
MSE
SHEET
SHT 14 / 14
7305835
860 of 1311
ACS CONTROLLER
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
HARNESS PART NUMBER

J1-ACS
CONTROLLER
ACS 7164144 EXMF, LF
H 2280/BLK
ACS 7190593 MF
2280/BLK
SEE MANUAL CONTROL
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER
G B HANDLE
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 FLOW

H 2270/BLK 2510/BLK 3 F
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2660/BRN 2 GND C428 TILT ACTUATOR
C
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
5750/YEL 3990/LBL 2 SIG
5650/YEL 5980/YEL
5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL

S650 S/N A3NV25640
A3NV26199 Printed On December 2018
A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
Sheet 15 of 16
861 of 1311

S650 S/N A3NV25640
A3NV26199 Printed On December 2018
A3NU13060 through
through A3NU13299
A3NW14199 7305835_0
Sheet 16 of 16
862 of 1311
Index Diagram
1 SH01 - INDEX
3 SH03 - SWITCHED POWER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND
5 SH05 - CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
6 SH06 - ENGINE
9 SH09 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT LEGEND
11 SH11 - LIGHTS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CONNECTOR
12 SH12 - HVAC
BATTERY GROUND 2000 THROUGH 2999 1 1
13 SH13 - OPTIONS 1 BLACK BLK
14 SH14 - OPTIONS 2
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN PARTIAL CONNECTOR
HARNESS PART NUMBER MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
1 1
EXMF 7322222
LF MFR 7322220
1 1
DLX CAB 7304511 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
STD CAB 7210557 WIRE BREAK
STD FUEL LIGHTS 6000 THROUGH 6999 PINK PNK
7149219 WIRE BREAK
SHT1/F2 SHT1/F2
S/R (STARTER) 6733370 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
WIRE BREAK
TAILGATE DOM 7217484 SHT1/F2 SHT1/F2
(1 PC) TRK 2 SPD 7243409 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
SUSP JSTK 7163706 COMMUNICATION CAN HI

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Service Manual

Dealer Copy -- Not for Resale

S/N A3NV11001 & Above

CORRECT CORRECT CORRECT

P-90216 NA1694 NA1693

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

NA1682 NA1683 B-6589

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 1311 1-3 S650 Service Manual

6 of 1311 1-4 S650 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Dealer Copy -- Not for Resale

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7 of 1311 1-5 S650 Service Manual

8 of 1311 1-6 S650 Service Manual

3. The seat belt must be 11. Bob-Tach® attachment

Dealer Copy -- Not for Resale

5. Check lift arm support, 13. Check for correct function of

6. Machine signs (decals) must 14. Check all machine fluid

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 1311 1-7 S650 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

10 of 1311 1-8 S650 Service Manual

Dealer Copy -- Not for Resale

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

11 of 1311 1-9 S650 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

12 of 1311 1-10 S650 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

13 of 1311 1-11 S650 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as