tl470 6990103 SM 5-11

Service Manual
TL470(X) Telescopic Handler
S/N ANL711001 & Above

S/N ANMG11001 & Above
Dealer Copy -- Not for Resale
6990103 (05-11) Printed in Belgium © Bobcat Company 2011
1 of 770
2 of 770
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
CORRECT
Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.
P-90216
Never service the Bobcat telescopic
handler without instructions.
CORRECT WRONG WRONG

NA5428 NA5432 NA5433
Cleaning and maintenance are Disconnecting or loosening any Never work on telescopic
required daily. hydraulic tubeline, hose, fitting, handler with boom up unless
component or a part failure can boom is held by an approved
cause boom to drop. Do not go boom stop. Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.
WRONG WRONG WRONG
NA5434 NA5436 B-6589
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator
without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be
performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.
MSW43-EN-0211
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4 of 770
CONTENTS
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
5 of 770 1-3 TL470(X) Service Manual


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Telescopic Handler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14


FOREWORD
This manual is for the Bobcat telescopic handler mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat telescopic handler and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the telescopic handler has had service or repair:
1. Check that ROPS/FOPS 9. Enclosure door latches must
(Including right side window) open and close freely.
is in good condition and is not
modified.
2. Check that ROPS mounting 10. Attachment locking pins must

hardware is tightened and is function correctly and be in
Bobcat approved. good condition.
3. The seat belt must be 11. Safety treads must be in good

correctly installed, functional condition.
and in good condition.

4. Check boom support device, 12. Check for correct function of
replace if damaged. indicator lamps and gauges.
5. Machine signs must be 13. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
6. Check tires for wear and 14. Inspect for fuel, oil or
pressure. Use only approved hydraulic fluid leaks.
tires.
7. Check for correct function of 15. Lubricate the telescopic

the work lights. handler.
8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.
FW TLS EMEA-0411 SM

17. Inspect the air cleaner for 20. Operate the telescopic
damage or leaks. Check the handler and check all
condition of the element. functions.
18. Check the electrical charging 21. Check for any field
system. modification not completed.
19. Inspect for loose or broken 22. Recommend to the owner

parts or connections. that all necessary corrections
be made before the machine
is returned to service.
FW TLS EMEA-0411 SM

SAFETY INSTRUCTIONS Safe Operation Needs A Qualified Operator
For an operator to be qualified, he or she must not use
Safe Operation Is The Operator’s Responsibility
drugs or alcoholic drinks which impair alertness or co-
ordination while working. An operator who is taking
Safety Alert Symbol prescription drugs must get medical advice to determine
if he or she can safely operate a machine.
This symbol with a warning statement means: A Qualified Operator Must Do The Following:
“Warning, be alert! Your safety is involved!”
Understand the Written Instructions, Rules and
Carefully read the message that follows.
Regulations
• The written instructions from Bobcat Company
include the Delivery Report, Operation &
Maintenance Manual, Operator’s Handbook and
WARNING machine signs (decals).
• Check the rules and regulations at your location. The
rules may include an employer’s work safety
Operator must have instructions before operating the
requirements. For driving on public roads, the
machine. Untrained operators can cause injury or
machine must be equipped as stipulated by the local
death.
regulations authorising operation on public roads in
W-2001-0502
your specific country. Regulations may identify a
hazard such as a utility line.
• For operating the machine, some countries require an
operator license. Check the regulations at your
IMPORTANT

location.
This notice identifies procedures which must be Have Training with Actual Operation
followed to avoid damage to the machine. • Operator training must consist of a demonstration and
I-2019-0284 verbal instruction. This training is given by your
Bobcat dealer before the product is delivered.
• The new operator must start in an area without
bystanders or structures and use all the controls until
he or she can operate the machine and attachment
DANGER safely under all conditions of the work area. Always
fasten seat belt before operating.
The signal word DANGER on the machine and in the Know the Work Conditions
manuals indicates a hazardous situation which, if not • Know the weight of the materials being handled.
avoided, will result in death or serious injury. Avoid exceeding the Rated Load Capacity of the
D-1002-1107 machine (as indicated on the Load Capacity Charts).
Material which is very dense will be heavier than the
same volume of less dense material. Reduce the size
of load if handling dense material.
WARNING • The operator must know any prohibited uses or work

areas, for example, he or she needs to know about
excessive slopes.
The signal word WARNING on the machine and in the • Know the location of any underground lines.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious • Wear tight fitting clothing. Always wear safety glasses
when doing maintenance or service. Safety glasses,
injury.
W-2044-1107
respiratory equipment, hearing protection or Front
Window Guard are required for some work See your
Bobcat dealer about Bobcat Safety Equipment.
The Bobcat telescopic handler and attachment must be
in good operating condition before use.
Check all of the items on the Bobcat Service Schedule
Decal under the 8-10 hour column or as shown in the
Operation & Maintenance Manual.
SI VH EMEA-1010 SM

SAFETY INSTRUCTIONS (CONT’D) FIRE PREVENTION
Safe Operation Needs A Qualified Operator (Cont’d)
Where overhead power lines are present in the operating

area, ensure sufficient clearance between the nearest of
these lines and any part of the machine.
VOLTAGE MINIMUM DISTANCE Maintenance
up to 50 kV 3m The machine and some attachments have components

that are at high temperatures under normal operating
beyond 50 kV 5m
conditions. The primary source of high temperatures is
the engine and exhaust system. The electrical system, if
The operator must survey his/her field of vision when damaged or incorrectly maintained, can be a source of
operating the Telescopic Handler. Adjust mirrors to obtain arcs or sparks.
the best visibility. Clean mirrors every day and more often
when necessary. Immediately replace any broken or Flammable debris (leaves, straw, etc.) must be removed
damaged mirrors. If a suspended load or the resulting regularly. If flammable debris is allowed to accumulate, it
boom geometry blocks the vision of the operator can cause a fire hazard. Clean often to avoid this
alternative carrying means must be considered. accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
The operator must know the wind speed. Do not use the
telescopic handler with wind speeds over 12,5 m/s. The operator’s area, engine compartment and engine

cooling system must be inspected every day and cleaned
Avoid Silica Dust if necessary to prevent fire hazards and overheating.
All fuels, most lubricants and some coolants mixtures are

flammable. Flammable fluids that are leaking or spilled
onto hot surfaces or onto electrical components can
cause a fire.
Operation
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material,
Cutting or drilling concrete containing sand or rock explosive dust or gases.
containing quartz may result in exposure to silica dust.
Use a respirator, water spray or other means to control Electrical
dust.
Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
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 VH EMEA-1010 SM

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

the battery, and disconnect the wiring from the Bobcat
Check hydraulic tubes, hoses and fittings for damage controllers before welding. Cover rubber hoses, battery
and leakage. Never use open flame or bare skin to check and all other flammable parts. Keep a fire extinguisher
for leaks. Hydraulic tubes and hoses must be properly near the machine when welding.
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage. Have good ventilation when grinding or welding painted
parts. Wear dust mask when grinding painted parts.
Always clean fluid spills. Do not use petrol or diesel fuel Toxic dust or gas can be produced.
for cleaning parts. Use commercial non-flammable
solvents. Dust generated from repairing non-metallic parts such as
hoods, fenders or covers can be flammable or explosive.
Fueling Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Stop the engine and let it cool before adding fuel. No

smoking! Do not refuel a machine near open flames or

sparks. Fill the fuel tank outdoors.
Starting
Do not use ether or starting fluids on any engine that has

glow plugs. These starting aids can cause explosion and Know where fire extinguishers and first aid kits are
injure you or bystanders. located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Use the procedure in the Operation & Maintenance Obey the recommendations on the instructions plate.
Manual for connecting the battery and for jump starting.
Sl VH EMEA-1010 SM

SERIAL NUMBER LOCATION Telescopic Handler Serial Number
Always use the serial number of the telescopic handler The telescopic handler serial number plate is located on
when requesting service information or when ordering the right side of the frame in front [Figure 1].
parts.
Explanation of telescopic handler serial number:
If any serial number plate is damaged, contact your XXXX XXXXX
Bobcat dealer.
Module 2. - Production
Figure 1 Sequence (Series)
Module 1. - Model / Engine

Combination
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 telescopic handler is produced.

S38967
S38966

SERIAL NUMBER LOCATION (CONT'D) DELIVERY REPORT
Engine Serial Number Figure 3
Figure 2
B-16315
S38000
The delivery report must be completed by the dealer and
signed by the owner or operator when the Bobcat
telescopic handler is delivered. An explanation of the
form must be given to the owner. Make sure it is complete

[Figure 3].
S38001
The engine serial number can be found on the engine

serial number plate [Figure 2] in front of you when
opening the engine cover. Always use the full number
when ordering replacement parts.
Other Serial Numbers
Other components can also have serial numbers and an

identification plate. Always use these serial numbers
when ordering parts.

BOBCAT TELESCOPIC HANDLER IDENTIFICATION
[1] FRONT WORK
WINDOW GUARD LIGHTS
MIRROR
FRONT
LIGHTS
TELESCOPING [3] OPERATOR
BOOM CAB
(ROPS / FOPS)
BOOM HEAD
[1] BOOM
STOP
[2] PALLET FORK

ATTACHMENT
SEAT

BELT
BOOM PARKING BRAKE
[1] ROTATING
BEACON
LOAD CAPACITY CHARTS MIRRORS
REAR
WORK
LIGHT
REAR [4] TIRES (Use only approved tires ENGINE EM7506

LIGHTS at correct pressure.) COVER EM8039
[1] Optional or Field Accessory. (Not Standard Equipment).

[2] Attachments - Several different attachments are available for the Bobcat telescopic handler.
[3] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure
per ISO 3449, Level II.
[4] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat telescopic handler.

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Rear Cab Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
Cab Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER . . . . . . . . . . . . . . . . 10-30-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TOWING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Primary Fuel Filter (Pre-Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-5
Fill / Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-6

AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking And Adding Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking And Adding Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Removing And Replacing Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Checking And Adding Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing And Replacing Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Checking And Adding Oil (Gear Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Removing And Replacing Oil (Gear Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
ATTACHMENT CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

APPROVED BOOM STOP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Installing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Removing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER . . . . . . . . . 10-170-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TRACTOR HOMOLOGATED EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181-1

Right Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181-1
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563 . . . . . . . . . . . . . . . . . . . . 10-200-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . . . . . . . . . . . . . . . . 10-201-1

Remote Start Tool (Service Tool) - 7003030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201-1
Telescopic Handler Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . 10-201-2
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201-4

LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER
Procedure
Always park the machine on a level surface.
WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service. S39237
W-2718-0208
Figure 10-10-1 Put the floor jack under the right side of the front axle. Lift
the telescopic handler and install the second jackstand
[Figure 10-10-2].
Figure 10-10-3

S39236
STOP the engine. Put the floor jack under the left side of
the front axle. Lift the telescopic handler and install the S38065
first jackstand [Figure 10-10-1].

Put the floor jack under the center of the rear axle. Lift the
telescopic handler and install jackstands [Figure 10-10-
3].
19 of 770 10-10-1 TL470(X) Service Manual


OPERATOR CAB Cab Door
Description Figure 10-20-1
The Bobcat telescopic handler has an operator cab

(ROPS / FOPS) as standard equipment to protect the
operator. The seat belt must be worn for ROPS / FOPS
protection. 1
Check the ROPS / FOPS cab, mounting, and hardware

for damage. Never modify the ROPS / FOPS cab.
Replace the cab and hardware if damaged. See your 2
Bobcat dealer for parts.
ROPS / FOPS - Roll Over Protective Structure per ISO

3471, Falling Object Protective Structure per ISO 3449
(FOPS Level II) and OECD code 4 and code 9.
S38156
Operator cab category 1 per EN 15695-1:2009.
The operator cab does not provide protection against Figure 10-20-2
hazardous substances. Do not use this machine under
conditions requiring protection against hazardous
substances.

WARNING
Never modify operator cab by welding, grinding, 1
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or
S38162
death.
W-2906-0211
The cab door can be opened from the outside of the cab
using the latch (Item 1) [Figure 10-20-1] and opened
from the inside of the cab when you push the lever
(Item 1) [Figure 10-20-2] (as shown).
The cab door can be locked (Item 2) [Figure 10-20-1]

with the same key as the Starter switch.

OPERATOR CAB (CONT’D) Figure 10-20-5
Cab Door Window
Figure 10-20-3
1
S38163
Turn the handle (Item 1) [Figure 10-20-5] back into the

S38163 original position (as shown) to lock the window.
Figure 10-20-6
Turn the handle (Item 1) [Figure 10-20-3] (as shown) to
unlock the window. Push the window fully open until it

latches against the cab.
Figure 10-20-4
1 1
S38385
The handle (Item 1) [Figure 10-20-6] can also be used to

lock the window in a partly open position.
S38164
Push the knob (Item 1) [Figure 10-20-4] inside the cab to

disengage the latch and close the window.

OPERATOR CAB (CONT’D) Cab Light
Rear Cab Window Figure 10-20-9
Figure 10-20-7
1
2
1
1
S38912
S38910
The Cab Light [Figure 10-20-9] is located above the
operator’s right shoulder.
Turn the handle (Item 1) [Figure 10-20-7] (as shown) to
unlock the rear window. Move the lens to the left or right (Item 1) to turn the light

ON. Move the lens to the center position (Item 2) [Figure
Figure 10-20-8 10-20-9] to turn the light OFF.
S38911
Push the rear window open until the handle lock (Item 1)
[Figure 10-20-8] is locked in the open position (as
shown).


TRANSPORTING THE TELESCOPIC HANDLER ON A Fastening
TRAILER
Figure 10-30-2
Loading And Unloading
Figure 10-30-1
3
2
4
1 1
EM7143
1 S38166 Fasten the telescopic handler to the transport vehicle to

prevent it from moving during sudden stops or when
going up or down slopes.
The telescopic handler must be loaded backward on the
trailer.

• Block the wheels (Item 1) [Figure 10-30-2].
The rear of the trailer must be blocked or supported • Use chains to fasten the machine frame to the
(Item 1) [Figure 10-30-1] when loading or unloading the transport vehicle (Items 2 and 3) [Figure 10-30-2].
telescopic handler to prevent the front end of the trailer Use chain binders to tighten the chains.
from raising up.
• Attach the forks or Bucket attachment to the transport
Be sure the transport and towing vehicles are of vehicle (Item 4) [Figure 10-30-2].
adequate size and capacity. (See Weights on Page
SPEC-10-2.) for the weight of the telescopic handler.
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807


TOWING THE TELESCOPIC HANDLER Figure 10-40-2
Procedure
The telescopic handler can be towed a short distance

such as removing it from mud or loading onto a transport
vehicle.
1
Tow the telescopic handler at a slow speed, not
exceeding 5 km/h (3 mph). Do not tow the machine for
more than 3 minutes.
WARNING
S39411
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
Figure 10-40-3
• Block wheels to prevent roll away before
adjusting screws to bypass the park brake
system.
• Return adjustment screws to the operating
position before operating the machine.
W-2808-0909

1
Block the wheels to prevent the machine from rolling.
S38175
Disengaging The Parking Brake Pads
The parking brake is engaged by spring pressure and

released by hydraulic pressure. The parking brake must
be released manually before towing. 1
The following procedure describes how to disengage the
S38173
parking brake pads:
Release the parking brake. (See Operation &
Turn the adjustment screw (Item 1) [Figure 10-40-3]
Maintenance Manual for the correct procedure.)
counterclockwise until the brake pads no longer make
Figure 10-40-1 contact with the brake disc.
The parking brake is released manually now for towing
the machine.
NOTE: The parking brake will not work until the
adjustment screw is returned to the original
1 position.
S38174
Remove the cap (Item 1) [Figure 10-40-1]. The cap can

be accessed from the underside of the machine, through
the oval hole (Item 1) [Figure 10-40-2].

TOWING THE TELESCOPIC HANDLER (CONT’D) Engaging The Parking Brake Pads
Procedure (Cont’d)
Disengaging The Transmission
Open the engine cover. (See Opening And Closing on

WARNING
Page 10-160-1.) UNEXPECTED MACHINE MOVEMENT CAN CAUSE
Figure 10-40-4
• Block wheels to prevent roll away before
adjusting screws to bypass the park brake
system.
position before operating the machine.
W-2808-0909
Block the wheels to prevent the machine from rolling.
1 Figure 10-40-5

S38176
1
Locate the two identical multi-function valves (Item 1) on
the hydrostatic transmission pump (Item 2) [Figure 10-
40-4].
Loosen the valves (Item 1) [Figure 10-40-4] by turning
them three times counterclockwise. 1
NOTE: Do not turn more than three times. This can S38173
result in leakage. S38175
This action will bypass the oil flow of the hydrostatic NOTE: Before re-engaging the parking brake pads,
transmission. make sure the parking brake is released. (See
Tow the telescopic handler at a slow speed, not Operation & Maintenance Manual for the
exceeding 5 km/h (3 mph). Do not tow the machine for correct procedure.)
more than 3 minutes.
Engaging The Transmission
clockwise until the parking brake pads make contact with
the brake disc.
Tighten the valves (Item 1) [Figure 10-40-4] to 70 N•m
(52 ft-lb) torque to re-engage the hydrostatic Turn the adjustment screw counterclockwise for 180°.
transmission. Engage the parking brake (See Operation &
Maintenance Manual for the correct procedure.) and
make sure it functions correctly (the engagement
between the parking brake pads and the brake disc
prevents the machine from moving).

SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat telescopic handler.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals when making repairs, adjustments
WARNING or servicing. Check for correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions can cause injury or death.
W-2003-EN-0903
SERVICE SCHEDULE HOURS

[4]
ITEM SERVICE REQUIRED
10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Hydraulic Fluid Check fluid level and add as needed.
Safety Signs (Decals), Safety Check for damaged signs (decals), safety tread and mirrors. Replace if
Tread And Mirrors damaged or worn.
Fuel Filter Remove the trapped water.
Seat Belt Check condition. Check mounting hardware.
Service Brakes Check for function. Service as necessary.
Parking Brake Check for function. Adjust or service as necessary.
Back-up Alarm (if equipped) Check for correct operation and repair as needed.
Tires Check for wear or damage. Inflate to correct pressure. Be sure all tires are
inflated to the same pressure. Use only approved tires.

Engine Air Filter And Air System Check condition indicator and empty dust cup as needed. Check air system
for leaks.
Engine Cooling System Check oil cooler, radiator and air conditioner condenser. check coolant level
cold in reservoir. Add premixed coolant as necessary. (See ENGINE
COOLING SYSTEM.) Check cooling system for leaks.
Tilt Cylinder Lubricate with lithium based multipurpose grease.
Attachment Carrier Pins Lubricate with lithium based multipurpose grease.
Articulation Pins, Axle Oscillation Lubricate with lithium based multipurpose grease.
(Front/Rear), Lift Cyl., Boom
Pivot, Leveling Cyl.
Telescopic Boom Wear Pads Lubricate with lithium based multipurpose grease.
Hydraulic Hoses, Tubelines and Check for damage and leaks. Repair or replace as needed.
Connections
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE [1]
MAINTENANCE in this manual.)
LLMC System Test LLMC calibration. (See LLMC CALIBRATION TEST.) [2]
Alt. & Air Cond. Belt (if equipped) Check condition. Replace as needed. [2]
Engine Oil and Filter Replace oil and filter.
[2]
Fuel Filter, Secondary Replace fuel filter. [2]
Fuel Filter, Primary Replace fuel filter. [2]
Telescopic Boom Wear Pads Check wear pads for wear. Replace as necessary.
Service Brake Pedal Spring Lubricate with lithium based multipurpose grease.
Cab Air Filter Check condition. Replace as necessary.
Hydraulic/Hydrostatic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. [2]
Axle and Differential Fluid Replace the fluid. See SPECIFICATIONS for correct oil type and capacities. [2]
Planetary Carriers Replace the fluid. See SPECIFICATIONS for correct oil type and capacities. [3]
Gear Box Fluid Replace the fluid. See SPECIFICATIONS for correct oil type and capacities. [2] [3]
Hydraulic Tank Breather Replace the hydraulic tank breather.
Hydraulic Fluid Replace the hydraulic fluid. See SPECIFICATIONS for correct oil type and
capacities.
Engine Coolant Replace the coolant.
Every 2 years
[1] Check wheel nut torque every 8 hours for the first 24 hours.
[2] Perform service first time, then as indicated in chart.
[3] Check level.
[4] Or every 12 months.


AIR CLEANER SERVICE Figure 10-60-3
Replacing Filter Elements
Outer Filter
Figure 10-60-1
S38012
Pull the outer filter element straight out [Figure 10-60-3]

and discard.
S38011
S38055
NOTE: Make sure all sealing surfaces are free of dirt
and debris.

Replace the large (outer) filter element only when the Install a new outer element.
yellow ring has reached the red zone on the condition
indicator (Item 1) [Figure 10-60-1]. Figure 10-60-4
NOTE: Before replacing the filter element, push the 1

button on the condition indicator (Item 2)
[Figure 10-60-1]. Start the engine. If the yellow 2
ring of the condition indicator does not reach
the red zone, do not replace the filter element.
1
Figure 10-60-2
3 1
1 S6803
Install the dust cover (Item 2) with the dust extractor

(Item 3) [Figure 10-60-4] facing down.
Fasten the filter housing clamps (Item 1) [Figure 10-60-

4].
1
S6803
Loosen the filter housing clamps (Item 1) [Figure 10-60-

2].
Remove the dust cover (Item 2) [Figure 10-60-2].

AIR CLEANER SERVICE (CONT’D)
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

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

engine and run at full rpm. If the yellow ring is still in
the red zone of the indicator window, replace the inner
filter element.
Remove the outer element.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
NOTE: DO NOT use compressed air.

Figure 10-60-5
S38014
Remove the inner filter element (Item 1) [Figure 10-60-5]

and install a new element.
Install the outer element.
Install the dust cover (Item 2) with the dust extractor (Item
3) [Figure 10-60-4] facing down.
Fasten the filter housing clamps (Item 1) [Figure 10-60-

4].

ENGINE COOLING SYSTEM Figure 10-70-2
Check the cooling system every day to prevent over- 1

heating, loss of performance or engine damage. 3
Cleaning

Page 10-160-1.) 2
Figure 10-70-1
S38023
Raise the condenser (Item 1) and keep in position by

1 installing the rod (Item 2) [Figure 10-70-2] in the
condenser mount.
Use low air pressure or water pressure to clean the top of

the cooler (Item 3) [Figure 10-70-2].

S38023 NOTE: The cooler is a combined radiator, intercooler
and hydraulic oil cooler.
Remove the nut (Item 1) [Figure 10-70-1]. NOTE: When cleaning with water, DO NOT aim the
waterjet directly towards the battery.

ENGINE COOLING SYSTEM (CONT’D) Figure 10-70-4
Removing And Replacing The Coolant
WARNING 1
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
Stop the engine and allow the engine to cool.

S38024
Open the engine cover.

Remove the engine block drain plug (Item 1) [Figure 10-
Figure 10-70-3 70-4] and drain all of the coolant into a container.
Dispose of used coolant in an environmentally safe
manner.
1
Reinstall the engine block drain plug (Item 1) [Figure 10-

70-4].
NOTE: The cooling system is factory filled with

propylene glycol (PG) coolant. DO NOT mix
propylene glycol with ethylene glycol.
Add premixed coolant to the reservoir if the coolant level

is low. (See Fluid Capacities on Page SPEC-10-4.)
Use a refractometer to check the condition of propylene

S38010 glycol in your cooling system.
Fill the system with the premixed coolant. Install the cap
Remove the cap (Item 1) [Figure 10-70-3] from the
on the coolant reservoir.
coolant reservoir.

ENGINE COOLING SYSTEM (CONT’D) Checking Level
Removing And Replacing The Coolant (Cont’d) Open the engine cover. (See Opening And Closing on
Page 10-160-1.)
Add coolant to the reservoir. The coolant level must be
between the MIN and MAX marks (Item 1) [Figure 10- Check the coolant level in the coolant reservoir.
70-5] on the coolant reservoir.
Figure 10-70-5
Follow the following steps when using concentrated
coolant instead of a ready-to-use premix:
• Mix the coolant in a separate container:

1
4,3 L (one gallon and one pint) of propylene glycol
mixed with 3,8 L (one gallon) of water is the correct
mixture of coolant to provide a -37°C (-34°F) freeze
protection.
• Add premixed coolant, 47% water and 53% propylene

glycol to the coolant tank until the coolant level
reaches the MIN marker on the tank (Item 1) [Figure
10-70-5].
Run the engine until it is at operating temperature. S38010

Stop the engine.
The coolant level must be between the MIN and MAX
Check the coolant level (COLD) in the reservoir when marks (Item 1) [Figure 10-70-5] on the coolant reservoir
cool. when the engine is cold.
Add coolant to the reservoir as needed.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
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:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling problems in cold • Biodiesel blend fuel is an excellent medium for
temperatures: microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
TEMPERATURE NO. 2 NO. 1 • Use of biodiesel blend fuel can result in premature
failure of fuel system components, such as plugged
-9°C (+15°F) 100% 0%
fuel filters and deteriorated fuel lines.
Down to -29°C (-20°F) 50% 50%
• Shorter maintenance intervals can be required, such
Below -29°C (-20°F) 0% 100% as cleaning the fuel system and replacing fuel filters
and fuel lines.
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
must be used in this machine: • Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
The following fuels can also be used in this machine: deterioration of hoses, tubelines, injectors, injector
pump and seals.
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel. Apply the following guidelines if biodiesel blend fuel is

used:
• Biodiesel Blend Fuel - Must contain no more than
20% biodiesel mixed with low sulfur or ultra low sulfur • Ensure the fuel tank is as full as possible at all times
petroleum based diesel. This is commonly marketed to prevent moisture from collecting in the fuel tank.
as B20 blended diesel fuel. B20 blended diesel fuel
must meet ASTM D975 (US Standard) or EN590 (EU • Ensure that the fuel tank cap is securely tightened.
Standard) specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term
stability and should not be stored for more
than three months.

FUEL SYSTEM (CONT’D) Primary Fuel Filter (Pre-Filter)
Filling The Fuel Tank See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Removing Water
WARNING
Figure 10-80-2
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-80-1
1
S39063

Open the drain valve (Item 1) [Figure 10-80-2] on the
fuel pre-filter bottom cover to remove water from the filter.
When clean fuel drains from the water separator, tighten

the drain valve (Item 1) [Figure 10-80-2] by hand
S38015 pressure.
Replacing Element
Remove the fuel fill cap (Item 1) [Figure 10-80-1].
Figure 10-80-3
Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING!
Install and tighten the fuel fill cap [Figure 10-80-1].
1
WARNING
AVOID INJURY OR DEATH 2
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause S39064
explosion or fire.
W-2103-0508
Remove the two bolts (Item 1) and remove the cover
plate (Item 2) [Figure 10-80-3].

FUEL SYSTEM (CONT’D) Figure 10-80-6
Primary Fuel Filter (Pre-Filter) (Cont’d)
Figure 10-80-4
S39063
1 Clean the area around the filter housing.

S39063
Remove the filter element (Item 1), bowl (Item 2) and
bottom cover (Item 3) [Figure 10-80-6] from the filter
Open the drain valve (Item 1) [Figure 10-80-4] on the housing.
bottom cover of the fuel primary filter and allow the fluid

to drain into a container. Install a new filter element (Item 1) and reinstall the bowl
(Item 2) and bottom cover (Item 3) [Figure 10-80-6] in
Tighten the drain valve (Item 1) [Figure 10-80-4] by hand the filter housing.
pressure.
Reinstall the screw (Item 2) [Figure 10-80-5] and tighten.
Figure 10-80-5
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)
2
S39065
Support the filter assembly (Item 1) and remove the

screw (Item 2) [Figure 10-80-5].

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Secondary Fuel Filter Figure 10-80-8
See the SERVICE SCHEDULE for the service interval

when to replace the secondary fuel filter. (See SERVICE
Figure 10-80-7
S0007
1
After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system before starting the engine.
S38016

Clean the area around the filter housing.
Remove the filter element (Item 1) [Figure 10-80-7].

WARNING
Install the new filter element with a new seal, and hand AVOID INJURY OR DEATH
tighten. Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Remove air from the fuel system. (See Removing Air death. Fluid leaks under pressure may not be visible.
From The Fuel System on Page 10-80-4.) Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
WARNING
Turn the key switch to the RUN / PREHEAT position
AVOID INJURY OR DEATH [Figure 10-80-8] and wait 3 minutes.
sparks or lighted tobacco away from fuel and oil. Crank the engine with the accelerator pedal released
Failure to use care around combustibles can cause (low idle position) until the engine starts.
explosion or fire.
W-2103-0508 Run the engine at low idle for approximately five seconds
then cycle the accelerator pedal rapidly from the low idle
position to the high idle position three times. The time
taken to cycle the accelerator pedal to be typically one to
three seconds. This will assist in displacing any residual
trapped air in the fuel injection pump.
Check for fuel leaks in the fuel system.

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-90-1 CRANKCASE)
S38019
S6808

Open the engine cover and remove the dipstick (Item 1) TEMPERATURE RANGE ANTICIPATED BEFORE
[Figure 10-90-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick [1] Synthetic Oil - Use recommendation from Synthetic
(Inset) [Figure 10-90-1]. Do not overfill. Oil Manufacturer.
Use good quality engine oil that meets API Service

Classification of CI-4 or better [Figure 10-90-2]. (See
Operation & Maintenance Manual for the correct
procedure.)
WARNING
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-4
Removing And Replacing Oil And Filter
See the SERVICE SCHEDULE for the service interval for

replacing the engine oil and filter. (See SERVICE
Run the engine until it is at operating temperature. Stop

the engine. 1
Figure 10-90-3
S38021
Clean the filter housing surface.

1
Remove the oil filter (Item 1) [Figure 10-90-4].
Put clean oil on the new filter gasket, install the filter and
and hand tighten until the gasket contacts the surface,

then an additional 180 - 270°.
S38020

Page 10-160-1.)
WARNING
Remove the cap (Item 1) [Figure 10-90-3].
Drain the oil into a container and recycle or dispose of
used oil in an environmentally safe manner.
explosion or fire.
W-2103-0508
Install the cap (Item 1) [Figure 10-90-3].
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 LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter (Cont’d)
Figure 10-90-5
WARNING
1
2 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
WARNING
S38019
S6808 Wear safety glasses to prevent eye injury when any
Remove the oil fill cap (Item 1) [Figure 10-90-5]. • Flying debris or loose material is present.

Put oil in the engine. (See Fluid Capacities on Page • Tools are being used.
SPEC-10-4.) for capacity. (See Engine Oil Chart on Page W-2019-0907
10-90-1.) for type.
Install oil fill cap, start the engine and let it run for several
minutes.
Stop the engine, and check for leaks at the oil filter.
Remove the dipstick (Item 2) [Figure 10-90-5] and check

the oil level. Add oil as needed if it is not at the top mark
on the dipstick.


HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-100-3
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system.

(See Hydraulic / Hydrostatic Fluid Chart on Page 10-100-
1
2.)
Stop the machine on a level surface.
Stop the engine.
Oil must be at ambient temperature for this procedure.
Figure 10-100-1
S38035
Remove the fill / breather cap (Item 1) [Figure 10-100-3]

and add hydraulic fluid.
Reinstall the fill / breather cap (Item 1) [Figure 10-100-3].
1 Reposition the cover (Item 3), tighten the locking knob

and remove the key (Item 1) [Figure 10-100-2].
S38034 WARNING
Check the fluid level at the sight gauge (Item 1) [Figure
10-100-1].
Figure 10-100-2
explosion or fire.
W-2103-0508
1
2 3
S38034
Install the key (Item 1) and loosen the locking knob

(Item 2) [Figure 10-100-2].
Rotate the cover (Item 3) [Figure 10-100-2] clockwise.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Fluid
Hydraulic / Hydrostatic Fluid Chart See the SERVICE SCHEDULE for the correct service
intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-100-4
HYDRAULIC / HYDROSTATIC FLUID Replace the fluid if it becomes contaminated or after
RECOMMENDED ISO VISCOSITY GRADE (VG) major repair.
AND VISCOSITY INDEX (VI)
Always replace the hydraulic / hydrostatic filter whenever
the hydraulic fluid is replaced. (See Removing And
Replacing Hydraulic / Hydrostatic Filter on Page 10-100-
3.)
WARNING
explosion or fire.
W-2103-0508
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE

[1] VG 100; Minimum VI 120 Figure 10-100-5
[2] VG 46; Minimum VI 140
[3] Synthetic Fluid; VG 46; Minimum VI 150
[4] Bobcat Hydraulic / Hydrostatic Fluid
Use only recommended fluid in the hydraulic system

[Figure 10-100-4]. (See HYDRAULIC / HYDROSTATIC 2
FLUID SPECIFICATIONS on Page SPEC-50-1.)
WARNING
AVOID INJURY OR DEATH 1
Diesel fuel or hydraulic fluid under pressure can S38036
death. Fluid leaks under pressure may not be visible.
Remove the reservoir drain plug (Item 1) [Figure 10-100-
Use a piece of cardboard or wood to find leaks. Do
5] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner.
from a physician familiar with this injury.
W-2072-0807
Put a new seal on the drain plug. Install the drain plug
(Item 1) [Figure 10-100-5] and tighten.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic / Hydrostatic
Filter
Removing And Replacing Hydraulic Fluid (Cont’d)
See the SERVICE SCHEDULE for the correct service
Figure 10-100-6 intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-100-8
1
2 3
1
S38034
S38037
Install the key (Item 1) and loosen the locking knob
(Item 2) [Figure 10-100-6].

Remove the cover (Item 1) [Figure 10-100-8] at the
Rotate the cover (Item 3) [Figure 10-100-6] clockwise. bottom of the frame.
Figure 10-100-7 Figure 10-100-9
S38035 S38038
Remove the fill / breather cap (Item 1) [Figure 10-100-7]. Remove the filter housing (Item 1) [Figure 10-100-9].
Add fluid until it is at the center of the sight gauge (Item 2)

[Figure 10-100-5].
Install the fill / breather cap (Item 1) [Figure 10-100-7].
Reposition the cover (Item 3), tighten the locking knob


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

Filter (Cont’d)
Figure 10-100-10
S38295
Remove the filter element (Item 1) [Figure 10-100-10]

and discard.
Install new filter element ensuring that element is fully

seated in the housing.
Install the filter housing and hand tighten.
Start the engine and let the engine run for one minute
(low idle) before operating the boom hydraulics.
Stop the engine and check for leaks at the filter. Check
the fluid level in the reservoir and add as needed. (See
Checking And Adding Fluid on Page 10-100-1.)
Install the cover.
WARNING
explosion or fire.
W-2103-0508

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Stop the engine and check for leaks at the filter. Check
the fluid level in the reservoir and add as needed. (See
Removing And Replacing Hydraulic Charge Filter Checking And Adding Fluid on Page 10-100-1.)
See the SERVICE SCHEDULE for the correct service

intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-100-11
S38238

Place a suitable container below the filter housing and
remove the filter housing (Item 1) [Figure 10-100-11]
using a socket wrench.
Figure 10-100-12
S38296
Remove the filter element (Item 1) [Figure 10-100-12]

and discard.
Install new filter element ensuring that element is fully

seated in the housing.
Install the filter housing and hand tighten.
Start the engine and let the engine run for one minute
(low idle) before operating the boom hydraulics.

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

replacement interval. (See SERVICE SCHEDULE on
Page 10-50-1.)
Figure 10-100-13
1
2 3
S38034

Install the key (Item 1) and loosen the locking knob (Item
2) [Figure 10-100-13].
Rotate the cover (Item 3) [Figure 10-100-13] clockwise.
Figure 10-100-14
S38035
Remove the fill / breather cap (Item 1) [Figure 10-100-

14] and discard.
Install the new fill / breather cap (Item 1) [Figure 10-100-

14].
Reposition the cover (Item 3), tighten the locking knob


AXLES (FRONT AND REAR) Removing And Replacing Oil (Planetary Carrier)
Checking And Adding Oil (Planetary Carrier) (See SERVICE SCHEDULE on Page 10-50-1.) for the
correct service interval.
Figure 10-110-1
Figure 10-110-2
S38039
S38040
Put the machine on a level surface with the plug (Item 1)

[Figure 10-110-1] positioned as shown. Put the machine on a level surface with the plug (Item 1)

[Figure 10-110-2] positioned as shown.
Remove the plug (Item 1) [Figure 10-110-1]. The oil level
should be at the bottom edge of the plug hole. Remove the plug (Item 1) [Figure 10-110-2] and drain oil
into a container. Recycle or dispose of the used lubricant
Add oil through the hole if the oil level is below the hole. in an environmentally safe manner.
(See Specifications on Page SPEC-50-1.) for capacity. Reposition the plug hole as shown in [Figure 10-110-1]
(See Fluid Capacities on Page SPEC-10-4.) for type. and add gear lube until the lube level is at the bottom
edge of the plug hole (Item 1) [Figure 10-110-1].
Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)
torque. (See Specifications on Page SPEC-50-1.) for capacity.
(See Fluid Capacities on Page SPEC-10-4.) for type.
Repeat the procedure for the other side.
torque.
Repeat the procedure for the other side.

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Rear Differential)
Checking And Adding Oil (Rear Differential) (See SERVICE SCHEDULE on Page 10-50-1.) for the
(See SERVICE SCHEDULE on Page 10-50-1.) for the
correct service interval. Figure 10-110-4
Figure 10-110-3
1 1
1
S38062
S38041
With the machine on a level surface remove the three

plugs (Item 1) [Figure 10-110-4] and drain oil into a
Put the machine on a level surface. container. Recycle or dispose of the used lubricant in an
Remove the plug (Item 1) [Figure 10-110-3]. The oil level
should be at the bottom edge of the plug hole.
Install and tighten the plugs (Item 1) [Figure 10-110-4] to
35 - 50 N•m (26 - 37 ft-lb) torque.
Add oil through the hole if the oil level is below the hole.
Figure 10-110-5
(See Specifications on Page SPEC-50-1.) for capacity.

torque.
S38042
Add oil through the hole (Item 1) [Figure 10-110-5].


torque.

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Front Differential)
Checking And Adding Oil (Front Differential) Figure 10-110-8

Figure 10-110-6 2
1
1
1 1
S38048

S38043
With the machine on a level surface remove the plugs

(Item 1) [Figure 10-110-8] and drain oil into a container.
Figure 10-110-7 Recycle or dispose of the used lubricant in an
Install and tighten the plugs (Item 1) [Figure 10-110-8] to

35 - 50 N•m (26 - 37 ft-lb) torque.
Add oil through the hole (Item 2) [Figure 10-110-8].

1
torque.
S38044
Remove the plugs (Item 1) [Figure 10-110-6] and

[Figure 10-110-7]. The oil level should be at the bottom
edge of the plug hole.
Add oil through the hole if the oil level is below the hole.


torque.

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Gear Box)
Checking And Adding Oil (Gear Box) Figure 10-110-10
Figure 10-110-9
2
1
2
S38045
S38097
S38098
With the machine on a level surface, remove the plug
(Item 2) [Figure 10-110-10] and drain oil into a container.
Remove the plug (Item 1) [Figure 10-110-9]. The oil level Recycle or dispose of the used lubricant in an
should be at the bottom edge of the plug hole. environmentally safe manner.

Add oil through the hole if the oil level is below the hole. Install and tighten the plug (Item 2) [Figure 10-110-10].
(See Specifications on Page SPEC-50-1.) for capacity. Remove the plug (Item 1) [Figure 10-110-9] and [Figure
(See Fluid Capacities on Page SPEC-10-4.) for type. 10-110-10] and add oil through the hole.
Install and tighten the plug. (See Specifications on Page SPEC-50-1.) for capacity.
Install and tighten the plug (Item 1) [Figure 10-110-9]

and [Figure 10-110-10].

LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-2
Lubrication Locations
Lubricate as specified in the SERVICE SCHEDULE for

the best performance of the machine. (See SERVICE
1
Record the operating hours each time you lubricate so
that it is performed at the correct interval.
Always use a good quality lithium based multipurpose

grease. Apply lubricant until extra grease shows.
1
Remove the attachment from the telescopic handler
before lubricating. (See Operation & Maintenance S38063
Manual for the correct procedure.)
Lubricate the following locations on the telescopic Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-2].
handler:
Figure 10-120-3
Figure 10-120-1

1 1
1 2
S38100
S38049
Attachment carrier pins - Left and right (Item 1) [Figure

Axle Pivots - Top and bottom (Item 1) [Figure 10-120-1] 10-120-3].
all four wheels.
Tilt Cylinder Rod End (Item 2) [Figure 10-120-3].

LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-6
(CONT’D)
Lubrication Locations (Cont’d)
Figure 10-120-4
1
2
1
S38052
Lift Cylinder Base End (Item 1), Self Leveling Cylinder

Rod End (Item 2), Self Leveling Cylinder Base End
S38101 (Item 3) [Figure 10-120-6].
Figure 10-120-7
Tilt Cylinder Base End (Item 1) [Figure 10-120-4].

1
Figure 10-120-5
1
2
S38102
S38051 Boom Pivot (Item 1) [Figure 10-120-7] (One Place).
NOTE: Raise the boom and install the approved

Boom Stop before lubricating the Lift and Self
Leveling Cylinders. (See Installing The
Approved Boom Stop on Page 10-150-1.)
Lift Cylinder Rod End (Item 1) and Pivot (Item 2) [Figure

10-120-5].

ATTACHMENT CARRIER Figure 10-130-3
Inspection And Maintenance
Figure 10-130-1
P-23856
The telescopic handler attachment locking pins (if

S38053 equipped) (Item 1) [Figure 10-130-3] (both sides) must
move freely. The pins must not be bent or the ends
deformed.
The attachment carrier mounting hook (Item 1) [Figure
10-130-1] must not be damaged or worn. Inspect Figure 10-130-4

attachment carrier condition. Replace as needed.
Figure 10-130-2
1
EM8547
S38054 The pins (if equipped) (both sides) must extend through
the holes in the attachment mounting frame (Item 1)
[Figure 10-130-4].
The stop plate (Item 1) [Figure 10-130-2] (both sides)
must not be damaged or worn. Inspect stop plate Lubricate the attachment carrier. (See SERVICE
condition. Replace as needed. SCHEDULE on Page 10-50-1.) (See LUBRICATING THE
TELESCOPIC HANDLER on Page 10-120-1.)


TIRE MAINTENANCE Mounting
Wheel Nuts Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.
Figure 10-140-1
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.
Pressure
S38099 (See Traction on Page SPEC-10-4.) for the correct tire

pressure.
See the SERVICE SCHEDULE for the service interval to

check the wheel nuts. (See SERVICE SCHEDULE on

Page 10-50-1.) The correct torque is 360 N•m (266 ft-lb)
torque [Figure 10-140-1]. WARNING
Rotating AVOID INJURY OR DEATH
Do not inflate tyres above specified pressure. Failure
Check the tires regularly for wear, damage and pressure. to use correct tyre mounting procedure can cause an
(See Traction on Page SPEC-10-4.) for the correct tire explosion which can result in injury or death.
pressure. W-2078-EN-0909
Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires
to the front.
It is important to keep the same size tires on each side of IMPORTANT

the telescopic handler. If different sizes are used, each
tire will be turning at a different rate and cause excessive Inflate tyres to the MAXIMUM pressure shown on the
wear. The tread bars of all the tires must face the same sidewall of the tyre. DO NOT mix brands of tyres
direction. used on the same loader.
I-2057-EN-0909
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capacity. Check for the correct pressure before operating
the telescopic handler.


APPROVED BOOM STOP (IF EQUIPPED) Figure 10-150-3
If the boom is raised for service or maintenance, use the

following procedure to install and remove the approved
boom stop.
Installing The Approved Boom Stop
• Put the telescopic handler on a flat, solid and level

surface.
• With the operator in the seat, the seat belt fastened,

travel direction switch/control lever (optional) in
neutral and the parking brake engaged, start the
engine, raise the boom and stop the engine.
S38006
Figure 10-150-1
• Install the pins and secure with fasteners

[Figure 10-150-3].
• Start the engine and lower the boom slowly [Figure

10-150-3] so that the boom stop is held securely.
Removing The Approved Boom Stop

1
• Start the engine and raise the boom. Stop the engine.
• Remove the fasteners, pins and boom stop.
• Reinstall the boom stop in the storage position

(Item 1) [Figure 10-150-1].
S38239
• Remove the boom stop (Item 1) [Figure 10-150-1]

from the storage position.
WARNING
Figure 10-150-2
Never work on a machine with the boom up unless
the boom is held by an approved boom stop. Failure
to use an approved boom stop can allow the boom to
drop and cause injury or death.
Service boom stop if damaged or if parts are
missing. Using a damaged boom stop or with
missing parts can cause boom to drop causing injury
or death.
W-2899-1210
S38132
• Install the boom stop (Item 1) [Figure 10-150-2] from

the left back side of the machine.


ENGINE COVER
Opening And Closing
Figure 10-160-1
P-52162
Pull the latch handle (Item 1) [Figure 10-160-1] out and

rotate clockwise. Raise the engine cover to provide

access to the engine compartment for maintenance.
NOTE: The tailgate can be locked.


STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER
Procedure WARNING
• Stop the telescopic handler on solid, flat and level
ground. Before you exit the operator’s position:
• Put the Travel Direction Control and the Joystick
NOTE: Ensure the machine is parked safely, taking in neutral.
into consideration the surrounding traffic. • Engage the parking brake.
• Retract and lower the boom and attachment flat
• Put the Travel Direction Control in neutral. (See on the ground.
Operation & Maintenance Manual for the correct • Stop the engine.
W-2907-0211
procedure.)
• Engage the parking brake. (See Operation &

Maintenance Manual for the correct procedure.)
Figure 10-170-1

S38907
• Retract and lower the boom and attachment flat on

the ground [Figure 10-170-1].
• Turn the key switch to STOP and unfasten the seat

belt.
• Use grab handles, safety tread and steps when

getting off.
DO NOT JUMP.


EMERGENCY EXIT
Rear Window
Open the rear window. (See Operation & Maintenance

Figure 10-180-1
S38911

Pull the handle (Item 1) [Figure 10-180-1] inwards (as
shown) and push the rear window fully open.
Figure 10-180-2
S38169
Exit through the rear window opening [Figure 10-180-2].


TRACTOR HOMOLOGATED EMERGENCY EXIT
Right Rear Window
Tractor Homologated Telescopic Handlers are equipped

with a secondary emergency exit.
Figure 10-181-1
S38985

Remove the safety hammer (Item 1) [Figure 10-181-1]
from its holder behind the operator’s seat.
Use the safety hammer to break the right rear window.
Exit through the right rear window opening.
Figure 10-181-2
7197819
NOTE: A decal illustrating this procedure is located

on the right rear window [Figure 10-181-2].


TELESCOPIC HANDLER STORAGE AND RETURN TO Return To Service
SERVICE
After the Bobcat telescopic handler has been in storage,
Storage it is necessary to follow a list of items to return the
telescopic handler to service.
Sometimes it can be necessary to store your Bobcat
telescopic handler for an extend period of time. Below is • Check the engine and hydraulic oil levels; check
a list of items to perform before storage. coolant level.
• Thoroughly clean the telescopic handler including the • Install a fully charged battery.
engine compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the telescopic handler.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in place.
• Park the telescopic handler in a dry protected shelter.
• Lubricate the telescopic handler.
• Lower the boom all the way and put the attachment (if
equipped) flat on the ground. • Check tire inflation and remove blocks from under
frame.
• Put grease on any exposed cylinder rods.
• Remove cover from exhaust pipe opening.
• Put fuel stabilizer in the fuel tank and run the engine

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


REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-200-2
MEL1563
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are: 2
3
MEL1563 - Remote Start Tool 1
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Figure 10-200-1
P16117
1
The Traction Lock switch (Item 1) [Figure 10-200-2] is
not used for this machine.
The Maximum Flow / Variable Flow switch (Item 2)

[Figure 10-200-2] is used to activate the auxiliary
hydraulics. Pressing the switch once will activate variable

flow. Pressing the switch again will activate maximum
flow. The switch will illuminate to indicate which flow rate
is active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
P16114
The Auxiliary Pressure Release switch (Item 3)

[Figure 10-200-2] is used to release hydraulic pressure
The remote start tool (Item 1) [Figure 10-200-1] is to the front and / or rear auxiliary couplers. To release
required when the service technician is checking the pressure; push and hold the switch for three seconds.
hydraulic / hydrostatic system.
NOTE: With the engine running; pushing and holding
the Pressure Release switch will cause the
engine to stop in 3 seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

MEL1563 (CONT'D)
Service Tool Harness Control - MEL1565
Figure 10-200-3
1
1
S97029
Locate the ACD connector (Item 1) [Figure 10-200-5]

and remove the cap from the connector.
P16114
Connect the main connector of the Service Tool Harness
Control to the ACD connector (Item 1) [Figure 10-200-5].
The service tool harness control (Item 1) is used to

connect the Remote Start Tool (Item 2) [Figure 10-200- NOTE: To monitor, diagnose or load new software
3] to the electrical system on the telescopic handler. the Service PC must be connected to the
Remote Start Tool switch.
Connect the service tool harness control to the Remote
Start Tool.
Figure 10-200-4
S38026
Loosen the retainer screw (Item 1) and remove the fuse

box cover (Item 2) [Figure 10-200-4].

REMOTE START TOOL (SERVICE TOOL) KIT -
MEL1563 (CONT'D)
Service Tool Harness Communicator - MEL1566
Figure 10-200-6
P16119
The service tool harness communicator (Item 1) is

required to connect the remote start tool to the Service
PC (Item 2) [Figure 10-200-6].


7003031
2
Remote Start Tool (Service Tool) - 7003030

5 3
are:
Order from Bobcat Parts P/N: 7003031 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
1
7003030 - Remote Start Tool (Service Tool)
6689747 - Telescopic Handler Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS® Service Tool Harness
The Remote Start Tool (Service Tool) (Item 1)

Figure 10-201-1 [Figure 10-201-2] has five buttons.
The STOP button (Item 2) [Figure 10-201-2] is used to

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

The RUN button (Item 3) [Figure 10-201-2] is used to
turn the Remote Start Tool (Service Tool) on and
activates the telescopic handler ignition power. The
button will illuminate to indicate the service tool is active.
1
The START button (Item 4) [Figure 10-201-2] is used to
start the telescopic handler engine.
The PARKING BRAKE button (Item 5) [Figure 10-201-2]

P-76678 is not used on this machine.
The auxiliary button (Item 6) [Figure 10-201-2] is used to

The remote start tool (Item 1) [Figure 10-201-1] is activate the auxiliary hydraulics. The button will illuminate
required when the service technician is checking the to indicate the auxiliary hydraulics are active. Pressing
hydraulic / hydrostatic system. the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

7003031 (CONT'D)
Telescopic Handler Service Tool Harness - 6689747
Figure 10-201-3
1
1
S97029
2
Locate the ACD connector (Item 1) [Figure 10-201-5]

and remove the cap from the connector.
P-76678
The telescopic handler service tool harness (Item 1) is

used to connect the remote start tool (service tool) (Item
2) [Figure 10-201-3] to the electrical system on the
telescopic handler.
Figure 10-201-4
S38026
Loosen the retainer screw (Item 1) and remove the fuse


REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 (CONT'D)
Telescopic Handler Service Tool Harness - 6689747

(Cont’d)
Figure 10-201-6
2
S39238
Connect the main connector (Item 1) [Figure 10-201-6]

of the Service Tool Harness Control to the ACD
connector (Item 1) [Figure 10-201-5].
NOTE: The remote start tool connection harness has

two connectors (Item 1) and (Item 2). The
main connector (Item 1) [Figure 10-201-6] is
always used for connection to the engine
harness.
The second connector (Item 2) [Figure 10-201-

6] is used for ACD upgrades or attachment
operational diagnostics only. This connector
has a cap attached to it to prevent damage or
corrosion when not in use.
WARNING
• 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 - Remote Start Procedure
7003031 (CONT'D)
Computer Service Tool Harness - 6689746
Figure 10-201-7 WARNING

UNAUTHORIZED AND UNEXPECTED ENGINE
STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
1 With the 7-pin connector plugged into the machine
and Remote Start Tool RUN button not illuminated,
the engine can be started from the operator panel
inside the cab.
• Press the RUN button of the Remote Start Tool to
disconnect the operator panel from the start
circuit.
• Remove the operator panel key (key switch), lock
the keypad with a unique password (keyless) or
2 otherwise disable the starter before working in
P-76450 the engine area.
W-2661-1110
The computer service tool harness (Item 1) is required to

The tool listed will be needed to do the following

connect remote start tool (service tool) to the Service PC
(Item 2) [Figure 10-201-7]. procedure:
7003031 - Remote Start Tool (Service Tool) Kit
Figure 10-201-8
P-76450
The Remote Start Tool (Service Tool) (Item 1)

[Figure 10-201-8] is required when the service
technician needs to turn on the telescopic handler or
start the engine without entering the cab.

7003031 (CONT'D)
Remote Start Procedure (Cont'd) 1
Figure 10-201-9
2
2 S39238
Connect the main connector (Item 1) [Figure 10-201-11]

of the Service Tool Harness Control to the ACD
S38026 connector (Item 1) [Figure 10-201-10].
NOTE: The remote start tool connection harness has

Loosen the retainer screw (Item 1) and remove the fuse two connectors (Item 1) and (Item 2). The

main connector (Item 1) [Figure 10-201-11] is
always used for connection to the engine
Figure 10-201-10 harness.
The second connector (Item 2) [Figure 10-201-

11] is used for ACD upgrades or operational
diagnostics only. This connector has a cap
attached to it to prevent damage or corrosion
when not in use.
1
WARNING
• Lift and block the machine.
S97029
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
Locate the ACD connector (Item 1) [Figure 10-201-10] start the engine with the Service Tool (if
and remove the cap from the connector. applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7003031 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-201-12
2
1 2
5 3
6 4
P-76441
1
The gear icon with the left facing arrows (Item 1)

[Figure 10-201-13] will illuminate and blink when the
P-76439 RUN key is pressed and the telescopic handler is
communicating with the service tool.
The Remote Start Tool (Service Tool) (Item 1) The computer icon with the right facing arrows (Item 2)
[Figure 10-201-12] has five buttons.

[Figure 10-201-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
The STOP button (Item 2) [Figure 10-201-12] is used to and from the computer.
stop the Remote Start Tool (Service Tool) from
communicating and stop the telescopic handler engine. NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
The RUN button (Item 3) [Figure 10-201-12] is used to the RUN button on the remote start tool. Then
turn the Remote Start Tool (Service Tool) on and press the auxiliary (AUX) hydraulics button on
activates the telescopic handler ignition power. The the remote start tool and move the AUXILIARY
button will illuminate to indicate the service tool is active. Hydraulic switch on the telescopic handler to
the right and left several times.
The START button (Item 4) [Figure 10-201-12] is used to
start the telescopic handler engine.
The PARKING BRAKE button (Item 5) [Figure 10-201-

12] is used to turn Traction Lock ON or OFF. Push the
button and the button will illuminate indicating the parking
brake is disabled in which the wheels are able to turn.
The auxiliary button (Item 6) [Figure 10-201-12] is used

to 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 checking pressures and flow
rate.

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

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
SELF LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-7
SELF LEVELING CYLINDER (LOCK VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1


EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Upper Tubeline Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Extension Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Tubeline Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
STEERING CYLINDER (FRONT/REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Removing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Installing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
GEAR CONTROL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Testing And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Parts Identification (Single Speed Version) (Standard) . . . . . . . . . . . . . . . . . . . . . . 20-120-3
Disassembly And Assembly (Single Speed Version) (Standard) . . . . . . . . . . . . . . 20-120-4

Parts Identification (Variable Speed Version) (Optional) . . . . . . . . . . . . . . . . . . . . . 20-120-7
Disassembly And Assembly (Variable Speed Version) (Optional) . . . . . . . . . . . . . 20-120-8
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Troubleshooting Chart (Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-2
Troubleshooting Chart (Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-6
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-10
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-150-11
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-12
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-16
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-150-20
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-150-24
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-28
PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Parking Brake Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

ACCUMULATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1


HYDRAULIC/HYDROSTATIC SCHEMATIC
TL470 (S/N ANL711001 AND ABOVE)
Printable Version Click Here
(Printed MARCH 2011)
V-1440legend
LEGEND
1 RESERVOIR: 18 FLUSHING VALVE: 14 Bar (203 psi) 35 SERVO PISTON - Swash Plate
Reservoir Capacity 51 L (53.9 qt)
36 SPEED SENSOR - Driveshaft
19 LOAD SENSE RELIEF VALVE:
2 250 - 260 Bar (3626 – 3771 psi ) 37 SPRING APPLIED PRESSURE RELEASE
FILTER - Hydraulic
20 LOAD SENSE DUMP VALVE (SAPR) – Park brake: Minumum Release
3 SPRING LOADED FILTER BYPASS Pressure 100 Bar (1450 psi)
VALVE – 3,4 Bar (49 psi) 21 ANTICAVITATION/WORK PORT RELIEF
38 PARK BRAKE PRESSURE SWITCH:
VALVE – Boom Cylinder Base End:
4 COLD START CHECK VALVE – With 100 Bar (1450 psi)
280 Bar (4061 psi)
3,0 Bar (43 psi) Spring
22 ANTICAVITATION/WORK PORT RELIEF 39 PRESSURE REDUCING VALVE – Park
5 HYDRAULIC PUMP - Gear type VALVE – Boom Cylinder Rod End: Brake: 120 Bar (1740 psi)
100 Lpm (26.4 gpm @ High Engine Idle 280 Bar (4061 psi) 40 PRESSURE REDUCING VALVE – Service
Brake: 40 Bar (580 psi)
6 HYDRAULIC PUMP - Gear type 23 ANTICAVITATION/WORK PORT RELIEF
38 Lpm (10.0 gpm @ High Engine Idle VALVE – Tilt Cylinder Base End: 41 CHECK VALVE – Park Brake
280 Bar (4061 psi)
7 PRIORTITY VALVE – Implement / Steering 42 SOLENOID ACTIVATED DIRECTIONAL
24 ANTICAVITATION/WORK PORT RELIEF
CONTROL VALVE – Steering Mode
VALVE – Tilt Cylinder Rod End:
8 PRIORTITY VALVE – Fan / Brake 280 Bar (4061 psi) 43 RELIEF VALVE – Brake Pressure:
120 Bar (1740 psi)
9 CHARGE PUMP 25 ANTICAVITATION/WORK PORT RELIEF Dealer Copy -- Not for Resale
38 Lpm (10.0 gpm) @ High Engine Idle VALVE – Telescopic Cylinder Base End: 44 SOLENOID ACTIVATED DIRECTIONAL
280 Bar (4061 psi) CONTROL VALVE – Gear Box
10 RELIEF VALVE – Charge:
26 ANTICAVITATION/WORK PORT RELIEF 45 RELIEF VALVE – Steering:
22 - 25 Bar (152 - 172 psi) @ low engine idle
VALVE – Telescopic Cylinder Rod End: 175 Bar (2538 psi)
27 - 30 Bar (186 - 207 psi) @ high engine idle
280 Bar (4061 psi) 46 RELIEF VALVE – Steering:
11 TRANSMISSION PUMP
27 SELF LEVELING CYLINDER LOCK VALVE: 235 Bar (3408 psi)
175 Lpm (46.2 gpm) @ High Engine Idle
250 Bar (3626 psi ) 47 ANTICAVITATION / RELIEF VALVE –
12 RELIEF/REPLENISHING VALVE - HIGH
28 BOOM CYLINDER LOCK VALVE: Fan Motor: 175 Bar (2538 psi)
PRESSURE (2) - 420 Bar (6092 psi)
380 Bar (5511 psi )
48 PILOT ACTIVATED CONTROL VALVE –
13 SOLENOID ACTIVATED DIRECTIONAL 29 TILT CYLINDER LOCK VALVE: Fan Motor Reverse Portection (If
CONTROL VALVE – Drive Dump Valve 280 Bar (4061 psi ) Equipped)
14 SERVO PRESSURE SENSOR - Forward 30 TELESCOPIC CYLINDER LOCK VALVE:
49 SOLENOID ACTIVATED DIRECTIONAL
280 Bar (4061 psi )
CONTROL VALVE – Fan Reverse (If
15 FILTER – Hydraulic Charge 31 DISPLACEMENT CONTROL VALVE: Equipped)
with Low Speed Solenoid
50 ACCUMULATOR (With Tractor Option
16 SPRING LOADED FILTER BYPASS 32 SHUTTLE VALVE - Drain Only): 80 Bar (1160 psi)
VALVE – 7 Bar (101 psi)
33 RELIEF VALVE 51 TEST PORT – Main Relief Pressure
17 TEST PORT – Charge Pressure NOTE: Unless otherwise specified
34 SHUTTLE VALVE – Drive Pressure springs have NO significant
pressure value.
Printed in Belgium V-1440le (2-15-11)
87 of 770
POWER QUICKTACH CYLINDER
REAR AUX / HYD HOOK
DIVERTER VALVE
A1 A2 (IF EQUIPPED) FEMALE
C1 C2 B1 B2
FRONT AUX / REAR AUX
COUPLERS (IF EQUIPPED)

FRONT AUXILIARY HYDRAULIC
FEMALE DIVERTER VALVE FEMALE
(IF EQUIPPED)
F D EC
A REAR AUXILIARY HYDRAULIC

MALE
DRAIN COUPLERS (IF EQUIPPED)
REAR HOOK CYLINDER
B A L V B (IF EQUIPPED)
15
16 MALE
B
OIL COOLER QUICKTACH PWR
CHARGE FILTER
LOCK / UNLOCK
17 U VALVE
P
2 4
V L HYDRAULIC CONTROL VALVE
CF1 EF1 3 1
A
T2
OUTLET
FAN INVERTER
LS1
49
VALVE (IF EQUIPPED) M4 F E M3 MA
48 47
CF2
IN A
EF2
7
CW ROTATION
9 12
F00B
LS2
OUT
B4
8
AUXILIARY
D FAN MOTOR A4
6 TELESCOPIC CYLINDER
TRACTOR SAFETY 5
VALVE (IF EQUIPPED)
F00A
13 IN WORK / AUX PUMP
11 26
10 12
TRAILER BRAKE VALVE MB
P T
3
Y B
1 2 M5 S L1 L2 4
HYDROSTATIC PUMP
30
U
P COLD START B
TELESCOPIC
A
N B BYPASS VALVE B3
TRAILER BRAKE
14
Dealer Copy -- Not for Resale SELF
LEVELING
A3
COUPLER CYLINDER
25
SELF LEVELING VALVE
MAIN OIL
FILTER
3
HYDROSTATIC MOTOR
31
STEERING UNIT L1 M4 24
B
L M3 27
46
46
38 35 A B
32 33
GEARBOX B2
R
TILT
1 2 A A2
TILT CYLINDER
SAHR BRAKE B A HYDRAULIC TANK
Vg min
LS TEMP 23
45 29
T 37 34
P XA XB 22
A
L2
n 36
B1
BOOM
A1
COLLECTOR BLOCK
BOOM
42 CYLINDER
CRAB 21
A4 L4 BOOM CYL LLHV
FWS
B4 R4
TRACTOR
28
4WS 20
ACCUMULATOR 40
INLET
43 (IF EQUIPPED)
SERVICE BRAKE
19
50 39 18
LS 4
T T 51
F PARK BRAKE
41 P LS P
T2 2 T
MF
X
P MACHINE
P2 S OIL FILL
COUPLER
COMPONENT ENCLOSURE DRAIN LINE

WORKING CIRCUIT PILOT LINE
P0 A3 B3 T0 T4 1 INTERSECTION OF HYDRAULIC LINES
INDICATED BY JUNCTION DOT
AXLE FRONT
44 AXLE REAR
HYDRAULIC SCHEMATIC
TL470 (S/N ANL711001 & ABOVE)
88 of 770 PRINTED MARCH 2011
Printed In Belgium V-1440
HYDRAULIC/HYDROSTATIC SCHEMATIC
TL470 (S/N ANMG11001 AND ABOVE)
(Printed MARCH 2011)
V-1440legend
LEGEND
1 RESERVOIR: 18 FLUSHING VALVE: 14 Bar (203 psi) 35 SERVO PISTON - Swash Plate
Reservoir Capacity 51 L (53.9 qt)
36 SPEED SENSOR - Driveshaft
19 LOAD SENSE RELIEF VALVE:
2 250 - 260 Bar (3626 – 3771 psi ) 37 SPRING APPLIED PRESSURE RELEASE
FILTER - Hydraulic
20 LOAD SENSE DUMP VALVE (SAPR) – Park brake: Minumum Release
3 SPRING LOADED FILTER BYPASS Pressure 100 Bar (1450 psi)
VALVE – 3,4 Bar (49 psi) 21 ANTICAVITATION/WORK PORT RELIEF
38 PARK BRAKE PRESSURE SWITCH:
VALVE – Boom Cylinder Base End:
4 COLD START CHECK VALVE – With 100 Bar (1450 psi)
280 Bar (4061 psi)
3,0 Bar (43 psi) Spring
22 ANTICAVITATION/WORK PORT RELIEF 39 PRESSURE REDUCING VALVE – Park
5 HYDRAULIC PUMP - Gear type VALVE – Boom Cylinder Rod End: Brake: 120 Bar (1740 psi)
100 Lpm (26.4 gpm @ High Engine Idle 280 Bar (4061 psi) 40 PRESSURE REDUCING VALVE – Service
Brake: 80 Bar (1160 psi)
6 HYDRAULIC PUMP - Gear type 23 ANTICAVITATION/WORK PORT RELIEF
38 Lpm (10.0 gpm @ High Engine Idle VALVE – Tilt Cylinder Base End: 41 CHECK VALVE – Park Brake
280 Bar (4061 psi)
7 PRIORTITY VALVE – Implement / Steering 42 SOLENOID ACTIVATED DIRECTIONAL
24 ANTICAVITATION/WORK PORT RELIEF
CONTROL VALVE – Steering Mode
VALVE – Tilt Cylinder Rod End:
8 PRIORTITY VALVE – Fan / Brake 280 Bar (4061 psi) 43 RELIEF VALVE – Brake Pressure:
120 Bar (1740 psi)
9 CHARGE PUMP 25 ANTICAVITATION/WORK PORT RELIEF Dealer Copy -- Not for Resale
38 Lpm (10.0 gpm) @ High Engine Idle VALVE – Telescopic Cylinder Base End: 44 SOLENOID ACTIVATED DIRECTIONAL
280 Bar (4061 psi) CONTROL VALVE – Gear Box
10 RELIEF VALVE – Charge:
26 ANTICAVITATION/WORK PORT RELIEF 45 RELIEF VALVE – Steering:
22 - 25 Bar (152 - 172 psi) @ low engine idle
VALVE – Telescopic Cylinder Rod End: 175 Bar (2538 psi)
27 - 30 Bar (186 - 207 psi) @ high engine idle
280 Bar (4061 psi) 46 RELIEF VALVE – Steering:
11 TRANSMISSION PUMP
27 SELF LEVELING CYLINDER LOCK VALVE: 235 Bar (3408 psi)
175 Lpm (46.2 gpm) @ High Engine Idle
250 Bar (3626 psi ) 47 ANTICAVITATION / RELIEF VALVE –
12 RELIEF/REPLENISHING VALVE - HIGH
28 BOOM CYLINDER LOCK VALVE: Fan Motor: 175 Bar (2538 psi)
PRESSURE (2) - 420 Bar (6092 psi)
380 Bar (5511 psi )
48 PILOT ACTIVATED CONTROL VALVE –
13 SOLENOID ACTIVATED DIRECTIONAL 29 TILT CYLINDER LOCK VALVE: Fan Motor Reverse Portection (If
CONTROL VALVE – Drive Dump Valve 280 Bar (4061 psi ) Equipped)
14 SERVO PRESSURE SENSOR - Forward 30 TELESCOPIC CYLINDER LOCK VALVE:
49 SOLENOID ACTIVATED DIRECTIONAL
280 Bar (4061 psi )
CONTROL VALVE – Fan Reverse (If
15 FILTER – Hydraulic Charge 31 DISPLACEMENT CONTROL VALVE: Equipped)
with Low Speed Solenoid
50 ACCUMULATOR (With Tractor Option
16 SPRING LOADED FILTER BYPASS 32 SHUTTLE VALVE - Drain Only): 80 Bar (1160 psi)
VALVE – 7 Bar (101 psi)
33 RELIEF VALVE 51 TEST PORT – Main Relief Pressure
17 TEST PORT – Charge Pressure NOTE: Unless otherwise specified
34 SHUTTLE VALVE – Drive Pressure springs have NO significant
pressure value.
Printed in Belgium V-1440le (2-15-11)
89 of 770
POWER QUICKTACH CYLINDER
REAR AUX / HYD HOOK
DIVERTER VALVE
A1 A2 (IF EQUIPPED) FEMALE
C1 C2 B1 B2
FRONT AUX / REAR AUX
COUPLERS (IF EQUIPPED)

FRONT AUXILIARY HYDRAULIC
FEMALE DIVERTER VALVE FEMALE
(IF EQUIPPED)
F D EC
A REAR AUXILIARY HYDRAULIC

MALE
DRAIN COUPLERS (IF EQUIPPED)
REAR HOOK CYLINDER
B A L V B (IF EQUIPPED)
15
16 MALE
B
OIL COOLER QUICKTACH PWR
CHARGE FILTER
LOCK / UNLOCK
17 U VALVE
P
2 4
V L HYDRAULIC CONTROL VALVE
CF1 EF1 3 1
A
T2
OUTLET
FAN INVERTER
LS1
49
VALVE (IF EQUIPPED) M4 F E M3 MA
48 47
CF2
IN A
EF2
7
CW ROTATION
9 12
F00B
LS2
OUT
B4
8
AUXILIARY
D FAN MOTOR A4
6 TELESCOPIC CYLINDER
TRACTOR SAFETY 5
VALVE (IF EQUIPPED)
F00A
13 IN WORK / AUX PUMP
11 26
10 12
TRAILER BRAKE VALVE MB
P T
3
Y B
1 2 M5 S L1 L2 4
HYDROSTATIC PUMP
30
U
P COLD START B
TELESCOPIC
A
N B BYPASS VALVE B3
TRAILER BRAKE
14
Dealer Copy -- Not for Resale SELF
LEVELING
A3
COUPLER CYLINDER
25
SELF LEVELING VALVE
MAIN OIL
FILTER
3
HYDROSTATIC MOTOR
31
STEERING UNIT L1 M4 24
B
L M3 27
46
46
38 35 A B
32 33
GEARBOX B2
R
TILT
1 2 A A2
TILT CYLINDER
SAHR BRAKE B A HYDRAULIC TANK
Vg min
LS TEMP 23
45 29
T 37 34
P XA XB 22
A
L2
n 36
B1
BOOM
A1
COLLECTOR BLOCK
BOOM
42 CYLINDER
CRAB 21
A4 L4 BOOM CYL LLHV
FWS
B4 R4
TRACTOR
28
4WS 20
ACCUMULATOR 40
INLET
43 (IF EQUIPPED)
SERVICE BRAKE
19
50 39 18
LS 4
T T 51
F PARK BRAKE
41 P LS P
T2 2 T
MF
X
P MACHINE
P2 S OIL FILL
COUPLER
COMPONENT ENCLOSURE DRAIN LINE

WORKING CIRCUIT PILOT LINE
P0 A3 B3 T0 T4 1 INTERSECTION OF HYDRAULIC LINES
INDICATED BY JUNCTION DOT
AXLE FRONT
44 AXLE REAR
HYDRAULIC SCHEMATIC
TL470 (S/N ANMG11001 & ABOVE)
90 of 770 PRINTED MARCH 2011
Printed In Belgium V-1440
HYDRAULIC SYSTEM INFORMATION
mc-2340

HYDRAULIC SYSTEM INFORMATION (CONT’D)
mc-2340
2

mc-2340-3

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic oil temperature warning light comes ON when hydraulics are operating. 1, 2
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine rpm. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct
2. The hydraulic pump has damage.

3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See Section SPEC-01.)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

Tightening Procedures
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
To tighten the hydraulic fittings, tubelines etc. (See

HYDRAULIC CONNECTION SPECIFICATIONS on Page
SPEC-40-1.) for the correct procedure and torque.
WARNING

Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290


LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1
S38852
Support the lift cylinder using a cinch strap (Item 1)

[Figure 20-20-3].
S38207
Remove the roll pin (Item 2) [Figure 20-20-3].

Raise the boom and install on adequate stands [Figure
20-20-1]. Figure 20-20-4
Figure 20-20-2

1 2
S38853
S38851
Install a puller (Item 1) and remove the upper pivot pin
(Item 2) [Figure 20-20-4].
Position a wooden block (Item 1) [Figure 20-20-2] under
the lift and self leveling cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-20-3]
and lower the lift cylinder onto a block.

LIFT CYLINDER (CONT’D) Figure 20-20-7
Removal And Installation (Cont’d)
Figure 20-20-5
S38857
Lift and support the base end of the cylinder [Figure 20-
20-7].
S38854
Figure 20-20-8
Remove the two hoses (Item 1) [Figure 20-20-5] from

the lift lock on the lift cylinder.
2

NOTE: Mark all hoses for correct installation.
Figure 20-20-6
1 1
S38856
Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 20-20-8] from the lower pivot pin.
S38855
IMPORTANT
Remove the bolt and nut (Item 1) [Figure 20-20-6] and
separate the lift cylinder and self leveling cylinder. When repairing hydrostatic and hydraulic systems,
Installation: Tighten the bolt to 30 - 41 N•m (22 - 30 ft-lb) parts clean. Always use caps and plugs on hoses,
torque. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

LIFT CYLINDER (CONT’D)
Figure 20-20-9
S38858
Remove the lower pivot pin (Item 1) [Figure 20-20-9].
Lift and remove the lift cylinder from the machine.

LIFT CYLINDER (CONT'D)
Parts Identification
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring 2
6. Seal 1 3
7. Set Screw
8. Piston
9. O-ring
10. Back-up Ring
11. Head Gland
12. Wiper 2

9
6
8
7
5 9
2 4
10
11
6
12
EM7533

Disassembly
Figure 20-20-10
WARNING
immediately.
W-2145-0290
Figure 20-20-12
S38827
Use the following tools to disassemble the cylinders:

MEL1354 - Spanner Wrench
MEL1076 - Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-10].
Figure 20-20-11 S39387
1 Carefully peen the two pinches (Item 1) [Figure 20-20-

12] in the head gland lock ring until flush.
2
S38828
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-11].
NOTE: Oil can still be under pressure. Equally

loosen the four bolts (Item 1) [Figure 20-20-11]
to allow residual oil pressure to escape.

LIFT CYLINDER (CONT'D) Figure 20-20-15
Disassembly (Cont'd)
Figure 20-20-13
P-29909
Put the rod end of the cylinder in a vise [Figure 20-20-

P-29906 15].
Figure 20-20-16
Heat the head gland (Item 1) [Figure 20-20-13].

Use a spanner wrench to loosen the head gland [Figure
20-20-13].
NOTE: Heating the head gland can damage the seals.

Always replace the seals. Heating is meant to
melt the Loctite® for ease of removal.
Figure 20-20-14
S39081
Support the cylinder rod on a wood block [Figure 20-20-

16].
P-29907
Remove the rod assembly (Item 1) [Figure 20-20-14]

from the housing.

Figure 20-20-17
S39087
Remove the O-ring (Item 1) [Figure 20-20-19] from the

S39082 inside of the piston.
Figure 20-20-20
Remove the set screw (Item 1) [Figure 20-20-17].

Figure 20-20-18
1
S39084
S39083 Remove the two wear rings (Item 1) [Figure 20-20-20]

from the piston.
Heat the piston (Item 1) [Figure 20-20-18].
Loosen and remove the piston (Item 1) [Figure 20-20-18]

from the rod.
NOTE: Heating the piston can damage the seals.

melt the Loctite® for ease of removal.

Figure 20-20-21 1
1 1
P-29918
Remove the head gland (Item 1) [Figure 20-20-23] from

S39085 the rod.
Remove the two back-up rings (Item 1) [Figure 20-20-

21].

Figure 20-20-22
S39086
Remove the seal (Item 1) [Figure 20-20-22].

2 3
Figure 20-20-24
1 1
P-29921
2
Remove seal (Item 1), wear ring (Item 2) and wiper (Item
P-29919
3) [Figure 20-20-26] from the head gland.
Remove the two O-rings (Item 1) and the back-up ring

(Item 2) [Figure 20-20-24] from the head gland.

Figure 20-20-25
P-29920
Remove the wear ring (Item 1) [Figure 20-20-25].

Assembly
Use the following tools to assemble the cylinders:
MEL1354 - Spanner Wrench 1

MEL1076 - Cylinder Wrench
MEL1033 - Rod Seal Installation Tool
Wash the cylinder parts in solvent and dry with

compressed air.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
P-29885
Lubricate all O-rings and seals with hydraulic oil during
installation. Always use new O-rings and seals.
Install the center seal (Item 1) [Figure 20-20-29].
Figure 20-20-27
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-20-27].
1
Figure 20-20-30

2
2
P-29884
1
Install the wiper (Item 1) and wear ring (Item 2) [Figure
20-20-27] in the head gland. P-29919
Figure 20-20-28
Install the back-up ring (Item 1) and two O-rings (Item 2)
[Figure 20-20-30].
1
P-29883
Install the wear ring (Item 1) [Figure 20-20-28].

Assembly (Cont'd)
1 1
Figure 20-20-31
S39085
Install the two back-up rings (Item 1) [Figure 20-20-33].

P-29918
Figure 20-20-34
Install the head gland (Item 1) [Figure 20-20-31] onto the

rod.

Figure 20-20-32
1
S39084
Install the two wear rings (Item 1) [Figure 20-20-34] onto

the piston.
S39086
Install the seal (Item 1) [Figure 20-20-32].

Assembly (Cont'd)
Figure 20-20-35
S39092
Install the piston (Item 1) [Figure 20-20-37] onto the rod.

P-32047
Tighten the piston to 720 - 1080 N•m (530 - 797 ft-lb)
torque.
Clean off any old residue, and apply Loctite® 243 or
equivalent to the threads on the rod [Figure 20-20-35]. Figure 20-20-38

Figure 20-20-36
P-29887
S39087
Apply Loctite® 243 or equivalent to the set screw (Item 1)
[Figure 20-20-38].
Install the O-ring (Item 1) [Figure 20-20-36] into the
inside of the piston.

Assembly (Cont'd) 2
Figure 20-20-39
P-29907
Install the rod assembly (Item 1) [Figure 20-20-41] into

S39082 the housing.
Clean off any old residue, and apply Loctite® 262 to the
Install the set screw (Item 1) [Figure 20-20-39]. threads of the head (Item 2) [Figure 20-20-41].

Tighten the set screw to 20 N•m (15 ft-lb) torque. Figure 20-20-42
Figure 20-20-40
P-29925
S39082
Use the spanner wrench to tighten the head gland
[Figure 20-20-42].
Lock the set screw with a punch [Figure 20-20-40] on the
edge of the hole.
Tighten the head to 400 - 500 N•m (295 - 370 ft-lb)
torque.

Assembly (Cont'd)
Figure 20-20-43
S39387
Peen the lock ring on both locations (Item 1) [Figure 20-

20-43] in the head gland.

NOTE: Do not peen the lock ring for more than 1 - 1,5
mm (0.04 - 0.06 in).
Figure 20-20-44
S38828
Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-44].

SELF LEVELING CYLINDER Figure 20-30-3
Figure 20-30-1
S38852
Support the lift cylinder using a cinch strap (Item 1)

[Figure 20-30-3].
S38207
Remove the roll pin (Item 2) [Figure 20-30-3].

Raise the boom and install on adequate stands [Figure
20-30-1]. Figure 20-30-4
Figure 20-30-2

1
2
S38853
S38851
Install a puller (Item 1) and remove the upper pivot pin
(Item 2) [Figure 20-30-4].
Position a wooden block (Item 1) [Figure 20-30-2] under
the lift and self leveling cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-30-3]
and lower the lift cylinder onto a block.

SELF LEVELING CYLINDER (CONT’D) Figure 20-30-7

2
Figure 20-30-5
1
S38856
Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 20-30-7] from the lower pivot pin.
S38859
Figure 20-30-8

the lift lock on the lift cylinder.

Figure 20-30-6
1
S38858
Remove the self leveling cylinder from the machine.
S38855
Remove the bolt and nut (Item 1) [Figure 20-30-6] and IMPORTANT
separate the lift cylinder and self leveling cylinder.
Installation: Tighten the bolt to 30 - 41 N•m (22 - 30 ft-lb) clean the work area before disassembly and keep all
torque. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888

SELF LEVELING CYLINDER (CONT’D)
1. Bushing
2. Housing 1
3. Back-up Ring
4. Seal
5. Piston
6. O-ring 1
7. Spacer
8. Head Gland
9. Wear Ring
10. Wiper
11. Rod
12. Grease Fitting

3
4
3
5
6
7
6
8
4
9
10
11
12
EM7528

SELF LEVELING CYLINDER (CONT'D) Figure 20-30-11
Disassembly
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook
Figure 20-30-9
S38833
Use a spanner wrench to remove the head gland [Figure

20-30-11].
Figure 20-30-12

S38831
1
Figure 20-30-10
S38834
Remove the rod assembly (Item 1) [Figure 20-30-12]

from the housing.
S38832

1
Figure 20-30-13
S39421

S38835 piston.
Figure 20-30-16
Put the rod end of the cylinder in a vise and support the
cylinder rod on a wood block [Figure 20-30-13]. 1

Figure 20-30-14
1
2
S39419
2 Remove the two wear rings (Item 1) and seal (Item 2)

S39418 [Figure 20-30-16] from the piston.
Remove the piston (Item 2) [Figure 20-30-14] from the

rod with a spanner wrench.

Figure 20-30-17 3
2
1
S38842
Remove the dust ring (Item 1), wear ring (Item 2) and
S39420 wiper seal (Item 3) [Figure 20-30-19].
Figure 20-30-20
Remove the expander O-ring (Item 1) [Figure 20-30-17].

Figure 20-30-18 2
1
S38843
S38841 Remove the back-up ring (Item 1) and two O-rings (Item
2) [Figure 20-30-20].
Remove the spacer (Item 1) and the head gland (Item 2)

[Figure 20-30-18] from the rod.

Assembly
MEL1353 - Spanner Wrench 1

MEL1033 - Rod Seal Installation Tool 2
Clean all parts in solvent and dry with compressed air.

Inspect all parts for nicks, scratches or other damage.
Replace any damaged parts.
3
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.
Figure 20-30-21
S38842
2
Install the dust ring (Item 1), wear ring (Item 2) and wiper
seal (Item 3) [Figure 20-30-22].
Figure 20-30-23

2
1
S38843
Install the back-up ring (Item 1) and two O-rings (Item 2)

[Figure 20-30-21] onto the head gland.
S38841
Install the head gland (Item 1) and the spacer (Item 2)

[Figure 20-30-23] onto the rod.

Assembly (Cont'd)
1
Figure 20-30-24
S39421
Install the O-ring (Item 1) [Figure 20-30-26] in the piston.

S39420
Figure 20-30-27
Install the O-ring (Item 1) [Figure 20-30-24] onto the

piston.

Figure 20-30-25
S38844
Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about
1 S39419 3 minutes [Figure 20-30-27].
Install the seal (Item 1) and two wear rings (Item 2)

[Figure 20-30-25].

Assembly (Cont'd)
Figure 20-30-28
P-29887

P-32047 [Figure 20-30-30].
Figure 20-30-31
equivalent to the threads on the rod [Figure 20-30-28].

Figure 20-30-29
1
2
S39418
Install and tighten the set screw (Item 1) [Figure 20-30-

S39422 31].
Install the piston (Item 1) [Figure 20-30-29] onto the rod.

torque.

Assembly (Cont'd)
Figure 20-30-32
1
S38832
Apply Loctite® 243 and install the set screw (Item 1)

S38834 [Figure 20-30-34].

the housing.

threads of the head (Item 2) [Figure 20-30-32].
Figure 20-30-33
S38845

[Figure 20-30-33].

SELF LEVELING CYLINDER (LOCK VALVE)
Figure 20-31-1
S38006
Raise the boom and install the boom stop (Item 1)

[Figure 20-31-1]. (See Installing The Approved Boom

Stop on Page 10-150-1.)
Stop the engine.
Relieve hydraulic pressure.
Remove the Starter switch key.
Figure 20-31-2
3
1
1
1
S39446
Remove the four hoses (Item 1) [Figure 20-31-2] from

the self leveling cylinder lock valve.
Remove the two nuts (Item 2) and bolts and remove the
lock valve (Item 3) [Figure 20-31-2].


EXTENSION CYLINDER Figure 20-40-3
Cylinder Group Removal And Installation
Remove the inner boom. (See Removal And Installation

on Page 50-40-1.) 1
1
Figure 20-40-1 1
S39098
Disconnect the five fittings (Item 1) [Figure 20-40-3] in

the top opening of the boom head.
NOTE: Mark the hoses for correct installation.

S39097
Remove the two plastic caps (Item 1) [Figure 20-40-1]

IMPORTANT

from the boom head.
Figure 20-40-2 When repairing hydrostatic and hydraulic systems,

damage the system.
I-2003-0888
1
Figure 20-40-4
1
S39069

the tilt cylinder.
S39099
Remove the two bolts (Item 1) [Figure 20-40-4] from the

top of the boom.

EXTENSION CYLINDER (CONT’D) Figure 20-40-7
Cylinder Group Removal And Installation (Cont’d)
Figure 20-40-5
S39102
Remove the extension cylinder assembly from the boom

[Figure 20-40-7].
S39100
Figure 20-40-8
Remove the snap ring (Item 1) [Figure 20-40-5] and
washer.
Figure 20-40-6

1
S39103
Support the extension cylinder on a work surface [Figure

20-40-8].
S39101
Remove the extension cylinder rod end pivot (Item 1)

[Figure 20-40-6].
WARNING
W-2019-0907

Upper Tubeline Removal And Installation

1
Figure 20-40-9
1
1
S39110
Remove the tie-straps (Item 1) [Figure 20-40-11].

S39107
Figure 20-40-12
Remove the bolt (Item 1) [Figure 20-40-9].
Move the upper tubeline assembly away from the cylinder 1

[Figure 20-40-9].

Figure 20-40-10
2
2 1
S39109
1
1 Disconnect the four fittings (Item 1) [Figure 20-40-12].
1
S39111 IMPORTANT
Remove the tie-straps / clamps (Item 1) [Figure 20-40- When repairing hydrostatic and hydraulic systems,
10] from the electrical harness (if equipped). clean the work area before disassembly and keep all
Remove the clamps (Item 2) [Figure 20-40-10] from the tubelines and ports to keep dirt out. Dirt can quickly
tubelines. damage the system.
I-2003-0888

EXTENSION CYLINDER (CONT’D)
Upper Tubeline Removal And Installation (Cont’d)
Figure 20-40-13
2
1
2
3
S39112
Remove the three bolts and nuts (Item 1) [Figure 20-40-

13].
Remove the two plates (Item 2) [Figure 20-40-13].

Remove the harness and grommet (Item 3) [Figure 20-
40-13].

Extension Cylinder Removal And Installation
Figure 20-40-14
1
1
S39106
1
Remove the two bolts (Item 1) [Figure 20-40-16] and

nuts.
S39104
Figure 20-40-17
Disconnect the two fittings (Item 1) [Figure 20-40-14].
Figure 20-40-15

1
S39108
Install a hoist (Item 1) [Figure 20-40-17] to lift and

S39105
support the extension cylinder.
Remove the two bolts (Item 1) [Figure 20-40-15] and Slide the extension cylinder through the tubelines
nuts. [Figure 20-40-17] and remove the cylinder.
NOTE: It can be necessary to reposition the lifting

strap.

EXTENSION CYLINDER (CONT'D) Figure 20-40-20
Tubeline Tray Disassembly
Figure 20-40-18 1 1
1 1
S39116
1
S39113
Figure 20-40-21

1
1
Figure 20-40-19
1

2 1
1
2
1
S39115
1 Remove the tie-straps (Item 1) [Figure 20-40-21].

S39114
Remove the two bolts (Item 2) [Figure 20-40-21] and
nuts.
Disconnect the six fittings (Item 1) [Figure 20-40-19].
IMPORTANT
damage the system.
I-2003-0888

EXTENSION CYLINDER (CONT'D)
Tubeline Tray Disassembly (Cont’d)
Figure 20-40-22
2
5
4 3
S39116
Remove the three bolts (Item 1) and remove the clamp

(Item 2) [Figure 20-40-22].
Remove the bolt and nut (Item 3) and remove the plate

(Item 4) [Figure 20-40-22].
Remove the electrical harness (Item 5) [Figure 20-40-

22] and grommet.
Remove the eight tubelines.

1. Housing
2. Safety Valve
3. O-ring
4. Expander O-ring 2
5. Wear ring
6. O-ring
7. Rod 2
8. Back-up Ring
9. Piston
10. Head Gland
11. Wiper
12. Set Screw

1 9
6
4
8 12
7
3
10
4
11 8
EM7534

Disassembly
1
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook
Figure 20-40-23
S38918
1
Use the spanner wrench to loosen the head gland

(Item 1) [Figure 20-40-25].
Figure 20-40-26

S38922
Clamp the base end of the housing (Item 1) [Figure 20- 1

40-23] in a vise. Support the other end of the cylinder
with a wooden block.
Figure 20-40-24
S38919
1
Place a drain pan below the housing and slowly move the
rod (Item 1) [Figure 20-40-26] in and out to remove the
fluid from the cylinder.
Remove the rod (Item 1) [Figure 20-40-26] from the

housing.
S38917
Carefully peen the lock ring (Item 1) [Figure 20-40-24]

up and out of the lock groove.

Disassembly (Cont’d)
Figure 20-40-27
1
1
S39425
Remove the set screw (Item 1) [Figure 20-40-29] from

S38919 the piston.
Figure 20-40-30
Clamp the rod end (Item 1) [Figure 20-40-27] of the rod
assembly in a vise. Support the other end of the rod

assembly with a wooden block.
2
Figure 20-40-28
1
S38923
Use the cylinder wrench to remove the piston (Item 1)

from the rod (Item 2) [Figure 20-40-30].
S38921
Remove the wear ring (Item 1) [Figure 20-40-28] from

the piston.

Figure 20-40-31 1
S38926

S39426 the rod.
Figure 20-40-34
Remove the wear ring (Item 1) [Figure 20-40-31] from
the piston.

Figure 20-40-32 1
3
1 2
2 S38927
Remove the wiper seal (Item 1), the two wear rings (Item
S38925 2) and the seal (Item 3) [Figure 20-40-34] from the head
gland.
Remove the seal (Item 1) and the two O-rings (Item 2)

[Figure 20-40-32] from the piston.

Figure 20-40-35
2
1
S38928
Remove the two O-rings (Item 1) and back-up ring (Item

2) [Figure 20-40-35] from the head gland.

Assembly
Use the following tools to assemble the cylinder: 1
Spanner Wrench 3
2
Cylinder Wrench
Rod Seal Installation Tool

compressed air.
Inspect the cylinder parts for nicks, scratches or other S38927

damage. Replace any damaged parts.
Lubricate all O-rings and seals with hydraulic oil during Install the wiper seal (Item 1) and two wear rings (Item 2)
installation. Always use new O-rings and seals. [Figure 20-40-37] into the head gland.
Figure 20-40-36 Install the seal (Item 3) [Figure 20-40-37] using the seal
installation tool.
2

NOTE: The groove in the seal must point away from
1 the wiper seal.
2 Figure 20-40-38
S38928
Install the back-up ring (Item 1) and two O-rings and

(Item 2) [Figure 20-40-36] on the head gland.
S38931
Install the head gland (Item 1) [Figure 20-40-38] on the

rod.

Assembly (Cont’d)
Figure 20-40-39
2
2 S38923

S38925 equivalent to the threads on the piston (Item 1) [Figure
20-40-41].
Install the seal (Item 1) and the two O-rings (Item 2) Use the cylinder wrench to install the piston (Item 1) on
[Figure 20-40-39] on the piston. the cylinder rod (Item 2) [Figure 20-40-41].

Figure 20-40-40 Tighten the piston to 414 N•m (305 ft-lb) torque.
1 Figure 20-40-42
S39426
P-29887
Install the backside wear ring (Item 1) [Figure 20-40-40]
on the piston. The second wear ring will be installed at a
later stage. Apply Loctite® 243 or equivalent to the set screw (Item 1)
[Figure 20-40-42].

Assembly (Cont’d)
Figure 20-40-43
S38919

S38921 the housing.
Figure 20-40-46
Install the set screw (Item 1) [Figure 20-40-43] into the
piston.

Tighten the set screw to 20 N•m (15 ft-lb) torque.
1
Figure 20-40-44
S38918

(Item 1) [Figure 20-40-46].
S38921 Tighten the head to 250 N•m (184 ft-lb) torque.
Install the second wear ring (Item 1) [Figure 20-40-44]

on the piston.

Assembly (Cont’d)
Figure 20-40-47
S38917
Carefully peen the lock ring into the groove in the head
gland (Item 1) [Figure 20-40-47].

NOTE: Do not peen the lock ring for more than
1 - 1,5 mm (0.04 - 0.06 in).

TILT CYLINDER Figure 20-50-3
Figure 20-50-1
1
1
S39069

the tilt cylinder.
S39074

Fully lower the attachment carrier [Figure 20-50-1] to
rest on a flat surface. Figure 20-50-4
Figure 20-50-2

1
S39068
S39071
Install a hoist and lifting strap (Item 1) [Figure 20-50-4] to
the tilt cylinder.
Remove the plastic cap (Item 1) [Figure 20-50-2] from
the boom head.
IMPORTANT
damage the system.
I-2003-0888

TILT CYLINDER (CONT’D) Figure 20-50-7
Figure 20-50-5
S39389
1
Remove the snap ring (Item 1) and washer (Item 2)
[Figure 20-50-7] from the upper pivot pin.
S39146
Figure 20-50-8
[Figure 20-50-5] from the lower pivot pin.
Figure 20-50-6

1
1 S39388
Remove the upper pivot pin (Item 1) [Figure 20-50-8].

S39147
NOTE: Make sure the hoist and strap are tight to
prevent the cylinder from falling.

TILT CYLINDER (CONT’D)
Figure 20-50-9
S39075
Carefully lower and remove the tilt cylinder (Item 1)

[Figure 20-50-9].

TILT CYLINDER (CONT’D)
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring 2
6. Seal 1 3
7. Set Screw
8. Piston
9. O-ring
10. Back-up Ring
11. Head Gland
12. Wiper 2

9
6
8
7
5 9
2 4
10
11
6
12
EM7533

TILT CYLINDER (CONT'D)
Disassembly
Use the following tool to disassemble the cylinder:

WARNING
MEL1075 - Adjustable Gland Wrench
Figure 20-50-10
immediately.
W-2145-0290
Figure 20-50-12
1 1
S39076

Figure 20-50-11
S39091
Remove the three O-rings and back-up rings (Item 1)

[Figure 20-50-12].
1
Figure 20-50-13
S39077
Remove the relief cartridge (Item 1) [Figure 20-50-11].
NOTE: Oil can still be under pressure. Carefully

loosen the relief cartridge (Item 1) [Figure 20-
50-11] to allow residual oil pressure to S39390
escape.
Carefully peen the two pinches (Item 1) [Figure 20-50-

13] in the head gland lock ring until flush.

TILT CYLINDER (CONT'D) Figure 20-50-16
Figure 20-50-14
S39080
Put the rod end of the cylinder in a vise [Figure 20-50-

S39078 16].
Figure 20-50-17
Heat the head gland (Item 1) [Figure 20-50-14].
Use a spanner wrench to loosen the head gland [Figure

20-50-14].

NOTE: Heating the head gland can damage the seals.
melt the Loctite® for ease of removal. Always
be careful with hot parts.
Figure 20-50-15
S39081
1
Support the cylinder rod on a wood block [Figure 20-50-
17].
S39079
Remove the rod assembly (Item 1) [Figure 20-50-15].

Figure 20-50-18
S39087
S39082
inside of the piston.
Remove the set screw (Item 1) [Figure 20-50-18]. Figure 20-50-21
Figure 20-50-19

1
1
S39084
S39083
Remove the two wear rings (Item 1) [Figure 20-50-21]

Loosen and remove the piston (Item 1) [Figure 20-50-19] from the piston.
from the rod.

Figure 20-50-22 1
1 1
S39088

the rod.
S39085
Figure 20-50-25
Remove the two back-up rings (Item 1) [Figure 20-50- 2 1

22].

Figure 20-50-23
S39089
Remove the O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-50-25] from the head gland.
S39086

TILT CYLINDER (CONT'D)
Figure 20-50-26
3 1
S39090
Remove the wiper (Item 1), two wear rings (Item 2) and
seal (Item 3) [Figure 20-50-26] from the head gland.

Assembly
1
Use the following tool to assemble the cylinder:
MEL1075 - Adjustable Gland Nut Wrench

compressed air.
Inspect the cylinder parts for damage. Replace any

damaged parts.
Lubricate all O-rings and seals with hydraulic oil during S39088
installation. Always use new O-rings and seals.
Install the head gland (Item 1) [Figure 20-50-29] onto the
Figure 20-50-27
rod.
Figure 20-50-30
3 1

2
S39090
Install the wiper seal (Item 1), wear rings (Item 2), and
seal (Item 3) [Figure 20-50-27]. S39087
NOTE: The lip in the seal (Item 3) must point away

Install the O-ring (Item 1) [Figure 20-50-30] on the inside
from the wiper seal (Item 1) [Figure 20-50-27].
of the piston.
Figure 20-50-28
1 2
S39089
Install the back-up ring (Item 1) and O-ring (Item 2)

[Figure 20-50-28] onto the head gland.

Assembly (Cont'd)
Figure 20-50-31
1
S39084
Install the two wear rings (Item 1) [Figure 20-50-33].

S39086
Figure 20-50-34
Install the O-ring (Item 1) [Figure 20-50-31] onto the

piston.

Figure 20-50-32
1 1
P-32047

equivalent to the threads on the rod [Figure 20-50-34].
S39085
Install the two back-up rings (Item 1) [Figure 20-50-32].

Assembly (Cont'd)
Figure 20-50-35
1
1
S39082
Install the set screw (Item 1) [Figure 20-50-37].

S39092
Tighten the set screw to 20 N•m (15 ft-lb) torque.
Install the piston (Item 1) [Figure 20-50-35] onto the rod Figure 20-50-38
and tighten.

torque.
Figure 20-50-36
S39082
Lock the set screw with a punch [Figure 20-50-38] on the

edge of the hole.
P-29887

[Figure 20-50-36].

Assembly (Cont'd)
1
Figure 20-50-39
S39390
Peen the lock ring on both locations (Item 1) [Figure 20-

S39079 50-41] in the head gland.
NOTE: Do not peen the lock ring for more than 1 - 1,5
Install the piston / rod assembly (Item 1) [Figure 20-50- mm (0.04 - 0.06 in).
39] into the housing.
Figure 20-50-42

threads of the head (Item 2) [Figure 20-50-39].
Figure 20-50-40
S39077
Install the relief cartridge (Item 1) [Figure 20-50-42].

S39093
Tighten the relief cartridge to 45 - 50 N•m (33 - 37 ft-lb)
torque.
Install the head gland [Figure 20-50-40].
Tighten the head to 400 - 500 N•m (295 - 370 ft-lb)

torque.


STEERING CYLINDER (FRONT/REAR) Figure 20-60-3
Removing The Steering Cylinder
Remove:
2
• the front axle. (See Removal And Installation on Page 1
40-30-1.)
or
• the rear axle. (See Removal And Installation on Page

40-90-1.)
Figure 20-60-1
S2515
Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-60-3].
2
3 Figure 20-60-4

1
1
S2513
Remove the two bolts (Item 1) and remove the centering

sensor (Item 2) from the steering cylinder
(Item 3) [Figure 20-60-1].
Figure 20-60-2 S2516
Remove the nut (Item 1) [Figure 20-60-4].
S2514
Remove the cotter pin (Item 1) [Figure 20-60-2].

STEERING CYLINDER (FRONT/REAR) (CONT’D) Figure 20-60-7
Removing The Steering Cylinder (Cont’d)
Figure 20-60-5 2
S2519
Remove the bolts (Item 1) from the steering cylinder

S2517 (Item 2) [Figure 20-60-7].
Figure 20-60-8
Remove the tie rod end (Item 1) [Figure 20-60-5] by
means of a puller.

Figure 20-60-6 1
2
1
S2520
Extract the cylinder (Item 1) [Figure 20-60-8] using a

S2518 plastic hammer.
NOTE: For cylinder disassembly (See Disassembling

Disconnect the left and right steering bars (Item 1) from The Steering Cylinder on Page 20-60-5.).
the piston (Item 2) [Figure 20-60-6].

STEERING CYLINDER (FRONT/REAR) (CONT’D) Figure 20-60-11
Installing The Steering Cylinder
Figure 20-60-9
S2523
Apply Loctite® 243 to the thread and install the two tie
S2521 rods [Figure 20-60-11]. Tighten the tie rods to 240 - 270
N•m (177 - 199 ft-Ib) torque.
Lubricate the seats of the seals and install the steering Figure 20-60-12
cylinder (Item 1) [Figure 20-60-9] into its seat.

Figure 20-60-10
2
1
S2524
S2522 Insert the tie rods (Item 1) in the steering case

(Item 2) [Figure 20-60-12]. Tighten the nuts to 260 - 290
N•m (192 - 214 ft-Ib) torque.
Tighten the bolts (Item 1) [Figure 20-60-10] to 116 - 128
N•m (85 - 95 ft-lb) torque. Tighten the nut (Item 3) [Figure 20-60-12] until the
cotter pin hole is visible.
NOTE: Check that the rubber boots [Figure 20-60-12]

are intact.

STEERING CYLINDER (FRONT / REAR) (CONT’D)
Installing The Steering Cylinder (Cont’d)
Figure 20-60-13
S2525
Insert the cotter pins (Item 1) [Figure 20-60-13] and

bend the ends.

NOTE: Use new cotter pins.
Figure 20-60-14
S2526
Install the centering sensor for checking piston centering.
Tighten the bolt (Item 1) [Figure 20-60-14] to 5 - 6 N•m

(44.25 - 53 in-Ib) torque.

STEERING CYLINDER (FRONT / REAR) (CONT’D) Figure 20-60-17
Disassembling The Steering Cylinder
Figure 20-60-15 2
2
S1518
With the help of a drift, apply pressure to the stop ring

S1516
(Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-60-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-60-15]. Figure 20-60-18

Figure 20-60-16
1
1
3
2
S1519
S1517
Hammer the piston (Item 1) on the rear of the head
(Item 2) [Figure 20-60-18] using a plastic hammer.
With the help of a plastic hammer, push the head
Continue hammering until the head (Item 2) is ejected
(Item 1) inside the cylinder (Item 2) [Figure 20-60-16].
from the cylinder (Item 3) [Figure 20-60-18].
NOTE: The head should line up with the edge of the
cylinder.

STEERING CYLINDER (FRONT / REAR) (CONT’D)
Disassembling The Steering Cylinder (Cont’d)
Figure 20-60-19
A
S1520
Disassemble the cylinder unit (Item 1) by extracting first

the head, then the piston (Item 2) [Figure 20-60-19].
NOTE: Mark the assembly side of the piston. The

bevelled part “A” of the piston is oriented
toward the piston rod end.
Remove all seals, anti-extrusion rings and scraper rings

from head, cylinder and piston.
NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

Assembling The Steering Cylinder

1
Figure 20-60-20
1 2 3
S1523
Install the seal (Item 1) [Figure 20-60-22] onto the

S1521
outside of the head.
After applying grease, install the sealing ring (Item 1) on NOTE: In order to facilitate assembly, apply grease to
the shaft, the anti-extrusion ring (Item 2) and the scraper the outer surface of the piston.
ring (Item 3) [Figure 20-60-20] inside the cylinder. Do not roll the seal (Item 1) [Figure 20-60-22].

NOTE: Thoroughly check that positioning of the anti- Figure 20-60-23
extrusion ring (Item 2) [Figure 20-60-20] is
correct.
5 3 2
Figure 20-60-21
1
3 2 1 4
S1524
Prepare the piston (Item 1) by installing it with the guide

ring (Item 2), the magnetic ring (Item 3), the O-ring
S1522 (Item 4) and the seal (Item 5) [Figure 20-60-23].
NOTE: In order to facilitate assembly, apply grease.

After applying grease, install the sealing ring (Item 1) on
the shaft, the anti-extrusion ring (Item 2) and the scraper
ring (Item 3) [Figure 20-60-21] in the head.
NOTE: Thoroughly check that positioning of the anti-

extrusion ring (Item 2) [Figure 20-60-21] is
correct.

Assembling The Steering Cylinder (Cont’d)
Figure 20-60-24 1
T18
T18
2
1
S1527
Remove tool T18 and apply it to the opposite side of the

S1525 piston (Item 1) [Figure 20-60-26].
Figure 20-60-27
Apply tool T18 to the shaft on the opposite side of the
head and center it on the cylinder (Item 1) so that it fits
into the piston (Item 2) [Figure 20-60-24].

1
NOTE: Apply a little grease to seals and cylinder.
T18
Figure 20-60-25
1 3
2
S1528
Apply grease to the head seals (Item 1), install the head
onto the piston (Item 2) and push it onto the cylinder
2
(Item 3) [Figure 20-60-27].
S1526
Push the piston (Item 1) into the cylinder (Item 2)

[Figure 20-60-25] for 100 mm (4 in). Using a plastic
hammer.

Assembling The Steering Cylinder (Cont’d) 2
Figure 20-60-28
S1531
2 install the snap ring (Item 1) on the head (Item 2)

S1529 [Figure 20-60-30].
NOTE: Make sure that the snap ring

Insert the stop ring (Item 1) ensuring that it fits into the (Item 1) [Figure 20-60-30] is securely
seat of the cylinder (Item 2) [Figure 20-60-28]. fastened in its seat.
If necessary, force it into its seat using a drift

Figure 20-60-29 and a hammer.
S1530
Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-60-29].


GEAR CONTROL CYLINDER Figure 20-70-3
Removal
Remove the engine / hydrostat assembly. (See Removal

And Installation on Page 70-100-1.)
Figure 20-70-1
1
1
S38227
3
Remove the piston (Item 1) [Figure 20-70-3].
Figure 20-70-4
2
S38224

Remove the two hoses (Item 1) from the gear control
cylinder (Item 2) [Figure 20-70-1].
NOTE: Mark the hoses for installation.
Remove the two bolts (Item 3) from the gear control

Remove the gear control cylinder (Item 2) [Figure 20-70-

1]. 1
S38229
Figure 20-70-2
Remove the cover plate (Item 1) [Figure 20-70-4].
1
2
S38225
Remove the screw (Item 1) from inside the cylinder rod

(Item 2) [Figure 20-70-2].

GEAR CONTROL CYLINDER (CONT’D)
Removal (Cont’d)
Figure 20-70-5
1
S38230
Remove the O-ring (Item 1) [Figure 20-70-5].

GEAR CONTROL CYLINDER (CONT’D)
1. O-ring
2. Seal
3. Cylinder
4. Rod
5. Piston
6. Cover Plate
7. Sealant
8. Screw

2
3 5
6
1
1 1
7
1
EM7541

GEAR CONTROL CYLINDER (CONT’D) Figure 20-70-8
Disassembly
2
Figure 20-70-6
2 S38231
1
Remove the O-ring (Item 1) from the cylinder housing

S38228 (Item 2) [Figure 20-70-8].

Inspect the cylinder rod (Item 2) [Figure 20-70-6] for
nicks and scratches.
Figure 20-70-7
1
2
S38226
Remove the seal (Item 1) from the cylinder housing (Item

2) [Figure 20-70-7].

Assembly
Figure 20-70-9
S38228
Install the O-ring (Item 1) [Figure 20-70-11].

S38231
Figure 20-70-12
Install the O-ring (Item 1) on the cylinder housing (Item 2)

[Figure 20-70-9].

Figure 20-70-10
1
2
1
S38230
Install the O-ring (Item 1) [Figure 20-70-12].
S38226
Install the seal (Item 1) on the cylinder housing (Item 2)

[Figure 20-70-10].

Installation
Figure 20-70-13
1
2
S38225
Install the screw (Item 1) inside the cylinder rod (Item 2)

[Figure 20-70-15]. Apply Loctite® 243 to the threads
S36809 before installation. Torque to 25 - 26 N•m (18.4 - 19.2 ft-
lb) torque.
Apply Loctite® 510 and install the cover plate (Item 1) Figure 20-70-16

[Figure 20-70-13].
Figure 20-70-14 3
2
1 S38224
S38227 Apply some hydraulic oil on the control rod and piston
before installing the gear control cylinder (Item 2) [Figure
20-70-16].
Install the piston (Item 1) [Figure 20-70-14].
Install the gear control cylinder (Item 2) with the two bolts
(Item 3) [Figure 20-70-16].
Tighten the bolts (Item 3) [Figure 20-70-16] to 49 - 51

N•m (36.1 - 37.7 ft-lb) torque.
Install the two hoses (Item 1) onto the gear control


MAIN RELIEF VALVE Figure 20-80-2
Testing And Adjustment
The following tool will be needed to do the following

procedure:
MEL10003 - Hydraulic Tester
Figure 20-80-1
2
4 1
S38158
5
Start the engine and run at low idle rpm. Press the front
3 auxiliary hydraulics button (Item 1) [Figure 20-80-2].
Make sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to 2400 rpm.

1 S39186
Warm the fluid to 60°C (140°F) by turning the restrictor
control (Item 5) [Figure 20-80-1] on the tester to about
Connect the inlet hose (Item 1) from the tester (Item 5) to 6,9 MPa (69 bar) (1000 psi). DO NOT exceed system
the front coupler (Item 2) [Figure 20-80-1]. relief pressure. Open the restrictor control knob and
record the free flow (U.S. gpm) at 2400 rpm.
Connect the outlet hose (Item 3) from the tester (Item 5)
to the rear coupler (Item 4) [Figure 20-80-1]. There should be 95 L/min (25 U.S. gpm) free flow. Turn
the restrictor control (Item 5) [Figure 20-80-1] on the
tester until the main relief opens. The correct pressure
should be 25,5 MPa (255 bar) (3698 psi).
IMPORTANT If adjustment is needed, see [Figure 20-80-3].
The hydraulic tester must be in the fully open

position before you start the engine.
I-2024-0284

MAIN RELIEF VALVE (CONT’D) Removal And Installation
Testing And Adjustment (Cont’d)
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.) IMPORTANT
1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 20-80-5
S39398

Locate the main relief valve (Item 1) on the front upper
side of the control valve [Figure 20-80-3].
Figure 20-80-4
S39398
2
Locate the main relief valve (Item 1) [Figure 20-80-5] on
the front upper side of the control valve.
1
Clean the area around the control valve.
Remove the main relief valve (Item 1) [Figure 20-80-5].
Installation: Tighten the main relief valve to 45 N•m (33

ft-lb) torque.
S38604
Loosen the lock nut (Item 1) and turn the adjustment

screw (Item 2) [Figure 20-80-4] clockwise to increase the
pressure or counterclockwise to decrease the pressure.
Retest the main relief valve after adjustment.

MANIFOLD Figure 20-90-2
WARNING 1

immediately.
W-2145-0290 S39415
Figure 20-90-1 Disconnect the four connectors (Item 1) [Figure 20-90-2]

from the solenoids.
3
Figure 20-90-3
BOTTOM VIEW

2
1 1
S39413
Remove the bolt (Item 1) and remove the bracket (Item 2)

S39412
from the manifold (Item 3) [Figure 20-90-1].
Remove the fifteen hydraulic connections from the Remove the two bolts (Item 1) [Figure 20-90-3] located
manifold (Item 3) [Figure 20-90-1]. outside of the frame, in front of the hydraulic tank.
NOTE: Mark the hoses for installation. Remove the manifold from the machine.
IMPORTANT
damage the system.
I-2003-0888

MANIFOLD (CONT’D)
2
1

3
5
5
4
3
4
5
4
1. Block
2. Load Sense Valve
3. Solenoid Valve 4
Stem
4. Solenoid
5. Plug
5. Check Valve
EM9300

MANIFOLD (CONT’D) Figure 20-90-6
Disassembly And Assembly
Figure 20-90-4 1
3
1
4
2
S39858
6
5 Inspect the O-rings and back-up washer (Item 1)
S39414 [Figure 20-90-6] for damage.
Assembly: Put oil on O-ring and back-up washer.

Remove the nut (Item 1) from the solenoid valve stem Tighten to 25,8 - 28,6 N•m (19 - 21 ft-lb) torque.
and remove the two gear shift solenoids (Item 2)

[Figure 20-90-4]. Remove both solenoid valve stems from the manifold.
Remove the nut (Item 3) from the solenoid valve stem Figure 20-90-7
and remove the two steering mode solenoids (Item 4)
[Figure 20-90-4].
Remove the load sense valve (Item 5) [Figure 20-90-4]

from the manifold. 1
Figure 20-90-5
S39859
Inspect the O-rings and back-up washers (Item 1)

[Figure 20-90-7] for damage.
Assembly: Put oil on O-ring and back-up washers.

S39857 Tighten the long solenoid valve stem to 32.7 - 35.4 N•m
(24 - 26 ft-lb) torque.
Tighten the short solenoid valve stem to 25,8 - 28,6 N•m
Inspect the O-rings and back-up washer (Item 1) (19 - 21 ft-lb) torque.
[Figure 20-90-5] for damage.
Assembly: Put oil on O-ring and back-up washer.

Tighten to 25,8 - 28,6 N•m (19 - 21 ft-lb) torque.
Remove the check valve (Item 6) [Figure 20-90-4] from

the manifold.


BRAKE VALVE Figure 20-100-3
Remove the steering column cover. (See Removal And

Installation on Page 50-110-1.)
Figure 20-100-1
1
1 1
S39132
Remove the two bolts (Item 1) [Figure 20-100-3] from

2
1 inside the operator cab.
Figure 20-100-4
S38084

Remove the three bolts (Item 1) and remove the cover
(Item 2) [Figure 20-100-1] from the front of the operator
cab.
Figure 20-100-2
1 S39134
2 Remove the brake valve (Item 1) [Figure 20-100-4] from

the outer cab.
1
1
S39131
IMPORTANT
Disconnect the three hoses (Item 1) and the tubeline When repairing hydrostatic and hydraulic systems,
(Item 2) from the brake valve (Item 3) [Figure 20-100-2]. clean the work area before disassembly and keep all
NOTE: Some additional hoses may need to be tubelines and ports to keep dirt out. Dirt can quickly
disconnected from the steering valve in order damage the system.
to disconnect the tubeline. I-2003-0888

BRAKE VALVE (CONT’D)
Figure 20-100-5
S39135
Remove all fittings [Figure 20-100-5] from the brake

valve.

GEAR PUMP Figure 20-110-1
Stop the engine. 1
Relieve the hydraulic pressure. Drain the hydraulic

reservoir. (See Removing And Replacing Hydraulic Fluid 2
on Page 10-100-2.)
Remove the battery. (See Removing And Installing

Battery on Page 60-20-1.)
WARNING S38066
Hydraulic fluid escaping under pressure can have Loosen the two bolts (Item 1) and remove the cover (Item
sufficient force to enter a person’s body by 2) [Figure 20-110-1] from the front side of the engine /
penetrating the skin. This can cause serious injury hydrostat assembly.
physician familiar with this injury is not received Figure 20-110-2
immediately.

W-2145-0290
IMPORTANT
damage the system.
I-2003-0888 S38067
Remove the two bolts that hold the plate (Item 1) and
remove the plate (Item 1) [Figure 20-110-2].

GEAR PUMP (CONT'D) Figure 20-110-5
Removal And Installation (Cont'd) 1
Figure 20-110-3 1
1
1
1
2
S39400
Remove the three hoses (Item 1) [Figure 20-110-5] from

S39399 the gear pump assembly.
Figure 20-110-6
Loosen the two fittings (Item 1) and remove the tubeline
(Item 2) [Figure 20-110-3].

Figure 20-110-4
2
1
1 1 1
S39401
2 Install a wooden block under the gear pump assembly.

S38070
Remove the four mounting bolts (Item 1) (both sides)
[Figure 20-110-6] from the gear pump.
Loosen / remove the four bolts (Item 1) and remove the
fitting (Item 2) [Figure 20-110-4] from the gear pump. Installation: Tighten the mounting bolts to 50 - 80 N•m
(38 - 59 ft-lb) torque.
Remove the gear pump assembly (Item 2) [Figure 20-

110-6].
NOTE: It can be necessary to reposition any hose or

wires.

GEAR PUMP (CONT’D)
Figure 20-110-7
19
22
23 17 16
20
15
24
25
14
17
18 16

9 10
2
4 3
2
1. Fitting
2. O-ring 5 1
6
3. Spring 10 2 7
4. Spring Seat
5. Spool
6. Screen
7. Orifice Spool 18 10
8. Bolt 19 2
18
9. Cover
17 16 7
10. Plug 6
11. Bolt
12. Washer 5
13. Front Cover 17 2
16
14. Seal Ring
15. Pump Housing 13
16. Back-up Ring
17. Seal Ring
18. Holder
19. Gear
20. Spline Shaft
21. Mount Plate
4
22. Thrust Plate
23. Mount Plate 2 3
24. Seal 2
15
25. Snap Ring
1
EM7530


1 1
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1 1
damage the system.
I-2003-0888
2
S39437
Figure 20-110-8
Remove the four bolts (Item 1) [Figure 20-110-9].
Assembly: Tighten the bolts to 70 N•m (51 ft-lb) torque.
Remove the flow divider (Item 2) [Figure 20-110-9] from

the housing.

Figure 20-110-10
5 4 3 2 1
6
S38103
Mark the pump housing for correct assembly and remove

all fittings [Figure 20-110-8].
S39248
Remove the plug (Item 1), O-ring (Item 2), spring (Item
3), spring seat (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-110-10].
Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque.
NOTE: Always use new O-rings.

Disassembly And Assembly (Cont'd)
Figure 20-110-11
2
1
P-25296
To remove the orifice assembly (Item 1) [Figure 20-110-

P-25294 13] from the spool, make a holding fixture from a 19 mm
thick x 38 mm wide x 50 mm long (0.750 in thick x 1.500
in wide x 2.0 in long) piece of hardwood. Drill a 14 mm
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- (0.550 in) hole in the center of the hardwood block. Cut
110-11] from the housing. the block lengthwise [Figure 20-110-12].

Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque. Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-110-13].
Figure 20-110-12
Cut NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.
Figure 20-110-14
14 mm dia.
(0.550’’ dia.) 1 2
38 mm
(1.500’’) 19 mm
(0.750’’) B-14674
P-25295
Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-110-14] and clean.

Figure 20-110-15 1
2
3
1 1
2 4
S39351
1 1 Remove the housing (Item 1) from the gear assembly

S39437 (Item 2) [Figure 20-110-17].
Assembly: The position of the small opening (Item 3) on

Remove the four bolts (Item 1) and cover (Item 2) the gear holders will point toward the cut-away (Item 4)
[Figure 20-110-15]. [Figure 20-110-17] on the housing.

Assembly: Tighten the bolts to 70 N•m (51 ft-lb) torque. Figure 20-110-18
Figure 20-110-16
1
1
S39252
S39350
Remove both O-rings (Item 1) [Figure 20-110-18] from
the housing.
Remove the housing / gear assembly (Item 1)
[Figure 20-110-16] from the main housing.

Figure 20-110-19 1 1
1 1
2
P-25304
1
Remove the four bolts (Item 1) and drive shaft (Item 2)

P-56453 [Figure 20-110-21].
Assembly: Tighten the bolts to 140 N•m (103 ft-lb)

Remove the back-up ring (Item 1) and seal ring (Item 2) torque.
[Figure 20-110-19] from the gear holder.

Figure 20-110-22
Assembly: The seal ring (Item 2) [Figure 20-110-19] is
installed onto the gear holder first followed by the back-
up ring.
Figure 20-110-20
P-25305
Turn the housing over and remove the mount plate

[Figure 20-110-22].
P-25322
Remove and discard the O-ring (Item 1) [Figure 20-110-

20] from the flange.


2
Figure 20-110-23
1
1
3
4
P-25310
Remove the O-ring (Item 1) and gear assembly (Item 2)

P-25306 [Figure 20-110-25] from the housing.
Assembly: The position of the V portion (Item 3) on the

Remove the snap ring (Item 1) [Figure 20-110-23]. thrust plate must point toward the larger port (Item 4)
[Figure 20-110-25] on the housing.

Figure 20-110-24
Figure 20-110-26
1 2 2
3 1 3
1
P-25307
P-25313
Remove both shaft seals (Item 1) [Figure 20-110-24].

Remove the two thrust plates (Item 1), seal ring (Item 2)
Assembly: The open part of the first seal goes into the and back-up ring (Item 3) [Figure 20-110-26] from the
mount plate first. For the second seal the closed side gears.
goes into the mount plate first (reversed orientation).
Assembly: The seal ring (Item 2) will be installed on the
thrust plate (Item 1) first followed by the back-up ring
(Item 3) [Figure 20-110-26].

FAN MOTOR Figure 20-120-2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system. 1
I-2003-0888
S38799
Drain the radiator. (See Removing And Replacing The
Coolant on Page 10-70-2.)
Remove the four fan guard mount bolts and nuts (Item 1)
Remove the radiator. (See Removal And Installation on [Figure 20-120-2].
Page 70-60-1.)
Flip the fan assembly around.
Figure 20-120-1
Figure 20-120-3

2
1
1
1 S38861
S38796
Remove the four bolts and washers (Item 1) [Figure 20-

120-1]. Remove the nut and lock washer (Item 1) [Figure 20-
120-3].
Installation: Tighten the bolts to 15 - 22 N•m (11 - 16 ft-
lb) torque. Installation: Tighten the bolts to 19 - 20 N•m (14 - 14.8
ft-lb) torque.
Remove the fan guard with fan motor (Item 2) [Figure 20-
120-1].

FAN MOTOR (CONT’D)
Figure 20-120-4
S38801
Install the fan assembly onto blocks as shown in [Figure

20-120-4].

Figure 20-120-5
S38797
Tap on the shaft to release the fan motor from the blade
assembly [Figure 20-120-5].
Remove the fan motor.

Parts Identification (Single Speed Version) (Standard)
1. Seal
2. Check Valve
3. Motor Housing
4. Gear Assembly
5. Rear Cover
6. Front Cover
7. Back-up Ring
8. Holder
9. Gear
10. Pin
11. Snap Ring
2
7
3 1
8
1
5 9
8
10 7

1
1 6
10
11
EM7529

FAN MOTOR (CONT’D) Figure 20-120-8
Disassembly And Assembly (Single Speed Version)

(Standard)
Figure 20-120-6
2
1
1
P-53277

plug. Replace as needed.
P-53275
Figure 20-120-9
Remove the solenoid stem (Item 1) and three fittings

(Item 2) [Figure 20-120-6].

1
NOTE: Mark the housing for correct assembly.
1
Figure 20-120-7
1 1
P-53278
4 Remove the four bolts (Item 1) [Figure 20-120-9] from

3
the front cover.
2
1 Assembly: Tighten bolts to 43 - 47 N•m (32 - 35 ft-lb)
P-53276 torque.
Remove the plug (Item 1), spring (Item 2) and check

valve (Item 3) from the front cover (Item 4) [Figure 20-
120-7].

Disassembly And Assembly (Single Speed Version) 2

(Standard) (Cont’d)
1
Figure 20-120-10
P-53282
Remove the gear assembly (Item 1) from the motor

P-53279
Figure 20-120-13
Remove the front cover (Item 1) from the motor housing

(Item 2) [Figure 20-120-10].
Figure 20-120-11
P-53283
Remove the back-up ring / seal (Item 1) [Figure 20-120-

13] from the gear holder.
P-53281
Remove the seal (Item 1) [Figure 20-120-11] from the

housing.

Disassembly And Assembly (Single Speed Version)

(Standard) (Cont’d)
Figure 20-120-14
P-53256
Remove the snap ring (Item 1) and remove the seal (Item

2) [Figure 20-120-14].
Assembly: The open part of the seal goes into the rear
cover first.
Figure 20-120-15
P-53285
Inspect the gears (Item 1) [Figure 20-120-15] for

damage or wear.

Parts Identification (Variable Speed Version) (Optional)
1. Seal
2. Back-up Ring
3. Plug
4. Solenoid 5
5. Gear Assembly
6. Check Valve
7. Snap Ring
8. Motor Housing
9. Rear Cover 11
10. Front Cover 9
11. Pin 1
12. Holder
13. Gear
14. Bolts
15. Washers
1
7
12
13
12
2 14

1
11
15
4
11 1
10
11 3
6
1
2 3
EM7531

Disassembly And Assembly (Variable Speed Version)

(Optional)
2
1
IMPORTANT
damage the system.
I-2003-0888
S38804
Figure 20-120-16
Remove the fitting (Item 1) from the “IN” port and the
fitting (Item 2) [Figure 20-120-18] from the “OUT” port.
Figure 20-120-19

1
1
S38802
Remove the nut (Item 1) and solenoid (Item 2) [Figure

20-120-16].
S38805
Mark the housing for correct assembly.
Figure 20-120-17 Remove the O-ring (Item 1) [Figure 20-120-19] from the
“IN” port fitting.
S38803
Remove the two O-rings (Item 1) and the washer (Item 2)

[Figure 20-120-17].


(Optional) (Cont’d)
Figure 20-120-20 1
S38808

fitting.
S38806
Figure 20-120-23

“OUT” port fitting.
Figure 20-120-21
S38809
Remove the solenoid stem (Item 1) [Figure 20-120-23]

from the front cover.
1
S38807
Assembly: Tighten the stem to 27 N•m (20 ft-lb) torque.
Remove the fitting (Item 1) [Figure 20-120-21].


Figure 20-120-24
2
S38812
1 Remove six back-up rings (Item 1) and four O-rings (Item

2) [Figure 20-120-26].
S38810
Figure 20-120-27
Remove the back-up ring (Item 1) and two O-rings (Item

2) [Figure 20-120-24] from the solenoid stem.
1
Figure 20-120-25
1 1
1 S38813
Remove five plugs (Item 1) [Figure 20-120-27] from the

front cover.
S38811
Remove the solenoid stem (Item 1) [Figure 20-120-25]

from the front cover.


Figure 20-120-28 1
S38817

plug.
S38814
Figure 20-120-31
Remove the O-rings (Item 1) [Figure 20-120-28] from the

plugs.
Figure 20-120-29
2
1 1
S38816
Remove the spring (Item 1) and piston (Item 2) [Figure

20-120-31] from the front cover.
S38815
Remove the plug (Item 1) [Figure 20-120-29] from the

front cover.

Disassembly And Assembly (Variable Speed Version) 1

2
Figure 20-120-32
S38820
Remove the rear cover (Item 1) from the motor housing

(Item 2) [Figure 20-120-34].
1 S38818
Figure 20-120-35
Remove the four bolts and washers (Item 1) and remove

the front cover (Item 2) [Figure 20-120-32].
2
Assembly: Tighten the bolts to 49 - 68 N•m (36 - 50 ft-lb)
torque.
1
Figure 20-120-33
1
1
S38821
1
Remove the two pins (Item 1) and the seal (Item 2)
[Figure 20-120-35] from the motor housing.
S38819
Remove the two pins (Item 1) and the seal (Item 2)

[Figure 20-120-33] from the motor housing.


Figure 20-120-36
1
2 1
S38824

S38822
Figure 20-120-39
Remove the gear assembly (Item 1) from the motor

Figure 20-120-37 2
1
1
S38825
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-120-39].
S38823
Assembly: The open part of the seal goes into the cover
first.


Figure 20-120-40
S38826
Inspect the gears (Item 1) [Figure 20-120-40] for

damage or wear.

HYDRAULIC RESERVOIR Figure 20-130-2
The Approved Boom Stop on Page 10-150-1.)
Remove the fuel tank. (See Removal And Installation on

Page 50-70-1.)
Drain the hydraulic reservoir. (See Removing And 1

Replacing Hydraulic Fluid on Page 10-100-2.)
Figure 20-130-1 1
S38294
2
1 Remove the two hoses (Item 1) [Figure 20-130-2] from
the hydraulic tank.
Figure 20-130-3
1

1 3
S38105
2
Loosen the two bolts (Item 1) and remove the cover (Item
2) [Figure 20-130-1].
4
S38080
Loosen the hose clamps (Item 1) and remove the hose

(Item 2) [Figure 20-130-3] from the hydraulic tank.
Remove the hose (Item 3) [Figure 20-130-3] from the

hydraulic tank.
Disconnect the hydraulic oil temperature sensor

connector (Item 4) [Figure 20-130-3] from the hydraulic
tank.

HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-6
Figure 20-130-4
S38292
2
Remove the two mounting bolts (Item 1) [Figure 20-130-
S38798 6] from the hydraulic tank.
Figure 20-130-7
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 20-130-4].

Figure 20-130-5
S38293

S38800 7] from the hydraulic tank.
Remove the hydraulic tank.

hydraulic tank.
Support the hydraulic tank using a jack or forklift.

STEERING VALVE

IMPORTANT
Installation on Page 50-110-1.) When repairing hydrostatic and hydraulic systems,
Figure 20-140-1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 20-140-3
1 1
2 1
1
1
S38084

cab. S39130
Figure 20-140-2
Remove the four bolts (Item 1) [Figure 20-140-3] and
1 remove the steering valve.
1 NOTE: The steering valve is not serviceable. If the

1
steering valve is damaged, the entire valve
must be replaced.
1
S38125
Remove the five hoses (Item 1) [Figure 20-140-2] from

the steering valve.
NOTE: Mark hoses for correct installation.


HYDRAULIC CONTROL VALVE
Troubleshooting Chart (Controllers)

WARNING
must be done by authorized Bobcat Service Personnel. adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE CORRECTION

None of the solenoid valves work Insufficient power supply Check battery voltage
Insufficient pilot pressure Check pilot / charge pressure
Plugged solenoid valve filter Clean filter
Only one solenoid valve works No actuation signal Check signal voltage
Unsuitable actuation signal Check signal voltage
Insufficient actuation power supply Check signal voltage
All solenoid valves not working or Plugged solenoid valve filter Clean filter
jerky
One solenoid valve not working or Faulty actuation signal Check signal
jerky Friction or jamming of the plunger Replace solenoid valve
One solenoid valve not working or Contamination of the proportional Replace solenoid valve

jerky in one direction valve in the solenoid valve
Solenoid valve creeps Neutral position incorrect Adjust neutral adjustment
Oil leakage between control valve Faulty seals Replace seal
and solenoid valve

HYDRAULIC CONTROL VALVE (CONT’D)
Valve Section Troubleshooting CODE FUNCTION REF

W2305 Lift Down Output Short To Battery 1
Record the serial number of the machine, control valve
W2306 Lift Down Output Short To Ground 1
and control module.
W2307 Lift Down Output Open Circuit 1
The following procedure must be done with the control W2332 Lift Down Output Overcurrent 1
valve in the machine. The control valve is removed for
W2205 Lift Up Output Short To Battery 2
photo clarity.
W2206 Lift Up Output Short To Ground 2
Raise the boom and install the boom stop. (See Installing W2207 Lift Up Output Open Circuit 2
W2232 Lift Up Output Overcurrent 2
Figure 20-150-1 W2405 Tilt Out Output Short To Battery 3
W2406 Tilt Out Output Short To Ground 3
W2407 Tilt Out Output Open Circuit 3
W2432 Tilt Out Output Overcurrent 3
W2505 Tilt Back Output Short To Battery 4
1 W2506 Tilt Back Output Short To Ground 4

W2507 Tilt Back Output Open Circuit 4
W2532 Tilt Back Output Overcurrent 4

W2605 Extend Output Short To Battery 5
W2606 Extend Output Short To Ground 5
W2607 Extend Output Open Circuit 5
2 W2632 Extend Output Overcurrent 5
S38158
W2705 Retract Output Short To Battery 6
W2706 Retract Output Short To Ground 6
The joystick lockout function must be disabled (light (Item
W2707 Retract Output Open Circuit 6
1) [Figure 20-150-1] is OFF).
W2732 Retract Output Overcurrent 6
To disable, press the button (Item 1) [Figure 20-150-1] to D7705 Aux Male Output Short To Battery 7
turn OFF for all testing procedures.
D7706 Aux Male Output Short To Battery 7
1. Check for diagnostic service codes. (See Operation & D7707 Aux Male Output Open Circuit 7
Maintenance Manual for the correct procedure.) D7732 Aux Male Output Overcurrent 7
When no service code is read, go to step 11.
D7605 Aux Female Output Short To Battery 8
Figure 20-150-2 D7606 Aux Female Output Short To Battery 8
D7607 Aux Female Output Open Circuit 8
8
7 D7632 Aux Female Output Overcurrent 8
6
2. Locate the valve section and solenoid valve to which
5 4 the service code refers [Figure 20-150-2]:
3 2
S38679

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-150-4
Valve Section Troubleshooting (Cont’d)
3. Disconnect the solenoid valve of the valve which has

been diagnosed and plug back in. 2
4. With adequate room in front of the machine, start the

1
engine and run the engine at 900 rpm, then run at low
idle rpm. Operate the function which has been
diagnosed [Figure 20-150-3]. Move forward and
back to see if the function works. Stop the engine.
Figure 20-150-3
S38678
1
5. Disconnect the solenoid valve connector (Item 1)

7 [Figure 20-150-4] which has been diagnosed (“Tilt
5 Up” solenoid valve shown in picture).
3
6. Remove the two screws (Item 2) [Figure 20-150-4]
and pull out the solenoid valve (“Tilt Up” solenoid

8 valve shown in picture).
4
6 NOTE: Install a cap on the valve opening to prevent
2 contamination.
S38004
Figure 20-150-5
REF FUNCTION
1 Lower Boom
2 Raise Boom 1
3 Tilt Down
4 Tilt Up
5 Extend Telescopic Boom
6 Retract Telescopic Boom
7 Front Auxiliary Hydraulics B4 (Male Coupler)
8 Front Auxiliary Hydraulics A4 (Female Coupler)
S39181
IMPORTANT 7. Use an ohmmeter to check the solenoid. The reading

between both electrical connector terminals must be
approximately 5 ohm (Item 1) [Figure 20-150-5].
clean the work area before disassembly and keep all If the solenoid measurement is correct, the error could be
parts clean. Always use caps and plugs on hoses, located in wiring / connectors to the solenoid.
damage the system. 8. Reinstall the solenoid valve.
I-2003-0888

HYDRAULIC CONTROL VALVE (CONT’D) P-Standby Pressure Checking
Telescoping Valve Section Troubleshooting (Cont’d) Figure 20-150-8
Pilot Pressure Checking

1
Figure 20-150-6
S39398
13. Locate the test fitting (Item 1) [Figure 20-150-8] and

S39392 remove the cap.
14. Install a 7,0 MPa (70 bar) (1000 psi) gauge on the test

9. Locate the test fitting (Item 1) [Figure 20-150-6] and fitting (Item 1) [Figure 20-150-8] located on the P-
remove the cap. port of the control valve.
Figure 20-150-7 15. Start the engine and run the engine at low idle (900
rpm). Record the pressure. The pressure at the gauge
should be within the following range: 1,3 - 1,5 MPa
(13 - 15 bar) (189 - 218 psi).
16. Run the engine at high idle (2315 rpm) and record the
pressure. The pressure at the gauge should be within
the following range: 1,6 - 1,8 MPa (16 - 18 bar) (232 -
261 psi).
S39393
10. Install a 7,0 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-150-7].
11. Start the engine and run the engine at 2315 rpm.
Record the pressure. The pressure at the gauge
should be within the following range: 2,5 - 3,5 MPa
(25 - 35 bar) (363 - 508 psi).
12. Remove the gauge.

Valve Section Troubleshooting (Cont’d)
17. With adequate room in front of the machine, start the

engine and run the engine at 900 rpm, then run at low 2
idle rpm. Operate the function which has been
diagnosed [Figure 20-150-9]. Move forward and
1
back to see if the function works. Stop the engine.
Figure 20-150-9
S38678
7
5
3 18. Remove the two screws (Item 2) [Figure 20-150-10]
and pull out the solenoid valve (“Tilt Up” controller
shown in picture).
4 8
NOTE: Install a cap on the valve opening to prevent
6 dust penetration.

2
S38004 Figure 20-150-11
REF FUNCTION
1 Lower Boom
2 Raise Boom
3 Tilt Down
4 Tilt Up
5 Extend Telescopic Boom
6 Retract Telescopic Boom
7 Front Auxiliary Hydraulics B4 (Male Coupler)
8 Front Auxiliary Hydraulics A4 (Female Coupler) 1
S7171
19. Turn the Ignition key switch ON, but DO NOT start the
engine. Check the function of each solenoid valve by
having another person move the telescopic control
switch (Item 1) [Figure 20-150-11]. The solenoid
valve piston, which can be seen through the valve
orifices (Item 1) [Figure 20-150-11] must be moving
according to the switch movement.
20. If a solenoid valve does not function properly, it must

be replaced.

Troubleshooting Chart (Control Valve)

WARNING
must be done by authorized Bobcat Service Personnel. adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE CORRECTION

Lack of strength at all actuators Load sense relief cartridge defective Replace relief cartridge
Load sense relief cartridge out of Make necessary adjustments
adjustment
Lack of force on one actuator only Secondary relief valve out of adjust- Reset to original pressure
ment
Secondary relief valve blocked open Replace relief valve
Lack of load hold Load check valve failure Replace load check valve
Excessive clearance between housing Replace housing and spool
and spool
Simultaneous movement of con- Blockage of individual compensator Remove and clean orifice
trols orifice

Individual pressure compensator Replace housing and compensator
blocked
Load sense line leakage Replace load sense regulator
Engine remains under load after Flow regulator blocked Replace flow regulator
spools are returned to neutral Flow regulator filter clogged Replace filter
Detent malfunction Controller defective Replace controller
Spool return difficult Tie rod bolts too tight Re-torque tie rod bolts
Spool leaking oil Defective spool seal Replace spool seal
Oil leakage between valve section Defective seals Replace seals

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: Mark all hoses and harnesses for correct
installation.
Figure 20-150-13
2 3
WARNING
Hydraulic fluid escaping under pressure can have 1
4
and possible death if proper medical treatment by a 5
physician familiar with this injury is not received S38604
immediately.
W-2145-0290
Replace the bolt (Item 1) by a longer bolt (Item 2)
equipped with a nut (Item 3). Tighten the nut (Item 3)
[Figure 20-150-13].

IMPORTANT Repeat the above step for the bolt (Item 4) [Figure 20-
150-13].
When repairing hydrostatic and hydraulic systems, Remove the bolt (Item 5) [Figure 20-150-13].
damage the system.
I-2003-0888
Figure 20-150-12
S38604
Remove the thirteen hoses from the hydraulic control

valve [Figure 20-150-12].
Remove the nine electrical harnesses from the hydraulic

control valve [Figure 20-150-12].

Figure 20-150-14
1
1
1
S38607
Remove the bolts (Item 1) [Figure 20-150-16].

S38607
Remove the hydraulic control valve.
Loosen the nuts (Item 1) [Figure 20-150-14] in order to Use care not to damage the tubelines or fittings.
create a gap between the frame and control valve.

Figure 20-150-15
2
S38608
Install a hoist and lifting strap (Item 1) [Figure 20-150-

15] on the control valve.
NOTE: The wire harness (Item 2) [Figure 20-150-15]

which is located below the control valve
should be excluded from the loop when
installing the lifting strap.

1. End Housing
2. Auxiliary Valve Section
3. Telescoping Valve Section
4. Tilting Valve Section
5. Lifting Valve Section
6. Inlet-Outlet Valve Section

1 6
2 3 4 5
S38609

IMPORTANT
damage the system.
I-2003-0888
1
S38611
Mark the valve sections for ease of assembly. (See Parts
Identification on Page 20-150-9.)
Remove the three nuts (Item 1) [Figure 20-150-18] from
Figure 20-150-17 the tie rod bolts.
Assembly: Tighten the nuts to 35 N•m (25.8 ft-lb) torque.

S38610
Remove all hydraulic fittings. Mark the valve sections for

proper assembly [Figure 20-150-17].

Inlet-Outlet Valve Section Disassembly And

Assembly
Figure 20-150-19 2
1 S38614
Remove the valve stem (Item 1) [Figure 20-150-21] from

the inlet-outlet valve section.
S38612
Remove the main relief valve (Item 2) [Figure 20-150-21]
from the inlet-outlet valve section.
Remove the inlet-outlet valve section (Item 1) [Figure 20-

150-19]. Figure 20-150-22
Figure 20-150-20
3
2
2
S38615
1
S38613
Remove the O-ring (Item 1), two back-up rings (Item 2)
and O-ring (Item 3) [Figure 20-150-22] from the valve
Remove the nut (Item 1) and valve stem solenoid (Item 2) stem.
[Figure 20-150-20] from the inlet-outlet valve section.

HYDRAULIC CONTROL VALVE (CONT’D) Lifting Valve Section Disassembly And Assembly
Inlet / Outlet Valve Section Disassembly And Figure 20-150-24

Assembly (Cont’d)
Figure 20-150-23
1
S38693
2
S38616 Remove the lifting valve section (Item 1) [Figure 20-150-

24].
Remove the O-ring (Item 1), back-up ring (Item 2) and O- Figure 20-150-25

ring (Item 3) [Figure 20-150-23] from the main relief
valve.
S38694
Remove the seven O-rings (Item 1) [Figure 20-150-25]

from the valve section.

Lifting Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-150-26
1 1
1
S38697
Remove the two screws (Item 1) [Figure 20-150-28] from

1 the controller.
S38695
Remove the two solenoids (Item 2) [Figure 20-150-28]
from the controller.
Remove the screws (Item 1) [Figure 20-150-26] from the

valve section. Figure 20-150-29
Figure 20-150-27
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-150-29]
Remove the three O-rings (Item 1) [Figure 20-150-27]



(Cont’d)
Figure 20-150-30
S38701
S38698 Figure 20-150-33
Remove the spool (Item 1) [Figure 20-150-30].

Figure 20-150-31
1
S38702
1 1
S38700
Remove the three screws (Item 1) and remove the cover

(Item 2) [Figure 20-150-31].


(Cont’d)
Figure 20-150-34
1
1
S38705
The relief pressure value (in bar) of the port relief valve is
indicated on the spool assembly (Item 1) [Figure 20-150-
S38703 36].
Repeat for the other side of the valve section.

Remove the plug (Item 1) [Figure 20-150-34].

Figure 20-150-37
Figure 20-150-35
3
S38705
S38704

Remove the port relief spool assembly (Item 1) and
spring (Item 2) [Figure 20-150-35].

plug.

HYDRAULIC CONTROL VALVE (CONT’D) Tilting Valve Section Disassembly And Assembly
Lifting Valve Section Disassembly And Assembly Figure 20-150-39

(Cont’d)
Figure 20-150-38
1
1
2
3
S40001
S38719 Remove the tilting valve section (Item 1) [Figure 20-150-

39].
Remove the spring (Item 1) and two shuttle spools (Items Figure 20-150-40

2 and 3) [Figure 20-150-38] from the valve section.
S38694


Tilting Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-150-41
1 1
1
S38697

1 the controller.
S38695

Figure 20-150-42
1
1
S38691
S38696



(Cont’d)
Figure 20-150-45
S38701
S38698 Figure 20-150-48

Figure 20-150-46
1
S38702
1 1
S38700

(Item 2) [Figure 20-150-46].


(Cont’d)
Figure 20-150-49
1
1
S38705
S38703 51].


Figure 20-150-52
Figure 20-150-50
3
S38705
S38704


plug.

HYDRAULIC CONTROL VALVE (CONT’D) Telescoping Valve Section Disassembly And
Assembly
(Cont’d) Figure 20-150-54
Figure 20-150-53
1
1
2
3
S40002
S38719
Remove the telescoping valve section (Item 1)
[Figure 20-150-54].
Remove the spring (Item 1) and two shuttle spools (Items

2 and 3) [Figure 20-150-53] from the valve section. Figure 20-150-55
S38694


Telescoping Valve Section Disassembly And

2
Assembly (Cont’d)
Figure 20-150-56
1 1
1
S38697

1 the controller.
S38695

Figure 20-150-57
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-150-59].



Assembly (Cont’d)
Figure 20-150-60
S38701
S38698 Figure 20-150-63

Figure 20-150-61
1
S38702
1 1
S38700

(Item 2) [Figure 20-150-61].


Assembly (Cont’d)
Figure 20-150-64
1
1
S38705
S38703 66].


Figure 20-150-67
Figure 20-150-65
3
S38705
S38704


plug.

HYDRAULIC CONTROL VALVE (CONT’D) Auxiliary Valve Section Disassembly And Assembly
Telescoping Valve Section Disassembly And Figure 20-150-69

Assembly (Cont’d)
1
Figure 20-150-68
1
2
3
S40003
S38719 Remove the auxiliary valve section (Item 1) [Figure 20-

150-69].
Remove the spring (Item 1) and two shuttle spools (Items Figure 20-150-70

S38694


Auxiliary Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-150-71
1 1
1
S38697

1 the controller.
S38695

Figure 20-150-72
1
1
S38691
S38696



(Cont’d)
Figure 20-150-75
S38701
S38698 Figure 20-150-78

Figure 20-150-76
1
S38702
1 1
S38700

(Item 2) [Figure 20-150-76].


(Cont’d)
Figure 20-150-79
1 1
S38705
S38741 Figure 20-150-82
Remove the plug (Item 1) [Figure 20-150-79]. 1

2
Figure 20-150-80
3
1
2
S38719
Remove the spring (Item 1) and two shuttle spools (Items

S38740

[Figure 20-150-80] from the plug.

End Housing Disassembly And Assembly
Figure 20-150-83 1
S38744
1
1

S38742 valve section.
Figure 20-150-86
Remove the tie rods (Item 1) [Figure 20-150-83] from the
end housing.

1
Figure 20-150-84
S38745
1
S38743 plug.
Remove the nine O-rings (Item 1) [Figure 20-150-84]


End Housing Disassembly And Assembly (Cont’d)
Figure 20-150-87
S38747
Flip the end housing and remove the valve (Item 1)

S38746 [Figure 20-150-89].
Figure 20-150-90

Figure 20-150-88
1 1
S38748
S38745 Remove the two O-rings (Item 1) [Figure 20-150-90].

plug.


PORT RELIEF VALVES Replacement Procedure
Adjustment Procedure Figure 20-160-2
6
IMPORTANT 5 4
When repairing hydrostatic and hydraulic systems, 2

3
damage the system.
I-2003-0888
A portable hydraulic hand pump will be used to test the

work port relief valves. The hand pump must have clean S38679
hydraulic fluid that is compatible with the Bobcat
hydraulic fluid.
REF FUNCTION
NOTE: The valve is shown removed from the
machine for photo clarity. 1 Lower Boom Port Relief Valve
2 Raise Boom Port Relief Valve

Figure 20-160-1 3 Tilt Down Port Relief Valve
4 Tilt Up Port Relief Valve
5 Retract Telescopic Boom Port Relief Valve
6 Extend Telescopic Boom Port Relief Valve
Remove the port relief valve plug [Figure 20-160-2].
Figure 20-160-3
1
S39247
Install the hand pump, hose and a pressure gauge

(minimum of 34,4 MPa [344 bar] [5000 psi]) into the valve
section work port in which the port relief valve is located
[Figure 20-160-1]. Pressurize this section with the hand
pump until the port relief valve opens and record the 3
pressure reading.
S38749
If the port relief pressure setting is too high / low, release
the hand pump pressure valve and replace the port relief
Remove the spring (Item 1) and port relief valve
valve.
assembly (Item 2) [Figure 20-160-3] from the hydraulic
control valve.

plug.

PORT RELIEF VALVES (CONT’D)
Replacement Procedure (Cont’d)
Figure 20-160-4
S38705
Replace the port relief valve (Item 1) [Figure 20-160-4]

indicated on the end of the assembly (Item 2) [Figure 20-
160-4].
Figure 20-160-5
2
3
S38749
Install the port relief valve spool (Item 1), spring (Item 2)
and the plug (Item 3) [Figure 20-160-5]
Tighten the plug (Item 3) [Figure 20-160-5] to 24 N•m

(18 ft-lb) torque.

PARKING BRAKE
Parking Brake Valve Removal And Installation
Figure 20-170-1
WARNING
immediately.
W-2145-0290
IMPORTANT
S39431
Remove the bolt (Item 1) [Figure 20-170-1]. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-170-2
1
1 1
S39428
Remove the three hydraulic hoses (Item 1) [Figure 20-

170-2].
Remove the two bolts (Item 2) [Figure 20-170-2].
Remove the parking brake valve (Item 3) [Figure 20-170-

2].


ACCUMULATOR (IF EQUIPPED) Figure 20-180-2
Figure 20-180-1
S38074
1
Remove the cover plate (Item 1) to access the

S38006 accumulator which is mounted right below the frame
(Item 2) [Figure 20-180-2].
Raise the boom and install the boom stop (Item 1) Figure 20-180-3
[Figure 20-180-1].

Stop the engine.
WARNING
1 3
2
and possible death if proper medical treatment by a S38720
immediately.
W-2145-0290 Remove the hose (Item 1) [Figure 20-180-3] from the
accumulator.
Loosen the clamp (Item 2) [Figure 20-180-3].
WARNING Remove the accumulator (Item 3) [Figure 20-180-3].
Load, unload and turn on flat level ground. Do not

exceed Rated Operating Capacity (ROC) shown on
sign (decal) in cab. Failure to obey warnings can
cause the machine to tip or roll over and cause injury
or death.
W-2056-0903


HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-18
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Relief Valves Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-10

Charge Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-11
Piston Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-13
Solenoid Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-18
Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-20
Charge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-24
Solenoid Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-26
Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-28


HYDROSTATIC SYSTEM INFORMATION
WARNING
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The telescopic handler does not move 1, 2
The telescopic handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

1. The hydrostatic pump has damage.

2. The hydrostatic drive motor has damage.
3. The tires do not have the correct tire pressure.
4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The telescopic handler is not being operated at the correct rpm.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.

HYDROSTATIC SYSTEM INFORMATION (CONT’D) The functions of the replenishing valves are:
Replenishing Valve Function 1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
Figure 30-10-1 because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1
[Figure 30-10-1].
2. To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry; Function 2
[Figure 30-10-1].
Valve Moves For

Function 1 Charge Oil
Replacement

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2 B-2804
IMPORTANT
damage the system.
I-2003-0888

OIL COOLER
Description
The oil cooler is a combined radiator / oil cooler. (See OIL

COOLER / INTERCOOLER / RADIATOR on Page 70-60-
1.).


HYDROSTATIC DRIVE MOTOR Figure 30-30-3
Remove the engine / hydrostat assembly. (See Removal 1

Figure 30-30-1
1
1
S38670
1
Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-3].
Remove the four mounting bolts (Item 1) [Figure 30-30-

S39861 3] from the drive motor.

Installation: Tighten the mounting bolts to 190 - 210
Remove the hose (Item 1) [Figure 30-30-1] from the N•m (140 - 155 ft-lb) torque.
hydrostatic drive motor.
Remove the hydrostatic drive motor from the gear box
Figure 30-30-2 housing.
1 Figure 30-30-4
1
S39860
S38247
Remove the five hoses (Item 1) [Figure 30-30-2] from
the hydrostatic drive motor.
Installation: Replace the O-ring (Item 1) [Figure 30-30-
4].

HYDROSTATIC DRIVE MOTOR (CONT'D)
1. Plug
2. O-ring
3. Spring
4. Poppet
5. Housing
6. Bolt 1
7. Spring Seat
8. Spool 2
9. Gasket
10. Spacer 3
11. Back-up Ring 4
12. Shaft
13. Housing 5
2 1
1

2 2
6 13
3
7
1 2 2
1 1
9
1
7
3
2
1
B-15938

Parts Identification (Cont’d)
1. Valve Segment
2. Plate
3. Pins
4. Bearing
5. Cylinder
6. Pin
7. Synchronizing Shaft
8. Rollers
9. Bolt
10. Nut
11. Cap
12. Plug
13. O-ring
14. Ring
15. Piston
16. Spring Seat
17. Spring

18. Shaft
19. Bearing
20. Spacer
21. Nut
22. O-ring
23. Seal
24. Housing
B-15937


1. Nut
2. Solenoid
3. Solenoid Shaft
4. O-ring
5. Spring
6. Plug
7. Fitting
8. Bolt
9. Orifice
10. Housing
11. Spool
12. Adjustment Spool
13. End Nut
14. Nut
15. Spring Seat
16. Limiter
B-15939

HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-7
Disassembly
Clean the outside of the drive motor before disassembly.
IMPORTANT
damage the system.
P-22328
I-2003-0888
Figure 30-30-5 Remove the solenoid nut (Item 1) [Figure 30-30-7].
Figure 30-30-8

1
S39402
P-22329
Place the hydrostatic drive motor on a work surface, mark
the sections for correct assembly [Figure 30-30-5].
Remove the solenoid (Item 1) [Figure 30-30-8] from the
Figure 30-30-6 shaft.
1 1
S39403

remove the solenoid housing.

Figure 30-30-9 3
P-22333
1 Remove the O-ring (Item 1) and pin (Item 2) from the

P-22330 solenoid shaft (Item 3) [Figure 30-30-11].
Figure 30-30-12
Remove and discard the O-ring (Item 1) [Figure 30-30-9]
from the solenoid.

Figure 30-30-10
2
P-22335
2
Loosen the large nut (Item 1) [Figure 30-30-12] on the

P-22331 compensator valve.
Do not loosen the small nut (Item 2) [Figure 30-30-12].

Remove the solenoid shaft (Item 1) and O-ring (Item 2)
[Figure 30-30-10] from the housing.

Figure 30-30-13
3
2
1 1
P-22338

P-22336 housing.
Figure 30-30-16
Remove the adjusting screw (Item 1), valve spring (Item
2) and spool assembly (Item 3) [Figure 30-30-13] from

the housing.
Figure 30-30-14
1
1
P-22339

16] from the plug.
P-22337

14] from the adjustment screw.

Figure 30-30-17
1
P-27537

P-27534
Remove the two fittings (Item 1) [Figure 30-30-17] from

the housing.

Figure 30-30-18
P-27536
Remove both spool limiters (Item 1) [Figure 30-30-18].

1
Figure 30-30-20
P-22346
1
Lift and remove the end cap (Item 1) [Figure 30-30-22]
P-22344 from the housing.
Figure 30-30-23
Remove and discard the six O-rings (Item 1) [Figure 30-
30-20] from the housing.

Figure 30-30-21 1
1
1
P-22347
1
1
Remove the gasket (Item 1) [Figure 30-30-23] from the
S39404 end cap.
Remove the eight bolts (Item 1) [Figure 30-30-21] from

the end cap.

Figure 30-30-24
S39406
1
Loosen the plug (Item 1) [Figure 30-30-26].

S39405
Figure 30-30-27
Remove the piston (Item 1) [Figure 30-30-24] from the

end cap.

Figure 30-30-25
3
1
2
1
S39407
Remove the plug (Item 1), spring (Item 2), spring seat
(Item 3) and spool (Item 4) [Figure 30-30-27] from the
P-22375 housing.
Remove the seal (Item 1) [Figure 30-30-25] from the

piston.

Figure 30-30-28
1 1
3
S39408
Remove the plug (Item 1), spring (Item 2) and spring seat
P-22378 (Item 3) [Figure 30-30-30] from the housing.
Figure 30-30-31
28] from the plug.

Figure 30-30-29
1
P-22378

P-22379 31] from the plug.
Loosen the plug (Item 1) [Figure 30-30-29].

Figure 30-30-32 1
P-22384
Remove the valve segment (Item 1) [Figure 30-30-34]

S39409 from the cylinder.
Figure 30-30-35
Loosen and remove the relief valve (Item 1) [Figure 30-
30-32] from the housing. 2

Figure 30-30-33 2 1
1 2 3 4 5 2
2
P-22386
Remove and discard the O-ring (Item 1). Remove eight

P-22501 mounting bolts (Item 2) [Figure 30-30-35] from the
mounting plate.
Remove the plug (Item 1), O-rings (Item 2), spring (Item
3) and poppet (Item 4) from the relief valve housing (Item
5) [Figure 30-30-33].

Figure 30-30-36
1
2
P-22503
Remove the cylinder block (Item 1) and synchronizing

P-22504 shaft assembly (Item 2) [Figure 30-30-38] from the
housing.
Remove the mounting plate [Figure 30-30-36] using a NOTE: It is not important that the pistons are
suitable puller. installed in their original position.

Figure 30-30-37 Figure 30-30-39
P-22378 P-22459
Remove and discard the seal (Item 1) [Figure 30-30-37] Remove the bearing plate (Item 1) [Figure 30-30-39]
from the mounting plate. from the cylinder block.

Figure 30-30-40
P-22390
Press the piston / shaft assembly from the housing

P-22458 [Figure 30-30-42].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-40]. Figure 30-30-43

DO NOT damage the bearing plate surface of the
cylinder block.
Figure 30-30-41
1 P-22505
Pry up the peened notch (Item 1) [Figure 30-30-43] in

the ring nut.
P-22388

housing.

Figure 30-30-44
1
P-22446
Using a clamp, compress the spring seat and spring, and

P-22506 drive the pin (Item 1) [Figure 30-30-46] inwards. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-44] from the Figure 30-30-47
shaft.

Figure 30-30-45
2
3
2
1
3
1
P-22447
P-22507 Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-47] from the shaft assembly.
Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3)
[Figure 30-30-45] from the shaft.

HYDROSTATIC DRIVE MOTOR (CONT'D) Inspection
Disassembly (Cont'd) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-48 material can get into the system and cause damage.
Figure 30-30-49
1
2
1
P-22508 2
P-22461
Remove the piston rings (Item 1) [Figure 30-30-48] from
the pistons.

Inspect the running (bronze) surface of the bearing plate
NOTE: If any portion of the shaft assembly, bearings (Item 1) and locating pin holes (Item 2) [Figure 30-30-49]
or races must be replaced, the complete shaft for wear. Replace if damaged or worn.
/ bearing assembly must be replaced. The
only serviceable part is the piston rings (Item Figure 30-30-50
1) [Figure 30-30-48].
P-22462
Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-50]
must not be worn.
If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.

Inspection (Cont'd)
Figure 30-30-51
1
B-15936
Inspect the valve segment for damage or wear on the

P-22375 sealing surface (Item 1) [Figure 30-30-53].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-51] for wear or segment by measuring distance "A" [Figure 30-30-53]. If
damage. this dimension is not within 34,5 - 34,7 mm (1.36 - 1.37

in) the assembly must be replaced.
Figure 30-30-52
P-22349
Inspect the swash plate running surface (Item 1)

[Figure 30-30-52] in the end cap for wear or damage.

Assembly
IMPORTANT
damage the system.
I-2003-0888
P-22446
Inspect all parts for wear or damage. Replace any worn Using a clamp, compress the spring and spring seat
or damaged parts. [Figure 30-30-55].
Always install new seals and O-rings. Lubricate all seals Figure 30-30-56

Figure 30-30-54
1 2 1
P-22441
P-22447
Install the pin (Item 1) [Figure 30-30-56] as shown.
NOTE: Clamp is removed for photo clarity.

Install the spring (Item 1) and spring seat (Item 2) into the
shaft assembly (Item 3) [Figure 30-30-54].

Assembly (Cont'd)
Figure 30-30-57
2
P-22509
1
Using a punch seat the ring nut into the groove in the
P-22453 shaft. [Figure 30-30-59].
Figure 30-30-60
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race

(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-57] into the shaft assembly.
NOTE: Be sure not to over press the bearings, they

should be able to roll freely.
Figure 30-30-58
P-22455
Press the piston / shaft assembly into the housing

1
[Figure 30-30-60].
DO NOT DAMAGE THE PISTONS.
P-22505
Install the ring nut (Item 1) [Figure 30-30-58] onto the

shaft.
NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.

Assembly (Cont'd)
Figure 30-30-61 1
1
1
1
P-22387
Install the mounting plate onto the housing, install the

P-22450 eight mounting bolts (Item 1) [Figure 30-30-63] and
tighten to 63 N•m (46 ft-lb) torque.
Install a new seal (Item 1) [Figure 30-30-61] into the Figure 30-30-64
mounting plate until it is fully seated.

Figure 30-30-62
1
P-22386
P-22388 Install a new O-ring (Item 1) [Figure 30-30-64] onto the

mounting plate.
Install a new O-ring (Item 1) [Figure 30-30-62] onto the

housing.

Assembly (Cont'd) 2
Figure 30-30-65
1
13,5 - 14,0 mm
(0.53 - 0.55 in)
P-22440
Figure 30-30-67
B-15933
Piston End
Press a new bearing into the cylinder block until it is

located 13,5 - 14,0 mm (0.53 - 0.55 in) below the bearing 2

plate surface [Figure 30-30-65].
B-15935
Install new piston rings (Item 1) [Figure 30-30-66] onto

the pistons, make sure the spherical surface (Item 1)
[Figure 30-30-67] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-66] and

[Figure 30-30-67] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.

Assembly (Cont'd)
Figure 30-30-68
1 1
P-22511
Install the synchronizing shaft support pin (Item 1)

P-22459 [Figure 30-30-70] into the cylinder block and retain with
grease.
Install the bearing plate (Item 1) [Figure 30-30-68] with Figure 30-30-71
the bronze surface facing up onto the cylinder block.

Figure 30-30-69
1
P-22499
P-22464 Install the six synchronizing shaft rollers (Item 1)

[Figure 30-30-71] onto the synchronizing shaft and
retain with grease.
Position the housing on end, tip the three pistons (Item 1)
[Figure 30-30-69] closest to the minimum angle stop out
toward the housing.

Assembly (Cont'd)
Figure 30-30-72 1
2 2
1
P-22513
Install the synchronizing shaft and rollers (Item 1)

B-15934 [Figure 30-30-74] into the motor shaft races. When
properly installed the synchronizing shaft should move
freely in all directions.
NOTE: The recess (Item 1) [Figure 30-30-72] on each
roller MUST face the synchronizing shaft. NOTE: The motor shaft end of the synchronizing

shaft is smaller than the cylinder end.
Figure 30-30-73
Figure 30-30-75
2
1
3 1
1
P-22512
P-22511
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-73] into the motor shaft assembly and When installing the cylinder block, the races (Item 1)
retain with grease. [Figure 30-30-75] in the cylinder block must be
positioned so the synchronizing shaft rollers (Item 2)
[Figure 30-30-74] and pistons (Item 3) [Figure 30-30-
74] and their bores (Item 2) [Figure 30-30-75] are
aligned.
Install the six pistons (Item 3) [Figure 30-30-74] into the

cylinder bores, tilt the block so the synchronizing shaft
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-75] enter the recess.
Lift the cylinder block slightly and guide the three

remaining pistons in position.

Assembly (Cont'd)
Figure 30-30-76
1
1
P-22375
Install a new seal (Item 1) [Figure 30-30-78] onto the

P-22500
piston.
If the cylinder block (Item 1) [Figure 30-30-76] is properly Figure 30-30-79

installed, there should be very little rotational free-play
between the block and the motor shaft.

NOTE: A brass rod can be used to guide the pistons 1
into their bores.
Lubricate the pistons and cylinder block bores with

hydraulic oil.
Figure 30-30-77
S39405
3
Lubricate and install the piston (Item 1) [Figure 30-30-

79] into the end cap.
2
4 P-22511
Install a new gasket (Item 1) [Figure 30-30-77] onto the

housing.
Install the valve segment (Item 2) [Figure 30-30-77] onto

the cylinder block and retain with heavy grease.
NOTE: The hole (Item 3) in the valve segment should

be opposite the minimum displacement
adjustment screw (Item 4) [Figure 30-30-77].

Assembly (Cont'd)
1
Figure 30-30-80
S39409
Install the relief valve (Item 1) [Figure 30-30-82] into the

P-22349 housing and tighten to 52 N•m (38 ft-lb) torque.
Figure 30-30-83
NOTE: Note the position of the hole (Item 1)
[Figure 30-30-80] in the end cap.

Figure 30-30-81
1
3
5 1 4
4 2
P-22378

P-22501 plug.
Assemble the poppet (Item 1) and spring (Item 2) into the

relief valve housing (Item 3) install O-rings (Item 4) and
plug (Item 5) [Figure 30-30-81].

Assembly (Cont'd)
Figure 30-30-84
1
2
2
3
3 S39408
4
Install the spring seat (Item 1), spring (Item 2) and plug
S39407 (Item 3) [Figure 30-30-86] into the housing and tighten to
41 N•m (30 ft-lb) torque.
Install the spool (Item 1), spring seat (Item 2), spring Figure 30-30-87
(Item 3) and plug (Item 4) [Figure 30-30-84] into the

housing and tighten to 41 N•m (30 ft-lb) torque.
Figure 30-30-85 2
1
1
P-22346
Align the hole in the piston (Item 1) and the valve

P-22378 segment (Item 2) [Figure 30-30-87].

plug.

Assembly (Cont'd)
Figure 30-30-88
1
1
P-22339
1
1
S39404 plug.
Figure 30-30-91
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-88] to 115 N•m (85 ft-lb) torque.

Figure 30-30-89
P-22338
1
Install the plug (Item 1) [Figure 30-30-91] into the
P-22344 housing.
Install six new O-rings (Item 1) [Figure 30-30-89] onto

the housing.

Assembly (Cont'd)
Figure 30-30-92
1
1
2
P-22333

P-22337 solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-94] and

Install a new O-ring (Item 1) [Figure 30-30-92] onto the install into the solenoid shaft.
adjustment screw.

Figure 30-30-95
Figure 30-30-93
1
2
3 1
P-22340
P-22336
Install a new O-ring (Item 1) and solenoid shaft assembly

Install the spool (Item 1), spring (Item 2) and adjusting (Item 2) [Figure 30-30-95] into the housing.
screw (Item 3) [Figure 30-30-93] into the housing and
tighten to 9 N•m (79.7 in-lb) torque.

Assembly (Cont'd)
Figure 30-30-96
1 1
S39403
2
Install the solenoid housing assembly with four bolts
(Item 1) [Figure 30-30-98]. Tighten the bolts to 78 N•m
P-22342
(58 ft-lb) torque.
Install the solenoid housing (Item 1) onto the shaft and

install a new O-ring (Item 2) [Figure 30-30-96].

Figure 30-30-97
P-22343
Install the solenoid nut (Item 1) [Figure 30-30-97] and

hand tighten.


HYDROSTATIC PUMP Figure 30-40-2

1
1
Remove the gear pump. (See Removal And Installation
on Page 20-110-1.)
Figure 30-40-1
S38624
1
Remove the four hoses (Item 1) [Figure 30-40-2] from

the hydrostatic pump.
Figure 30-40-3
S38625

the back side of the hydrostatic pump. 1
IMPORTANT
S38626
damage the system. Remove the hose (Item 1) [Figure 30-40-3].
I-2003-0888

HYDROSTATIC PUMP (CONT’D)
Figure 30-40-4
S38627
Install blocks to support the hydrostatic pump.

Remove the four mounting bolts (both sides) (Item 1)
[Figure 30-40-4].
Installation: Tighten the bolts (Item 1) [Figure 30-40-4]

to 139 - 140 N•m (102.5 - 103.3 ft-lb).
Figure 30-40-5
S38628
Remove the hydrostatic pump from the machine (Item 1)

[Figure 30-40-5].

HYDROSTATIC PUMP (CONT'D)
1. Multi-Function Valve Assembly

2. O-ring
3. O-ring
4. Charge Relief Valve
5. O-ring
6. Plug
7. O-ring
8. Lifting Bracket
9. Bolt
10. Plug
11. O-ring
8
10 10
9 11

11
6
7
9 7
6
EM7521

1. Orifice
2. Pin
3. Gasket
4. Filter Screen
5. O-ring
6. Solenoid
7. Plug
8. O-ring
9. Bolt
10. Actuator
11. O-ring
12. Coil
13. O-ring
14. Nut
15. Screw
16. Solenoid, Safety
10

11
16 6
13
14
15
EM7522

1. Roll Pin
2. Valve Plate
3. Retainer
4. Spring Seat
5. Spring
6. Washer
7. Cylinder Block
8. Spring
9. Ball Guide Retainer
10. Slipper Guide
11. Piston
12. Filter Screen
13. Pin
14. Bearing Assembly
15. Swash Plate
16. Piston Pump Housing
16
12

12
13 14
13
11
14
8 15
6 10
9
4
7
2 5
EM7523

1. Bolt
2. O-ring
3. Flange Adapter
4. Gasket
5. Thrust bearing
6. Coupling
7. Seal
8. Pressure Balance Plate
9. Ring
10. Charge Pump Gears
11. Valve Plate 14
12. Charge Pump Housing
13. Bushing
14. Gasket
15. Pin
12
13

15
7
11
10
15
7
4
5
3
9
6
8
EM7524

1. Piston Ring
2. O-ring
3. Servo Piston
4. Block
5. Swash Plate
6. Cylinder
7. O-ring
8. Lock Plate
9. Bolt
10. Snap Ring
11. Bearing
12. Shaft
13. Snap Ring
14. Seal
EM7525

HYDROSTATIC PUMP (CONT'D) Figure 30-40-7
Shaft Disassembly
Clean the outside of the pump before disassembly.
Mark the outside of the pump for ease of assembly. 1
IMPORTANT
S38630
damage the system.
I-2003-0888 Remove the snap ring (Item 1) [Figure 30-40-7] from the
pump housing
Figure 30-40-6
Figure 30-40-8

1
1
S38629
S38631
Loosen the retainer bolt (Item 1). Remove the coupler

gear (Item 2) [Figure 30-40-6] from the shaft. Remove the seal (Item 1) [Figure 30-40-8] from the
housing.
NOTE: The seal may need to be punctured in order to

pull out the seal. Do not damage the pump
housing, shaft or bearing.

Shaft Disassembly (Cont'd)
Figure 30-40-9
S38634
Remove the snap ring (Item 1) [Figure 30-40-11] from

S38632 the shaft.
Figure 30-40-12
Remove the snap ring (Item 1) [Figure 30-40-9] from the
pump housing.

2
Figure 30-40-10
1
3
S38635
Press the bearing off the shaft. The bearing exists of

S38633 three parts (Items 1, 2 and 3) [Figure 30-40-12].
Remove the shaft and bearing assembly from the

housing [Figure 30-40-10].
NOTE: For easier removal, use a hammer and drifter

to tap lightly on the rear side of the shaft.

Relief Valves Disassembly And Assembly
Figure 30-40-13
1 4
2 3
3
2 EM1218
S10264
The valve has the following components: adjustable valve

S38636 housing (Item 1), spring (Item 2), spring (Item 3) and
spool (Item 4) [Figure 30-40-15].
• Charge pressure relief valve (gearset pump pressure Figure 30-40-16

relief) (Item 1) [Figure 30-40-13].

• High pressure relief valves (piston pump pressure
relief):
‘A’ port side (Item 2) [Figure 30-40-13]. 2
‘B’ port side (Item 3) [Figure 30-40-13].
Figure 30-40-14
1 S38636
Remove the A port side relief valve (Item 1) [Figure 30-

40-16].
Repeat for the B port side relief valve (Item 2).
S38636 Installation: Tighten the valves to 110 N•m (81 ft-lb)

torque.
Remove the charge pressure relief valve (Item 1)

[Figure 30-40-14].
Installation: Tighten the valve to 52 N•m (38 ft-lb)

torque.

Charge Pump Disassembly

1
Place the pump on the work surface with the charge
pump up.
Mark the pump housings for correct assembly.
Figure 30-40-17
1 1
2
S38639
1 Remove the gasket (Item 1) [Figure 30-40-19] from the

1
charge pump.
Figure 30-40-20

S38638 1
Remove the four bolts (Item 1) and remove the cover

(Item 2) [Figure 30-40-17] from the charge pump
housing.
Figure 30-40-18
1 S38640
Lift the pressure balance plate (Item 1) [Figure 30-40-

20] from the charge pump.
EM1220
Remove the thrust washer (Item 1) [Figure 30-40-18]

from the cover.

Charge Pump Disassembly (Cont'd)

1
Figure 30-40-21
S38643
Remove the valve plate (Item 1) [Figure 30-40-23].

S38641
Figure 30-40-24
Remove the coupler shaft (Item 1) [Figure 30-40-21].

2 1

Figure 30-40-22
EM1225
Remove the seal from the pressure balance plate

S38642 (Item 1) and the valve plate (Item 2) [Figure 30-40-24].
Remove the gearset (Item 1) and ring (Item 2)

[Figure 30-40-22] from the pump.

Piston Pump Disassembly

1
Figure 30-40-25
1 1
2 2
S38645
3
Remove the gasket (Item 1) [Figure 30-40-27].
S38644
Figure 30-40-28
Remove the two bolts (Item 1) first. Then remove the four
bolts (Item 2) [Figure 30-40-25] from the housing.

Remove the charge pump housing (including charge
pump) (Item 3) [Figure 30-40-25] from the pump
housing.
Figure 30-40-26
1
1
S38647
Tilt the pump housing on its side as shown [Figure 30-

40-28].
Remove the cylinder block / piston assembly (Item 1)

[Figure 30-40-28].
S38645
Remove the valve plate (Item 1) [Figure 30-40-26] from

the charge pump housing.

Piston Pump Disassembly (Cont'd)

1
Figure 30-40-29
S38650
Remove the ball guide retainer (Item 1) [Figure 30-40-

S38648 31] from the cylinder block.
Figure 30-40-32
Mark the piston assembly (Item 1) [Figure 30-40-29]
position. Remove the piston assembly from the cylinder

block.
Figure 30-40-30
1
S38651
Mark the servo cylinder position (Item 1) [Figure 30-40-

32]. Repeat for the other side.
S38649
NOTE: Also apply marks to distinguish the left
cylinder from the right.
Remove the piston assembly (Item 1) [Figure 30-40-30]
from the cylinder block. Remove both screws (Item 2) [Figure 30-40-32] from the
servo cylinder locking plate. Repeat for the other side.
Remove the servo cylinder (Item 1) [Figure 30-40-32]

from the housing. Repeat for the other side.

Piston Pump Disassembly (Cont'd)
Figure 30-40-33
EM1238
Remove the bronze slider block (Item 1) [Figure 30-40-

S38653 35] from the servo piston.
Figure 30-40-36
Remove the servo piston assembly (Item 1) [Figure 30-
40-33] from the housing.

Figure 30-40-34
1
1
S38654
Remove the swash plate (Item 1) [Figure 30-40-36] from

EM1237 the pump housing.
Remove the O-ring (Item 1) [Figure 30-40-34] from both

servo cylinders.

HYDROSTATIC PUMP (CONT'D) Solenoid Block Disassembly
Piston Pump Disassembly (Cont'd) Figure 30-40-38
Figure 30-40-37
1
1
1 1 1
S38656
S38655
Remove the six screws (Item 1) [Figure 30-40-38] from
the solenoid block.
Remove the two swash plate bearings (Item 1)
[Figure 30-40-37] from the swash plate. Figure 30-40-39

1
S38657
Remove the gasket (Item 1) [Figure 30-40-39] from the

pump housing.

Solenoid Block Disassembly (Cont'd)
Figure 30-40-40
1
1
3 EM1706
Remove the O-ring (Item 1) [Figure 30-40-42] from each

S38659
S38660
solenoid.
Figure 30-40-43
Remove the filter retaining ring (Item 1) and filter screen
(Item 2) from the orifice (Item 3) [Figure 30-40-40] in the

solenoid block.
NOTE: Install the filter screen (Item 2) [Figure 30-40-

40] with the mesh facing outward.
Figure 30-40-41
2
1 1
1
S38667
1 Remove the spool (Item 1) and spring (Item 2)

1 [Figure 30-40-43] from the solenoid block.
S38661
Remove the three screws (Item 1) [Figure 30-40-41]

from each solenoid.
Remove both solenoids.

Inspection
1
Figure 30-40-44
1
2 3 1
EM1710
Inspect the servo piston and seal rings (Item 1)

EM1225 [Figure 30-40-46] for wear. If worn, remove the seal
rings and expander O-rings from the piston.
Clean all parts in solvent and use air pressure to dry Install new expander O-rings into the grooves in the
them. DO NOT use cloth or paper as small pieces of servo piston. Carefully install the piston seal rings over

material can get into the system and cause damage. the expander rings. Do not overstretch the piston seal
rings.
Check the pressure balance plate (Item 1) and the valve
plate (Item 2) and charge pump gears (Item 3) Lubricate the seal rings and install them into the two
[Figure 30-40-44] for damage or wear. (disassembled) servo cylinders to allow the assembly to
set for 5 minutes for the seal rings to return to their
Figure 30-40-45 original size. Remove the servo cylinders afterwards.
Figure 30-40-47
EM1709 2
S38662
Check the valve plate [Figure 30-40-45], the surface
must be smooth and free of scratches. If scratches can
be felt with a finger nail, replace the part. Check the swash plate bearing race (Item 1) and bearing
rollers (Item 2) [Figure 30-40-47] for wear and damage.
Replace as needed.
Repeat for the other swash plate bearing.

Inspection (Cont'd)
Figure 30-40-48
1
S38664
2
Check the shaft for wear or damage in the spline and

S38649 bearing areas [Figure 30-40-50].
Check the bearing for correct operation. Remove the race

Check each piston (Item 1) and piston shoe (Item 2) (Item 1) [Figure 30-40-50] from the shaft only if it is
[Figure 30-40-48] for wear or scratches. necessary to replace the bearing.

Figure 30-40-49 Figure 30-40-51
S38663 EM1715
S10264
Check the cylinder block bores for wear or scratches Inspect both high pressure relief valves. (See Relief
[Figure 30-40-49]. Valves Disassembly And Assembly on Page 30-40-10.)
If there is any defect in the cylinder block or pistons, the Replace O-rings as needed [Figure 30-40-51].
complete rotating group must be replaced.

Piston Pump Assembly
IMPORTANT 1

damage the system.
I-2003-0888
S38654
Inspect all parts for wear or damage. Replace any worn Install the swash plate (Item 1) [Figure 30-40-53].
or damaged parts.
Figure 30-40-54
Always install new seals and O-rings. Lubricate all seals

Figure 30-40-52
1
1
1
EM1238
Install the bronze slider block (Item 1) [Figure 30-40-54]

onto the servo piston.
S38655
Install the two swash plate bearings (Item 1) [Figure 30-

40-52] onto the swash plate.

Piston Pump Assembly (Cont’d)
Figure 30-40-55
2 2
1 1
S38651
Check that the servo piston assembly (Item 1) is free of

S38653 play. Both gaps (Item 2) [Figure 30-40-57] must be zero
between both cylinders and the piston assembly.
Install the servo piston assembly (Item 1) [Figure 30-40- Figure 30-40-58
55] into the housing.

Figure 30-40-56
1
1
S38651
EM1237 Install the servo cylinder locking plate (Item 1) and both
screws (Item 2) [Figure 30-40-58]. Repeat for the other
side.
Install a new O-ring (Item 1) [Figure 30-40-56] on both
servo cylinders.
Install both servo cylinders until the marks are aligned.
NOTE: Respect right and left side servo cylinders.

Figure 30-40-59
S38648
Install the piston assembly (Item 1) [Figure 30-40-61]

S38649 into the cylinder block.
Figure 30-40-62
Put the piston assemblies (Item 1) [Figure 30-40-59] into
the slipper guide.

Figure 30-40-60
S38647
Install the cylinder block / piston assembly (Item 1)

S38650 [Figure 30-40-62] into the pump housing.
NOTE: When installing, make sure the ball guide

Place the ball guide retainer (Item 1) [Figure 30-40-60] retainer (Item 1) [Figure 30-40-60] is kept in
onto the cylinder block. place.

Figure 30-40-63 2 2
1
1 1
2 2
S38644
Lower the charge pump housing onto the pump housing.

S38645 Make sure the alignment pins (Item 2) [Figure 30-40-63]
are correctly installed.
Install the gasket (Item 1) [Figure 30-40-63]. Install and gradually tighten the four bolts (Item 1)
[Figure 30-40-65]. Tighten the bolts to 140 N•m (103 ft-

NOTE: Verify that both alignment pins (Item 2) lb) torque.
[Figure 30-40-63] are installed.
Tighten the two bolts (Item 2) to 25 N•m (18.4 ft-lb)
Figure 30-40-64 torque. Now re-check torque of the four bolts (Item 1)
[Figure 30-40-65].
S38645
Install the valve plate (Item 1) [Figure 30-40-64].

Charge Pump Assembly

2
Place the pump on the work surface with the charge
pump up.
Figure 30-40-66
1
2 1
S38642
Lubricate and install the gearset (Item 1) and ring (Item

2) [Figure 30-40-68].
Figure 30-40-69
S39209

Install the seals onto the pressure balance plate (Item 1) 1
and the valve plate (Item 2) [Figure 30-40-66].
Figure 30-40-67
S38641
Install the coupler shaft (Item 1) [Figure 30-40-69].
S38643
Install the valve plate (Item 1) [Figure 30-40-67].

Charge Pump Assembly (Cont'd)
Figure 30-40-70
1
EM1220
Install the thrust washer (Item 1) [Figure 30-40-72] onto

S38640 the charge pump cover. The coated side goes toward
charge pump coupling
Install the pressure balance plate (Item 1) [Figure 30-40- Figure 30-40-73
70].

Figure 30-40-71 1
1
2 2 1
1
EM1219
S38639 Install the cover and the four bolts (Item 1) [Figure 30-
40-73]. Tighten the bolts to 92 N•m (68 ft-lb) torque.
Install the gasket (Item 1) [Figure 30-40-71].
NOTE: Verify that both alignment pins (Item 2)

[Figure 30-40-71] are installed.

Solenoid Block Assembly 2
Figure 30-40-74 1
S38659
S38660
1
Install the filter screen (Item 1) and filter retaining ring

S38667 (Item 2) into the orifice (Item 3) [Figure 30-40-76] in the
solenoid block.
Install the spring (Item 1) and spool (Item 2) [Figure 30- NOTE: Install the filter screen (Item 2) [Figure 30-40-
40-74] into the solenoid block. 76] with the mesh facing outward.

Figure 30-40-75 Figure 30-40-77
1
1
EM1706 S38658
Install a new O-ring (Item 1) [Figure 30-40-75] onto each Install the two orifices (Item 1) [Figure 30-40-77] into the
solenoid. pump housing. Tighten to 2.5 N•m (22.1 in-lb) torque.

Solenoid Block Assembly (Cont'd)

1
Figure 30-40-78
1 1
1 1
1
1
1
S38656
Install the six screws (Item 1) [Figure 30-40-80]. Tighten

S38661 to 13.5 N•m (9.9 ft-lb) torque.
Install the three screws (Item 1) [Figure 30-40-78] for

each solenoid. Tighten to 5 N•m (44.2 in-lb) torque.

Figure 30-40-79
2
1
S38657
Install the gasket (Item 1) and two alignment pins (Item 2)

[Figure 30-40-79] onto the pump housing.

Shaft Assembly
IMPORTANT
damage the system.
I-2003-0888
S38633
Figure 30-40-81
Install the shaft and bearing assembly into the housing as

2 shown in [Figure 30-40-83].
Figure 30-40-84

3
S38635
Install the bearing onto the shaft in the order as shown

(Items 1, 2 and 3) [Figure 30-40-81].
S38668
Figure 30-40-82
Use a hydraulic press to position the bearing such that

the (second) snap ring seat is visible [Figure 30-40-84].
1
NOTE: Pressing the shaft down results in
compressing the spring located in the
cylinder block (Item 1) [Figure 30-40-49].
S38634
Install the snap ring (Item 1) [Figure 30-40-82].

Shaft Assembly (Cont'd)
Figure 30-40-85
S38630

S38669
Figure 30-40-88

1

Figure 30-40-86
S38629
Install the coupler gear (Item 1) flush with the pump shaft.
S38668 Fasten the retainer bolt (Item 2) [Figure 30-40-88].
Tighten the retainer bolt to 67 - 71 N•m (50 - 52 ft-lb)

Use a hydraulic press to install a new seal [Figure 30-40- torque.
86].


DRIVE SYSTEM
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-10
Brake System Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake System Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-16
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-17
Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-22
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-23
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-26
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-34
Brake System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-40

Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-43
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-45
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-48
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-53
AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-16
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-17
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-20
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-28
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-42
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Brake Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Brake Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-5
Brake Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-5
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Rear Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Front Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1


GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-15

TROUBLESHOOTING
Chart
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Machine intensively operated or overloaded
20. Wheel loose
21. Beam housing bent


AXLE AND DIFFERENTIAL (FRONT) with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
General Information
• Front Axle Removal (See Removal And Installation on
For photo clarity, the following axle procedures are done Page 40-30-1.), Front Steering Cylinder Removal.
with the complete axle assembly removed from the (See Removing The Steering Cylinder on Page 20-
machine. However, the planetary carrier, wheel hub, 60-1.)
steering knuckle and drive axle procedures can be done
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support

9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Nut
19. Stud
20. Snap ring
S38371

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) Figure 40-20-3
Planetary Carrier Disassembly
Figure 40-20-1 1 1
S2465X
S2465A
Remove the two securing bolts and lift the planet gear
S2463A carrier (Item 1) [Figure 40-20-3].
Figure 40-20-4
Loosen the two securing bolts (Item 1) [Figure 40-20-1].
NOTE: Loosen but do not remove the securing bolts

at this time. The bolts will keep the planetary
1
gear carrier from falling when prying it loose
in the next step.
Figure 40-20-2
1 2
S2466
Remove the snap ring (Item 1) [Figure 40-20-4].
S2464A
Loosen the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-20-2] by alternatively forcing a
screwdriver into the appropriate slots.

Planetary Carrier Disassembly (Cont’d)
Figure 40-20-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-20-7] by pressing on the stud bolts.
Figure 40-20-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-20-5].

Figure 40-20-6
1
S2469
Partially remove the wheel hub (Item 1) [Figure 40-20-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-20-6].
points.

Figure 40-20-9
1
1
1 1
1
S2473A
Remove the four snap rings (Item 1) [Figure 40-20-11].

S2470A
Figure 40-20-12
Remove the external bearing (Item 1) [Figure 40-20-9].
Figure 40-20-10

1
S2474A
With the help of a puller, remove the four planet wheel

S2471A
gears (Item 1) [Figure 40-20-12].
NOTE: Mark the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-20-
10] by hand.


1
Figure 40-20-13
1 S2477A
Remove the sealing ring Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-20-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-20-16
[Figure 40-20-13].
1
Figure 40-20-14

1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-20-16].
Remove the ring gear support (Item 1) [Figure 40-20-

14].

AXLE AND DIFFERENTIAL (FRONT) (CONT’D)
Figure 40-20-17
S2479A
Remove the external bearing races from the bearing by

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-20-17].

NOTE: Hammer in an alternate way so as to avoid
crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Drive axle
8. Seal
9. Thrust bushing
10. Centering ring
15. Cover
16. Plug
17. Tie rod
18. Grease fitting

19. Tie rod assembly
20. Plug
21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Bushing
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S38372

Steering Knuckle Disassembly
Figure 40-20-18
1 2
3
3
2
4 S38374
1
Using two levers, remove the top tie rod (Item 1)
complete with front sealing ring (Item 2) and shims
S2591
(Item 3) [Figure 40-20-20].
Figure 40-20-21
Loosen and remove the six bolts (Item 1) from the bottom
tie rod (Item 2) [Figure 40-20-18].

Loosen and remove the four nuts (Item 3), the four 2
washers and the four studs from the top tie rod (Item 4)
1
[Figure 40-20-18]. 3
Figure 40-20-19
UPPER TIE ROD BOTTOM TIE ROD

2
S1393
Configuration of the upper (Item 1) tie rod with shims

(Item 2) and the bottom tie rod (Item 3) [Figure 40-20-
21].
S2427
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-20-
19].

Steering Knuckle Disassembly (Cont’d)
Figure 40-20-22
S2539
Remove the complete steering case (Item 1) [Figure 40-

20-22].
Figure 40-20-23

1
2 4
S1387
Use a puller to remove the centering ring (Item 1), the

sealing ring (Item 2) and the bushing (Item 3) from the
steering case (Item 4) [Figure 40-20-23].
NOTE: Mark the orientation of both centering and

sealing ring.

Drive Axle Disassembly
Figure 40-20-24
1
2
1 S1402
Remove the snap ring (Item 1) from the bushing unit

S2592 (Item 2) [Figure 40-20-26].
Figure 40-20-27
Loosen and remove the top and bottom check nuts
(Item 1) from the dowels (Item 2) [Figure 40-20-24]. 1

Figure 40-20-25
S1403
Position the entire drive axle (Item 1) under a press and

remove the bearing (Item 2) [Figure 40-20-27].
S2593
Remove the entire drive axle (Item 1) [Figure 40-20-25].
NOTE: To remove the drive axle use, if necessary, a

plastic hammer or a lever.

Drive Axle Disassembly (Cont’d)
Figure 40-20-28
2 1
S3567
Remove the snap ring (Item 1) from the bearing (Item 2)

[Figure 40-20-28].

Figure 40-20-29
2
1
S1404
Use a puller to remove the bearing (Item 1), the sealing

ring (Item 2) [Figure 40-20-29] and the O-ring.

Brake System Parts Identification

1. Oil-level plug
2. Seal
3. Arm
4. Screw
5. Washer
6. Central body
7. Brake discs
8. Return spring
9. Piston
10. Pin screw
11. O-ring
12. O-ring
13. Back-up ring
14. Back-up ring
15. Regulation spring
16. Drive axle

EM8516

Brake System Disassembly
Figure 40-20-30
1
1
S37106
Remove the tie rod from the steering case (See

S37103 Removing The Steering Cylinder on Page 20-60-1.)
Install a sling under the arm (Item 1) [Figure 40-20-32] to

NOTE: Perform all operations on both arms. be removed and put the hoist under slight tension.

Remove the oil-level plug (Item 1) [Figure 40-20-30]. Figure 40-20-33
Figure 40-20-31
2 1
4
3
S37107
S37104 EM6817
Remove the bolts (Item 1) and washers (Item 2) that
secure the arm (Item 3) to the central body (Item 4)
Pressurize the brakes and, keeping them under pressure, [Figure 40-20-33].
inspect the linings "S" between the discs using tool T1
(Item 1) [Figure 40-20-31]. Minimum "S": 4,5 mm (0.177
in).
NOTE: Replace the brake discs and the intermediate

discs on both sides if necessary.

Brake System Disassembly (Cont’d)
Figure 40-20-34
2 1
2
1
S37110
Remove the return springs (Item 1) from the piston (Item

1 S37108 2) [Figure 40-20-36].
NOTE: If the springs (Item 1) [Figure 40-20-36] are

Remove the arm (Item 1) together with the pack of the weak or deformed, replace them.
brake discs (Item 2) [Figure 40-20-34]. Place the arm on

a bench. Figure 40-20-37
Figure 40-20-35
2
1
1
1
1
1
S37111
S37109
Remove the pin screws (Item 1) that guide the piston
(Item 2) [Figure 40-20-37].
Remove the brake discs (Item 1) [Figure 40-20-35] and
mark their order of assembly. NOTE: If the screws must be replaced, there are
different colors for the different brake gap.
NOTE: If the discs do not need replacing, avoid (See Brake System Assembly (Cont’d) on
switching their position. Page 40-20-41.)
Extract the drive axle (Item 2) [Figure 40-20-35].

Brake System Disassembly (Cont’d)
Figure 40-20-38
1
S37112
Use low air pressure through the connection of the

braking circuit in order to extract the entire piston (Item 1)

[Figure 40-20-38].
NOTE: Hold on to the piston as it can be suddenly

ejected and damaged.

Differential Parts Identification
11. Bolt
12. Crown
13. Washer
14. Planetary gear
15. Differential carrier
16. Snap ring
17. Pin
18. Planet wheel gear
19. Friction washer
20. Snap ring

1. Ring nut
2. Central body
3. Set screw
4. Bolt
5. Middle cover
6. Differential
7. Taper roller bearing
9. O-ring
10. Top plug
S38377

Differential Disassembly
Figure 40-20-39
T13
S38864
1
S38862 Apply tool T13 and remove the ring nuts [Figure 40-20-
41].
Mark the position of the ring nuts (Item 1). Remove the NOTE: Clean the threaded parts of the ring nuts.
locking screw (Item 2) from the ring nuts (Item 1) [Figure
40-20-39]. Figure 40-20-42

Figure 40-20-40 1 2
1
1
1
S38865
S38863
Remove screws (Item 1) from the middle cover (Item 2)

Uniformly heat the ring nuts (Item 1) [Figure 40-20-40] [Figure 40-20-42].
up to a temperature of 80°C (176°F).

Differential Disassembly (Cont’d)

1
Figure 40-20-43
S2545
Remove the top plug (Item 1) [Figure 40-20-45].
S37203 Figure 40-20-46
Insert a screwdriver in the opposing slots then force and

remove the middle cover (Item 1) and the complete

differential unit (Item 2) [Figure 40-20-43].
1
NOTE: Support the pieces using a rod.
2
Figure 40-20-44
4
2
S1414
Remove the bolts (Item 1) from the ring gear (Item 2)

3 1 [Figure 40-20-46].
S1412
If the bearings need replacing, extract the bearing race

(Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-20-44].
NOTE: Inspect for damaged O-rings (Item 5) [Figure

40-20-44].

Figure 40-20-47
1
1
2
S1417
If the bearing needs to be replaced, extract the bearing

S1415 (Item 1) from the differential carrier (Item 2) [Figure 40-
20-49].
If the bearing needs to be replaced, extract the bearing Figure 40-20-50

(Item 1) and remove the ring gear (Item 2) [Figure 40-20-
47].

Figure 40-20-48
2
1
2
S1418
Remove the snap rings (Item 1) from the four pins

S1416 (Item 2) [Figure 40-20-50] of the planet wheel gears.
Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-20-48].

Figure 40-20-51
T
2 1 2
1
S1422
Remove pinion and bushing [Figure 40-20-53].

S1419
NOTE: In this condition the tool contains the pin.
Insert a tool T between two planet wheel gears (Item 1) Figure 40-20-54
[Figure 40-20-51].

NOTE: Make sure that the tool is perfectly lined up
with the pins (Item 2) [Figure 40-20-51] when
locked.
Figure 40-20-52
3
2
3
1 S1423
2
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-20-54].
S1421
Place the differential carrier (Item 1) under a press,

position a bushing (Item 2) and insert a pin (Item 3)
[Figure 40-20-52]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-20-51].

Figure 40-20-55
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

40-20-55] in position and again lock the tool.

Repeat the operations for the extraction of the pin of the
second planet wheel gear (Item 2) [Figure 40-20-55].
Repeat the operations for the two remaining pins.
Figure 40-20-56
S1425
Remove the tool T and remove the planet wheel gears

(Item 1) and any shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-20-56].

Bevel Pinion Parts Identification
1. Check nut
2. Flange
3. O-ring
4. Guard
5. Shim washer
6. Seal
7. Ring nut
8. Pinion
9. Internal bearing
10. Spacer
11. Shim
12. Central body
13. External bearing

EM8518

Bevel Pinion Disassembly
Figure 40-20-57 1
2
2
1
S37165
Remove the flange (Item 1) complete with guard (Item 2)

S37163 [Figure 40-20-59] with a puller.
Figure 40-20-60
If needed, heat the nut (Item 1) of the flange (Item 2)
[Figure 40-20-57] at 80°C (176°F).

NOTE: Heating is meant to loosen the Loctite® on the
nut.
1
WARNING
AVOID BURN INJURY
Parts may be hot, use gloves when handling parts.

W-2762-1108
S37167
Figure 40-20-58
S37164
Position tool T20A (or T20B) (Item 1), to avoid pinion

rotation. Remove the nut and O-ring (Item 2) [Figure 40-
20-58].

Bevel Pinion Disassembly (Cont’d)
Figure 40-20-61
1
S37169
1
Install blocks T23 (Item 1) and, with a puller, press the
S37168 pinion (Item 1) [Figure 40-20-62] complete with internal
bearing, spacer and shims.
Position wrench T22 (Item 1) onto the ring nut and use NOTE: The thrust blocks of the bearings remain in
T21 (Item 2) to hold the pinion. When loose, hold wrench the central body (Item 3) [Figure 40-20-62].

T22 (Item 1) [Figure 40-20-61] and rotate the pinion to
remove the ring nut. Figure 40-20-63
NOTE: If needed, heat the ring nut at approximately

80°C (176°F).
2
WARNING
AVOID BURN INJURY 3

W-2762-1108
S37170
Remove the pinion (Item 1), shims (Item 2) and spacer

(Item 3) [Figure 40-20-63].

Figure 40-20-64
2
1 1
S37173
Insert a drift in the appropriate holes and remove the

S37171 thrust block of the internal bearing (Item 1) as well as the
shim washers (Item 2) [Figure 40-20-66].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-20-64].

Figure 40-20-65
S37172
Remove the thrust block of the external bearing with a

puller (Item 1) [Figure 40-20-65].

Bevel Pinion Assembly
Figure 40-20-67
T25C
DG
T24
T25A S37176
S1569 Partially insert the thrust block of the external bearing

(Item 1) [Figure 40-20-69].
Using a surface plate, reset a magnetic based dial Figure 40-20-70

indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.2 in]).

Preset the indicator to approximately 2 mm (0.08 in).
T25B T24 T25C T25A
Figure 40-20-68
2
1
S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race (Item 1) [Figure 40-
1
20-70].
S1570
Bring the internal bearing (Item 1), complete with its

bearing race, under the indicator (Item 2) [Figure 40-20-
68].
Determine overall thickness “D” of the bearing checking
the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the center and take

several measurements while rotating the
bearing race.

Bevel Pinion Assembly (Cont’d)
Figure 40-20-71 1
GB
GB
S1575
Install a depth gauge with long stem into a perfectly flat

bar (Item 1) [Figure 40-20-73]; when the bar rests on
S37178 two gauge blocks “GB” of 57 mm (2.24 in) size, reset the
indicator.
Connect the tension rod to the press and move the thrust
block of the external bearing into its seat. Disconnect the

press and remove the tension rod [Figure 40-20-71].
Figure 40-20-74
NOTE: Before starting the next stage, make sure that
the thrust block has been completely inserted
into its seat.
2
Figure 40-20-72
3
4 1
2
1
S37181
Place bar T26A (Item 1) on gauged nut T26C (Item 2)

[Figure 40-20-74] and measure the size “A” at about 57
mm (2.24 in) corresponding to the maximum diameter of
S37179 arms centering.
See [Figure 40-20-75] for a sectional view.

Insert tool T26B (Item 1) complete with external bearing
(Item 2), measurement ring T24 (Item 3) and gauged ring
nut T26C (Item 4) [Figure 40-20-72]. Tighten manually.

Figure 40-20-75
T24 T26 (2)
T26 (1)
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
under the bearing race [Figure 40-20-77].
Calculate size “B” which will be the first useful value for Figure 40-20-78
calculating the size of the shims that are to be inserted
1

Figure 40-20-76
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-20-
78] that will go under the bearing race.
Check the nominal size (X) marked on the pinion

(Item 1) [Figure 40-20-76] and add or subtract the
indicated variation (Y) so as to obtain size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-20-79
1
3 4 2
S37186
1
2 Position tools T26C (Item 1) and T26B (Item 2) complete

S37184 with tapered bearings (Item 3) and (Item 4) [Figure 40-
20-81].
Insert shim "S" (Item 1) and the thrust block of the Manually tighten until a rolling torque has been obtained.
internal bearing (Item 2) [Figure 40-20-79] in the central

body. Figure 40-20-82
NOTE: To hold shim "S" (Item 1) [Figure 40-20-79] in

position, apply grease.
1
Figure 40-20-80
S37187
2
Insert the stem of a depth micrometer in either side hole
of tool T26C (Item 1) [Figure 40-20-82]. Zero the
S37185 micrometer with a presetting of approximately 3 mm.
Position tool T25A (Item 1) and tension rod T25C (Item 2)

[Figure 40-20-80]. Connect the tension rod to the press,
fasten the thrust block and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the thrust block has been completely
inserted.


1 S1
Figure 40-20-83
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12 -

S1585 0,13 mm, so as to obtain the size of shim “S1”
(Item 1) [Figure 40-20-85] which will be inserted
between the external bearing (Item 1) [Figure 40-20-84]
Remove the micrometer and release tools and bearings and the distance piece (Item 1) [Figure 40-20-83] and
from the central body. subsequently, to determine the preload for the bearings.

Re-install all and insert the spacer (Item 1) between both Figure 40-20-86
bearings (Items 2 and 3) [Figure 40-20-83]; manually
tighten the whole pack.
Figure 40-20-84
H
DDG
T26 (2) 2
1 1
T26 (1) S1588
Position the internal bearing (Item 1) and the pinion

S1586 (Item 2) [Figure 40-20-86] under a press. Press the
bearing onto the pinion.
Insert depth gauge into tool T26 and measure variation

“H” in relation to the zero setting performed in [Figure 40-
20-84].

Figure 40-20-87
1
2
1
3 S37194
Connect the pinion (Item 1) [Figure 40-20-89] to the tie

S37192 rod T28A and T28B. Connect the tie rod T28C (see
special tools) to the press and block.
Install the pinion (Item 1), shim "S1" (Item 2) and spacer Figure 40-20-90
(Item 3) [Figure 40-20-87] in the main body.

NOTE: The thinner shims must be placed in- between
the thicker ones.
Figure 40-20-88
2
S37195
Apply Loctite® 243 to the thread of the ring nut (Item 1)

and screw the nut onto the pinion (Item 2) [Figure 40-20-
90].
S37193
Insert the external bearing (Item 1) [Figure 40-20-88] in

the central body in order to complete the pack arranged
as in the figure.

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) NOTE: If torque does not reach the minimum value,
then the size of shim "S1" needs to be
Bevel Pinion Assembly (Cont’d) reduced.
Figure 40-20-91 NOTE: When calculating the increase or decrease in

size of shim "S1", bear in mind that a variation
of shim of 0,01 mm (0.00039 in) corresponds
to a variation of 0,6 N•m (5.31 in-lb) in the
torque of the pinion.
Figure 40-20-93
2
1
S37196
Apply special wrench T22 (Item 1) to the ring nut and bar-
hold T21 (Item 2) [Figure 40-20-91] to the pinion. Lock 3 2

the wrench T22 and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 500
S37198
N•m (368.8 ft-lb).
Figure 40-20-92 Lubricate the outer surface of the new seal (Item 1) and
install it onto the central body (Item 2) using tool T27
(Item 3) [Figure 40-20-93].
Figure 40-20-94
1 2
S37197
Use the bar-hold T21 (Item 1) [Figure 40-20-92] and a

torque meter to check the pinion torque. Torque: 1,2 - 1,7
S37200
N•m (10.6 - 15.0 in-lb).
NOTE: If torque exceeds the maximum value, then Install the flange (Item 1) complete with the guard (Item
the size of shim "S1" between the bearing and 2) and secure it. For keying the flange (Item 1) [Figure
the spacer needs to be increased. If torque 40-20-94], use a plastic hammer if necessary.
does not reach the set value, increase the
torque setting of the ring nut in different NOTE: Make sure that the guard (Item 2) [Figure 40-
stages to obtain a maximum value of 570 N•m 20-94] is secured onto the flange and that it is
(420.4 ft-lb). not deformed.

Figure 40-20-95
1
S37201
Apply Loctite® 243 to the threaded part of the pinion.

Position tool T20A (or T20B) (Item 1) [Figure 40-20-95]

and secure it in order to avoid rotation.
Insert the O-ring and the nut and tighten to 280 - 310
N•m (206.5 - 228.6 ft-lb) torque.
Figure 40-20-96
S37202
Remove blocks T23 (Item 1) [Figure 40-20-96] (used for

extracting the pinion).

Differential Assembly
2
Figure 40-20-97
1
2
S1534
With the help of a bar, position the second planet wheel

S1532 gear (Item 1) and the relative thrust washer
(Item 2) [Figure 40-20-99].
Insert the thrust washer (Item 1) and the planetary gear Figure 40-20-100
(Item 2) in the differential carrier (Item 3) [Figure 40-20-
97].

Figure 40-20-98
1
1
3
S1535
Insert a tool between the two planetary gears and line up

S1533 the entire unit and remove the bar (Item 1) [Figure 40-
20-100].
Position the thrust washer (Item 1) and the first planet

wheel gear (Item 2). Temporarily hold them in position
using a bar (Item 3) [Figure 40-20-98].

Differential Assembly (Cont’d) 2

1
Figure 40-20-101
2
1
1
S1538
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-20-103].
Lock tool (Item 2) behind the planet wheel gears Figure 40-20-104
(Item 1) [Figure 40-20-101].

Figure 40-20-102
2
1
S1539
S1537 Put a tool pin on top of the planet wheel pin

(Item 1) [Figure 40-20-104].
Install the snap rings (Item 1) onto the pins

(Item 2) [Figure 40-20-102].

Differential Assembly (Cont’d)
Figure 40-20-105
1
1
S1542
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-20-107].
Figure 40-20-108
Press the pin all the way down (Item 1) [Figure 40-20-
105].

Figure 40-20-106 1
2
S1543
Position the thrust washer (Item 1) on the ring gear

S1541 (Item 2) [Figure 40-20-108].
NOTE: In order to hold the shim washer in position,

Remove the tool pin, bushing and install the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-20-106].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-20-109
1
3
1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races in the middle cover (Item 1) [Figure 40-20-111]
and in the central body.
Position the ring gear (Item 1) on the differential carrier Figure 40-20-112
(Item 2) and install the bolts (Item 3) [Figure 40-20-109]
with Loctite® 243.
3

Tighten the bolts to 128 - 142 N•m (95 - 105 ft-lb) torque. 1
2
NOTE: Tighten the bolts using the cross tightening
method.
Figure 40-20-110
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
cover (Item 2) [Figure 40-20-112].
NOTE: Check the position of the O-ring

(Item 3) [Figure 40-20-112] and make sure
S1545 that the cover is installed with the hole (see
arrow on [Figure 40-20-112]) in the lower
position.
Install the bearing races (Items 1 and 2) [Figure 40-20-
110] using tool T17.

Figure 40-20-113
2 T19
2
S1550
2
Pre-set the bearings by means of the ring nut situated on

the opposite side of the ring gear, so as to increase
S38866 pinion torque up to 1,40 - 2,10 N•m (12.4 - 18.6 in-lb)
[Figure 40-20-115].
Lock the middle cover (Item 1) with four bolts
NOTE: If bearings are not new, check the static
(Item 2) [Figure 40-20-113].
torque. If bearings are new, check the

continuous torque.
Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.5 ft-lb)
torque.
Figure 40-20-116
Figure 40-20-114
1
A
T13
2
S1551
S38864
Install a dial indicator with rotary key “A” through the top
plug hole (Item 1). Position the indicator on the center of
NOTE: If the ring nuts [Figure 40-20-114] are one of the teeth of the ring gear (Item 2) [Figure 40-20-
removed, apply some Loctite® 243 to them. 116] and pre-set it to 1 mm (0.039 in) and reset it.
Tighten ring nuts on the ring gear side until
clearance between pinion and ring gear is
zero. Lock the ring gear. Turn the ring nuts
back 90 - 180°.

Figure 40-20-117
1
S38867
S1552 Apply Loctite® 243 to the bolts (Item 1) [Figure 40-20-

119], install them into one of the two holes and tighten.
Manually move the ring gear (Item 1) [Figure 40-20-117] Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.3 ft-lb)
in both directions in order to check the existing backlash torque.
between the pinion and the crown.

Install the plug in the hole (Item 1) [Figure 40-20-45]
Figure 40-20-118 after applying flexible gasket compound for seals to the
rims.
T13
S38864
Adjust the backlash between the pinion and the crown by

loosening one of the ring nuts [Figure 40-20-118] and
tightening the opposite to compensate.
Normal backlash: see table
CLEARANCE
RATIO
MINIMUM MAXIMUM
14 – 32 0.18 mm 0.23 mm
(0.0071 in) (0.0091 in)
NOTE: Difference between MINIMUM and MAXIMUM

clearance for whole circumference should not
exceed 0,09 mm (0.0035 in).

Brake System Assembly
Figure 40-20-120 2 3
4
2
3
5 1
EM6818
1 S37115
Lubricate the seals and install the piston (Item 1) into the
S37113 arm (Item 2) [Figure 40-20-122].
NOTE: Make sure that the piston seat fits into the
Clean the piston (Item 1) and the seats of slide and seal. stop pin (Item 3) [Figure 40-20-122] inside the
Replace the O-rings (Item 2 and 3) and the back-up rings arm.

(Item 4 and 5) [Figure 40-20-120]. Make sure that the
assembly side is correct. Figure 40-20-123
NOTE: Check the positioning of the back-up rings

(Items 4 and 5) [Figure 40-20-120].
Figure 40-20-121
1
1
1
S37116
1
2
Facilitate the insertion of the piston (Item 1) [Figure 40-
20-123] by lightly tapping around the edge with a plastic
S37114 hammer.
Insert the stroke automatic regulation springs (Item 1);

place them in line with the piston (Item 2) [Figure 40-20-
121].

Brake System Assembly (Cont’d)
Figure 40-20-124
1 S37119
Slightly lubricate the brake discs (Item 1) and install them

S37117 in the arm following the correct sequence. Orient them so
that the oil circulation holes and the marks (Item 2)
[Figure 40-20-126] are perfectly lined up.
Install the pin screws (Item 1) [Figure 40-20-124] making
sure that they are all of the same color: NOTE: When installing the steel discs, the slot

corresponding to the oil level cap should
• White: 1 mm (0.039 in) gap; always be kept free.
• Yellow: 0,75 mm (0.029 in) gap;
• Blue: 0,5 mm (0.019 in) gap; Figure 40-20-127
Apply Loctite® 270 to the thread. Tighten the screws to 5

- 7 N•m (44.3 - 62 in-lb) torque.
Figure 40-20-125
2 1
1
1 S37120
Check that the positioning of the seal (Item 1) [Figure 40-

20-127] on the arm is intact, install the complete arm.
S37118 Lock it into position using two facing screws and washers.
Install the return springs (Item 1) on the piston (Item 2)

[Figure 40-20-125].
NOTE: Pay due attention not to deform the

connections of the springs.

Brake System Assembly (Cont’d)
Figure 40-20-128
S37121
Check the flatness of the arms using tool T2 (Item 1)

[Figure 40-20-128] and finally lock the arms with the

screws and the washer, using the cross tightening
method. Tighten the screws to 298 N•m (220 ft-lb) torque.

Drive Axle Assembly
Figure 40-20-129
1
T5 T6
1 2 S1399
3
3 Heat the bearing in oil at an approximate temperature of
S1397 100°C (212°F) and install the entire bearing (Item 1) on
the drive axle (Item 2) [Figure 40-20-131].
Using tools T5 and T6, insert the sealing ring (Item 1) Figure 40-20-132
and the bearing (Item 2) in the bearing (Item 3) [Figure
40-20-129].

NOTE: Carefully check the assembly side of the
sealing ring. 3
Figure 40-20-130
2
1
S1400
2 1
Install the snap ring (Item 1) on the axle shaft (Item 2).
After the bearing has cooled, install the O-ring
(Item 3) [Figure 40-20-132].
S1398
Install the snap ring (Item 1) on the bearing

(Item 2) [Figure 40-20-130].

Drive Axle Assembly (Cont’d)
Figure 40-20-133
S2592
Insert the drive axle and tighten the top and bottom
dowels (Item 1) [Figure 40-20-133]. Tighten to
maximum 15 N•m (11 ft-lb) torque.

NOTE: Center the point of the check dowels in the
slot.
Figure 40-20-134
1
2 1
2
S1507
Install the lock nuts (Item 1) on the dowels

(Item 2) [Figure 40-20-134] and tighten them to
122 N•m (90 ft-lb) torque.

Steering Knuckle Assembly
Figure 40-20-135
T7
1
1
S1496
Lubricate the splines of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-20-137].
Pay attention not to damage the dust cover rings and the
Lubricate the bushing (Item 1) and the seat of the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-20-135], using tool T7. Figure 40-20-138

Figure 40-20-136
2
1 2
T8
1
S2395
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).
To be assembled under the upper tie rod
Lubricate the outer surface of the sealing ring (Item 1) (Item 2) [Figure 40-20-138].
and centering ring (Item 2) [Figure 40-20-136]. Install
them into their seat using tool T8.

Steering Knuckle Assembly (Cont’d)
Figure 40-20-139
1
2
2
3
1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 orientated as shown in the inset. Lubricate the pivot pin
(Item 2) and the seal (Item 1). Install the pivot pin (Item 2)
and the six bolts (Item 3) [Figure 40-20-141]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts in sequence using the
orientated as shown in the inset. Lubricate the pivot pin cross tightening method, to 140 N•m (103 ft-lb) torque.

[Figure 40-20-139], four studs, four washers and four Check for the correct assembly side of the seal
nuts. (Studs, washers and nuts not shown in photo.) (Item 2) [Figure 40-20-141].
Tighten to 140 N•m (103 ft-lb) torque.
Check the correct assembly side of the seal

(Item 1) [Figure 40-20-139].
Figure 40-20-140
S38375
Lubricate the group with grease and mount it in the


Figure 40-20-142
S2568
Install a magnetic based dial indicator on the steering

housing. Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the

width and reduce it by removing shims [Figure 40-20-
142].
Figure 40-20-143
S2569
Check the torque of the studs, which has to be 40 -

60 N•m (30 - 44 ft-lb). If the preliminary measured value
is too high, the shims have to be increased [Figure 40-
20-143].

Planetary Carrier Assembly
Figure 40-20-144
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-20-146] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-20-147
of the external bearing (Item 1) [Figure 40-20-144]
under the press.

Figure 40-20-145
1
2
1
S2587
T9A Install the bearing (Item 1) [Figure 40-20-147] into the

S2586 bearing race.
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-20-145] (wide side up).
NOTE: Check that the bearing race is correctly

oriented.

Planetary Carrier Assembly (Cont’d)
Figure 40-20-148
1
T10
3
S1456
1
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-20-150].
NOTE: Make sure the snap ring (Item 1) [Figure 40-20-

Position tool T10 and press the sealing ring 150] is firmly seated in the groove.
(Item 1) [Figure 40-20-148] into its seat.
Figure 40-20-151

Figure 40-20-149
DOWN
T11
1
2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-20-151].
40-20-149].
Accurately check the orientation.

Figure 40-20-152
S2470A
Install the external bearing (Item 1) [Figure 40-20-154].

S2473A
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-20-152]. edge.
Figure 40-20-153

1
S2471A
Connect the steering bars and install the hub

(Item 1) [Figure 40-20-153].

Figure 40-20-155
1
1
S2647
Cross tighten the nuts (Item 1) [Figure 40-20-157] in two

S2646 stages.
Initial torque setting: 120 N•m (88 ft-lb).

Install the complete crown flange (Item 1) [Figure 40-20-
155]. The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.

NOTE: In order to fasten the flange, use a plastic
hammer and alternatively hammer on several Figure 40-20-158
equidistant points.
Figure 40-20-156
1
2
S2466
S2467 Install the snap ring (Item 1) [Figure 40-20-158].
Apply silicone-based grease to the surface of the locking

plate (Item 1) that touches the crown flange (Item 2)
[Figure 40-20-156].
Install the locking plate (Item 1) [Figure 40-20-156].

Figure 40-20-159 1
2
3 2
S2648
1 Lock the planetary carrier cover (Item 1) by tightening the

S2465A bolts (Item 2) [Figure 40-20-160]. Tighten the bolts to 40
- 50 N•m (30 - 37 ft-lb) torque.
Install the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-20-159].

NOTE: Check that the O-ring (Item 3) [Figure 40-20-
159] is in good condition and in position.

Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS

6912197 PINION RING NUT T19
T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27


AXLE AND DIFFERENTIAL (REAR) with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
General Information
• Rear Axle Removal (See Removal And Installation on
For photo clarity, the following axle procedures are done Page 40-90-1.), Rear Steering Cylinder Removal
with the complete axle assembly removed from the (See Removing The Steering Cylinder on Page 20-
machine. However, the planetary carrier, wheel hub, 60-1.)
steering knuckle and drive axle procedures can be done
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support

9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Nut
19. Stud
20. Snap ring
S38371

AXLE AND DIFFERENTIAL (REAR) (CONT’D) Figure 40-21-3
Figure 40-21-1 1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-21-3].
Figure 40-21-4
Loosen the two securing bolts (Item 1) [Figure 40-21-1].
Figure 40-21-2

1
1 2
S2466
S2464A Remove the snap ring (Item 1) [Figure 40-21-4].
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-21-2] by alternatively forcing a
screwdriver into the appropriate slots.

Figure 40-21-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-21-7] by acting on the stud bolts.
Figure 40-21-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-21-5].

Figure 40-21-6 1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-21-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-21-6].
points.

Figure 40-21-9
1
1
1
1
1
S2473A
Remove the four snap rings (Item 1) [Figure 40-21-11].

S2470A
Figure 40-21-12
Remove the external bearing (Item 1) [Figure 40-21-9].
Figure 40-21-10

1
S2474A
With the help of a puller, remove the planet wheel gears

S2471A
(Item 1) [Figure 40-21-12].
NOTE: Note the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-21-
10] by hand.

Figure 40-21-13 1
1 S2477A
Remove the sealing ring (Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-21-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-21-16
[Figure 40-21-13].
Figure 40-21-14

1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-21-16].
Remove the ring gear support (Item 1) [Figure 40-21-

14].

AXLE AND DIFFERENTIAL (REAR) (CONT’D)
Figure 40-21-17
S2479A
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-21-17].

NOTE: Hammer in an alternate way so as to avoid
crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Drive axle
8. Seal
9. Thrust bushing
10. Centering ring
15. Cover
16. Plug
17. Tie rod
18. Grease fitting

19. Tie rod assembly
20. Plug
21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Bushing
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S38372

Steering Knuckle Disassembly
Figure 40-21-18
1 2
3
3
2
4 S38374
1
Using two levers, remove the top tie rod (Item 1)
complete with front seal (Item 2) and shims (Item 3)
S2591
[Figure 40-21-20].
Figure 40-21-21
Loosen and remove the six bolts (Item 1) from the bottom
tie rod (Item 2) [Figure 40-21-18].

Loosen and remove the four nuts (Item 3), the four
washers and the four studs from the top tie rod (Item 4) 2
[Figure 40-21-18]. 1
3
Figure 40-21-19
UPPER TIE ROD BOTTOM TIE ROD

2 S1393
Configuration of the upper (Item 1) tie rod with shims

(Item 2) and the lower tie rod (Item 3) [Figure 40-21-21].
S2427A
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-21-
19].

Steering Knuckle Disassembly (Cont’d)
Figure 40-21-22
1 1
S2540
Remove the entire drive axle (Item 1) [Figure 40-21-24].

S2539
NOTE: To remove the drive axle use, if necessary, a

Remove the complete steering case (Item 1) [Figure 40- plastic hammer or a lever.
21-22].
Figure 40-21-23

1
3
1 2 3
4
S1387
Use a puller to remove the centering ring (Item 1), the

sealing ring (Item 2) and the bushing (Item 3) from the
NOTE: Mark the orientation of both centering and

sealing ring.

Differential Parts Identification
11. Bolt
12. Crown
13. Washer
14. Planetary gear
15. Differential carrier
16. Snap ring
17. Pin
18. Planet wheel gear
19. Friction washer
20. Snap ring

1. Ring nut
2. Central body
3. Set screw
4. Bolt
5. Middle cover
6. Differential
9. O-ring
10. Top plug
S38377

Differential Disassembly
Figure 40-21-25
2
S38862
Mark the position of the ring nuts (Item 1). Remove the
S2541 set screw (Item 2) from the ring nuts (Item 1) [Figure 40-
21-27].
Remove the nuts (Item 1) [Figure 40-21-25]. Figure 40-21-28
Figure 40-21-26

1
S38863
1 S2542
Uniformly heat the ring nuts (Item 1) [Figure 40-21-28]
up to a temperature of 80°C (176°F).
Remove the complete arm (Item 1) [Figure 40-21-26].

Differential Disassembly (Cont’d) 2
Figure 40-21-29 1
T13
S37203
Insert a screwdriver in the opposing slots then force and

S38864 remove the middle cover (Item 1) and the complete
differential unit (Item 2) [Figure 40-21-31].
Apply tool T13 and remove the ring nuts [Figure 40-21- NOTE: Support the pieces using a rod.
29].

Figure 40-21-32
NOTE: Clean the threaded parts of the ring nuts.
Figure 40-21-30 4
2
1 2
1
3 1
S1412
1
1 If the bearings need replacing, extract the bearing race
S38865 (Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-21-32].
Remove screws (Item 1) from the middle cover (Item 2) NOTE: Inspect for damaged O-rings (Item 5) [Figure
[Figure 40-21-30]. 40-21-32].

Figure 40-21-33
1
1
2
S1415
If the bearing needs to be replaced, extract the bearing

S2545 (Item 1) and remove the crown (Item 2) [Figure 40-21-
35].
Remove the top plug (Item 1) [Figure 40-21-33]. Figure 40-21-36
Figure 40-21-34

1
S1416
S1414
Remove the shim washer (Item 1) and the planetary gear
(Item 2) [Figure 40-21-36].
Remove the twelve bolts (Item 1) from the crown (Item 2)
[Figure 40-21-34].

Figure 40-21-37 T
2 1 1 2
2
S1419
Insert a tool T between two planet wheel gears (Item 1)

S1417 [Figure 40-21-39].
NOTE: Make sure that the tool is perfectly lined up

If the bearing needs to be replaced, extract the bearing with the pins (Item 2) [Figure 40-21-39] when
(Item 1) from the differential carrier (Item 2) [Figure 40- locked.
21-37].

Figure 40-21-40
Figure 40-21-38
3
2
3
1
2
1
2
S1421
S1418
Place the differential carrier (Item 1) under a press,

Remove the snap rings (Item 1) from the four pins position a bushing (Item 2) and insert a pin (Item 3)
(Item 2) [Figure 40-21-38] of the planet wheel gears. [Figure 40-21-40]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-21-40].

Figure 40-21-41
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

S1422 40-21-43] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

Remove the pin and bushing [Figure 40-21-41]. second planet wheel gear (Item 2) [Figure 40-21-43].
NOTE: In this condition the tool contains the pin. Repeat the operations for the two remaining pins.

Figure 40-21-42 Figure 40-21-44
S1423 S1425
Remove the tool with inside the pin of the planet wheel Remove the tool T and remove the planet wheel gears
gear [Figure 40-21-42]. (Item 1) and the relative shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-21-44].

Bevel Pinion Parts Identification
1. Check nut
2. Flange
3. O-ring
4. Guard
5. Swinging support
6. Seal
7. Ring nut
8. Pinion
9. Internal bearing
10. Spacer
11. Shim
12. Central body
13. External bearing
14. Shim washer

EM6813

Bevel Pinion Disassembly
Figure 40-21-45 1
2
2
1
S37165
Remove the flange (Item 1) complete with guard (Item 2)

S37163 [Figure 40-21-47] by means of a puller.
Figure 40-21-48
If needed, heat the check nut (Item 1) of the flange (Item
2) [Figure 40-21-45] at 80°C (176°F).

NOTE: Heating is meant to loosen the Loctite® on the 1
nut.
WARNING
AVOID BURN INJURY
W-2762-1108
Figure 40-21-46 S37166
Remove the swing support (Item 1) [Figure 40-21-48].
S37164
Position tool T20A (or T20B) (Item 1), to avoid pinion

rotation. Remove the nut and O-ring (Item 2) [Figure 40-
21-46].

Figure 40-21-49
WARNING
AVOID BURN INJURY
W-2762-1108
Figure 40-21-51
2
S37167

Figure 40-21-50
S37169
Apply blocks T23 (Item 1) and, with a puller, extract the

pinion (Item 1) [Figure 40-21-51] complete with internal
bearing, spacer and shims.
2 NOTE: The thrust blocks of the bearings remain in

the central body (Item 3) [Figure 40-21-51].
Figure 40-21-52
S37168 2
1
Position wrench T22 (Item 1) onto the ring nut and use
T21 (Item 2) to hold the pinion. When loose, hold wrench
T22 (Item 1) [Figure 40-21-50] and rotate the pinion to
remove the ring nut. 3
NOTE: If needed, heat the ring nut at approximately

80°C (176°F).
S37170
Remove the pinion (Item 1), shims (Item 2) and spacer

(Item 3) [Figure 40-21-52].

Figure 40-21-53
2
1 1
S37173
Insert a drift in the appropriate holes and remove the

S37171 thrust block of the internal bearing (Item 1) as well as the
shim washers (Item 2) [Figure 40-21-55].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-21-53].

Figure 40-21-54
S37172
Remove the thrust block of the external bearing with a

puller (Item 1) [Figure 40-21-54].

Bevel Pinion Assembly
Figure 40-21-56
T25C
DG
T24
T25A S37176
S1569 Partially insert the thrust block of the external bearing

(Item 1) [Figure 40-21-58].
Using a surface plate, reset a magnetic based dial Figure 40-21-59

indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.2 in]) [Figure 40-21-56].

T25B T24 T25C T25A
Figure 40-21-57
DG
1
S1572
Install tension rod T25C, measurement ring T24 and front

1 guide tool T25A on the bearing race of the external
bearing (Item 1) [Figure 40-21-59].
S1570
Bring the internal bearing (Item 1) [Figure 40-21-57],

complete with its bearing race, under the indicator.
Determine overall thickness “D” of the bearing checking

the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the center and take

several measurements while rotating the
bearing race.

Figure 40-21-60
S37180
Install a centesimal comparator “DG1” with long stem into

S37178 bar T26A (Item 1) [Figure 40-21-62]. Zero the
comparator when the bar rests on two size - blocks “GB”
of 57 mm (2.24 in). Preset the comparator to
Connect the tension rod to the press and move the thrust approximately 2 mm (0.078 in) and zero again.
block of the external bearing into its seat. Disconnect the

press and remove the tension rod [Figure 40-21-60]. Figure 40-21-63
NOTE: Before starting the next stage, make sure that

the thrust block has been completely inserted
into its seat.
2
Figure 40-21-61
3
4 1
2
1
S37181
Place bar T26A (Item 1) on gauged nut T26C (Item 2)

[Figure 40-21-63] and measure the size “A” at about 57
mm (2.24 in) corresponding to the maximum diameter of
S37179 arms centering.
Insert tool T26B (Item 1) complete with external bearing

(Item 2), measurement ring T24 (Item 3) and gauged ring
nut T26C (Item 4) [Figure 40-21-61]. Tighten manually.

Figure 40-21-64
T26 (2)
T24
T26 (1)
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
Calculate size “B” which will be the first useful value for Figure 40-21-67
calculating the size of the shims that are to be inserted
1

Figure 40-21-65
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-21-
67] that will go under the bearing race.
Inspect the nominal size (X) marked on the pinion

(Item 1) [Figure 40-21-65] and add or subtract the
indicated variation (Y) so as to obtain size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-21-68
1
3 4 2
S37186
1
2 Position tools T26C (Item 1) and T26B (Item 2) complete

S37184 with tapered bearings (Item 3) and (Item 4) [Figure 40-
21-70].
Insert shim "S" (Item 1) and the thrust block of the Manually tighten until a rolling torque has been obtained.
internal bearing (Item 2) [Figure 40-21-68] in the central

body. Figure 40-21-71
NOTE: To hold shim "S" (Item 1) [Figure 40-21-68] in

position, apply grease.
1
Figure 40-21-69
S37187
2
Insert the stem of a depth comparator "DDG" in either
side hole of tool T26C (Item 1) [Figure 40-21-71]. Zero
S37185 the comparator with a presetting of approximately 3 mm.
Position tool T25A (Item 1) and tension rod T25C (Item 2)

[Figure 40-21-69]. Connect the tension rod to the press,
fasten the thrust block and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the thrust block has been completely
inserted.


1 S1
Figure 40-21-72
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12 -

S1585 0,13 mm (0.004 - 0.005 in), so as to obtain the size of
shim “S1” (Item 1) [Figure 40-21-74] which will be
inserted between the external bearing (Item 1) [Figure
Remove the indicator and release tools and bearings 40-21-73] and the distance piece (Item 1) [Figure 40-
from the central body. 21-72] and subsequently, to determine the preload for the
bearings.

Re-install all and insert the distance piece (Item 1)
between both bearings (Item 2 and 3) [Figure 40-21-72]; Figure 40-21-75
manually tighten the whole pack.
Figure 40-21-73
H
DDG
2
T26 (2)
1
1
T26 (1)
S1588
S1586 Position the internal bearing (Item 1) and the pinion

(Item 2) [Figure 40-21-75] under a press. Force the
bearing onto the pinion.
Insert depth dial indicator into tool T26B-T26C and
measure variation “H” in relation to the zero setting
performed in [Figure 40-21-73].

Figure 40-21-76
1
2
1
S37194
S37192
Connect the pinion (Item 1) [Figure 40-21-78] to the tie
rod T28A and T28B. Connect the tie rod T28C (see
Install the pinion (Item 1), shim "S1" (Item 2) and spacer special tools) to the press and block.
(Item 3) [Figure 40-21-76] in the main body.
Figure 40-21-79
NOTE: The thinner shims must be placed in- between

the thicker ones.
Figure 40-21-77
1
1
2
S37195
Apply Loctite® 243 to the thread of the ring nut (Item 1)

S37193 and screw the nut onto the pinion (Item 2) [Figure 40-21-
79].
Insert the external bearing (Item 1) [Figure 40-21-77] in

the central body in order to complete the pack arranged
as in the figure.

AXLE AND DIFFERENTIAL (REAR) (CONT’D) NOTE: If torque does not reach the minimum value,
then the size of shim "S1" needs to be
Bevel Pinion Assembly (Cont’d) reduced.
Figure 40-21-80 NOTE: When calculating the increase or decrease in

size of shim "S1", bear in mind that a variation
of shim of 0,01 mm (0.00039 in) corresponds
to a variation of 0,6 N•m (5.31 lb-in) in the
torque of the pinion.
Figure 40-21-82
2
1
S37196
Apply special wrench T22 (Item 1) to the ring nut and bar-
hold T21 (Item 2) [Figure 40-21-80] to the pinion. Lock 3 2

the wrench T22 and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 500
S37198
N•m (368.8 ft-lb).
Figure 40-21-81 Lubricate the outer surface of the new seal (Item 1) and
install it onto the central body (Item 2) using tool T27
(Item 3) [Figure 40-21-82].
Figure 40-21-83
1
1
S37197
Use the bar-hold T21 (Item 1) [Figure 40-21-81] and a

torque meter to inspect the pinion torque. Torque: 1,2 -
S37199
1,7 N•m (10.6 - 15.0 lb-in).
NOTE: If torque exceeds the maximum value, then Install the swing support (Item 1) [Figure 40-21-83].
the size of shim "S1" between the bearing and
the spacer needs to be increased. If torque NOTE: Inspect that the swing support is properly
does not reach the set value, increase the oriented.
torque setting of the ring nut in different
stages to obtain a maximum value of 570 N•m
(420.4 ft-lb).

Figure 40-21-84
4 2 1
S37202
Remove blocks T23 (Item 1) [Figure 40-21-86] (used for

S37200 extracting the pinion).
Install the flange (Item 1) complete with the guard (Item

2) and fasten it. For keying the flange (Item 1) [Figure

40-21-84], use a plastic hammer if necessary.
NOTE: Make sure that the guard (Item 2) [Figure 40-

21-84] is securely fastened onto the flange
and that it is not deformed.
Figure 40-21-85
1
S37201
Apply Loctite® 243 to the threaded part of the pinion.

Position tool T20A (or T20B) (Item 1) [Figure 40-21-85]
and fasten it in order to avoid rotation.
Insert the O-ring and the nut and tighten it to 280 - 310
N•m (206.5 - 228.6 ft-lb) torque.

Differential Assembly
2
Figure 40-21-87
1
2
S1534
With the help of a bar, position the second planet wheel

S1532 gear (Item 1) and the relative shim washer
(Item 2) [Figure 40-21-89].
Insert the shim washer (Item 1) and the planetary gear Figure 40-21-90
(Item 2) in the differential carrier (Item 3) [Figure 40-21-
87].

Figure 40-21-88
1
1
3
S1535
Insert a tool between the two planetary gears and. Line

S1533 up the entire unit by pushing the bar (Item 1) [Figure 40-
21-90] all the way down until it is ejected.
Position the shim washer (Item 1) and the first planet

wheel gear (Item 2). Hold them in position using a bar
(Item 3) [Figure 40-21-88].

Differential Assembly (Cont’d) 2

1
Figure 40-21-91
1
1
S1538
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-21-93].
Lock the tool behind the planet wheel gears Figure 40-21-94
(Item 1) [Figure 40-21-91]. After locking, remove bar
T16C.

Figure 40-21-92
2
1
S1539
Put a tool pin on top of the planet wheel pin

S1537 (Item 1) [Figure 40-21-94].
Install the snap rings (Item 1) onto the pins

(Item 2) [Figure 40-21-92].

Figure 40-21-95
1
S1542
1
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-21-97].
Figure 40-21-98
Press the pin all the way down (Item 1) [Figure 40-21-
95].

Figure 40-21-96 1
2
S1543
Position the shim washer (Item 1) on the crown

S1541 (Item 2) [Figure 40-21-98].
NOTE: In order to hold the shim washer in position,

Remove tool pin, bushing and install the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-21-96].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-21-99 1
3 1 2
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races (Item 1) in the central body (Item 2) [Figure 40-21-
101].
Position the crown (Item 1) on the differential carrier Figure 40-21-102

(Item 2) and lock the bolts (Item 3) [Figure 40-21-99]
with Loctite® 243.
3

Tighten the bolts to 128 - 142 N•m (94 - 105 ft-lb) torque. 1
2
NOTE: Secure the bolts using the cross tightening
method.
Figure 40-21-100
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
NOTE: Thoroughly inspect the state of the O-ring

(Item 3) [Figure 40-21-102] and make sure
S1545 that the cover is installed with the hole (see
arrow on [Figure 40-21-102]) in the lower
position.
Install the bearing races (Item 1 and 2) [Figure 40-21-
100] using tool T17.

Figure 40-21-103
2 T19
2
S1550
2
Pre-set the bearings by means of the ring nut situated on

the opposite side of the crown, so as to increase pinion
S38866 torque up to 1,40 - 2,10 N•m (1.0 - 1.55 ft-lb) [Figure 40-
21-105].
Lock the middle cover (Item 1) with bolts
NOTE: If bearings are not new, inspect the static
(Item 2) [Figure 40-21-103].
torque. If bearings are new, inspect the

continuous torque.
Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.5 ft-lb)
torque.
Figure 40-21-106
Figure 40-21-104
1
A
T13
2
S1551
S38864
Introduce a dial indicator with rotary key “A” through the
top plug hole (Item 1). Position the indicator on the center
NOTE: If the ring nuts [Figure 40-21-104] are of one of the teeth of the crown (Item 2) [Figure 40-21-
removed, apply some Loctite® 243 to them. 106] and pre-set it to 1 mm (0.039 in) and reset it.
Tighten ring nuts on the crown side until
clearance between pinion and crown is zero.
Lock the crown. Turn the ring nuts back 90 -
180°.

Figure 40-21-107
1
S38867
S1552 Apply Loctite® 243 to the bolts (Item 1) [Figure 40-21-

109], install them into one of the two holes and tighten.
Manually move the crown (Item 1) [Figure 40-21-107] in Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.3 ft-lb)
both directions in order to inspect the existing backlash torque.
between the pinion and the crown.

Install the plug in the hole (Item 1) [Figure 40-21-33 on
Figure 40-21-108 Page 13] after applying flexible gasket compound for
seals to the rims.
Figure 40-21-110
T13
S38864
S2542
Adjust the backlash between the pinion and the crown by
unloosing one of the ring nuts [Figure 40-21-108] and
tightening the opposite to compensate. Re-install the complete arms (Item 1) [Figure 40-21-
110].
Normal backlash: see table
CLEARANCE
RATIO
MINIMUM MAXIMUM
14 – 32 0.18 mm 0.23 mm
(0.0071 in) (0.0091 in)
NOTE: Difference between MINIMUM and MAXIMUM

clearance for whole circumference should not
exceed 0,09 mm (0.0035 in).

Steering Knuckle Assembly
Figure 40-21-111
T17
1
S1496
Lubricate the terminal of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-21-113].
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-21-111], using tool T17. Figure 40-21-114

Figure 40-21-112
2
1 2
T8
1
S2395
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.0035
in). To be assembled under the upper pin
Lubricate the outer surface of the sealing ring (Item 2) [Figure 40-21-114].
(Item 1) and centering ring (Item 2) [Figure 40-21-112].
Install them into their seat using tool T8.

Figure 40-21-115
3
2
2
1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 orientated as shown in the inset. Lubricate the pivot pin
and the six bolts (Item 2) [Figure 40-21-117]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
orientated as shown in the inset. Lubricate the pivot pin torque.

[Figure 40-21-115], four studs, four washers and four Check for the correct assembly side of the seal
nuts. (Studs, washers and nuts not shown in photo.) (Item 3) [Figure 40-21-117].
Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-21-118
Inspect the correct assembly side of the seal
(Item 1) [Figure 40-21-115].
Figure 40-21-116
S38991
Tighten the bolts (Item 1) [Figure 40-21-118] of the

S38375 bottom tie rod in sequence using the cross tightening
method, to 140 N•m (103 ft-lb).
Lubricate the group with grease and mount it in the


Figure 40-21-119
S2568
Install a magnetic based dial indicator on the steering

housing. Inspect by means of a lever that there is no
vertical gap. In case there is any gap, determine the

width and reduce it by removing shims [Figure 40-21-
119].
Figure 40-21-120
S2569
Inspect the torque of the pins, which has to be between

30 - 60 N•m (22 - 44 ft-lb). If the preliminary measured
value is too high, the shims have to be increased [Figure
40-21-120].

Figure 40-21-121
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-21-123] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-21-124
of the external bearing (Item 1) [Figure 40-21-121]
under the press.

Figure 40-21-122
1
2
1
S2587
T9A Install the bearing (Item 1) [Figure 40-21-124] into the

S2586 internal bearing race (wide side up).
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-21-122] (wide side up).
NOTE: Inspect that the bearing race is correctly

oriented.

Figure 40-21-125
1
T10
3
S1456
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-21-127].
NOTE: Make sure the snap ring (Item 1) [Figure 40-21-

Position tool T10 and press the sealing ring into its seat 127] is firmly seated in the groove.
[Figure 40-21-125].
Figure 40-21-128

Figure 40-21-126
DOWN
T11
1
1
2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-21-128].
40-21-126].
Accurately check the orientation.

Figure 40-21-129
S2470A
Install the external bearing (Item 1) [Figure 40-21-131].

S2473A
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-21-129]. edge.
Figure 40-21-130 Figure 40-21-132

1
1
S2471A S2646
Connect the steering bars and install the hub Install the complete crown flange (Item 1) [Figure 40-21-
(Item 1) [Figure 40-21-130]. 132].
NOTE: In order to fasten the flange, use a plastic

hammer and alternatively hammer on several
equidistant points.

Planetary Reduction Assembly (Cont’d)
Figure 40-21-133
1
1
2
S2466

S2467
Figure 40-21-136
Apply silicone-based grease to the surface of the locking

plate (Item 1) that touches the crown flange (Item 2)
2
[Figure 40-21-133].
3

Install the locking plate (Item 1) [Figure 40-21-133].
Figure 40-21-134
1
S2465A
1
Installed the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-21-136].
NOTE: Inspect that the O-ring (Item 3) [Figure 40-21-

136] is in good condition and in position.
S2647
Cross tighten the nuts (Item 1) [Figure 40-21-134] in two

stages.
Initial torque setting: 120 N•m (88 ft-lb).
The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.

Planetary Reduction Assembly (Cont’d)
Figure 40-21-137
S1468
Lock the planetary carrier cover (Item 1) by tightening

the bolts (Item 2) [Figure 40-21-137]. Tighten the bolts
to 40 - 50 N•m (30 - 37 ft-lb) torque.

Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS

6912197 PINION RING NUT T19
T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

FRONT AXLE Figure 40-30-2
Fully retract the telescoping boom. Raise the boom and

install the boom stop. (See Installing The Approved
Boom Stop on Page 10-150-1.)
WARNING
penetrating the skin. This can cause serious injury S38617
immediately. Lift the front of the machine and place jack stands (Item
W-2145-0290 1) [Figure 40-30-2] under the frame as shown.
Place a block in front and behind one of the rear wheels.

Remove the eight lug nuts and washers (Item 1)
Figure 40-30-1

[Figure 40-30-1] from each front tire.
Remove both front wheels.
1 Figure 40-30-3
S1954
2
Loosen the eight lug nuts and washers (Item 1)
[Figure 40-30-1] on each front tire.
S1951
Remove both front wheels.

Remove the four bolts (Item 1) from both front fender
mount brackets (Item 2) [Figure 40-30-3].
Remove the front fenders.

FRONT AXLE (CONT’D) Figure 40-30-6
Figure 40-30-4
1 1
S38298
Remove the four mounting bolts (Item 1) [Figure 40-30-

S39180 6] on each side.
Assembly: Install the mounting bolts (Item 1)

Remove the four drive shaft mounting bolts (Item 1) [Figure 40-30-6] (Both sides). Tighten to 370 - 410 N•m
[Figure 40-30-4] and remove the two clamps from the (275 - 300 ft-lb) torque.

front axle U-joint.
Installation: Apply Loctite® 242 or equivalent to the

threads of the bolts (Item 1) [Figure 40-30-4] and tighten
to 33 - 41 N•m (24.3 - 30.2 ft-lb). IMPORTANT
damage the system.
I-2003-0888
Figure 40-30-7
S38618
Using a jack, apply upward pressure to lift and support

the front axle [Figure 40-30-5].
S38619
Gently lower the front axle [Figure 40-30-7]

approximately 100 mm (4 in).

FRONT AXLE (CONT’D) Figure 40-30-10
Figure 40-30-8
1
1
S38622

S38621 right (operator’s view) side of the front axle.
Remove the hose (Item 1) [Figure 40-30-8] from the left

(operator’s view) side of the front axle.
IMPORTANT

Figure 40-30-9
2 damage the system.
I-2003-0888
Figure 40-30-11
S38620
Remove the hose (Item 1) and disconnect the wire

harness (Item 2) [Figure 40-30-9] from the left
(operator’s view) side of the front axle.
S38623
Have an assistant balance the axle on the jack and lower

the jack slowly while rolling the axle out from under the
frame [Figure 40-30-11].


AXLE TOE-IN Figure 40-40-3
Adjustment
The axle is removed from the machine for photo clarity,

1 2
but this procedure can be completed with the axle
installed in the machine.
3
Turn the steering wheel until the steering cylinder rod is
positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-40-1
S2056
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-40-3] of both tie rods until the measurement
is the same.
1 Tighten the nut (Item 3) [Figure 40-40-3] to 360 N•m

(266 ft-lb) torque.

1
S2056
Install two identical, straight bars (Item 1) [Figure 40-40-

1] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

ground.
Figure 40-40-2
S2057
Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.


PARKING BRAKE Figure 40-50-2
Releasing The Brake For Towing

1
The towing procedure is described earlier in this manual.
(See TOWING THE TELESCOPIC HANDLER on Page
10-40-1.)
Parking Brake Adjustment
Figure 40-50-1
S38727
2 2
3 4 7. Install the cap (Item 1) [Figure 40-50-2].
WARNING

S38218 UNEXPECTED MACHINE MOVEMENT CAN CAUSE
1. Apply hydraulic pressure of 9 - 20,7 MPa (90 - 207 • Block wheels to prevent roll away before
bar) (1300 - 3000 psi) to the brake (using a hand adjusting screws to bypass the park brake
pump or portapower). system.
2. Turn the adjustment screw (Item 1) [Figure 40-50-1] position before operating the machine.
W-2808-0909
until the brake is clamped onto the disc. Turn back
90°.
3. Loosen the nut (Item 3) and adjust the bolt (Item 2)

until it makes contact with the bumpstop (Item 4) on
the mounting bracket, then turn the bolt (Item 2)
[Figure 40-50-1] back 90°.
4. Hold the bolt (Item 2) in place while tightening the nut

(Item 3) [Figure 40-50-1] against the inner nut to 41 -
47 N•m (30 - 35 ft-lb).
5. Turn the adjustment screw (Item 1) [Figure 40-50-1]

back 180°.
6. Release the hydraulic pressure and remove the hand

pump or portapower.

PARKING BRAKE (CONT'D) Brake Cylinder Disassembly And Assembly
Brake Cylinder Removal Remove the brake cylinder from the machine. (See Brake
Cylinder Removal on Page 40-50-2.)
Figure 40-50-3
Figure 40-50-5
1
2
S38672
S38673
Remove the rubber cap (Item 1) [Figure 40-50-3].

Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-

Figure 40-50-4 50-5].
Figure 40-50-6
2
1
3
S38671
S38674
Remove the pressure sensor (Item 1) [Figure 40-50-4]
and its fittings.
Remove the brake pads (Item 1) [Figure 40-50-6] from
Loosen the inner bolt (Item 2) [Figure 40-50-4] until the the brake cylinder.
brake pads show a gap.
Inspect the brake pads (Item 1) [Figure 40-50-6] for
Loosen the two bolts (Item 3) [Figure 40-50-4] and wear.
remove the brake cylinder.

PARKING BRAKE (CONT'D) Figure 40-50-9
Brake Cylinder Disassembly And Assembly (Cont’d)
Figure 40-50-7
1
S38721
Remove the set of springs (Belleville washers) (Item 1)

S38675 [Figure 40-50-9].
Figure 40-50-10
Remove the cylinder cover (Item 1) [Figure 40-50-7].

NOTE: Be careful when removing the cylinder cover
(Item 1) [Figure 40-50-7]. The cover is under TOP
spring pressure.
Figure 40-50-8
S38722
2
Assembly: Verify that the Belleville washers are installed
as shown in [Figure 40-50-10].
S38726
Remove the two O-rings (Items 1 and 2) [Figure 40-50-

8].

PARKING BRAKE (CONT'D) Figure 40-50-13
Brake Cylinder Disassembly And Assembly (Cont’d)
Figure 40-50-11
4 1
1
3
2
S38725

S38723 [Figure 40-50-13].

Remove the piston (Item 1) [Figure 40-50-11]. [Figure 40-50-13].

Figure 40-50-12
S38724
Inspect the piston surface for damage (Item 1)

[Figure 40-50-12].

PARKING BRAKE (CONT'D) Brake Cylinder Installation
Brake Disc Removal And Installation Figure 40-50-15
Figure 40-50-14
1
2 3
1
1 1
S38671
S38251
Position the brake cylinder on the disc.
Remove the front driveshaft. (See Front Driveshaft Install the mounting bolts (Item 1) [Figure 40-50-15] far
Removal And Installation on Page 40-70-1.) enough to support the brake.

Remove the brake cylinder. (See Brake Cylinder Tighten the adjustment screw (Item 2) clockwise until the
Removal on Page 40-50-2.) brake pads are clamped onto the disc. Make sure the bolt
(Item 3) [Figure 40-50-15] does not protrude out far
Remove the four bolts (Item 1) [Figure 40-50-14]. enough to make contact with the mounting bracket at this
time.
Remove the brake disc (Item 2) [Figure 40-50-14].
Figure 40-50-16
Measure the thickness of the brake disc. Replace the
brake disc if thickness is below 9,5 mm (0.374 in).
1
3
2
S38727
Tighten the mounting bolts (Item 1) until they make

contact with the urethane springs (Item 2), then tighten
240° more. This puts the proper amount of preload on the
urethane springs (Item 2) [Figure 40-50-16].
Tighten the nuts (Item 3) [Figure 40-50-16] against the

mounting bracket. Torque to 271 N•m (200 ft-lb)
The brake is now ready for adjustment. (See Parking

Brake Adjustment on Page 40-50-1.)


STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
The axle is removed from the machine for photo clarity,

but this procedure can be completed with the axle
installed in the machine.
Figure 40-60-1
37° - 45°
S2062
Turn the steering wheel completely to the other side

[Figure 40-60-3] and repeat above procedure.
S38218

Use an angle gauge, to obtain a reading of the correct
angle [Figure 40-60-1]:
• 45° = Tire sizes 400x20 / 400x24

• 42° = Tire size 460x24
• 37° = Tire size 500x24
Figure 40-60-2
S2061
Adjust the stop (Item 1) [Figure 40-60-2] as needed.

Tighten the lock nut to 150 N•m (110 ft-lb) torque.


DRIVESHAFT Front Driveshaft Removal And Installation
Rear Driveshaft Removal And Installation Figure 40-70-3
Figure 40-70-1
1
1
2
1
1
2
2
S38223
S38220
Remove the four drive shaft mounting bolts (Item 1) and
remove the two clamps (Item 2) [Figure 40-70-3] from
Remove the four drive shaft mounting bolts (Item 1) and the parking brake disc U-joint.

the rear axle U-joint. Installation: Apply Loctite® 242 or equivalent to the
Installation: Apply Loctite® 242 or equivalent to the to 33 - 41 N•m (24.3 - 30.2 ft-lb).
to 33 - 41 N•m (24.3 - 30.2 ft-lb). Figure 40-70-4
Figure 40-70-2
1
1
2 1
2
S38222
S38221
Remove the four drive shaft mounting bolts (Item 1)
[Figure 40-70-4] and remove the two clamps from the
Remove the four drive shaft mounting bolts (Item 1) and front axle U-joint.
the gear box U-joint. Installation: Apply Loctite® 242 or equivalent to the
Installation: Apply Loctite® 242 or equivalent to the to 33 - 41 N•m (24.3 - 30.2 ft-lb).
to 33 - 41 N•m (24.3 - 30.2 ft-lb). Remove the drive shaft out the front of the machine.
Remove the drive shaft out the rear of the machine.


SERVICE BRAKE Bleeding The Brake Circuit
Description Lift and block the machine. (See Procedure on Page 10-
10-1.).
There is a bleed screw located on each side of the front
axle differential housing. NOTE: Position the jack stands to allow starting the
machine and driving the wheels.
Air trapped in the brake lines can cause a spongy feel
and / or delayed activation of the service brake. Figure 40-80-1
Use the following procedure to remove air from the brake

circuit.
WARNING
1
physician familiar with this injury is not received S39118
immediately.

W-2145-0290
Figure 40-80-2
WARNING
1
MACHINE FALLING OR MOVING CAN CAUSE
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
S2014
Remove the caps and loosen the two bleed screws

(Items 1) [Figure 40-80-1] and [Figure 40-80-2].
With the aid of an assistant, start the engine and apply

the service brake until a continuous stream of clean
hydraulic fluid, with no air, flows from the inside bleed
screws (Item 1) [Figure 40-80-1] and [Figure 40-80-2].
Stop the engine and tighten the two inside bleed screws
(Item 1) [Figure 40-80-1] and [Figure 40-80-2].
Lower the machine and test for proper brake operation.


REAR AXLE Figure 40-90-2
WARNING
Hydraulic fluid escaping under pressure can have 1 1
immediately.
W-2145-0290 S39142
Relieve hydraulic pressure. Lift the rear of the machine and place jack stands (Item 1)
[Figure 40-90-2] under the frame as shown.
Figure 40-90-1
Remove the eight lug nuts and washers (Item 1)
[Figure 40-90-1] from both rear wheels.

1 Remove both rear wheels.
Figure 40-90-3
S1954
Loosen the eight lug nuts and washers (Item 1)

2
[Figure 40-90-1] on both rear wheels.
S1951
Remove the four bolts (Item 1) from both rear fender

mount brackets (Item 2) [Figure 40-90-3].
Remove the rear fenders.

REAR AXLE (CONT’D) Figure 40-90-6
Figure 40-90-4 1
2
2
1
1
1 S39144

S39177 the right hand side of the rear axle.
Remove the electrical harness (Item 2) [Figure 40-90-6]

Remove the tie-straps (Item 1) and disconnect the from the machine.
centering sensor electrical harness (Item 2) [Figure 40-

90-4] from the steering cylinder. NOTE: Remove any tie-straps if needed.
Remove the four drive shaft mounting bolts (Item 3) Figure 40-90-7
[Figure 40-90-4] and remove the two clamps from the
rear axle U-joint.
Installation: Apply Loctite® 242 or equivalent to the 1

to 33 - 41 N•m (24.3 - 30.2 ft-lb).
Figure 40-90-5
S39145
1

the right hand side of the rear axle.
S38075
Disconnect the connector (Item 1) [Figure 40-90-5]

located on the cab side below the boom.

REAR AXLE (CONT’D) Figure 40-90-10
Figure 40-90-8
1
S39178

S39143 the front mount bracket.

Roll the floor jack under the rear axle and apply upward threads of the bolts (Item 1) [Figure 40-90-10] and
pressure to the rear axle [Figure 40-90-8]. tighten to 33 - 41 N•m (24.3 - 30.2 ft-lb).

Figure 40-90-9 Figure 40-90-11
S39179 S39143
Remove the two bolts (Item 1) [Figure 40-90-9] from the Have an assistant balance the axle on the jack and lower
front mount bracket. the jack slowly while rolling the axle out from under the
frame [Figure 40-90-11].
to 33 - 41 N•m (24.3 - 30.2 ft-lb).


GEAR BOX Figure 40-100-3
Remove the engine / hydrostat assembly. (See Removal

2
Remove the brake disc. (See Brake Disc Removal And
Figure 40-100-1
1
S38224
2
Remove the plug (Item 1) [Figure 40-100-3] and drain

the gear box oil into a container.
Remove the two hoses (Item 1) from the gear control


Figure 40-100-4
S38234
Disconnect the low speed connector (Item 1) [Figure 40- 1

100-1] from the hydrostatic drive motor.

hydrostatic drive motor.
Figure 40-100-2
1 2
S38235
Support the gear box with a hoist (Item 1) [Figure 40-

2
100-4].
2
S38233
Remove the hydrostatic hoses (Item 1) [Figure 40-100-

2] from the hydrostatic drive motor.

the hydrostatic drive motor.

GEAR BOX (CONT’D) Figure 40-100-7

2
Figure 40-100-5 1
3 3
1 S38237
Install a chain hoist and lifting strap (Item 1) to lift and

S38236
support the hydrostatic drive motor (Item 2) [Figure 40-
100-7].
Remove the two mounting bolts (Item 1) [Figure 40-100- Remove the four mounting bolts (Item 3) [Figure 40-100-

5]. 7] from the hydrostatic drive motor.
Figure 40-100-6 Installation: Tighten the mounting bolts to 190 - 210

N•m (140 - 155 ft-lb) torque.
Remove the hydrostatic drive motor (Item 2) [Figure 40-

1 100-7] from the gear box housing.
Figure 40-100-8
S38235

6].
S38247
Remove the gear box and hydrostatic drive motor
assembly and place it on a bench.
Installation: Replace the O-ring (Item 1) [Figure 40-
100-8].

GEAR BOX (CONT’D)
1. O-ring
2. Vent
3. Cover
4. Seal
5. Shim
6. Ball bearing
7. Cover
8. Flange
9. Ball bearing
10. Elastic pin
11. Pin

12. Housing
13. Bolt
14. O-ring
15. Nut
16. Washer
17. Bolt
18. Cover
19. Bolt
20. Washer
21. Plate
22. Needle bearing
EM6868

GEAR BOX (CONT’D)
23. Shaft
24. Selector sleeve
25. Bolt
26. Plate
27. Magnetic plug
28. Spacer
29. Switch
30. Boot
31. Bolt
32. Spring
33. Ball bearing

34. Ball
35. Cylinder bolt
36. Seal
37. O-ring
38. Cylinder
39. Plug
40. O-ring
41. Rod
42. O-ring
43. Piston
44. O-ring
EM6868

GEAR BOX (CONT’D)
45. Cover plate

46. Bolt
47. Selector shaft
48. Slide pin
49. Selector fork
50. Seal
51. Shim
52. Seal
53. O-ring
54. Washer
55. Connector

56. Plug
57. O-ring
58. Cover
59. Bolt
60. Cover
61. Washer
62. Gear
63. Bolt
64. Gear
65. Gear
EM6868

Disassembly
Figure 40-100-9
1
2
2
1 1
S38243
Remove the O-ring (Item 1) and the flange (Item 2)

S36547 [Figure 40-100-11].
Remove the gear control cylinder. (See Removal on Page

Remove the four bolts (Item 1) from the motion input 20-70-1.)

Figure 40-100-12
Remove the motion input cover (Item 2) [Figure 40-100-
9].
Figure 40-100-10
S36543
Remove the plug (Item 1) [Figure 40-100-12] with the

washer and the rpm sensor.
S38242
Remove the nut (Item 1) from the flange (Item 2)

[Figure 40-100-10].

Figure 40-100-13
1
3
2
3 2
S36546
1
Remove the screw (Item 1), spring (Item 2) and neutral
position ball (Item 3) [Figure 40-100-15] (hydraulic
S36544
version).
Remove the gear-in-position switch (Item 1), O-ring (Item Figure 40-100-16
2) and washer (Item 3) [Figure 40-100-13].

Figure 40-100-14
3 2 1 2
1
3
S36546
Remove the screw (Item 1) and disconnect the connector

S36545
(Item 2) to remove the speed sensor cable (Item 3)
[Figure 40-100-16].
Remove the screw (Item 1), spring (Item 2), and gear-
and-neutral position spindle (Item 3) [Figure 40-100-14]
(mechanical version).

Figure 40-100-17
1 1
1
2 1
S36554
Remove the fourteen bolts (Item 1) [Figure 40-100-19].

S36551
Figure 40-100-20
Remove the four bolts (Item 1) from the cover (Item 2)

[Figure 40-100-17].
Figure 40-100-18
1
3 1
S36555
Remove the cover (Item 1) [Figure 40-100-20].
S36553
NOTE: Take care not to damage surfaces.
Remove the cover (Item 1) and install the spacers (Item

2) [Figure 40-100-18] onto the cover to keep them in the
correct position until reassembly.
NOTE: The notch (Item 3) [Figure 40-100-18] must be

facing upwards.

Figure 40-100-21
2 1
S36558
Remove the bearing (Item 1) [Figure 40-100-23] if it

S36556
needs replacing.
Figure 40-100-24

Pay attention to the position of the pins (Item 2)
[Figure 40-100-21].
Figure 40-100-22
S36559
Install the bearing (Item 1) [Figure 40-100-24] into the

gear box.
2
S36557
Remove the gear (Item 1), needle bearings (Item 2) and

spacer (Item 3) [Figure 40-100-22] from the gear box.

Figure 40-100-25
1 2
S36562
Install the oil shield plate into position, 5 - 5,5 mm (0.197

S36560
- 0.217 in) from box surface [Figure 40-100-27].
Figure 40-100-28
Remove the oil shield plate (Item 1) [Figure 40-100-25]

only if necessary.
NOTE: The oil inlet (Item 2) [Figure 40-100-25] must

face upward.
Figure 40-100-26
2
1 1
1
S36563
Remove the bolts (Item 1) from the flow regulator plate

(Item 2) [Figure 40-100-28].
S36561
Install the oil shield plate (Item 1) with oil inlet facing
upward [Figure 40-100-26].
Apply Loctite® 510 on the outside [Figure 40-100-26].

Figure 40-100-29
1
2 S36566
Remove the lower shaft (Item 1) [Figure 40-100-31].

S36564
Figure 40-100-32
Remove the plate (Item 1) and pull out coupling (Item 2)

and fork (Item 3) [Figure 40-100-29] at the same time.
Figure 40-100-30
1
2
1 3
2
S36567
Remove the entire shaft (Item 1) and the flow regulator

S36565
Check sliding blocks (Item 1), pin (Item 2), and sliding
coupling (Item 3) [Figure 40-100-30].
Replace if worn.

Figure 40-100-33
S36570
Assemble the lower shaft [Figure 40-100-35].

S36568
Figure 40-100-36
Disassemble the entire lower shaft [Figure 40-100-33].

Figure 40-100-34 1
S36571
Remove the upper shaft (Item 1) [Figure 40-100-36].

S36569
NOTE: In case of replacement, the shaft is supplied
already assembled.
Progressive arrangement of parts installed onto the lower
shaft [Figure 40-100-34].

Figure 40-100-37
S36574
Pull out the sealing ring (Item 1) [Figure 40-100-39] of

S36572
the cover.
Figure 40-100-40
Pull out the sealing ring (Item 1) [Figure 40-100-37].

Figure 40-100-38
S36575
S36573
Install a new sealing ring [Figure 40-100-40].
Install a new sealing ring (Item 1) [Figure 40-100-38].

GEAR BOX (CONT’D)
Figure 40-100-41
1 2
S36576
Remove the sealing ring (Item 1) from the motion input

Figure 40-100-42
S36577
Remove the bearing (Item 1) from the cover (Item 2)

[Figure 40-100-42] of the gear box.

Assembly
Figure 40-100-43
2
1
S36580
Apply Loctite® 510 on surfaces and bolts (Item 1). Install

S36578
the cover (Item 2) [Figure 40-100-45] on the gear box.
Figure 40-100-46
Install the bearing in the cover of the gear box

[Figure 40-100-43].
Figure 40-100-44
1
1
S36581
Tighten the four bolts (Item 1) [Figure 40-100-46] to 49 -

S36579
51 N•m (36.1 - 37.7 ft-lb) torque.
Install the new sealing ring in the motion input cover

[Figure 40-100-44].

Assembly (Cont’d)
Figure 40-100-47
S36584
Assemble the entire lower shaft (Item 1) and the flow

S36582
regulator plate (Item 2) [Figure 40-100-49].
Figure 40-100-50
Lubricate the lip of the sealing ring (Item 1) [Figure 40-

100-47] with grease.
Figure 40-100-48
S36585
Position the shaft (Item 1) [Figure 40-100-50] so that the

S36583
bearing protrudes approximately 5 mm (0.197 in) from
the cover of the gear box.
Install the motion upper shaft (Item 1) [Figure 40-100-

48].

Assembly (Cont’d)
Figure 40-100-51
1
S36588
Install bolts (Item 1) [Figure 40-100-53].

S36586
Figure 40-100-54
Temporarily re-assemble the cover (Item 1) [Figure 40-

100-51] with bolts.
NOTE: Make sure that the recess (Item 2) [Figure 40-

100-51] faces upward.
Figure 40-100-52
1
3 1
S36589
Tighten bolts (Item 1) [Figure 40-100-54] to 25 - 26 N•m

2 (18.4 - 19.2 ft-lb) torque.
S36587
Simultaneously insert fork and sliding blocks (Item 1),

coupling (Item 2) and flow regulator plate (Item 3)
[Figure 40-100-52].

Assembly (Cont’d)
Figure 40-100-55
1
1
3 1
S36592
Apply Loctite® 510 to the surface and assemble the

S36590
Figure 40-100-58
Re-assemble needle bearings (Item 1), gear (Item 2) and

spacer (Item 3) [Figure 40-100-55].
NOTE: Position spacer (Item 3) underneath needle

1
bearings (Item 1) [Figure 40-100-55].
Figure 40-100-56
1 1
S36593
Install the cover (Item 1) [Figure 40-100-58].
S36591
Check the insertion of pins (Item 1) [Figure 40-100-56].

Assembly (Cont’d)
Figure 40-100-59
3
1 1
2
S36546
Lubricate components and install ball (Item 1), spring

1 (Item 2) and screw (Item 3) [Figure 40-100-61] (hydraulic
S36594
version).
Tighten the 14 bolts (Item 1) [Figure 40-100-59] in a Tighten screw to 80 - 100 N•m (59 - 73.8 ft-lb) torque.

crisscross manner to 49 - 51 N•m (36.1 - 37.7 ft-lb)
torque. Figure 40-100-62
Figure 40-100-60
1 2 3 2 3
S36544
S36545
Install the gear-in position switch (Item 1) with washer
(Item 2) and O-ring (Item 3) [Figure 40-100-62].
Lubricate components and install spindle (Item 1), spring
(Item 2) and screw (Item 3) [Figure 40-100-60] Tighten screw (Item 1) [Figure 40-100-62] to 54,2 N•m
(mechanical version). (40 ft-lb) torque.
Tighten screw (Item 3) [Figure 40-100-60] to 80 - 100

N•m (59 - 73.8 ft-lb) torque.

Assembly (Cont’d)
Figure 40-100-63
S36800
1 Install the bearing [Figure 40-100-65].

S36543
Install the plug (Item 1) [Figure 40-100-63] with washer

and revolution indicator.
Tighten the plug (Item 1) [Figure 40-100-63] to 25 N•m

(18.4 ft-lb).
Figure 40-100-64
1 1
S36551
Remove bolts (Item 1) and remove the temporarily

assembled cover (Item 2) [Figure 40-100-64].

Assembly (Cont’d)
Figure 40-100-66
1
2
S38249
A
Apply Loctite® 510 on the surface, lubricate the sealing
S36801
ring, insert the distance washers and install the cover
(Item 1) with the slot (Item 2) [Figure 40-100-68] facing
upwards.
Measure dimension "A" between the bearing and the box
plane using an depth gauge [Figure 40-100-66].

Figure 40-100-69
NOTE: If parts are not replaced, use disassembled
distance washers.
Figure 40-100-67
B S38250
Install bolts [Figure 40-100-69]. Apply Loctite® 510 or

equivalent to the threads before installation.
S38248
Tighten bolts to 49 - 51 N•m (36.1 - 37.7 ft-lb) torque.
Measure dimension "B" on the cover, between the
bearing plane and bearing support [Figure 40-100-67].
Calculate the dimension of the distance washers
required:
S = Dimension B – Dimension A
Example: B = 5,2 mm (0.20 in); A = 4,6 mm (0.18 in);

Backlash = 0,2 - 0,3 mm (0.0079 - 0.0118 in);
Distance washer required = 0,4 - 0,3 mm (0.0157 -

0.0118 in)

Assembly (Cont’d)
Figure 40-100-70
2
3
S38242
S36546
Install the nut (Item 1) [Figure 40-100-72].
Tighten the nut (Item 1) [Figure 40-100-72] to 260 - 280

Install the connector (Item 1) with the screw (Item 2) to N•m (191.8 - 206.5 ft-lb) torque.
install the speed sensor cable (Item 3) [Figure 40-100-

70].
Figure 40-100-71
S38243
Install the flange (Item 1) and the O-ring (Item 2)

[Figure 40-100-71].

MAINFRAME
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

FIXED BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
INNER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1


ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

ATTACHMENT CARRIER (QUICK-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
STEERING COLUMN COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

DASH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

JOYSTICK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1



OPERATOR CAB Figure 50-10-2
Figure 50-10-1
4 3
2
1
S38077
1
Remove the A/C hose (Item 1) from the drier, and the A/C
S38006 hose (Item 2) [Figure 50-10-2] from the expansion valve.
NOTE: Plug the A/C hoses to prevent contamination.

Raise the boom and install the boom stop (Item 1)
[Figure 50-10-1]. (See Installing The Approved Boom Remove the heater hoses (Items 3 and 4) [Figure 50-10-

Stop on Page 10-150-1.) 2] from the heater.
Stop the engine. Figure 50-10-3
Remove the Starter switch key.
Remove the fuel tank. (See Removal And Installation on

Page 50-70-1.) 1 1
Remove the operator seat. (See Removal And

Remove the refrigerant from the A/C system. (See 2 1

Reclamation And Charging With Recovery / Charging
Unit on Page 80-100-1.)
S38084
Disconnect the ground (-) cable from the battery. (See
Removing And Installing Battery on Page 60-20-1.)
cab.

Figure 50-10-4
2 2
1
S39427
1
Remove the screw (Item 1) [Figure 50-10-5].
S38125
Remove the parking brake lever cover (Item 2) [Figure
50-10-5].
Remove all hoses from the steering valve and the brake
valve except for one hose (Item 1) [Figure 50-10-4]. Figure 50-10-6

Disconnect the electrical harness (Item 2) [Figure 50-10-
4].
Remove the engine speed control cable (only the

operator cab side). (See Removal And Installation on
Page 70-20-1.)
2
WARNING 1 1

sufficient force to enter a person’s body by S39428
physician familiar with this injury is not received Remove the three hydraulic hoses (Item 1) from the
immediately. parking brake valve (Item 2) [Figure 50-10-6].
W-2145-0290
IMPORTANT
damage the system.
I-2003-0888

Figure 50-10-7
1
1
S38127
2
Install a hoist to lift and support the cab [Figure 50-10-9].

S39811
Figure 50-10-10

(Item 2) [Figure 50-10-7]

Figure 50-10-8
1
1 1
S38126
2
Remove the cab mount bolt (Item 1) [Figure 50-10-10]

3 from the front right hand side of the cab.
S38075
Disconnect the four electrical connectors (Item 1) [Figure

50-10-8].
Disconnect the red / white cable (Item 2) [Figure 50-10-

8].
Remove the ground wires (Item 3) [Figure 50-10-8].
NOTE: Mark all hoses and electrical connectors for

correct installation.

Figure 50-10-11
1
1
S38130
Lift and remove the cab [Figure 50-10-13].

S38128
Remove the two cab mount bolts (Item 1) [Figure 50-10-

11] from the back of the cab.

Remove the floor mat.
Figure 50-10-12
S38128
Remove the cab mount bolt (Item 1) [Figure 50-10-12]

and washer from the cab floor.

OPERATOR SEAT
Figure 50-20-1
1 1
S38124

washers (on each corner of the plate).

Remove the seat.


FIXED BOOM Figure 50-30-3
Removal
Remove the lift and self leveling cylinders. (See LIFT 2

CYLINDER on Page 20-20-1.) and (See SELF
LEVELING CYLINDER on Page 20-30-1.)
Lower the boom and position horizontally on wooden

blocks.
Remove the inner boom. (See Removal And Installation 1

on Page 50-40-1.)
Figure 50-30-1 S39167
1 Remove the two nuts (Item 1) and the retainer bolt (Item
1
2) [Figure 50-30-3] from the boom pivot pin.
Figure 50-30-4

1
S38102
S39410
Install two lifting chains to the rear and two chains to the
front of the boom [Figure 50-30-1].
Figure 50-30-2 S39168
Remove the plastic cap (Item 1) [Figure 50-30-4].
S39166
Slightly bring the chains under tension, in order to safely

remove the boom pivot pin [Figure 50-30-2].

FIXED BOOM (CONT’D) Installation
Removal (Cont’d) Figure 50-30-7
Figure 50-30-5
S39166
S39169
Carefully lift and install the boom onto the machine
[Figure 50-30-7].
Remove the boom pivot pin [Figure 50-30-5].
Align the holes for installing the boom pivot pin (Item 1)
Figure 50-30-6 [Figure 50-30-7] while lowering the boom with the hoist.

Install the boom pivot pin (Item 1) [Figure 50-30-7].
Figure 50-30-8
S39166
2
Carefully lift and remove the boom from the machine
[Figure 50-30-6].
S39167
Install the retainer bolt (Item 1) and the two nuts (Item 2)
[Figure 50-30-8] onto the boom pivot pin.

FIXED BOOM (CONT’D)
Installation (Cont’d)
Figure 50-30-9
S39168
Install the plastic cap (Item 1) [Figure 50-30-9].
Figure 50-30-10

1
S38102
Grease the boom pivot (Item 1) [Figure 50-30-10] (one

place).
Position the boom horizontally on wooden blocks.
Install the inner boom. (See Removal And Installation on

Page 50-40-1.)
Install the lift and self leveling cylinders. (See LIFT

CYLINDER on Page 20-20-1.) and (See SELF
LEVELING CYLINDER on Page 20-30-1.)


INNER BOOM Figure 50-40-3
Figure 50-40-1
1 1
S38932
Remove the eight bolts (Item 1) [Figure 50-40-3] and

S39170 remove the four side wear pads. (Both sides)
Figure 50-40-4
Position the boom horizontally using wooden blocks
[Figure 50-40-1].

Extend the inner boom for approximately 500 mm (20 in).
Figure 50-40-2 1 1
2
1
S39070
Remove the two bolts (Item 1) (both sides) and remove

the cover (Item 2) [Figure 50-40-4] from the back of the
boom.
S38939

remove the two top wear pads.
NOTE: Mark the original position of each wear pad.

INNER BOOM (CONT’D) Figure 50-40-7
Figure 50-40-5
1
1
S38936
Remove the bolt (Item 1) [Figure 50-40-7] from the

S38930 cylinder.
Installation: Tighten the mounting bolt (Item 1)

Disconnect the ACD harness connector (Item 1) [Figure 50-40-7] to 760 N•m (560 ft-lb) torque.
[Figure 50-40-5] (If Equipped).

Figure 50-40-6
1 IMPORTANT
damage the system.
I-2003-0888
Figure 50-40-8
S38931
Remove the six hoses (Item 1) [Figure 50-40-6] from the

tubelines.
NOTE: Mark all hoses for correct installation. 1
S38937
Install a wooden block (Item 1) [Figure 50-40-8] under

the extension cylinder (as shown).

INNER BOOM (CONT’D)
Figure 50-40-9
S38938
Slide the inner boom from the fixed boom. Before the
inner boom is completely removed, position a hoist and

lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-9].
NOTE: Support the attachment carrier with a pallet

and pallet truck.
Figure 50-40-10
S39171
Install the inner boom on adequate stands [Figure 50-

40-10].


WEAR PADS (FRONT) Figure 50-50-3

service interval when to replace the wear pads.
Extend the inner boom for approximately 500 mm (20 in).
Figure 50-50-1
S39188
1
Lift the boom and rest the attachment carrier onto a
suitable stand, such that the lower wear pads become
free of pressure [Figure 50-50-3].
Figure 50-50-4

S38939
1

remove the two top wear pads from in between the inner 1
and fixed boom.
Installation: Tighten the bolts to 43 - 47 N•m (32 - 35 ft- 1

lb).
NOTE: Mark the original position of each wear pad. 1
Figure 50-50-2
S38940
Remove the six bolts (Item 1) [Figure 50-50-4] and

remove the two bottom wear pads.
Installation: Tighten the bolts to 57 - 63 N•m (42 - 46.5

1 1 ft-lb).
NOTE: DO NOT use fingers to remove the bottom

wear pads.
NOTE: When installing the wear pads, make sure to

install the correct color (same color as was
S38932
removed).
Remove the eight bolts (Item 1) [Figure 50-50-2] and

remove the four side wear pads from in between the inner
and fixed boom. (Both sides)

lb).


WEAR PADS (REAR) Figure 50-51-2

service interval when to replace the wear pads. 3
1
Remove the inner boom. (See Removal And Installation 2
on Page 50-40-1.)
4
4
3
Figure 50-51-1 3
1
2
5
S39161
Remove the two screws (Item 1) and remove the side

wear pad (Item 2) [Figure 50-51-2].
1 Repeat for the other three side wear pads (Item 3)

[Figure 50-51-2].
Remove the six screws (Item 4) and remove the bottom

wear pads (Item 5) [Figure 50-51-2].

S39162
With the inner boom supported, remove the six screws

(Item 1) and remove the two top wear pads (Item 2) Installation: Tighten the bolts to 43 - 47 N•m (32 - 35 ft-
[Figure 50-51-1]. lb).
Installation: Tighten the bolts to 43 - 47 N•m (32 - 35 ft- NOTE: Make sure that the surface of the boom is
lb). cleaned before installing the pads.
NOTE: Make sure that the surface of the boom is NOTE: When installing the wear pads, make sure to
cleaned before installing the pads. install the correct color (same color as was
removed).


ENGINE COVER
Gas Cylinder Removal And Installation
Figure 50-60-1
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
1
Remove the gas cylinder. (See Gas Cylinder Removal

Figure 50-60-3
1
S38113
Figure 50-60-2

1
S38115
1
Remove the two hinge mounting bolts (Item 1) [Figure
50-60-3].
S38114
Remove the engine cover.

Page 10-160-1.)
Add a support to prevent the cover from closing when the

gas cylinder is removed.
Remove the retainer clips (Item 1) [Figure 50-60-1] and

[Figure 50-60-2] at both of the ball joints ends. Remove
the ball joints from the ends.
Remove the gas cylinder.


FUEL TANK Figure 50-70-3
Figure 50-70-1
S39067
1
Remove the two fuel lines (Item 1) [Figure 50-70-3] from

S39066 the fuel filter / water separator.

Install a suitable container, large enough to contain all
fuel from the fuel tank, under the drain plug (Item 1) Figure 50-70-4

[Figure 50-70-1].
Remove the drain plug (Item 1) [Figure 50-70-1]. 1 1
Figure 50-70-2
2
1
S39137
Remove the bolts (Item 1) and remove the step (Item 2)

[Figure 50-70-4].
S39064
NOTE: Support the step while removing the bolts.

Remove the operator cab floor mat.

FUEL TANK (CONT'D) Figure 50-70-7
Removal And Installation (Cont'd)
Figure 50-70-5
1 1
S38008
Remove the two nuts (Item 1) and filter cover (Item 2)

S38291 [Figure 50-70-7].
Figure 50-70-8
Fully support the fuel tank using an appropriate lifting
device [Figure 50-70-5].

Figure 50-70-6
1
1
1
1
S38009
1
Remove the filter (Item 1) [Figure 50-70-8].

S38086

FUEL TANK (CONT'D) Figure 50-70-11
Figure 50-70-9
S38090
Disconnect the fuel level sensor connector (Item 1)

S38087 [Figure 50-70-11].
Figure 50-70-12

Figure 50-70-10
1 S38095
S38088 Remove the fuel return hose (Item 1) [Figure 50-70-12]

from the fuel tank.
Remove the bolt (Item 1) [Figure 50-70-10]. NOTE: Mark the hoses for correct installation.
Lower the fuel tank for approximately 200 mm (8 in).

FUEL TANK (CONT'D)
Figure 50-70-13
S38094
Remove the fuel tank [Figure 50-70-13].

ATTACHMENT CARRIER (QUICK-TACH) Figure 50-80-3
Figure 50-80-1
S39147
Remove the tilt cylinder lower pivot pin (Item 1)

S39120
[Figure 50-80-3].
Figure 50-80-4
Tilt the attachment carrier forward and place it on a flat
surface [Figure 50-80-1].
1
Figure 50-80-2

1
S39121
Remove the pivot pin retainer bolt (Item 1) [Figure 50-

S39146
80-4].

[Figure 50-80-2] from the tilt cylinder lower pivot pin.

ATTACHMENT CARRIER (QUICK-TACH) (CONT’D)
Figure 50-80-5
S39122
Remove the attachment carrier pivot pin (Item 1)

[Figure 50-80-5].
Installation: Apply grease using a grease pump.

Figure 50-80-6
S39123
Remove the attachment carrier [Figure 50-80-6].

COUNTERWEIGHT Figure 50-90-3
Figure 50-90-1
S39140
Slowly move the counterweight backward until it is

S39139 stopped by the inner frame [Figure 50-90-3].
Figure 50-90-4
Support the counterweight using a fork lift and pallet
[Figure 50-90-1].

NOTE: Counterweight mass is approx 855 kg (1885
lb). Use a fork lift rated for this mass.
Figure 50-90-2
1
S39141
Lower the counterweight and remove it from under the

machine [Figure 50-90-4].
1
EM7532
Remove the three bolts (Item 1) [Figure 50-90-2] from

inside the opening.
Installation: Tighten the mounting bolts (Item 1)

[Figure 50-90-2] to 370 - 410 N•m (273 - 302 ft-lb)
torque.


FENDER
Figure 50-100-1
S38680
Remove the four bolts (Item 1) from the fender mount

bracket (Item 2) [Figure 50-100-1].

Remove the fender.

lb) torque.


STEERING COLUMN COVER Figure 50-110-3
Figure 50-110-1
1
S39059
1 1
Loosen the clamp (Item 1) [Figure 50-110-3] and

S38732 remove the blower hose from the blower.
Remove the steering column cover.

from the steering column cover.

Figure 50-110-2
1
1
S39057
Remove the four screws (Item 1) [Figure 50-110-2] from

the steering column cover.
Lower the steering column cover.


DASH COVER Figure 50-120-3

1
Figure 50-120-1
S38299
Pull out the Hazard Lights switch (Item 1) [Figure 50-

S38728 120-3], disconnect the connector and remove the switch.
Pull out the indicator panel (Item 2) [Figure 50-120-3],

Remove the cap (Item 1) [Figure 50-120-1] from the disconnect the connector and remove the panel.
steering wheel.

Figure 50-120-4
Figure 50-120-2
1
1 1
1
2
S39051
S38732

Remove the nut (Item 1) [Figure 50-120-2] from the windscreen blower.
steering wheel.
Remove the steering wheel (Item 2) [Figure 50-120-2].
Remove the signal lever. (See Removal And Installation

on Page 60-60-1.)
Remove the instrument panels. (See Right Instrument

And Indicator Panel Removal And Installation on Page
60-80-1.)
Remove the display. (See Removal And Installation on

Page 60-70-1.)

DASH COVER (CONT’D) Figure 50-120-7
Removal And Installation (Cont’d) 1

Figure 50-120-5
S39054
Lift the dash cover (Item 1) [Figure 50-120-7].

S39052
Figure 50-120-8

the dash cover.

Figure 50-120-6
1 S39055
1 Loosen the clamp (Item 1) [Figure 50-120-8] and

remove the blower hose from the blower.
S39053

from the dash cover.

DASH COVER (CONT’D)
Figure 50-120-9
1
1
1
S39056
Loosen the three clamps (Item 1) [Figure 50-120-9] and

remove the three blower hoses from the blowers.

Remove the dash cover.


JOYSTICK PANEL Figure 50-130-3
Figure 50-130-1
1
1 1
S38732

S38728 from the steering column cover.
Figure 50-130-4
Remove the cap (Item 1) [Figure 50-130-1] from the
steering wheel. 1

Figure 50-130-2
1
1
1
1
S39057
2
Remove the four screws (Item 1) [Figure 50-130-4] from
S38732 the steering column cover.
Lower the steering column cover.

Remove the nut (Item 1) [Figure 50-130-2] from the
steering wheel.
Remove the steering wheel (Item 2) [Figure 50-130-2].
Remove the signal lever. (See Removal And Installation

on Page 60-60-1.)

JOYSTICK PANEL (CONT’D) Figure 50-130-7
Figure 50-130-5
1
1
1 1
2
S39245
1
Remove the temperature control knob (Item 1) and the

S39051 nut (Item 2) [Figure 50-130-7] and washer underneath.
Figure 50-130-8
windscreen blower.

Figure 50-130-6
1
1 1
1
1
1
S39244
1 Remove the screws (Item 1) [Figure 50-130-8] from the

S39243 joystick panel.
Lift the joystick panel.

dash cover. NOTE: Slightly lift the dash cover for easier removal
of the joystick panel.
Remove the joystick. (See Removal And Installation on
Page 60-170-1.) Mark and remove all harnesses from the joystick panel.
Remove the joystick panel.

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuses And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Front Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Right Instrument And Indicator Panel Removal And Installation . . . . . . . . . . . . . . . . 60-80-1
Left Instrument Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
BOOM ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
FRONT WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

TOP WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

REAR WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1


PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
INCHING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool (Service Tool) - MEL1563 . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . . . . . . . . . . 60-150-1
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
LLMI / LLMC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-3
System Failure Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-4

System Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-8
LLMS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-10
LLMS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-11
LLMC Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-12

FUSES OVEVIEW
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
FUSE LOCATION SIZE(A) CIRCUIT FUNCTION 1 FUNCTION 2 FUNCTION 3 FUNCTION 4 FUNCTION 5
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
F1 FRC1 (CAB) 20 BATTERY GATEWAY CONTROLLER IGNITION SWITCH DIAG. CONNECTOR BATT RADIO SUPPLY WARNING LIGHTS
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
F2 FRC1 (CAB) 7,5 IGNITION DISPLAY CONTROLLER LLMI DIAG. CONNECTOR IGN SHUNT KEY SWITCHES
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
F3 FRC1 (CAB) 10 IGNITION FRONT WIPER WASHERS CAB BUZZER FNR LEVER
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
F4 FRC1 (CAB) 20 IGNITION REAR/ROOF WIPER LLMC RADIO IGNITION DOME LIGHT BEACON
FRC1 (CAB)
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
F5 25 IGNITION HVAC HEATER/BLOWER FAN INVERTER ACD SKI SWITCHES
F6 FRC1 (CAB) 15 IGNITION HEAD LIGHTS TURN LIGHTS HORN CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
F7 FRC1 (CAB) 15 IGNITION LOW BEAM LIGHTS HIGH BEAM LIGHTS MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
F8 FRC1 (CAB) 15 IGNITION 12V SOCKET SUSPENSION SEAT HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
F9 FRC1 (CAB) 7,5 LIGHTS POSITION LIGHTS LEFT FOG LIGHT

CONTROLLER SUPLY
5000 THROUGH 5999 YELLOW YEL
(5V, 8V)
F10 FRC1 (CAB) 7,5 LIGHTS POSITION LIGHTS RIGHT
LIGHTS 6000 THROUGH 6999 PINK PNK
F11 FRC1 (CAB) 20 IGNITION CAB WORK LIGHTS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
F12 FRC1 (CAB) 20 IGNITION BOOM WORK LIGHTS BLUE WORK LIGHTS
ENGINE 8000 THROUGH 8999 TAN TAN
COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR

F21 FRC2 (FRAME) 15 IGNITION DRIVE CONTROLLER
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
F22 FRC2 (FRAME) 15 IGNITION WORKGROUP CONTROLLER
F23 FRC2 (FRAME) 25 BATTERY ACD BATTERY SUPPLY
F24 FRC2 (FRAME) 25 IGNITION ACD IGNITION SUPPLY

SCHEMATIC INDEX
F25 FRC2 (FRAME) 7,5 IGNITION LOW SPEED
F26 FRC2 (FRAME) 5 IGNITION JOYSTICK WHEELS ALIGNMENT RETRACT SWITCH REAR SHAFT SENSOR IGNITION SIGNAL
FUSES OVERVIEW PAGE 1
F27 FRC2 (FRAME) 15 IGNITION BOOM OPT. VALVE 1 BOOM OPT. VALVE 2 REAR DIVERTER 2 CONNECTORS ASSIGNMENT PAGE 2
F28 FRC2 (FRAME) 10 IGNITION STOP LIGHTS REVERSE LIGHT BACK UP ALARM
F29 FRC2 (FRAME) 5 IGNITION

TRACTOR TRAILER BRAKE ITALIAN TRAILER BRAKE CONTROLLERS CONNECTION PAGE 3 & 4
VALVE VALVE
POWER PAGE 5
ALTERNATOR
F41 FC3 (ENGINE) 25 IGNITION STARTER
EXCITATION GROUND PAGE 6
F42 FC3 (ENGINE) 10 IGNITION FUEL SOLENOID FUEL PUMP TEMP. SWITCH
CAN BUS PAGE 7
F50 MEGAFUSE 100 IGNITION MAIN IGNITION POWER GLOW PLUGS
IGNITION & ENGINE PAGE 8
LOWER CAB PAGE 9
UPPER CAB PAGE 10
TRANSMISSION PAGE 11
BRAKES PAGE 12
STEERING PAGE 13
WORKGROUP PAGE 14
FRC 1 FRAME LVL, LLM SYSTEM PAGE 15
AUXILIARY HYDRAULIC PAGE 16
FC 3 STANDARD LIGHTS PAGE 17
7199028 OPTIONAL LIGHTS PAGE 18
7179987
STOP
1 2
WIRING SCHEMATIC
FRC 2
STOP
R (S/N ANMG11001 AND ABOVE)
Sheet 1 of 18
(PRINTED MARCH 2011)
7179988
Printed
491 of 770In Belgium 7159062
ENGINE CONNECTORS ASSIGNMENT FRAME CONNECTORS ASSIGNMENT CAB CONNECTORS ASSIGNMENT CAB CONNECTORS ASSIGNMENT LIGHTS CONNECTORS ASSIGNMENT
CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET CONNECTOR DESCRIPTION PINS SHEET
9, 9,11,12,
C100 ENGINE TO FRAME 29 C100 FRAME TO ENGINE 29 C200 ICON DISPLAY CLUSTER 8 13,15,17 C280 SUSPENSION SEAT MOTOR 2 9
11,12,13 13 C302 FRONT LIGHTS LEFT 6 17
7,11,12,
C103 FUEL PUMP 2 8 C205 REAR AUX/HYD HOOK SWITCH 10 16 C281 FRONT WIPER MOTOR 6 9
C230 FRAME TO CAB 40 13, 14,15, C303 REAR LIGHTS LEFT 6 17
16,17,18 HYDRAULIC QUICKTACH SWITCH
C104 INJECTION CONTROLLER (130HP) 2 8 C209 DRIVE MODE SWITCH 5 11 C284 10 16
C304 FRONT LIGHTS RIGHT 6 17
C236 FRAME LVL TO CAB 8 15
C105 FUEL SOLENOID 2 8 C210 IGNITION KEY SWITCH 6 8 C286 PARK BRAKE SWITCH 10 12 C305 REAR LIGHTS RIGHT 6 17
C400 HYDRAULIC OIL TEMPERATURE 2 14
C109 ELECTRONIC BATTERY DISC. 2 5 C211 AC SWITCH 3 9 C290 DIAGNOSTIC CONNETCOR 7 18
C306 LICENSE PLATE LIGHT 2 17
C401 BACKUP ALARM 2 17
C110 ALTERNATOR 2 8 C212 BLOWER SPEED SWITCH 5 9
C332 LIGHTS TO BOOM 2 18
C402 GEAR 1 VALVE 2 11
C113 GLOW PLUGS 1 8 C213 HEATER AND BLOWER MOTOR 5 9 T26 LOWER CAB GND 1 6
C333 FRAME TO BLUE LIGHT LEFT 2 18
C403 GEAR 2 VALVE 2 11
C115 VARIABLE FAN SPEED 2 8 C214 THERMOSTAT MODULE 3 9 T50 AC PRESSURE SWITCH 1 9
C334 FRAME TO BLUE LIGHT RIGHT 2 18
C412 BOOM UP 2 14
C116 FAN INVERTER 2 8 C216 FAN INVERTER SWITCH 10 8 T51 AC PRESSURE SWITCH 1 9
C413 BOOM DOWN 2 14
C117 SWASH PLATE SENSOR 4 11 C217 BOOM SUSPENSION SWITCH 10 16 T59 CAB BUZZER 1 9
T70 BLUE WORK LIGHT LEFT 1 18
C414 TILT UP 2 14
C120 DRIVE PUMP FORWARD 2 11 C219 GEAR SELECT SWITCH 10 11 T60 CAB BUZZER 1 9
T71 BLUE WORK LIGHT LEFT 1 18
C415 TILT DOWN 2 14
C121 DRIVE PUMP REVERSE 2 11 C220 KEYLESS MODULE (RSS) 6 8 T68 SHUNT KEY 1 15
T72 BLUE WORK LIGHT RIGHT 1 18
C416 BOOM EXTEND 2 14
C123 AC COMPRESSOR CLUTCH 2 9 C221 FLASHER RELAY 6 17 T69 SHUNT KEY 1 15
T73 BLUE WORK LIGHT RIGHT 1 18
C417 BOOM RETRACT 2 14
C126 ICVD SWASH PLATE VALVE 2 11 C222 THROTTLE PEDAL SENSOR T90 BRAKE FAIL PRESSURE LAMP 1 12
T76 REVERSE LIGHT 1 17
C418 AUX A4 VALVE 2 14
C126 ICVD DEFEAT VALVE 2 11 C224 LEFT LEVER 12 9,11,17 T91 BRAKE FAIL PRESSURE LAMP 1 12
T77 REVERSE LIGHT 1 17
C419 AUX B4 VALVE 2 14
C130 LOW SPEED 2 11 C225 FNR LEVER 6 11 T92 TRAILER INDICATOR LAMP 1 17
C420 RETRACT SWITCH 4 14
C135 DUMP VALVE 2 11 C227 12V SOCKET 2 9 T93 TRAILER INDICATOR LAMP 1 17
C421 CRAB STEER VALVE 2 13
C141 1ST/2ND GEAR SWITH 2 11 C229 CAB TO LLMI SENSOR 8 7, 15 T94 CRAB STEER LAMP 1 13
C422 4 WHEEL STEER 2 13
C142 SERVO PRESSURE SENSOR 3 11 7,11,12, T95 CRAB STEER LAMP 1 13
C423 SAFETY VALVE 2 11 C230 CAB TO FRAME 40 12,14,15, BOOM CONNECTORS ASSIGNMENT
C143 STEERING PRESSURE SENSOR 3 13 16,17,18 T96 4 WHEEL STEER LAMP 1 13
C424 HORN 2 9 CONNECTOR DESCRIPTION PINS SHEET
C144 INLET PRESSURE SENSOR 3 14 C232 CAB TO UPPER CAB 4 5,10,18 T97 4 WHEEL STEER LAMP 1 13
C425 STEERING PRESS. SENSOR LS PUMP 3 13 C433 BOOM ACD TO FRAME 8 7, 14
C150 TRACTOR TRAILER BRAKE VALVE 2 12 C233 CAB TO ENGINE 24 5,7,8,9 C601 REAR WIPER MOTOR 2 10
C428 PASSIVE BRAKE VALVE 2 12 C501 ACD CONNECTOR 7 14
C158 ENGINE OIL PRESSURE 2 8 C235 CAB TO IGNITION 1 5 C602 ROOF WIPER MOTOR 3 10
C429 ITALIAN TRAILER BRAKE VALVE 2 12 C504 BOOM WORK LIGHT LEFT 2 18
C233 ENGINE TO CAB 24 5,7,8,9 C236 CAB TO FRAME LVL 8 15 C603 CAR RADIO SUPPLY 8 10
C431 REAR DIVERTER 1 2 16 C505 BOOM WORK LIGHT RIGHT 2 18
C235 IGNITION TO CAB 1 5 C237 LLMI 6 15 C604 CAR RADIO SPEAKERS 8 10
C432 REAR DIVERTER 2 2 16 Dealer Copy -- Not for Resale
C238 LLMC 6 15 C605 FRONT LEFT WORK LIGHT 2 18
C433 FRAME TO BOOM ACD 8 7,14 C700 BOOM VALVES OPT. TO FRAME 8 16
T1 MEGAFUSE F50 1 5 C240 DISPLAY (BLACK CONNECTOR) 12 7,9,13,17 C606 FRONT RIGHT WORK LIGHT 2 18
C435 FRONT/REAR DIVERTER SWITCH 2 16 C701 BOOM OPTION VALVE 1 2 16
T2 MEGAFUSE F50 1 5 C241 DISPLAY (GRAY CONNECTOR) 12 8 C607 REAR WORK LIGHT 2 28
C436 BOOM ANGLE SENSOR 8 14 C702 BOOM OPTION VALVE 2 2 16
T5 GLOW PLUGS RELAY 1 8 C242 WIPER SWITCH 10 9 C608 DOME LIGHT 3 20
C441 1ST/2ND GEAR SWITCH 2 13 C703 BOOM OPTION PRESS. SENSOR 1 2 16
T6 GLOW PLUGS RELAY 1 8 C243 FUEL LEVEL SENSOR 2 9 C620 ROOF WIPER SWITCH 10 10
C444 FRAME LEVELING 1 2 15 C704 BOOM OPTION PRESS. SENSOR 2 2 16
T7 GLOW PLUGS RELAY 1 8 C244 CAB TO FUEL LEVEL SENSOR 3 9 C621 BEACON SWITCH 10 10
C445 FRAME LEVELING 2 2 15
T8 GLOW PLUGS RELAY 1 8 C247 LLMI TO SENSOR 4 15
C451 REAR SHAFT SPEED SENSOR 2 11
T10 ELECTRONIC BATTERY DISC. 1 5 C248 LLMC TO SENSOR 4 15 T32 UPPER CAB GND 1 6
C452 REAR WHEELS ALLIGNMENT 3 13
T11 ELECTRONIC BATTERY DISC. 1 5 C250 KEYLESS PAD 6 8 T78 BEACON 1 10
C453 FRONT WHEELS ALLIGNMENT 3 13
T12 ELECTRONIC BATTERY DISC. 1 5 C251 BRAKE INCHING POTENTIOMETER 3 11 T79 BEACON 1 10
C455 SERVICE BRAKE PRESSURE SENSOR 3 12
T13 ELECTRONIC BATTERY DISC. C254 CREEP ENABLE SWITCH 10 11 T84 SPEAKER RIGHT 1 10
C456 PARK BRAKE PRESSUE SWITCH 2 12
T16 ALTERNATOR B+ 1 8 C255 FRAME LEVELING POTENTIOMETER 3 15 T85 SPEAKER RIGHT 1 10
C457 ITALIAN BRAKE PRESSURE SWITCH 2 12
T17 ALTERNATOR GND 1 8 C256 JOYSTICK 4 7, 14 T86 SPEAKER LEFT 1 10
C458 ICVD MOTOR RMP 2 11
T18 STARTER B 1 8 C257 LH SKI SWITCH 10 16 T87 SPEAKER LEFT 1 10
C460 HYDRAULIC QUICTACH VALVE 2 16
T19 STARTER TO MEGAFUSE 1 8 C258 ATACH SKI SWITCH 10 16
TRAILER PRESSURE RELEASE
C467 10 12
T20 STARTER S 8 SWITCH
1 C259 RH SKI SWITCH 10 16
C700 FRAME TO BOOM VALVES OPT. 8 16
T23 ENGINE GND 1 6 C260 STEER MODE SWITCH 10 13
T24 ENGINE GND 1 6

T35 FRAME GND 1 6
C265 FRONT WASHER MOTOR 2 9
WIRING SCHEMATIC
T30 BATTERY POSITIVE 1 5 C267 WASHER SWITCH 10 9
HYDRAULIC FILER 1
T80
(CLOGGING INDICATOR 1)
1 14 Printable Version Click Here
T31 BATTERY NEGATIVE 1 5 C270 WARNING SWITCH 10 17
HYDRAULIC FILER 1
T81 1 14
T44 ENGINE SPEED SENSOR 1 8
T82
HYDRAULIC FILER 2
1 14
C272 FOG LIGHT SWITCH 10 17
T45 ENGINE SPEED SENSOR 1 8 (CLOGGING INDICATOR 2)
T55 ENGINE COOLANT TEMPERATURE 1 8 T83

HYDRAULIC FILER 2
1 14 (S/N ANMG11001 AND ABOVE)
T56 ENGINE COOLANT TEMPERATURE 1 8 Sheet 2 of 18
Printed In770
492 of Belgium 7159062
J1 CONNECTOR ASSIGNMENT (GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENT (DRIVE CONTROLLER) J3 CONNECTOR ASSIGNMENT (WORKGROUP CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 VARIABLE FAN SPEED FDBK B-1 ENGINE OIL PRESSURE A-1 DRIVE PUMP FORWARD RETURN B-1 SERVO PRESSURE SENSOR A-1 BOOM EXTEND RETURN B-1 BOOM PRESSURE SENSOR 2
A-2 SAFETY VALVE RETURN B-2 POWER SUPPLY A-2 DUMP VALVE RETURN B-2 POWER SUPPLY A-2 BOOM DOWN RETURN B-2 POWER SUPPLY
A-3 BLUE WORKLIGH RELAY B-3 POWER SUPPLY A-3 LOW SPEED RELAY B-3 POWER SUPPLY A-3 BOOM OPTION VALVE 1 RELAY B-3 POWER SUPPLY
A-4 FRONT ALIGNMENT LAMP B-4 CRAB STEER VALVE A-4 TRACTOR TRAILER BRAKE RELAY B-4 DRIVE PUMP FORWARD A-4 SPARE B-4 BOOM EXTEND
A-5 STARTER RELAY B-5 4 WHEEL STEER VALVE A-5 ITALIAN TRAILER BRAKE RELAY B-5 DRIVE PUMP REVERSE A-5 REAR DIVERTER 2 RELAY B-5 BOOM RETRACT
A-6 REAR ALIGNMENT LAMP B-6 VARIABLE FAN SPEED A-6 BRAKE FAIL PRESSURE LAMP B-6 AUX A4 VALVE A-6 BOOM OPTION VALVE 2 RELAY B-6 BOOM UP
A-7 FAN INVERTER RELAY B-7 WORKLIGHT RELAY A-7 REVERSE LIGHT RELAY B-7 AUX B4 VALVE A-7 SPARE B-7 BOOM DOWN
A-8 FUEL SOLENOID RELAY B-8 CAN LO 1 A-8 CREEP STATUS B-8 CAN LO 1 A-8 SPARE B-8 CAN LO 1
A-9 GLOW PLUGS RELAY B-9 CAN HIGH 1 A-9 STOP LIGHT RELAY B-9 CAN HIGH 1 A-9 SPARE B-9 CAN HIGH 1
A-10 FRAME LEVELING 1 RETURN B-10 INCHING POTENTIOMETER A-10 DRIVE PUMP REVERSE RETURN B-10 ICVD SWASH PLATE SENSOR 1 A-10 TILT UP RETURN B-10 BOOM ANGLE 2
A-11 FRAME LEVELING POTENTIOMETER B-11 INLET MANIFOLD AIR TRACTOR TRAILER BRAKE A-11 SPARE B-11 SPARE
A-11 B-11 PARK BRAKE PRESSURE SWITCH
RELAY FDBK
A-12 POSITION LIGHTS STATUS B-12 FUEL LEVEL ITALIAN TRAILER BRAKE A-12 SPARE B-12 SPARE
A-12 STOP LIGHT RELAY FDBK B-12
PRESSURE SWITCH
A-13 CRANKING POSITION B-13 FRAME LEVELING 1 A-13 RETRACT SWITCH NO B-13 TILT UP
A-13 HIGH/LOW SPEED B-13 GEAR 1 VALVE/ICVD SWASH PLATE
A-14 CRAB STEER SWITCH B-14 CAN HI 2 A-14 SHUNT KEY POSITION B-14 SPARE
A-14 GEAR SELECTOR SWITCH B-14 SPARE
A-15 ENGINE SPEED B-15 GND A-15 SPARE B-15 GND
A-15 REAR SHAFT SPEED B-15 GND
A-16 STARTER RELAY FDBK B-16 GND A-16 BOOM OPTION VALVE 2 RELAY FDBK B-16 GND
A-16 SPARE B-16 GND
A-17 FUEL PUMP RELAY B-17 SENSOR GND A-17 SPARE B-17 SENSOR GND
A-17 SPARE B-17 SENSOR GND
A-18 FRAME LEVELING 2 RETURN B-18 SPARE A-18 BOOM RETRACT RETURN B-18 HYDRAULIC OIL TEMPERATURE
A-18 AUX B4 RETURN B-18 SERVICE BRAKE PRESSURE
A-19 FRONT ALIGNMENT STATUS B-19 SAFETY VALVE A-19 SPARE B-19 TILT DOWN
A-19 SPARE B-19 GEAR 2 VALVE/ICVD DEFEAT
A-20 FUEL SOLENOID RELAY FDBK B-20 CAN LO 2 A-20 SPARE B-20 SPARE
A-20 INLET PRESSURE SENSOR B-20 SPARE
A-21 ACK LH SKI SWITCH DOWN B-21 ATTACHMENT RUN A-21 RETRACT SWITCH NC B-21 IGNITION SIGNAL
A-21 AUTO MODE 1: SMOOTH B-21 IGNITION SIGNAL
A-22 ACD RH SKI SWITCH DOWN B-22 IGNITION POSITION
Dealer Copy -- Not for Resale A-22 BOOM SUSPENSION SWITCH B-22 HYDRAULIC QUICKTACH SWITCH
A-22 AUTO MODE 4: CONVERTER 2 B-22 FNR NEUTRAL
A-23 REAR ALIGNMENT STATUS B-23 SENSOR SUPPLY 5V ITALIAN TRAILER BRAKE A-23 SPARE B-23 SENSOR SUPPLY 5V
A-23 B-23 SENSOR SUPPLY 5V
RELAY FDBK
A-24 ACD LH SKI SWITCH UP B-24 LLMC OK A-24 SPARE B-24 BOOM ANGLE 1
A-24 AUTO MODE 3: CONVERTER 1 B-24 ICVD SWASH PLATE SENSOR 2
A-25 SEAT SWITCH B-25 BATTERY DISCONNECT A-25 BOOM PRESSURE SENSOR 1 B-25 HYDRAULIC QUICTACH
A-25 STEERING PRESSURE SENSOR B-25 DUMP VALVE
A-26 SPARE B-26 FRAME LEVELING 2 A-26 BOOM UP RETURN B-26 REAR DIVERTER 1
A-26 ICVD SWASH PLATE RETURN B-26 PASSIVE BRAKE VALVE
A-27 SPARE A-27 TILT DOWN RETURN
A-27 AUX A4 RETURN
A-28 ACD ATTACH SKI SWITCH A-28 BOOM OPTION VALVE 1 RELAY FDBK
A-28 FNR LEVER REVERSE
A-29 4 WHEEL STEER SWITCH A-29 REAR HOOK SWITCH
A-29 AUTO MODE 2: AGGRESIVE
A-30 ACD RH SKI SWITCH UP PARK BRAKE SWITCH / A-30 REAR AUXILIARY SWITCH
A-30
TRAILER PRESSURE RELEASE SWITCH
A-31 ACD ATTACH SKI SWITCH A-31 REAR DIVERTER 2 RELAY FDBK
A-31 FNR LEVER FORWARD
A-32 ENGINE COOLANT TEMPERATURE A-32 SPARE
HYDRAULIC FILTER CLOGGING
A-32
A-33 LORS BAR INDICATOR
A-33 FRONT/REAR DIVERTER SWITCH
A-33 1ST/2ND GEAR SWITCH
A-34 IGNITION FDBK A-34 SPARE
A-34 LOW SPEED RELAY FDBK
WIRING SCHEMATIC

(S/N ANMG11001 AND ABOVE)
Sheet 3 of 18
Printed In Belgium
493 of 770 7159062
C240, C241 CONNETCOR ASSIGNMENT (DISPLAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
C240-1 POWER SUPPLY C241-1 FAN INVERTER SWITCH
C240-2 GND C241-2 SPARE
C240-3 CAN HI C241-3 SPARE
C240-4 CAN LO C241-4 NOT USED
C240-5 IGNITION INPUT C241-5 NOT USED
C240-6 NOT USED C241-6 NOT USED
C240-7 CREEP SWITCH C241-7 NOT POPULATED
C240-8 HIGH BEAM STATUS C241-8 NOT USED
C240-9 STABILIZER SWITCH C241-9 NOT POPULATED
C240-10 BUZZER C241-10 NOT POPULATED
C240-11 TURN SIGNAL STATUS C241-11 NOT POPULATED
C240-12 NOT USED C241-12 AMBIENT TEMPERATURE
ACRONYMS DESCRIPTION
AC AIR-CONDITIONING
ACD ATTACHMENT CONTROL DEVICE
ACD LH SKI ATTACHMENT CONTROL DEVICE LEFT HAND SKI
ACD RH SKI ATTACHMENT CONTROL DEVICE RIGHT HAND SKI
DRV DRIVE CONTROLLER
EMEA EUROPE, MIDDLE EAST, AFRICA
FNR FORWARD, NEUTRAL, REVERSE
GTW GATEWAY CONTROLLER

HVAC HEATING VENTILATION AIR-CONDITIONING
ICVD INTEGRATED CONTINUOUSLY VARIABLE DRIVE
KSS KEYLESS START SYSTEM
LLMI LONGITUDINAL LOAD MOMENT INDICATOR
LLMC LONGITUDINAL LOAD MOMENT CONTROLLER
LS LOAD SENSING
NA NORTH AMERICA
RSS RUN, START, STOP
WGP WORKGROUP CONTROLLER
WIRING SCHEMATIC

Sheet 4 of 18
Printed In Belgium
494 of 770 7159062
F12
1520/RNG/WHT
POWER
SHT8/D5 20A
1865/RNG/WHT
SHT18/H6
JUMPER
1540/RNG/WHT F11
SHT8/C8 20A
F41 1855/RNG/WHT 1860/RNG/WHT
F50 25A SP2 SHT18/H7
1530/RNG/WHT 1535/RNG/WHT 1545/RNG/WHT
100A SHT8/D7
SP1
1090/RED T1 T2 1525/RNG/WHT F8
SHT8/C7 F42
1945/RNG/WHT 15A
10A 1950/RNG/WHT
1550/RNG/WHT 1555/RNG/WHT SHT9/H5
SHT8/D6
F7
15A
1995/RNG/WHT
SHT17/H4
1990/RNG/WHT
JUMPER
SHT17/H4
C235 F6
1 1 SP200 15A
1710/RNG/WHT 1710/RNG/WHT 1960/RNG/WHT 1975/RNG/WHT
SHT17/H5
1965/RNG/WHT
SHT17/H6
1575/RNG/WHT
F22 1605/RNG/WHT
15A SP14 SHT14/H8
1595/RNG/WHT
1720/RNG/WHT
1600/RNG/WHT SHT8/H3
SHT14/H8
JUMPER
C100
F21 1750/RNG/WHT
SHT16/H3
1 1 15A F5
1580/RNG/WHT 1580/RNG/WHT 1590/RNG/WHT 1735/RNG/WHT
SP39 SHT12/H8 25A SHT8/H2
1715/RNG/WHT 1730/RNG/WHT
1585/RNG/WHT SP74
SHT12/H8 1740/RNG/WHT
SHT9/H7
1745/RNG/WHT
SHT9/H7
1501/RNG/WHT
SHT12/H6
F29
5A 1725/RNG/WHT
1689/RNG/WHT
SHT12/E7
F28 F4
10A 1870/RNG/WHT 20A
SHT17/H2 SHT10/H5
1875/RNG/WHT
SHT15/H5
F27
15A
1665/RNG/WHT
SHT16/H8
JUMPER
1625/RNG/WHT
SHT14/H6
1935/RNG/WHT
SHT9/H6
Dealer Copy -- Not forSHT13/C7
1635/RNG/WHT Resale
1940/RNG/WHT
SHT9/H6
1655/RNG/WHT F3
SHT11/D3 10A
F26 1910/RNG/WHT 1930/RNG/WHT
5A SP52 SP9 SHT9/D5
1620/RNG/WHT 1640/RNG/WHT 1660/RNG/WHT SP23
SHT14/D7
1920/RNG/WHT
SHT13/C7
1915/RNG/WHT
SHT11/H7
F25
1610/RNG/WHT 2 2 7,5A
SHT11/H8
1785/RNG/WHT
SHT14/F2
1830/RNG/WHT
SHT11/H4
F24 1815/RNG/WHT
SHT15/H4
25A 1840/RNG/WHT
SHT11/H2
1700/RNG/WHT 4 4 1700/RNG/WHT 1705/RNG/WHT 1835/RNG/WHT
SHT14/D2 SHT12/H6
1820/RNG/WHT
SHT13/H6
F23 F2 1810/RNG/WHT
25A 7.5A SHT15/H3
1020/RED 3 3 1020/RED 1425/RED/WHT 1780/RNG/WHT 1790/RNG/WHT 1805/RNG/WHT
SHT14/D2 SHT16/H4
SP42 1800/RNG/WHT
SHT16/H6
1390/RED/WHT 1825/RNG/WHT
1695/RNG/WHT
SHT9/H6 SHT11/H6
8080/TAN
C109 1795/RNG/WHT
BATTERY
C233 1350/RED/WHT
SHT10/H7
SHT16/H7
1850/RNG/WHT
DISCONNECT SHT9/H4
F1 1360/RED/WHT 1845/RNG/WHT
BATTERY 1030/RED 16 16 1030/RED SHT8/H8 SHT9/H4
12.0 Volts T11 SP80 20A SP67 SP19
1010/RED 1050/RED 1310/RED/WHT 1340/RED/WHT 1370/RED/WHT 1696/RNG/WHT
SHT8/H8 SHT8/H6
2000/BLK 1000/RED 1040/RED 24 24 1040/RED SP81 1694/RNG/WHT
SP32 SHT8/H6
T31 T30 T10 1 1330/RED/WHT
SHT17/H6
2 1320/RED/WHT
SHT8/H7
T12
WIRING SCHEMATIC
1300/RED/WHT
SHT14/F2 Printable Version Click Here
1060/RED
2445/BLK
T23
STARTER
GND
SHT6/C8 SHT8/C7
Sheet 5 of 18
Printed In Belgium 7159062
495 of 770
GROUND SHT17/C6
SHT17/C8
2145/BLK
2265/BLK
SP11 2255/BLK 2575/BLK SP33
2585/BLK
2595/BLK
2315/BLK
SHT12/E8
SHT12/E8
SHT16/D5
2830/BLK 2220/BLK SHT13/G5

SHT9/C5 2625/BLK
SHT14/G6
2965/BLK 2420/BLK SHT13/G6
SHT17/G6 2610/BLK
2770/BLK SHT13/C6
2930/BLK 2640/BLK SHT9/D2
SHT9/G5 SHT11/G3 2230/BLK SHT13/C6
2545/BLK 2530/BLK SHT11/G4
SHT17/E4 2240/BLK SHT11/D3
2975/BLK SP4 2980/BLK 2490/BLK SP60 2495/BLK 2475/BLK
SHT17/E6 SHT16/G7 SHT12/C6 SP65
2615/BLK
2800/BLK 2600/BLK SHT16/G5 2845/BLK 2260/BLK SHT11/D2
SHT14/E1 SHT14/G4
SP12 FRAME
2465/BLK 2400/BLK SHT13/G6 2645/BLK 2660/BLK 2250/BLK SHT12/D4
SHT17/E5 SHT12/C7 GND
2875/BLK 2135/BLK 2525/BLK 2605/BLK
SHT15/G5 SHT12/G6 SHT12/C6 T35 SHT12/C5
2470/BLK SHT16/G4 2200/BLK
SHT14/G4
2720/BLK
SHT14/D1
SHT8/E8
2165/BLK T26 2405/BLK 2840/BLK
LOWER CAB SHT14/E8 SHT18/D6
2175/BLK GND 2375/BLK 2850/BLK
SHT8/E8 SHT16/D5 SHT18/D6
SP15 SP66
2440/BLK 2715/BLK 2775/BLK 2635/BLK SHT13/C7
SHT16/D5
2125/BLK
SHT9/E8 2415/BLK 2235/BLK
SP7 SHT14/E8 SHT17/C7
2540/BLK 2115/BLK
SHT9/E7 2460/BLK 2225/BLK
SHT16/D5 SHT17/C4
2955/BLK
SHT9/C5
2205/BLK
2590/BLK 2815/BLK SHT15/G4
SHT8/G6 2160/BLK
SHT14/D7
2790/BLK 2765/BLK SHT16/G2
SHT12/G7
C700
2
5
0
5
/
B
L
K
SP8 2780/BLK
2805/BLK 2956/BLK SHT18/C4 SP64
2
5
2
0
/
B
L
K
2735/BLK SHT9/C4 SP13 2520/BLK 3 3
SHT8/G2 SP6
2
5
1
5
/
B
L
K
2995/BLK 2620/BLK 2215/BLK
SHT9/G8 SHT17/C5 SHT16/D7
2985/BLK
SHT6/G8 2425/BLK SHT9/E4 2195/BLK BOOM OPTION GROUNDS
SHT17/C2
2785/BLK
SHT17/G7
2580/BLK
C332
2
5
8
5
/
B
L
K
SHT8/G6
Dealer Copy -- Not for Resale SP24
2
8
2
5
/
B
L
K
2825/BLK 2 2
2
6
2
0
/
B
L
K
SHT18/D5
LOWER CAB GROUNDS FRAME GROUNDS BOOM LIGHTS GROUNDS
T17
ALTERNATOR
GND 2025/BLK
2890/BLK
SHT10/D5
SP29
2075/BLK 2860/BLK 2695/BLK
SHT8/C7 SHT18/C7
2130/BLK 2700/BLK
SHT8/C5 SHT10/G5
2445/BLK SP3
T23
SHT5/B7 2015/BLK ENGINE
2170/BLK GND
SHT7/D4 2880/BLK
2655/BLK
SHT18/C8 T32
SHT8/C7 2900/BLK UPPER CAB
SHT10/D4
2185/BLK GND
SHT8/D3 2450/BLK
SHT10/D7
2105/BLK
2275/BLK
SHT11/D4
2210/BLK 2870/BLK
SHT11/D5 SHT18/C7
SP10
2065/BLK 2895/BLK 2865/BLK
SHT8/C5 SHT10/D4
2095/BLK 2680/BLK
SHT8/C7 SP5 SHT10/D5
SHT8/C6
2155/BLK
WIRING SCHEMATIC
2245/BLK
SHT8/C5 Printable Version Click Here
2190/BLK
SHT12/C7
SHT11/C8
2480/BLK
UPPER CAB GROUNDS TL470 (S/N ANL711001 AND ABOVE)
T35 T24 (S/N ANMG11001 AND ABOVE)
FRAME
GND
2005/BLK ENGINE
GND
Sheet 6 of 18
ENGINE GROUNDS (PRINTED MARCH 2011)
496 of 770 Printed In Belgium 7159062

LOWER CAB FRAME ENGINE 100HP
C240-3
C240-4
CAN LO 1
CAN HI 1
9100/PUR/WHT
9000/PUR
C233
SP50 SP58 SP21 SP61 8 8

9120/PUR/WHT 9140/PUR/WHT 9160/PUR/WHT 9180/PUR/WHT 9300/PUR/WHT 9300/PUR/WHT
SP76
SP75 SP57 SP72 SP51 SP62 9 9

9020/PUR 9040/PUR 9060/PUR 9080/PUR 9200/PUR 9200/PUR
C230
9110/PUR/WHT
9130/PUR/WHT
9150/PUR/WHT
9190/PUR/WHT
9170/PUR/WHT
9010/PUR
9030/PUR
9050/PUR
9090/PUR
9500/PUR/WHT 9 9 12 11
C100
9070/PUR
9500/PUR/WHT
9600/PUR 10 10
12 11
9600/PUR
9320/PUR/WHT
C290
J1B-14
J1B-20
CAN LO 1
CAN LO 1
CAN LO 1
CAN LO 1
J1B-9
J1B-8
CAN HI 1
CAN HI 1
CAN HI 1
CAN HI 1
CAN LO 2
CAN HI 2
C250-2
C250-4
C237-5
C237-6
C238-4
C238-5
9220/PUR
A B
A B
DIAGNOSTIC SP53 9330/PUR/WHT C256-1
CONNECTOR
CAN HI 1
C433 B A C256-2
SP54 9230/PUR
CAN LO 1
9340/PUR/WHT
B A
9240/PUR
6/BLK
5/BLK
SP55 9350/PUR/WHT J2B-9
CAN HI 1
CAN BUS SP56 9250/PUR J2B-8

CAN LO 1
9360/PUR/WHT
9260/PUR
C501 B A
B A
CAN LO 1
J3B-8
J3B-9
CAN HI 1
ACD
ON BOOM
BOOM
WIRING SCHEMATIC

Sheet 7 of 18
497 of 770
HARNESS LOWER CAB PN 7162047 REF
ENGINE, IGNITION
SHT5/C3 SHT5/F1
1694/RNG/WHT
1696/RNG/WHT
1735/RNG/WHT
1320/RED/WHT
1390/RED/WHT
C210 C216
IGNITION C220 C250 FAN
SWITCH RSS KSS INVERTER
1 5 1 5 6 2 8
2730/BLK
1725/RNG/WHT
1370/RED/WHT
1360/RED/WHT
2 4 2 4 3 3 3 7
1720/RNG/WHT
2590/BLK
2580/BLK
2735/BLK
8320/TAN
8290/TAN
3320/LBL
3290/LBL
3270/LBL
3735/LBL
SP34
SP38 SHT6/E8 SHT6/E8 SHT6/E8
8300/TAN
3300/LBL
CRANK
FAN INVERTOR
BATT
BATT
IGN FBCK
RUN
C241-1
J1A-34
J1A-13
J1B-22
GATEWAY CONTROLLER
J1B-2
J1B-3
VARIABLE FAN SPEED RET

BATTERY DISCONNECT
ENGINE OIL PRESSURE

FUEL SOLENOID FBCK
VARIABLE FAN SPEED

DISPLAY
COOLANT TEMP.
FUEL SOLENOID
STARTER FBCK
ENGINE SPEED
FAN INVERTER
GLOW PLUGS
FUEL PUMP
J1B-15
J1B-16
J1B-25
J1A-16
J1A-20
J1A-17
J1A-32
J1A-15
STARTER
CONTROLLER
J1A-5
J1A-8
J1A-9
J1B-1
J1A-1
J1B-6
J1A-7
GND
GND
2165/BLK
2175/BLK
4160/LGN
SHT9/E3 R6
2630/BRN
4630/LGN
8070/TAN
8020/TAN
8030/TAN
8110/TAN
8120/TAN
8140/TAN
8040/TAN
3100/LBL
3170/LBL
3750/LBL
30 86 FAN
INVERTER
87 85 RELAY
SHT6/F8 SHT6/F8
2750/BRN
2570/BLK
4170
SHT18/E5
C233 1 2 3 4 23 15 20 12 13 14 11 6 7 5
1 2 3 4 23 15 20 12 13 14 11 6 7 5
SHT5/H5
2750/BRN
8070/TAN
1555/RNG/WHT
8030/TAN
8120/TAN
8040/TAN
1545/RNG/WHT
1520/RNG/WHT
4170/LGN
8140/TAN
1632/RNG/WHT
SP59
SP92
8080/TAN
2185/BLK
1560/RNG/WHT 1570/RNG/WHT 8050
SP18 D17 SHT6/C8
30 86 R21 30 86 R24 30 86 R25 T5 T8 R22
D2
STARTER FUEL SOLENOID FUEL PUMP GLOW PLUGS
87 85 RELAY 87 85 RELAY 87 85 RELAY T7 T6 RELAY
2910/BRN
2630/BRN
4630/LGN
2170/BLK
3100/LBL
3170/LBL
3750/LBL
4180/LGN
2180/BLK
SHT12/C8 SHT5/C7
2055
2751/BRN
8020/TAN
8010/TAN
8110/TAN
8100/TAN
8130/TAN
2095/BLK
2155/BLK
2245/BLK
2065/BLK
C158
C116
C115
1 2 2 1 2 1
SP41 SP16
SHT6/B8 1 2 2 1 2 1
SHT6/B8 SHT6/B8
8060/TAN
SHT5/H5 SHT5/B7 SHT6/B8
SHT5/H8
8090/TAN
2075/BLK
1540/RNG/WHT
SHT6/C8 T55 T56 T44 T45

1060/RED
1090/RED
8000/TAN
D1
1565/RNG/WHT
P
8085/TAN
2085/BLK
2130/BLK
1070/RED VARIABLE
ENGINE ENGINE FAN SPEED FAN
1080/RED COOLANT ENGINE OIL SPEED or INVERTER
T16 T18 T19 T20 TEMPERATURE PRESSURE SENSOR FAN BYPASS 4,6 OHM 12V
C105
C103
C113
S L 2 1 1 2 1 36-221 OHM 5,8 OHM PWM

C110
B+ B S
S L 2 1 1 2 1
WIRING SCHEMATIC
T54

T
FUEL ENGINE FUEL GLOW

ALTERNATOR STARTER SOLENOID
16 OHM 12V
TEMPERATURE
SWITCH
PUMP PLUGS (S/N ANMG11001 AND ABOVE)
Sheet 8 of 18
HARNESS ENGINE 100HP PN 7162049 REF (PRINTED MARCH 2011)

SHT5/C1 SHT5/C1
LOWER CAB
1745/RNG/WHT
1740/RNG/WHT
1940/RNG/WHT
1935/RNG/WHT
1950/RNG/WHT
1920/RNG/WHT
1845/RNG/WHT
1850/RNG/WHT
C267 C242
C212 WASHER WIPER
C211 SWITCH SWITCH
AC SWITCH BLOWER 1941
SPEED 1937
2945 1942 INTERNALLY CONNECTED
C224 WITH PIN 1 - SEE SHEET 17/G5
1 5 1 3 4 6 8 14 11 8 LEFT LEVER
(HORN SWITCH) 1
2940/BLK
3 C 3 2 1 4 2 5 7 3 13 7
2620/BLK
7120/WHT
7110/WHT 2935/BLK
7040/WHT
7050/WHT
7020/WHT
7010/WHT
7030/WHT
2930/BLK
4
7080/WHT
7090/WHT
7100/WHT
SHT6/E5
SHT5/G8
C214 C213
BATTERY +
C240-1
IGNITION
C240-5
THERMOSTAT HEATER AND
MODULE BLOWER
GATEWAY CONTROLLER
A A B C E
DISPLAY
M CONTROLLER
C240-10
J1B-17
J1B-12
SENSOR GND
C240-2
C B D
FUEL LEVEL
BUZZER
2125/BLK
2540/BLK
GND
7170/WHT
7320/WHT
C283
2425/BLK
7130/WHT
2010/BRN
CAB
BUZZER
SHT6/F8 SHT6/F8
T59
2710/BRN SP40
SHT6/E5
2750/BRN
2020/BRN
2030/BRN
3330/LBL
7140/WHT
T51 T50 T60
SHT15/G7
P
PRESSURE SHT8/E4
SWITCH
SHT11/D1
C244-B C244-A
B A C
C230 4
C233 B A C
10
B A C 4
10 SP22
B A C
SHT6/G4
HARNESS FRAME PN 7162050 REF

2035/BRN
3335/LBL
7170/WHT
2770/BLK
7140/WHT
C243
SHT6/E5
B A
C424
1 2
2655/BLK
B A
1 2
1930/RNG/WHT
1955/RNG/WHT
1956/RNG/WHT
D18
7040/WHT
7050/WHT
7020/WHT
7010/WHT
7030/WHT
2830/BLK
2955/BLK
2956/BLK
7150/WHT
2650/BLK
FUEL LEVEL
C280
C227
C123
C281
C265
1 2 1 2 4 2 1 6 3 1 2 2 1 SENSOR
33 ~ 297 OHM HORN
3.5 Amps
1 2 1 2 4 2 1 6 3 1 2 2 1
12V SOCKET
15 Amps max. WIRING SCHEMATIC

SUSPENSION
AC CLUTCH
(COMPRESSOR)
48.00 Watts
FRONT/REAR
WASHER MOTOR
23.00 Watts
FRONT WIPER
MOTOR
.
32.00 Watts
SEAT
40.00 Watts
Sheet 9 of 18
499 of 770
UPPER CAB
C621 C620
BEACON ROOF WIPER
SWITCH SWITCH
1901 1902/RNG/WHT
2 8 1 3
3 7 2 8 7
2700/BLK
1905
2705/BLK
1880/RNG/WHT
1350/RED/WHT
1900/RNG/WHT
7060/WHT
7070/WHT
6000/PNK
SHT7/C6
1 4
C232
1 4
1880/RNG/WHT
SP20
SHT7/C6 SHT7/B6 SHT7/C6 SHT7/C6 SHT7/B6

1885/RNG/WHT
1890/RNG/WHT
1895/RNG/WHT
1350/RED/WHT
7060/WHT
7070/WHT
6680/PNK
6000/PNK
2450/BLK
2680/BLK
2890/BLK
2900/BLK
2895/BLK
C604
C603
C602
C608
C601
8 7 4 1 2 7 8 2 3 1 1 2 2 1 4 3
8 7 4 1 2 7 8 2 3 1 1 2 2 1 4 3
RADIO
7200/WHT
7210/WHT
7220/WHT
7230/WHT
SUPPLY
WIRING SCHEMATIC
- -
+ + Printable Version Click Here
T84 T85 T86 T87 T78 T79
RIGHT LEFT
SPEAKER
4 OHM
SPEAKER
4 OHM
DOME LIGHT
10.00 Watts
REAR WIPER
MOTOR
BEACON
55.00 Watts
ROOF WIPER
MOTOR TL470 (S/N ANL711001 AND ABOVE)
23.00 Watts 26.00 Watts
HARNESS UPPER CAB PN 7162048 REF
Sheet 10 of 18
500 of 770
TRANSMISSION
1915/RNG/WHT
1825/RNG/WHT
1830/RNG/WHT
1840/RNG/WHT
INTERNALLY CONNECTED C254
C224 WITH PIN 1 - SEE SHEET 17/G5
C219 CREEP
LEFT LEVER C225 C209 GEAR
1 DRIVE MODE ENABLE
(SPEED SELECTOR) FNR LEVER SELECTOR
SWITCH
1831
2640/BLK
3240/LBL
1 5 2 8 6 2 8
2740/BLK
NOT
CONNECTED
1615/RNG/WHT
12 4 5 6 4 3 2 1 3 7 3 7
2530/BLK
3470/LBL
3510/LBL
3520/LBL
3530/LBL
3670/LBL
3660/LBL
3650/LBL
3640/LBL
3430/LBL
3740/LBL
SHT7/G5
SHT6/G5
C230 21 27 28 26 25 24 23 22 15 3
21 27 28 26 25 24 23 22 15 3
3470/LBL
3510/LBL
3520/LBL
3530/LBL
3670/LBL
3660/LBL
3650/LBL
3640/LBL
3430/LBL
3240/LBL
4080/LGN
HIGH/LOW SPEED
FNR FORWARD
GEAR SELECTOR
FNR REVERSE
FNR NEUTRAL
LOW SPEED
AGRESSIVE MODE
SMOOTH MODE
CREEP ENABLE
CONV. 2 MODE
CONV. 1 MODE
J2A-28
J2A-31
J2B-22
C240-7
J2A-13
J2A-22
J2A-24
J2A-29
J2A-21
J2A-14
CREEP STATUS
DRIVE CONTROLLER GATEWAY
J2A-3
J2A-8
R9
GEAR 1/ICVD SWASH PLATE

30 86 LOW CONTROLLER
GEAR 2/DEFEAT VALVE

SPEED
1ST/2ND GEAR SWITCH

DRIVE PUMP FWD RET.
DRIVE PUMP REV RET.

DUMP VALVE RETURN
REAR SHAFT SPEED

RELAY
SERVO PRESSURE
VSENSOR 1 (5VDC)
INCHING SENSOR
ICVD RETURN
SENSOR GND
SWASH PLATE IN1
LOW SPEED FBCK
DRIVE PUMP REV.

DRIVE PUMP FWD
87 85
SWAH PLATE IN2
VSENSOR1
J2A-34
J2A-10
J2B-24
J2B-10
J2A-33
J2A-26
J2B-23
J2B-17
J2A-15
J2B-13
J2B-19
J1B-23
J1B-10
DISPLAY
J2B-25
J2A-2
J2A-1
J2B-4
J2B-5
J2B-1
DUMP VALVE
2280/BLK
CONTROLLER
2045/BRN
5030/YEL
2041/BRN
SHT17/E2 5041/YEL
4030/LGN
4050/LGN
3140/LBL
SHT15/H7
3380/LBL 5665/YEL 2060/BRN
SHT13/D4 SHT12/C5
SP84
SP31
2950/BRN
2670/BRN
2690/BRN
2150/BRN
4950/LGN
4670/LGN
4690/LGN
2041/BRN
3340/LBL
3350/LBL
3435/LBL
3210/LBL
4480/LGN
5041/YEL
SHT12/C5 5060/YEL 2665/BRN SHT13/D4
5000/YEL
5010/YEL
SP78
SP79
4250
4260
2050/BRN
5050/YEL
SP77
C100 5 16 15 6 7 8 9 26 27 29 28 20 10 22 Dealer
21 Copy25-- Not for Resale
5 16 15 6 7 8 9 26 27 29 28 20 10 22 21 25 SP89
3150/LBL
4260/LGN
SHT13/D3
2275/BLK
SHT5/E4
C458
2150/BRN
4250/LGN
SHT13/D3 3 1 2
3 1 2
2041/BRN
2455/BRN
SHT6/B8 SHT9/E3
1655/RNG/WHT
D12
2020/BRN
4270/LGN
4060/LGN
4020/LGN
4040/LGN
5041/YEL
2210/BLK
2270/BLK
2240/BLK
2260/BLK
5020/YEL
5455/YEL
3210/LBL
3155/LBL
2835/BRN
SP73
2950/BRN
2670/BRN
2690/BRN
4670/LGN
4690/LGN
4950/LGN
C251
C141
C451
C402
C126
C403
C127
5835/YEL 1 2 2 1 2 1 1 2 2 1 2 1 C B A
SP91 3 1 2 1 2
3 1 2 1 2
5435/YEL
1 2 2 1 2 1 1 2 2 1 2 1 C B A
1 2
Z1
2040/BRN
2435/BRN
5040/YEL
3340/LBL
3350/LBL
3435/LBL
1.00 k Ohms
4480/LGN
ICVD SWASH ICVD DEFEAT

2480/BLK
1ST/2ND PLATE VALVE VALVE ICVD REAR SHAFT GEAR 1 GEAR 2 INCHING
GEAR SWITCH 4,5 OHM PWM 8.2 OHM 12V MOTOR RPM SPEED SENSOR VALVE VALVE POTENTIOMETER
8,8 OHM 12V 8,8 OHM 12V 4,15 KOHM
C117
C121
C130
C135
C120
C142
2 1 2 1 2 1 2 1 4 2 3 1 A B C 30 / 40 KM ICVD TRANSMISSION 30/40 KM TRANSMISSION

TRANSMISSION
2 1 2 1 2 1 2 1 4 2 3 1 A B C
WIRING SCHEMATIC
P TL470 (S/N ANL711001 AND ABOVE)

LOW SPEED
(ACC. BEHAVIOUR)
4,6 OHM 12V
DUMP
VALVE
11.6 OHM 12V
DRIVE PUMP
FORWARD
8.4 OHM PWM
DRIVE PUMP
REVERSE
8.4 OHM PWM
SWASH PLATE
SENSOR
0.5 ~ 4.5V
SERVO PRESSURE
SENSOR
0,5 ~ 4,5V
Sheet 11 of 18
7159062
501 Printed
of 770 In Belgium
SHT5/F4 SHT5/F4
BRAKES
1835/RNG/WHT
1501/RNG/WHT
C286 C467
PARK BRAKE TRAILER BRAKE
BRAKE FAIL SWITCH PRESSURE RELEASE
PRESSURE (NA MACHINE) SWITCH
LAMP (EMEA)
1837
T91 2 8 2
2790/BLK
T90 3 7 3
1585/RNG/WHT
1590/RNG/WHT
2135/BLK
3090/LBL
3360/LBL
3000/LBL
SHT6/E8
SHT6/G5
C230 30 16
30 16
3360 3480/LBL
3090/LBL
SP96
PARK BRAKE
BRAKE FAIL PRESS. LAMP
BATT
BATT
J2A-30
DRIVE CONTROLLER
J2B-2
J2B-3
J2A-6
TRACTOR TRAILER B.V. FDBK
ITALIEN BRAKE PRESS. SW.

ITALIAN TRAILER B.V FDBK
SERVISE BRAKE PRESS.

TRACTOR TRAILER B.V.
ITALIAN TRAILER B.V.
PARK BRAKE PRESS.

PASSIVE BRAKE
J2B-15
J2B-16
J2B-21
J2A-11
J2A-23
J2B-26
J2B-11
J2B-12
J2A-4
J2B-18
IGN. SIGNAL
J2A-5
GND
GND
4140/LGN
4420/LGN
2585/BLK
2595/BLK
3390/LBL
3375/LBL
1630/RNG/WHT
R12 R13
30 86 TRACTOR TRAILER 30 86 ITALIAN TRAILER
SHT6/H1 SHT6/H1 BRAKE VALVE
RELAY
BRAKE VALVE
RELAY
87 85 (EMEA) 87 85
2485/BLK
2290/BLK
2300/BLK
SHT6/G1
SHT14/H8 1650/RNG/WHT
SP90
4190/LGN
1632/RNG/WHT
2250/BLK
3250/LBL
SHT17/E3 SHT16/D8
C100 19 17
C456
1 2
19 17
1 2
1632/RNG/WHT
SHT11/E3
SHT7/G4 SHT11/E4
P
2060/BRN
4190/LGN
4475/LGN
4605/LGN
2190/BLK
2475/BLK
2525/BLK
5060/YEL
2605/BLK
3525/LBL
3160/LBL
SHT8/D8 PARK BRAKE
PRESSURE
SWITCH
C150
C429
C428
C455
2 1 2 1 B A C 2 1
2 1 2 1 B A C 2 1
T98 T99
WIRING SCHEMATIC
P
P
TRACTOR TRAILER
BRAKE VALVE
ITALIAN TRAILER
BRAKE VALVE
ITALIAN BRAKE
PRESS. SWITCH
SERVICE BRAKE
PRESSURE
PASSIVE BRAKE
VALVE
9 OHM 12V 8 OHM 12V 0,5 ~ 4,5V ?? OHM 12V
EMEA TRACTOR EMEA ITALIAN GERMAN / NA

NA MACHINE
OPTION OPTION MACHINE Sheet 12 of 18
HARNESS ENGINE 100HP PN 7162049 REF HARNESS FRAME PN 7162050 REF
STEERING
1820/RNG/WHT
C200 C260
ICON CLUSTER STEER MODE
FRONT / REAR CRAB STEER 4 WHEEL STEER CRAB / 4 WHEEL
ALIGN. LAMP LAMP LAMP
1821
T95 T97
9 2
2400/BLK
2420/BLK
D E T94 T96
1 3 7
2220/BLK
3030/LBL
3040/LBL
3580/LBL
3570/LBL
3400/LBL
3420/LBL
SHT6/G5 SHT6/G5
REF
SHT17/E4 SHT6/G5
FRONT ALIGNMENT
REAR ALIGNMENT
CRAB STEER
4 WHEEL STEER
J1A-14
J1A-29
GATEWAY DRIVE
J1A-4
J1A-6
CONTROLLER CONTROLLER
STEERING PRESSURE
FRONT ALIGNMENT
REAR ALIGNMENT
J1A-19
J1A-23
J2A-25
J1B-4
J1B-5
CRAB STEER
4W STEER
4000/LGN
4220/LGN
3780/LBL
SP83
3635/LBL
3645/LBL
SP82
SP95
4010/LGN
4230/LGN
3455/LBL
C230 1 2 19 20 Dealer Copy -- Not for Resale C100 23
1 2 19 20 23
HARNESS ENGINE 100HP PN 7162049 REF

SHT11/E3 SHT11/D6
SHT11/E4 SHT11/D6
2665/BRN
2455/BRN
5665/YEL
5455/YEL
3665/LBL
3455/LBL
4010/LGN
4230/LGN
3635/LBL
3645/LBL
C425
C143
B A C B A C
B A C B A C
SHT5/D4 SHT5/D3
SHT6/F1 SHT6/G4
P P
1635/RNG/WHT
1645/RNG/WHT
STEERING PRESS. STEERING PRESS.

SENSOR SENSOR
2635/BLK
2645/BLK
2610/BLK
2230/BLK
0,5 ~ 4,5V 0,5 ~ 4,5V
EMEA TRACTOR EMEA TRACTOR

C421
C452
C422
C453
1 2 3 1 2 3 2 1 2 1 LS PUMP GEAR PUMP
1 2 3 1 2 3 2 1 2 1
WIRING SCHEMATIC

FRONT REAR CRAB STEER 4 WHEEL
ALIGNMENT
12V DC
ALIGNMENT
12V DC
VALVE
7.1 OHM 12V
STEER VALVE
7,1 OHM 12V
Sheet 13 of 18
Printed In Belgium HARNESS FRAME PN 7162050 REF 7159062
503 of 770
SHT5/E4
SHT5/G4 SHT5/G4 SHT12/D8
HYDRAULIC FILTER 1
LS PUMP
HYDRAULIC FILTER 2 WORKGROUP
1625/RNG/WHT
(CLOGGING (CLOGGING
INDICATOR 1) INDICATOR 2)
5V 5V
C256 P P
JOYSTICK
T80 T81 T82 T83 HARNESS LOWER CAB PN 7162047 REF

3
2200/BLK
2845/BLK
3200/LBL
3845/LBL
1600/RNG/WHT
1605/RNG/WHT
1650/RNG/WHT
4
2625/BLK
SP93
SHT6/G4 SHT14/G4
3840/LBL
SHT6/G4
SHT5/B4 SHT5/D1
HYD. FILTER
IGN. SIGNAL
BATT
BATT
J3B-21
J2A-32
WORKGROUP CONTROLLER DRIVE CONTROLLER GATEWAY CONTROLLER
J3B-2
J3B-3
HYD. OIL TEMPERATURE
SAFETY VALVE RETURN

RETRACT SWITCH NO
RETRACT SWITCH NC
1785/RNG/WHT
1300/RED/WHT
ATT RUN (RMT KEY)
BOOM RETRACT RET
BOOM EXTEND RET
BOOM DOWN RET
INLET PRESSURE
AUX A4 RETURN
AUX B4 RETURN
TILT DOWN RET
BOOM RETRACT
BOOM UP RET
SAFETY VALVE
BOOM ANGLE 1
BOOM ANGLE 2
BOOM EXTEND
J3B-15
J3B-16
J3B-23
J3B-17
J3B-24
J3B-10
J3B-18
J3A-13
J3A-21
J3A-26
J3A-10
J3B-13
J3A-27
J3B-19
J3A-18
J2A-27
J2A-18
J2A-20
J1B-19
J1B-21
SENSOR GND
J3B-6
J3A-2
J3B-7
J3A-1
J3B-4
J3B-5
J2B-6
J2B-7
J1A-2
BOOM DOWN
TILT UP RET
TILT DOWN
VSENSOR1
BOOM UP
TILT UP
AUX A4
AUX B4
GND
GND
2405/BLK
2415/BLK
C290
2800/BLK
3700/LBL
3720/LBL
D F E G
D F E G
2920/BRN
4920/LGN
3835/LBL
DIAGNOSTIC
SHT6/F4 SHT6/F4 CONNECTOR
SP26
3710/LBL
SHT6/G8
2070/BRN
5070/YEL
C100 24 38 39 11
Dealer Copy -- Not for Resale C230
24 38 39 11
5100/YEL SP17
SHT16/D6
SP63
2100/BRN
SHT16/D6 SHT6/E4
HARNESS ENGINE 100HP PN 7162049 REF

SHT5/C5 SHT5/C5 SHT6/F4
3710/LBL
2360/BRN
2380/BRN
2320/BRN
2340/BRN
2350/BRN
2330/BRN
2410/BRN
2430/BRN
4360/LGN
4380/LGN
4320/LGN
4340/LGN
4350/LGN
4330/LGN
4410/LGN
4430/LGN
SHT11/D6
2920/BRN
4920/LGN
SHT5/D3
1705/RNG/WHT
1425/RED/WHT
2720/BLK
SHT11/D6
1660/RNG/WHT
2835/BRN
5835/YEL
3835/LBL
2080/BRN
2090/BRN
2140/BRN
5080/YEL
5090/YEL
2160/BLK
3180/LBL
3190/LBL
3440/LBL
3450/LBL
3460/LBL
C433 D H F E G
D H F E G
C423
C144
C A B 2 1
6M PN 7162054 REF
7M PN 7162055 REF
GND/GN/YE
C A B 2 1
W/L3/BLK
U/L1/BLK
V/L2/BLK
HARNESS BOOM
8/BLK
C501
P D C 2 1 3
D C 2 1 3
INLET PRESSURE SAFETY
SENSOR VALVE
0,5 ~ 4,5V 5,3 OHM 12V ACD CONNECTOR
LS PUMP
C414
C418
C419
C436
C420
C412
C413
C416
C400
C415
C417
1 4 7 8 2 5 A B 1 3 2 4 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
1 4 7 8 2 5 A B 1 3 2 4 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
WIRING SCHEMATIC

BOOM UP BOOM DOWN TILT UP TILT DOWN BOOM EXTEND BOOM RETRACT AUX A4 AUX B4
BOOM ANGLE
SENSOR
0,5 ~ 4,5 V
HYDRAULIC
OIL TEMP
815-1696 OHM
RETRACT
SWITCH
12V DC
A1 VALVE
4.7 OHM PWM
B1 VALVE
4.7 OHM PWM
A2 VALVE
4.7 OHM PWM
B2 VALVE A3 VALVE
4.7 OHM PWM 4.7 OHM PWM
B3 VALVE VALVE
4.7 OHM PWM 4.7 OHM PWM
VALVE
4.7 OHM PWM (S/N ANMG11001 AND ABOVE)
HYDRAULIC BLOCK Sheet 14 of 18
504 of 770
FRAME LVL
1810/RNG/WHT
5010/YEL
LLM SYSTEM
C255 C200
FRAME LEVELING ICON CLUSTER
POTENTIOMETER FRAME LVL
LAMP SHUNT KEY
T68
1875/RNG/WHT
1815/RNG/WHT
2
1 3 B T69
3080/LBL
2710/BRN
3010/LBL
3020/LBL
3310/LBL
2875/BLK
2815/BLK
REF
SHT17/E4
C230
SHT9/E3 6 C238 3 1 2 C237 1 2 C230 8
6 3 1 2 1 2 8
3310/LBL
SHUNT KEY
FRAME LVL
GATEWAY CONTROLLER
LLMC OK
PWR SUPPLY
LLMC STATUS
PWR SUPPLY
GND
GND
J1A-11
J1B-24
J3A-14
LLMC CONTROLLER LLMI DISPLAY WORKGROUP
FRAME LVL 1 RET.
FRAME LVL 2 RET.

J1A-10
J1B-13
J1A-18
J1B-26
SENSOR +
SENSOR +
SENSOR -
SENSOR -
CONTROLLER
FRAME LVL 1
FRAME LVL 2
CAN LO
CAN LO
CAN HI
CAN HI

2970/BRN
2990/BRN
4970/LGN
4990/LGN
C236 1 2 3 4
C248
C247
1 2 3 4 4 3 2 1
1 2 3 4
1 2 3 4 4 3 2 1
C229 1 2 3 4 5 6 7 8
2970/BRN
2990/BRN
4970/LGN
4990/LGN
1 2 3 4 5 6 7 8
C444
C445
2 1 2 1
2 1 2 1
WIRING SCHEMATIC
FRAME FRAME
LEVELING 1 LEVELING 2 LLM SENSOR
X OHM PWM X OHM PWM (S/N ANMG11001 AND ABOVE)
HARNESS FRAME LVL PN 7186857 REF LLMI & LLMC Sheet 15 of 18
NA MACHINE EMEA MACHINE
505 of 770
AUXILIARY HYDRAULIC
SHT5/C1 SHT5/C1 SHT5/C1 SHT5/F1
1795/RNG/WHT
1800/RNG/WHT
1805/RNG/WHT
1750/RNG/WHT
C284 C257 C258 C259
C217 C205 ACD LH SKI ACD ATTACH SKI ACD RH SKI
BOOM REAR AUX / HOOK C205 HYDRAULIC
6 2 8 QUICKTACH SWITCH SWITCH SWITCH
SUSPENSION SWITCH REAR AUX
SWITCH 1807
1796 1801 1802 SWITCH 1755 1760 1765 1770 1775
OPTION
3495/LBL
6 2 8 2 5 8 2 8 2 8 2 8
1665/RNG/WHT
9 2 8
1 7
2395/BLK
3410/LBL
C205
2 8 HYD HOOK
3 7 3 6 7 1 3 7 1 3 7 1 3 7
1 3 7 SWITCH
OPTION
2495/BLK
2470/BLK
2396 2755/BLK 2760/BLK
2765/BLK
2600/BLK
3590/LBL
3870/LBL
3800/LBL
3810/LBL
3 7
3550/LBL
3540/LBL
3230/LBL
3220/LBL
3610/LBL
3600/LBL
SHT6/G5 SHT6/G5 SHT6/G5
SHT6/E5
C230 17 18 7 12 5 13
17 18 7 12 5 13
3590/LBL
3800/LBL
3810/LBL
3870/LBL
ACD LT SKI DOWN
ACD ATTACH SKI LT

BOOM SUSP.
ACD LT SKI UP
ACD ATTACH SKI RH
ACD RH SKI DOWN
ACD RH SKI UP
HYD. QUICKTACH
HYD. HOOK
REAR AUX
WORKGROUP CONTROLLER
J3A-22
J3A-30
J3A-29
J3B-22
J1A-21
J1A-24
J1A-28
J1A-31
J1A-22
J1A-30
HYDRAULIC QUICKTACH
REAR DIVERTER 2 FDBK
BOOM VALVE 1 FDBK
BOOM VALVE 2 FDBK
BOOM PRESSURE 1
BOOM PRESSURE 2
BOOM OPT. VALVE 1
BOOM OPT. VALVE 2
DIVERTER SWITCH
REAR DIVERTER 2
REAR DIVERTER 1
J3A-28
J3A-16
J3A-25
J3A-31
J3A-33
J3B-26
J3B-25
J3A-3
J3A-6
J3B-1
J3A-5
GATEWAY CONTROLLER
4370/LGN
4290/LGN
4450/LGN
3495/LBL
3490/LBL
3500/LBL
30 86
R14
30 86
R15 R16
30 86 Dealer Copy -- Not for Resale
4580/LGN
BOOM OPTION BOOM OPTION REAR
2395/BLK
VALVE 1 VLAVE 2 DIVERTER 2
87 85 RELAY 87 85 RELAY RELAY 87 85
2310/BLK
2315/BLK
2305/BLK
4460/LGN
2375/BLK
3370/LBL
2300/BLK
SHT12/D6
SHT14/D8 SHT6/F4
SHT6/H1 D4
D7
2100/BRN
4390/LGN
4300/LGN
4440/LGN
2520/BLK
5100/YEL
2460/BLK
2440/BLK
3110/LBL
3120/LBL
3560/LBL
4470/LGN
4590/LGN
2370/BLK
2390/BLK
C431
C432
C435
C460
C700 1 3 2 4 5 7 6 2 1 A B 2 1 1 2
1 3 2 4 5 7 6 2 1 A B 2 1 1 2
2100/BRN
2520
5100/YEL
4390/LGN
4300/LGN
2515/BLK
2505/BLK
SP64 SP35
SP36
D15 D16
2110/BRN
2120/BRN
5120/YEL
5110/YEL
3110/LBL
3120/LBL
REAR REAR HYDRAULIC

FRONT/REAR QUICKTACH
4400/LGN
4310/LGN
2500/BLK
DIVERTER 2 DIVERTER 1
2510/BLK
DIVERTER SWITCH VALVE

2,4 OHM 12V 6,8 OHM 12V
X OHM 12V
REAR AUXILIARY
C701
C702
C704
C703
2 1 2 1 B A C B A C
OPTION
2 1 2 1 B A C B A C
WIRING SCHEMATIC
P P
BOOM OPTION BOOM OPTION BOOM PRESSURE BOOM PRESSURE

VALVE 1 VALVE 2 SENSOR 1 SENSOR 2
? OHM 12V ? OHM 12V ?V ?V (S/N ANMG11001 AND ABOVE)
Sheet 16 of 18
HARNESS BOOM OPTION VALVES PN 7169711 REF HARNESS FRAME PN 7162050 REF
506 of 770
SHT5/C4 SHT5/G1
STD LIGHTS
INTERNALLY CONNECTED
SEE SHEET 11/H7 AND

1965/RNG/WHT
1975/RNG/WHT
1990/RNG/WHT
1995/RNG/WHT
1680/RNG/WHT
1330/RED/WHT
C272 C270 C224 C224
SHEET 9/G2
WITH PIN 1
FOG LIGHT TRAILER WARNING LEFT LEVER LEFT LEVER
SWITCH INDICATOR SWITCH (TURN SWITCH) (HEAD LIGHTS)
LAMP
1987 1967
2 8 T92 1 3 8 9 1 1 6 8
1
10 2965/BLK
3 7 T93 2 5 17 18 SHT5/G8 10 11 2 3 5 7
1980/RNG/WHT
6620/PNK 1977/RNG/WHT
2785/BLK
2985/BLK
6690/PNK
6610/PNK
1985/RNG/WHT
1970/RNG/WHT
6600/PNK
3770/LBL
JUMPER
SHT6/E8 SHT6/E8
7,5A
7,5A
6500/PNK
6540/PNK
F10
F9
3070/LBL
3050/LBL
POSITION LIGHTS STATUS
J1A-12
DISPLAY DRIVE CONTROLLER
C200
LAMP TRAILER(C2)
OUTPUT(49a)
SUPPLY(49)
CONTROLLER
6
4
C221 ICON CLUSTER
FLASHER POSITION/LOW BEAM
STOP LIGHT FBCK

ICON VEHICLE(C)
C240-11
C240-8
REVERSE LIGHT
RELAY LAMPS
TURN SIGNAL
STOP LIGHT
J2A-12
HIGH BEAM
GATEWAY
J2A-9
J2A-7
GND(31)
CONTROLLER F G
5
6010/PNK
2975/BLK
3130/LBL
6180/PNK
6070/PNK
3690/LBL
6130/PNK
6630/PNK
6700/PNK
3280/LBL
H
3060/LBL
6230/PNK
2465/BLK
1997 1685
SHT6/G8 R1 R2 R11 R10
LOW 30 86 30 86 HIGH STOP 30 86 30 86 REVERSE
BEAM BEAM LIGHT LIGHT
RELAY 87 85 87 85 RELAY RELAY 87 85 87 85 RELAY
SHT6/G8
2550/BLK
2280/BLK
2555/BLK
2290/BLK
6190/PNK
2545/BLK
2285/BLK
6510/PNK SHT6/G8 SHT18/E5 SHT12/D7 SHT11/F8
6550/PNK
C230 40 37 36 32 33 34 35
40 37 36 32 33 34 35
6510/PNK
6130/PNK
6630/PNK
6700/PNK
6230/PNK
6550/PNK
6520/PNK
6560/PNK SP27
SP28
6080/PNK
SP49 SP46 6710/PNK
6010/PNK
SP45 SHT6/E4
6250/PNK
SP48
SHT6/H4 SHT6/F1 6090/PNK SP43
6150/PNK
6650/PNK
6720/PNK
7190/WHT
2195/BLK
SP70 6280/PNK
SHT12/D4
SP71 6730/PNK
6160/PNK SP68 1 2
6660/PNK SP69 SHT6/E4 SHT6/F1
SHT6/H4
SP44 6030/PNK
6190/PNK
C401
6160/PNK
6020/PNK
6660/PNK
6520/PNK
6560/PNK
6140/PNK
6640/PNK
6260/PNK
6090/PNK
6730/PNK
6530/PNK
6570/PNK
6240/PNK
6710/PNK
2265/BLK
2235/BLK
2215/BLK
2225/BLK
BACK UP
ALARM
6220/PNK SP47 6210/PNK

WIRING SCHEMATIC
C303
C302
C305
C304
6030/PNK
6170/PNK
6670/PNK
6740/PNK
6200/PNK
6270/PNK
2145/BLK
4 3 1 5 2 2 6 4 3 1 4 3 1 5 2 2 6 4 3 1
4 3 1 5 2 2 6 4 3 1 4 3 1 5 2 2 6 4 3 1

C307
2 7 1 4 6 5 3
2 7 1 4 6 5 3
POSITION STOP FOG TURN LOW HIGH POSITION TURN TRAILER POSITION STOP REV TURN LOW HIGH POSITION TURN
REAR LEFT LIGHTS FRONT LEFT LIGHTS PLUG REAR RIGHT LIGHTS FRONT RIGHT LIGHTS Sheet 17 of 18
HARNESS FRAME PN 7162050 REF (PRINTED MARCH 2011)

OPTIONAL
1860/RNG/WHT
1865/RNG/WHT
LIGHTS
GATEWAY CONTROLLER
BLUE WK LIGHT
WORK LIGHT
J1A-3
J1B-7
6320/PNK
6390/PNK
6440/PNK
1867/RNG/WHT
R4
CAB WORK R3 R5
30 86 30 86 BLUE WORK 30 86 BOOM WORK
LIGHT
RELAY LIGHT LIGHT
87 85 87 85 RELAY 87 85 RELAY
2560/BLK
2565/BLK
6330/PNK
6400/PNK
2555/BLK
2570/BLK
6450/PNK

SHT17/E3 SHT8/E2
C232 2 C230 29 31
2 29 31
6330SP30
SHT6/D3
6450/PNK
6340/PNK
6400/PNK
6350/PNK
2850/BLK
2840/BLK
2825/BLK
C333 1 2 C334 1 2 C332 1 2 SHT6/E4
1 2 1 2 1 2
6280/PNK
2780/BLK
SP37
6400/PNK
2825/BLK
SHT6/C6 SHT6/C6 SHT6/B6 SP24
SP25 1 2
6480/PNK
6460/PNK
6470/PNK
6420/PNK
6410/PNK
2880/BLK
2860/BLK
2870/BLK
2820/BLK
2810/BLK
C306
6350/PNK
6340/PNK
2850/BLK
2840/BLK
LICENSE PLATE
LIGHT
10.00 Watts
C607
C606
C605
C504
C505
A B A B A B A B A B
WIRING SCHEMATIC
A B A B A B A B A B

T70 T71 T72 T73 (S/N ANMG11001 AND ABOVE)
REAR
WORK LIGHT
FRONT RIGHT
WORK LIGHT
FRONT LEFT
WORK LIGHT
LEFT BLUE
WORK LIGHT
RIGHT BLUE
WORK LIGHT
BOOM WORK
LIGHT LEFT
BOOM WORK
LIGHT RIGHT Sheet 18 of 18
50.00 Watts 50.00 Watts 50.00 Watts 55.00 Watts 55.00 Watts 50.00 Watts 50.00 Watts
HARNESS UPPER CAB PN 7162048 REF HARNESS BLUE LIGHTS HARNESS BOOM WK LIGHTS
Printed In Belgium LEFT PN 7178982 REF 6M PN 7169216 REF 7159062
508 of 770
RIGHT PN 7179236 REF 7M PN 7178823 REF
ELECTRICAL SYSTEM INFORMATION
WARNING
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Warning light comes ON. 5, 8, 9, 10, 11

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Description
The telescopic handler has a 12 volt, negative ground

alternator charging system. The electrical system is
protected by fuses on three locations. (See Fuses And
Relay Location / Identification on Page 60-10-3.)
The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Fuses And Relay Location / Identification

5 9 11 13 15
The electrical system is protected by fuses and relays on 1 6 17
three locations:
2 18
• in the cab below the dashboard. (See Cab on Page
60-10-3.)
• on the front frame left of the boom. (See Frame on 3 19
Page 60-10-4.)
• in the front left corner of the engine compartment. 4 20
(See Engine Compartment on Page 60-10-5.) 7 10 12 14 16
8
Cab
S38028
Figure 60-10-1
The location and description are shown below and in

[Figure 60-10-3].
REF DESCRIPTION AMP REF DESCRIPTION AMP

1
1 A/C and Heater / 25 11 Blue Worklights R

ACD Switches
2 Headlights / 15 12 Fan Inverter R
2 Direction Lights /
Horn
3 Low / High Beam 15 13 High Beam R
4 Auxiliary Power 15 14 Not Used R
Outlet /
S38026 Suspension Seat
(If equipped)
5 Gateway 20 15 Low Beam R
Loosen the retainer screw (Item 1) and remove the Controller /
console cover (Item 2) [Figure 60-10-1]. Ignition Switch /
Radio / Warning
Figure 60-10-2 Lights
6 Display Panel / 7,5 16 Not Used R
LMMI / Switches
1 7 Front Wiper / 10 17 Park Lights Left / 7.5

Washers / Cab Fog Light
Buzzer / Travel
Direction Lever
8 Rear and Roof 20 18 Park Lights Right 7.5
Wiper / LLMC /
Radio Ignition /
Cab Light /
2 Beacon (If
equipped)
1
9 Cab Work Lights R 19 Cab Work Lights 20
10 Boom Worklight R 20 Boom and Blue 20
S38027
Work Lights
Remove retainer screws (Item 1) and remove the cover R - Relay

(Item 2) [Figure 60-10-2] to inspect or replace fuses or
relays.

ELECTRICAL SYSTEM (CONT’D) Figure 60-10-6
Fuses And Relay Location / Identification (Cont’d)
Frame 5 7 9 11 13
1 14 17
Figure 60-10-4
2 18
1 3 19
20
2
4 6 8 10 12 16 15
1 S38056

1
[Figure 60-10-6].
S38058 REF DESCRIPTION AMP REF DESCRIPTION AMP

1 Not Used — 11 Trailer Brake R

Remove the three bolts (Item 1) and remove the cover Valve (Tractor)
(Item 2) [Figure 60-10-4]. 2 Not Used — 12 Trailer Brake R
Valve (Italy only)
Figure 60-10-5 3 Not Used — 13 ACD 25
Ignition Supply
4 Trailer Brake 5 14 ACD Battery 25
Valve Supply
2 5 Rear Diverter R 15 Work Group 15
Controller
6 Low Speed R 16 Drive Controller 15
7 Boom Auxiliary R 17 Stop Lights / 10
Hydraulics 1 Reverse Light /
Back-up Alarm
8 Reverse Light R 18 Valves 15
1 9 Boom Auxiliary R 19 Joystick / Wheels 5
Hydraulics 2 Alignment /
Retract Switch /
S38059 Rear Shaft
Sensor / Ignition
Signal
Remove the two retainer screws (Item 1) (both sides) and 10 Brake Light R 20 Low Speed 7.5
remove the cover (Item 2) [Figure 60-10-5] to check or
replace fuses or relays.
R - Relay

ELECTRICAL SYSTEM (CONT’D)
Fuses And Relay Location / Identification (Cont’d)
Engine Compartment
Figure 60-10-7
1 3
2 4
6 7
5

8 9
S38030
S38060
S38061

[Figure 60-10-7].
REF DESCRIPTION AMP

1 Not Used —
2 Not Used —
3 Starter / Alternator 25
4 Fuel Shutoff / Fuel Pump / Engine Temp Switch 10
5 Master Fuse 100
6 Starter Relay R
7 Glow Plug Relay R
8 Fuel Shutoff Relay R
9 Fuel Pump Relay R
R - Relay


BATTERY Figure 60-20-2
Removing And Installing Battery
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
1
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention S38032
and wash eye with clean, cool water for at least 15
minutes.
Always disconnect the ground (-) cable (Item 1)
If electrolyte is taken internally drink large quantities [Figure 60-20-2] first to prevent sparks.
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Remove the positive (+) battery cable (Item 2)
W-2065-0807 [Figure 60-20-2].

Figure 60-20-3
Figure 60-20-1
1
1 4
1
6
2
2
1
3
5
S38032
S38031
Disconnect the connector (Item 1) and remove the cables

Remove the three bolts (Item 1) and remove the battery from the Battery Disconnect switch terminals (Item 2)
cover (Item 2) [Figure 60-20-1]. [Figure 60-20-3].
Remove the bolt (Item 4) located at the back end of the

hold down plate (Item 5) [Figure 60-20-3].
Remove the hold down plate (Item 5) including the

Battery Disconnect switch (Item 6) [Figure 60-20-3].
Remove the battery.

ELECTRICAL SYSTEM (CONT’D) Using A Booster Battery (Jump Starting)
Removing And Installing Battery (Cont’d) If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
Figure 60-20-4 operator’s seat and one person to connect and
disconnect the battery cables.
The Key switch must be OFF. The booster battery must
be 12 volt.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the Telescopic
P-09589 P-09590
Handler. (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
Always clean the battery terminals and cable ends when connected wrong.
I-2345-0311
installing a new or used battery [Figure 60-20-4].

When installing the battery, do not touch any metal parts
with the battery terminals.
Install the battery hold down plate and tighten the nuts. WARNING
Connect and tighten the battery cables. Connect the
ground (-) cable last to prevent sparks.
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
WARNING In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
BATTERY GAS CAN EXPLODE and cause minutes.
serious INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away If electrolyte is taken internally drink large quantities
from batteries. When jumping from booster battery of water or milk! DO NOT induce vomiting. Get
make final connection (negative) at machine frame. prompt medical attention.
W-2065-0807
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910

ELECTRICAL SYSTEM (CONT’D) Figure 60-20-7
Using A Booster Battery (Jump Starting) (Cont’d)
Figure 60-20-5
1
1 2
1
1
S39417
Connect the end of the second cable to the ground (-)

S38031 terminal of the booster battery. Connect the other end of
the same cable to the ground (-) terminal (Item 1)
[Figure 60-20-7] on the telescopic handler battery.
Remove the three bolts (Item 1) and remove the battery
cover (Item 2) [Figure 60-20-5]. Keep cables away from moving parts. Start the engine.

Figure 60-20-6 After the engine has started, remove the ground (-) cable
(Item 1) [Figure 60-20-7] first.
Remove the cable from the positive (+) terminal (Item 1)

[Figure 60-20-6].
Install the battery cover (Item 2) with the three bolts (Item
1 1) [Figure 60-20-5].
DANGER
Be aware that vehicle batteries contain gases that are
S39416 flammable and can explode violently. The following
precautions should be taken before making battery
connection:
Connect the end of the first cable to the positive (+) • Wear eye protection.
terminal of the booster battery. Connect the other end of • Remove all jewelry.
the same cable to the positive (+) terminal (Item 1) • Keep spectators away.
[Figure 60-20-6] of the telescopic handler battery.
In the event of a battery explosion, acid should be
flushed away immediately. Seek medical help as
soon as possible.
D-1032-1210


ALTERNATOR Figure 60-30-3
Stop the engine and open the engine cover. (See

3 3
Opening And Closing on Page 10-160-1.)
Figure 60-30-1
1
1 1
2
S38685
Remove the engine oil filter (Item 1) [Figure 60-30-3].

2
Remove the connector and charge cable (Item 2) [Figure
60-30-3] from the back of the alternator.
S38684
Remove both mounting bolts (Item 3) [Figure 60-30-3].

Remove the two bolts (Item 1) and remove the cover Remove the alternator.
plate (Item 2) [Figure 60-30-1] from the back side of the
engine compartment.
Figure 60-30-2
S38683
NOTE: The nut side of the bolt is also used to ground

the alternator. When installing, make sure to
reinstall the ground cable along with the nut.
Remove the alternator belt (Item 2) from the alternator

pulley (Item 3) [Figure 60-30-2].

ALTERNATOR (CONT’D) Figure 60-30-5
Belt Adjustment
The alternator belt is a special maintenance free type

that is pretensioned over the pulleys. This belt eliminates
the need for a tensioning device and does not require
periodic adjustment. Contact your Bobcat dealer for
replacement parts.
Belt Replacement
Stop the engine and open the engine cover (See 1

Opening And Closing on Page 10-160-1.).
Remove the air conditioning belt. (See Removal And S38738

Figure 60-30-6
Figure 60-30-4

2 2
S38683
S38046
Remove the lower alternator mounting bolt (Item 1)

[Figure 60-30-5] and loosen the two top alternator
Remove the two bolts (Item 1) and cover (Item 2) [Figure mounting bolts (Item 2) [Figure 60-30-6].
60-30-4].
NOTE: The engine is removed in [Figure 60-30-6] for
photo clarity.
Move the alternator toward the engine as far as it will go

and remove the belt from the pulleys. Inspect the pulleys
for wear.
Install new belt.

Install the top and bottom alternator mounting bolts
(Items 1 and 2) [Figure 60-30-5] and [Figure 60-30-6].
Do not yet fully tighten.
Use a wedge or prybar to move the alternator until the
bottom alternator mounting bolt (Item 1) [Figure 60-30-5]
can be installed.
Tighten the top alternator mounting bolts (Item 2) [Figure
60-30-6].
Install the air conditioning belt. (See Removal And
Install the cover (Item 2) [Figure 60-30-4].
Close the engine cover.

STARTER Removal And Installation
Testing Disconnect the ground (-) cable from the battery. (See
Figure 60-40-1
Turn the Starter switch OFF and remove the key.
Bat Open the engine cover. (See Opening And Closing on

S Page 10-160-1.)
M
Figure 60-40-3
Cranking
Motor
2
A-1992 1 3
The Starter switch must be in the OFF position.
The battery must be at full charge.

The cable connections on the battery must be clean and S39232
tight.
Connect a jumper wire between S terminal and BAT Disconnect the three wires from the starter ground
terminal [Figure 60-40-1]. terminal (Item 1) [Figure 60-40-3].
If the starter turns but does not turn the engine, the Installation: Tighten the nut to 12 N•m (8.9 ft-lb) torque.
starter drive has a defect.
Disconnect the three wires from the starter positive
Figure 60-40-2 terminal (Item 2) [Figure 60-40-3].
Installation: Tighten the nut to 8,5 N•m (75.2 in-lb)

Bat torque.
S
M Disconnect the wire from the start signal terminal (Item 3)
[Figure 60-40-3].
Installation: Tighten the nut to 6 N•m (53.1 in-lb) torque.

Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT’D)
Figure 60-40-4
S39233
Remove the three bolts (Item 1) [Figure 60-40-4] and

remove the starter.

Installation: Tighten to 54 - 61 N•m (40 - 45 ft-lb) torque.
NOTE: The starter is not serviceable. If starter is

damaged the entire assembly must be
replaced.

LIGHTS Figure 60-50-3
Rear Light Removal And Installation RIGHT REAR LIGHT
Figure 60-50-1
1
S38258
Disconnect the electrical connector (Item 1) [Figure 60-

S38254 50-2] and [Figure 60-50-3].
Figure 60-50-4
Remove the nut (Item 1) and shift the cover (Item 2)
[Figure 60-50-1] off the rear light support.

Figure 60-50-2 2 2
LEFT REAR LIGHT
1
1
S38255
Pull the cable (Item 1) [Figure 60-50-4] out of the rear

S38259 light support.
Remove the two nuts (Item 1) [Figure 60-50-4].

LIGHTS (CONT'D)
Rear Light Bulb Replacement
Figure 60-50-5
1
1
1 1
S38681
Remove the four lens retainer screws (Item 1)

[Figure 60-50-5]. Remove the lens.

Figure 60-50-6
1 1 1
1
S38682
Replace any bulbs (Item 1) [Figure 60-50-6] if

necessary.

LIGHTS (CONT'D) Figure 60-50-9
Front Light Removal And Installation
Figure 60-50-7
1
LEFT FRONT LIGHT
2
S38260
1 Pull the cable (Item 1) [Figure 60-50-9] out of the front

S38256 light support.
Remove the nut (Item 2) and remove the front light (Item
Figure 60-50-8 3) [Figure 60-50-9].
RIGHT FRONT LIGHT

1
S38257

50-7] and [Figure 60-50-8].

LIGHTS (CONT'D) Figure 60-50-12
Front Light Bulb Replacement
Figure 60-50-10
2
1 1
S36332
Disconnect the connector (Item 1) and remove the

1 indicator light (Item 2) [Figure 60-50-12].
S38686
Remove six screws (Item 1) [Figure 60-50-10] from the

light.

Figure 60-50-11
3
2 1
1
S38687
Disconnect the connectors (Item 1) and remove the lights

(Item 2 and 3) [Figure 60-50-11].

SIGNAL LEVER Figure 60-60-3
Figure 60-60-1
S38297
1
Disconnect the signal control wire connector (Item 1)
S39423 [Figure 60-60-3].
Figure 60-60-4
Rotate the Starter switch key (Item 1) [Figure 60-60-1] to
the left and remove the key, to disconnect power supply

from the battery.
2
Figure 60-60-2
1
1
2 S39159
Remove the screw (Item 1) and cover (Item 2)

[Figure 60-60-4] from the signal lever.
S38026
Loosen the retainer screw (Item 1) and remove the

console cover (Item 2) [Figure 60-60-2].

SIGNAL LEVER (CONT’D)
Figure 60-60-5
P-52347

the signal lever.

Route the harness out of the cowling and remove the
signal lever.

DISPLAY

Remove the main instrument panel. (See Right

Instrument And Indicator Panel Removal And Installation
on Page 60-80-1.)
Figure 60-70-1

1 1
S39050
Remove the two knob nuts (Item 1) [Figure 60-70-1].
Pull out the display (Item 2) [Figure 60-70-1].
Figure 60-70-2
1 2
S36729
Disconnect the two connectors (Item 1) [Figure 60-70-2].
Remove the display (Item 2) [Figure 60-70-2].


INSTRUMENT PANELS Left Instrument Panel Removal And Installation
Right Instrument And Indicator Panel Removal And Disconnect the ground (-) cable from the battery. (See
Installation Removing And Installing Battery on Page 60-20-1.)
Disconnect the ground (-) cable from the battery. (See Figure 60-80-3
Figure 60-80-1
1
1
1
1
1
1
S38688
S38179 Remove the four screws (Item 1) [Figure 60-80-3] from

the left instrument panel.
Remove the four screws (Item 1) [Figure 60-80-1]. Figure 60-80-4
Figure 60-80-2
S38689
S38731
Pull out the left instrument panel (Item 1) [Figure 60-80-
4].
Disconnect the harness connectors from the back of the
switch panel [Figure 60-80-2]. Reconnect the ground (-) cable to the battery. (See
NOTE: Mark all connectors for ease of installation.
Remove the switch panel (Item 1) [Figure 60-80-2].
Reconnect the ground (-) cable to the battery. (See


INSTRUMENT PANELS (CONT’D)
Left Instrument Panel Removal And Installation

(Cont’d)
Figure 60-80-5
S38733
Disconnect the harness connectors from the back of the

switch panel [Figure 60-80-5].
NOTE: Mark all connectors for ease of installation.
Remove the switch panel.

BOOM ANGLE SENSOR Figure 60-90-3
Removal And Installation 2

1
Figure 60-90-1
1 1 3
S39433
2
Remove the nut (Item 1) from the connecting rod (Item 2)
S39070 and remove the rod from the boom angle sensor (Item 3)
[Figure 60-90-3].
Remove the two bolts (Item 1) (both sides) and remove Remove the two screws (Item 4) from the boom angle
the cover (Item 2) [Figure 60-90-1] from the back of the sensor (Item 3) [Figure 60-90-3].

boom.
Remove the boom angle sensor (Item 3) [Figure 60-90-
Figure 60-90-2 3].
S39396
Disconnect the electrical connector (Item 1) from the

boom angle sensor (Item 2) [Figure 60-90-2].

BOOM ANGLE SENSOR (CONT’D) Figure 60-90-5
Calibration
Connect the service tool to the telescopic handler.

(See REMOTE START TOOL (SERVICE TOOL) KIT -
MEL1563 on Page 10-200-1.)
7003031 on Page 10-201-1.)
Figure 60-90-4
2
EM7539
Fully lower the boom (display is showing [DOWN°])

[Figure 60-90-5].
Press the joystick lockout button (Item 3) [Figure 60-90-

4] once to validate and move to the next step.
1

3 Figure 60-90-6
S39434
Press the information button (Item 1) to cycle the display

screen (Item 2) [Figure 60-90-4] until the boom angle
menu is displayed. (See Operation & Maintenance

4] for 3 seconds until the boom angle calibration mode
[Figure 60-90-5] appears on the display screen.
NOTE: A service tool must be connected to the

telescopic handler in order to perform this
procedure. EM7540
Fully raise the boom (display is showing [UP°])

[Figure 60-90-6].

4] once to validate and finish the procedure.

BOOM ANGLE SENSOR (CONT’D)
Calibration (Cont’d)
Figure 60-90-7
EM8037
If calibration is successful, [STORE] [Figure 60-90-7]

appears on the display screen. The two calibration points

have been saved now.
Figure 60-90-8
EM7537
If an error occurred during calibration, [FAIL] [Figure 60-

90-8] appears on the display screen. Redo the calibration
procedure until the calibration is successful.
Press the information button (Item 1) [Figure 60-90-4]

once to return to the engine hour menu.


FRONT WIPER MOTOR Figure 60-100-3
Remove the dash cover. (See Removal And Installation

on Page 50-120-1.) 1
Figure 60-100-1
1
1
S38265
2 2 Remove both nuts (Item 1) [Figure 60-100-3].
Figure 60-100-4
S38262

1
Flip the wiper covers (Item 1) and remove the two nuts
(Item 2) [Figure 60-100-1]
Figure 60-100-2
2
S38265
Remove both plastic rings and seals (Item 1) [Figure 60-

100-4].
S38261
Remove the wiper arms (Item 1) [Figure 60-100-2] from

the wiper motor shafts.
Remove the window washer tube (Item 2) [Figure 60-

100-2].

FRONT WIPER MOTOR (CONT’D)
Figure 60-100-5
S38264
Disconnect the front wiper connector (Item 1) [Figure 60-

100-5] from the main harness.

Figure 60-100-6
S38263
Remove the wiper motor (Item 1) [Figure 60-100-6] from

inside the cab.

TOP WIPER MOTOR Figure 60-110-3
Figure 60-110-1
1 1
1
1 2
S38270
1
Disconnect the rear window washer tube (Item 1)
S38267 [Figure 60-110-3].
Disconnect the rear wiper motor connector (Item 2)

Remove the five screws (Item 1) [Figure 60-110-1] from [Figure 60-110-3].
the upper panel.

Figure 60-110-4
Figure 60-110-2
3
2
1
1
S38269
S38268
Disconnect the left speaker electrical connectors (Item 1)

Disconnect the right speaker electrical connectors (Item [Figure 60-110-4].
1) [Figure 60-110-2].
Remove the roof panel.
Disconnect the roof console electrical connectors (Item
2) [Figure 60-110-2].
Disconnect the cab light electrical connector (Item 3)

[Figure 60-110-2].

TOP WIPER MOTOR (CONT’D) Figure 60-110-7
Figure 60-110-5
1 S38272
Flip open the wiper cover (Item 1) and remove the nut
S38271 (Item 2) [Figure 60-110-7].
Figure 60-110-8
Disconnect the top wiper electrical connector (Item 1)
[Figure 60-110-5].

Figure 60-110-6
1
S38272
2
S38273
Remove the plastic ring and rubber seal (Item 2)
[Figure 60-110-8].
Remove the window washer tube (Item 1) [Figure 60-
110-6]. Remove the nut (Item 3) [Figure 60-110-8].
Remove the cap (Item 2) [Figure 60-110-6]. Remove the top wiper motor from inside the operator
cab.

REAR WIPER MOTOR Figure 60-120-3
Figure 60-120-1
1 1
1
1
2
S38270
1
Disconnect the rear window washer tube (Item 1)
S38267 [Figure 60-120-3].
Disconnect the rear wiper motor connector (Item 2)

Remove the five screws (Item 1) [Figure 60-120-1] from [Figure 60-120-3].
the upper panel.

Figure 60-120-4
Figure 60-120-2
3
2
1
1
S38269
S38268
Disconnect the left speaker electrical connectors (Item 1)

Disconnect the right speaker electrical connectors (Item [Figure 60-120-4].
1) [Figure 60-120-2].
Remove the roof panel.
Disconnect the roof console electrical connectors (Item
2) [Figure 60-120-2].
Disconnect the cab light electrical connector (Item 3)

[Figure 60-120-2].

REAR WIPER MOTOR (CONT’D) Figure 60-120-7
Figure 60-120-5
1
2
S38277

S38275
Remove the plastic ring (Item 2) [Figure 60-120-7].
Remove the two screws (Item 1) [Figure 60-120-5]. Remove the cap (Item 3) [Figure 60-120-7].

Figure 60-120-6 Figure 60-120-8
3 1
1 2
S38276 S38278
Remove the window washer tube (Item 1) [Figure 60- Remove the nut (Item 1) [Figure 60-120-8].
120-6].
Remove the rear wiper motor inside the operator cab.
Flip open the wiper cover (Item 2) and remove the nut
(Item 3) [Figure 60-120-6].

REAR WIPER MOTOR (CONT’D)
Figure 60-120-9
S38279
Inspect the grommets (Item 1) [Figure 60-120-9].

Replace if necessary.


PEDAL ASSEMBLY Figure 60-130-3

Figure 60-130-1 1
1 1
S39148

2 1
Figure 60-130-4
S38084

cab.
1
Figure 60-130-2
1
3 1
S39150
1
Remove the three fittings (Item 1) [Figure 60-130-4].

2
1
1
S39131
Remove the three hoses (Item 1) and the tubeline (Item

2) from the brake valve (Item 3) [Figure 60-130-2].

PEDAL ASSEMBLY (CONT’D) Figure 60-130-7
Figure 60-130-5
S39149
Remove the pedal assembly [Figure 60-130-7].

S39061
Figure 60-130-8

inside the operator cab.

1
Figure 60-130-6
2
S39151
1
Remove the two bolts (Item 1) and remove the brake
1 valve (Item 2) [Figure 60-130-8].
S39132

inside the operator cab.

INCHING SENSOR Figure 60-140-3

Figure 60-140-1
1 S39062
Remove the screws (Item 1) [Figure 60-140-3].
Installation: Perform the adjustment procedure after

installation. (See Calibration on Page 60-140-2.)
S39060
Remove the switch.

Remove the cover (Item 1) [Figure 60-140-1] from the
inching sensor.
Figure 60-140-2
S39061
Disconnect the connector (Item 1) [Figure 60-140-2].

INCHING SENSOR (CONT’D) Figure 60-140-5
Calibration
Connect the service tool to the telescopic handler.

MEL1563 on Page 10-200-1.)
7003031 on Page 10-201-1.)
Figure 60-140-4
2
EM7535
Fully release the brake pedal (display is showing [UP])

[Figure 60-140-5].
Press the AUX button (Item 3) [Figure 60-140-4] once to

validate and move to the next step.
1

3 Figure 60-140-6
S39432
Press the information button (Item 1) to cycle the display

screen (Item 2) [Figure 60-140-4] until the engine hours
menu is displayed. (See Operation & Maintenance
Press the AUX button (Item 3) [Figure 60-140-4] for 3

seconds until the inching calibration mode [Figure 60-
140-5] appears on the display screen.
NOTE: A service tool must be connected to the

telescopic handler in order to perform this
procedure. EM7536
Position the brake pedal at the brake point (display is

showing [BR]) [Figure 60-140-6].
NOTE: The brake point is the pedal position where

the brake pedal first touches the brake valve.
NOTE: Approximately the first half of the total brake

pedal travel is for inching control.

validate and move to the next step.

INCHING SENSOR (CONT’D) Figure 60-140-9
Calibration (Cont’d)
Figure 60-140-7
EM7537
If an error occurred during calibration, [FAIL] [Figure 60-

EM7537 140-9] appears on the display screen. Redo the
calibration procedure until the calibration is successful.
Fully press the brake pedal (display is showing [DN]) Press the information button (Item 1) [Figure 60-140-4]
[Figure 60-140-7]. once to return to the engine hour menu.

validate and finish the procedure.
Figure 60-140-8
EM8037
If calibration is successful, [STORE] [Figure 60-140-8]

appears on the display screen. The three calibration
points have been saved now.


SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool) -
6689778
Connecting Remote Start Tool (Service Tool) -
MEL1563 Figure 60-150-2
Figure 60-150-1
1 2
2
3
1
P-76450
P16119 The tools listed will be needed to do the following

procedure:
Order from Bobcat Parts P/N: 6689779 - Remote Start
are:

Tool (Service Tool) Kit. Kit Includes:
MEL1563 - Remote Start Tool
6689778 - Remote Start Tool (Service Tool)
MEL1565 - Service Tool Harness Control
6689747 - Telescopic Handler Service Tool Harness
MEL1566 - Service Tool Harness Communicator
6689746 - Computer Service Tool Harness
(Computer Interface)
6689745 - BOSS® Service Tool Harness
NOTE: Make all connections with the key in the OFF
NOTE: Make all connections with the key in the OFF
position.
position.
The Service PC (Item 1) with the remote start tool (Item
The Service PC (Item 1) with the Remote Start Tool
2) [Figure 60-150-1]. When connected to the telescopic
(Service Tool) (Item 2) [Figure 60-150-2]. When
handler, the Service PC is used to monitor, conduct
connected to the telescopic handler, the Service PC is
diagnostic and load software.
used to monitor, conduct diagnostics, and upgrade
software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 60-150-1] to the designated
Connect the Remote Start Tool (Service Tool) Computer
serial port on the Service PC.
Service Tool Harness (Item 3) [Figure 60-150-2] to the
designated serial port on the Service PC.
NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
NOTE: The recommended serial cable length should
15 feet will create a degraded signal causing
not exceed 15 feet. A serial cable longer than
communication errors.
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the Remote
Start Tool.
Connect the other end to the connector on the Remote
Start Tool (Service Tool).
Connect the Remote Start Tool to the telescopic handler.
Connect the Remote Start Tool (Service Tool) to the
MEL1563 on Page 10-200-1.)
telescopic handler. (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 on Page 10-201-1.)
NOTE: Refer to BobcatNET for PC requirements and
the latest Service Analyzer software.
NOTE: Refer to BobcatNET for PC requirements and
the latest Service Analyzer software.


FUEL LEVEL SENDER Figure 60-160-3
Figure 60-160-1
S39067
1
Remove the two fuel lines (Item 1) [Figure 60-160-3]

S39066 from the fuel filter / water separator.

Install a suitable container, large enough to contain all
fuel from the fuel tank, under the drain plug (Item 1) Figure 60-160-4

[Figure 60-160-1].
Remove the drain plug (Item 1) [Figure 60-160-1]. 1 1
Figure 60-160-2
2
1
S39137
Remove the bolts (Item 1) and remove the step (Item 2)

[Figure 60-160-4].
S39064
NOTE: Support the step while removing the bolts.

Remove the operator cab floor mat.

FUEL LEVEL SENDER (CONT'D) Figure 60-160-7
Figure 60-160-5
1 1
S38008
Remove the two nuts (Item 1) and filter cover (Item 2)

S38291 [Figure 60-160-7].
Figure 60-160-8
Fully support the fuel tank using an appropriate lifting
device [Figure 60-160-5].

Figure 60-160-6
1
1
1
1
S38009
1

S38086

FUEL LEVEL SENDER (CONT'D) Figure 60-160-11
Figure 60-160-9
S38090
Disconnect the fuel level sensor connector (Item 1)

S38087 [Figure 60-160-11].
Figure 60-160-12

Figure 60-160-10
1 S39810
S38088 Remove the fuel level sender (Item 1) [Figure 60-160-

12].
Lower the fuel tank for approximately 200 mm (8 in).

FUEL LEVEL SENDER (CONT'D)
Figure 60-160-13
P-85716
Inspect the fuel level sender and replace if worn or

damaged [Figure 60-160-13].

JOYSTICK Figure 60-170-3
Figure 60-170-1
1
1
S39172
Remove the joystick (Item 1) [Figure 60-170-3] from the

2 joystick panel.
S39811

(Item 2) [Figure 60-170-1]
Figure 60-170-2
2
2 2
1
S38241

170-2]
Remove the four nuts (Item 2) [Figure 60-170-2]


LLMI / LLMC SYSTEM Figure 60-180-2
System Calibration
Figure 60-180-1
1
1 3
2
2
S38711
Figure 60-180-3
S39205
Before calibration, drive the machine for a while in order

to warm the axles, then check tightening torque of the

two bolts (Item 1) of the LLMS (Longitudinal Load
Moment Sensor) (Item 2) [Figure 60-180-1]. Torque
value should be 65 N•m (48 ft-lb).
Follow the procedure below to calibrate the LLMC:
NOTE: Calibration must be performed within a time

span of 5 minutes. If longer, the LLMC will
return to its original settings.
S0007
NOTE: During the procedure below, the buzzer will
be activated whenever the TEST button is
pushed. 1. Push and hold the TEST button (Item 1) [Figure 60-
180-2] while starting the machine (START)
NOTE: A heavy load will be needed to do some of the [Figure 60-180-3] then quickly press the TEST button
calibration procedures. The load must be (Item 1) [Figure 60-180-2] for three times within the
heavy enough that the rear wheels will lifted first 4 seconds after power on.
off the ground for the calibration to be
performed successfully. NOTE: To indicate that the system enters calibration
mode, the LED bar (Items 2 and 3) [Figure 60-
180-2] will be blinking and the buzzer sounds
intermittent for 3 seconds.
2. The green LEDs (Item 2) [Figure 60-180-2] light up to

indicate the system is ready to record the first
calibration point.

LLMI / LLMC SYSTEM (CONT’D) 8. To indicate the calibration has been validated, the
LED bar (Items 2 and 3) [Figure 60-180-2] lights up
System Calibration (Cont’d) for 3 seconds.
Figure 60-180-4 NOTE: If the buzzer sounds and LEDs light up, a
calibration failure has occurred. (See System
Failure Reports on Page 60-180-4.)
Calibration is finished. The LLMC automatically returns to

normal mode.
Always perform the LLMI / LLMC calibration test after

system calibration. (See Calibration Test on Page 60-
180-3.)
Retract the boom fully, lower the load to the ground.

Remove the heavy load from the attachment.
S39202
3. Without attachment and with the attachment carrier

fully tilted up, fully retract and raise the boom

[Figure 60-180-4].
4. Press and release the TEST button (Item 1)

[Figure 60-180-2] to record the first calibration point.
5. The orange and red LEDs (Item 3) [Figure 60-180-2]

light up to indicate the system is ready to record the
second calibration point.
Figure 60-180-5
S39203
6. Install the attachment with the heavy load. Keep the

load as low as possible during this calibration
procedure. Extend the boom until the rear wheels
start to raise off of the ground [Figure 60-180-5].
7. Press and release the TEST button (Item 1)

[Figure 60-180-2] to record the second calibration
point.

LLMI / LLMC SYSTEM (CONT’D)
Calibration Test
The Longitudinal Load Moment Control (LLMC) system

calibration can be tested by performing the following
procedure:
Figure 60-180-6
S38711

1. Raise the boom, fully retracted and without
attachment.
2. Tilt the attachment carrier fully up.
3. Push and hold the TEST button (Item 1) [Figure 60-

180-6] for 5 seconds.
NOTE: All LEDs will shortly light up and the buzzer

sounds discontinuous.
4. Release the TEST button (Item 1) [Figure 60-180-6].
The calibration test is finished. Two test results are

possible:
- the four green LEDs (Item 2) [Figure 60-180-6] light

up, calibration is OK.
- the orange and red LEDs (Item 3) [Figure 60-180-
6] light up, calibration is out of range. Please redo
calibration of the LLMC. (See System Calibration on
Page 60-180-1.)
NOTE: After pressing the TEST button (Item 1)

[Figure 60-180-6] longer than 60 seconds, the
procedure will automatically end and the
system will return to normal mode.
NOTE: The system always returns to normal mode

when the TEST button (Item 1) [Figure 60-180-
6] is released during the procedure.

System Failure Reports
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
Power Supply LLMI Voltage Low Normal Battery voltage
low.
LLMI Voltage Out Normal

Of Range
LLMC Voltage Low No aggravating Battery voltage

movements low.
possible.
LLMC override is
allowed.
LLMC Voltage Out No aggravating

Of Range movements
possible.
LLMC override is
allowed.
Internal Cyclic LLMI or LLMC not Identify the faulty

Redundancy programmed controller and re-
Check Error - correctly. program.
Program Flash
Test Button - The Test button is Release the Test

pressed for more button. After 10
than 10 seconds seconds, system
when the LLMI / startup can be
LLMC is started. repeated.
- The Test button is If not successful,
pressed for more replace the LLMI.
than 60 seconds in
the calibration test
procedure.

System Failure Reports (Cont’d)
MACHINE
BEHAVIOR
LLMS Sensor Scale Too No aggravating Calibration points Do system calibration
Tight movements too close. again within a time span
possible. of less than 5 minutes.
LLMC override is
allowed.
Calibration Values No aggravating Calibration not Do system calibration

Reversed movements successful. again within a time span
possible. (Recordings of first of less than 5 minutes.
LLMC override is and second
allowed. calibration point
have been
swapped.)
Calibration Values No aggravating Do system calibration
Out of Range movements again within a time span

possible. of less than 5 minutes.
LLMC override is
allowed.
Calibration Time- No aggravating The calibration Do system calibration

out movements took more than 5 again within a time span
possible. minutes. of less than 5 minutes.
LLMC override is
allowed.
LLMI Linked The speed of the - The LLMI linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMI.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMI has the rear axle and do
stopped sending system calibration
CAN frame. again.
LLMC Linked The speed of the - The LLMC linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMC.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMC has the rear axle and do
stopped sending system calibration
CAN frame. again

MACHINE
BEHAVIOR
LLMS LLMI / LLMC No motion - The LLMS inputs - Check the harness
Sensor allowed. have been between the LLMS and
Signature swapped between the LLMI / LLMC.
the LLMI and the - Do system calibration
LLMC. again within a time span
- The LLMI and / or of less than 5 minutes.
the LLMC was
reprogrammed.
LLMS Value Shift After 30 seconds: No aggravating Do system calibration
(toward movements again within a time span
stability) possible. of less than 5 minutes.
LLMC override is
allowed.

LLMS Value Shift No aggravating Do system calibration
(toward movements again within a time span
instability) possible. of less than 5 minutes.
LLMC override is
allowed.
Sensor Normal The difference - Do system calibration

Redundancy 1 between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
first level. needed.
Sensor No motion The difference - Do system calibration

Redundancy 2 allowed. between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
second level. needed.
Sensor Frame No aggravating Faulty LLMS. Replace the LLMS and

Default movements do system calibration
possible. again within a time span
LLMC override is of less than 5 minutes.
allowed

MACHINE
BEHAVIOR
Switches Retract Switch Boom considered - The Retract - Check the harness
not retracted while switch is between the “boom
this failure is on. disconnected. retracted” switch and
- There is a short- the LLMC.
circuit in the switch - Check the function of
or in the harness. the switch.
5° Switch Boom angle - The 5° switch is - Check the harness

considered over disconnected. between the 5° switch
5° while this - There is a short- and the LLMC.
failure is on. circuit in the 5° - Check the function of
switch or in the the switch.
harness.

LLMI / LLMC SYSTEM (CONT’D) Figure 60-180-9
System Components Identification
Figure 60-180-7
1
S39246
The LLMS (Longitudinal Load Moment Sensor) (Item 1)

S38155 [Figure 60-180-9] measures the actual load on the rear
axle.
The LLMI (Longitudinal Load Moment Indicator) (Item 1) The LLMS is equipped with dual electronics, which
[Figure 60-180-7] which is located on the dashboard, independently measure the same load. The first

indicates the stability level of the machine, using a LED measurement is used by the LLMI, while the second
bargraph and a buzzer. measurement is used by the LLMC. The most critical
measurement of both will have priority.
Figure 60-180-8
Figure 60-180-10
S39395
S39424
The LLMC (Longitudinal Load Moment Controller) (Item

1) [Figure 60-180-8] which is located under the The safety valve (Item 1) [Figure 60-180-10] is used as a
dashboard, reduces and stops the boom motions in safety back-up. If machine instability keeps increasing
relation to the machine stability. This controller combines due to a certain failure, the safety valve will stop all boom
with other controllers in the machine. motions.

System Components Identification (Cont’d)
Figure 60-180-11
S38179
2
The LLMC Override Switch (Item 1) [Figure 60-180-12]
S39396 can be used to override the LLMC.
The boom angle sensor (5°) (Item 1) [Figure 60-180-11]

measures the boom angle. If the boom angle is lower
than five degrees and the machine is in unstable

condition, boom movement speed is reduced.
Turned clockwise (unstable position), the switch (Item 1)
[Figure 60-180-12] overrides the LLMC. The switch
The boom retracted sensor (Item 2) [Figure 60-180-11]
returns to the original position as soon as the switch is
detects if the boom is fully retracted. When the boom is
released and the LLMC becomes active again.
retracted all boom movements will be fully operational at
any angle. The buzzer is deactivated with retracted
boom.

LLMS Removal
2
Figure 60-180-13
1
S39246
Remove the two bolts (Item 1) and remove the LLMS

S38075 (Item 2) [Figure 60-180-15]

located on the cab side below the boom.

Figure 60-180-14
S39144
Remove the electrical harness (Item 1) [Figure 60-180-

14] from the machine.
NOTE: Remove any tie-straps if needed.

LLMS Installation
Raise the boom and install the approved boom stop. (See
the Operation And Maintenance Manual for the correct 1
procedure.)
Figure 60-180-16
S39144
Route the electrical harness (Item 1) [Figure 60-180-18]

into the machine.
Figure 60-180-19
S39355

Clean the axle sensor area (Item 1) [Figure 60-180-16]
to remove rust and / or dirt.
Figure 60-180-17 1
2
1
S38075
Plug the connector (Item 1) [Figure 60-180-19] located

on the cab side below the boom.
Attach the harness with tie-straps.
S39246
Position the LLMS (Item 1) and install the two bolts (Item
2) [Figure 60-180-17].
NOTE: Apply Loctite® 243 to the bolts.
Tighten the two bolts (Item 2) [Figure 60-180-17] in three

progressive steps:
- 25 N•m (18.4 ft-lb)
- 45 N•m (33.2 ft-lb)
- 65 N•m (47.9 ft-lb).

LLMC Removal And Installation
Remove the dash cover. (See Removal And Installation

on Page 50-120-1.)
Figure 60-180-20
S39353

Disconnect the two connectors (Item 1) [Figure 60-180-
20].
Figure 60-180-21
S39354
Remove the LLMC.

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
EXPANSION TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

OIL COOLER / INTERCOOLER / RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1


ENGINE AND ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
ENGINE COMPONENTS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Fuel Injectors Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Checking The Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-10
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-11
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-11
Glow Plugs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14
ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
ENGINE / HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Flywheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Turbo Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Turbo Charger Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Turbo Charger Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Exhaust Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Fuel Injector Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Rocker Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-9
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-9
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-10
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-10
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-11
Changing Valve Springs (With Cylinder Head Installed) . . . . . . . . . . . . . . . . . . . . . 70-10-12
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-13

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Timing Case And Drive Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Crankshaft Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Front Oil Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Timing Case And Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Camshaft And Tappets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Pistons And Connecting Rods Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Pistons And Connecting Rods Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Pistons And Connecting Rods Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Connecting Rod Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Crankshaft And Bearings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-10
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-11
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12
Rear Oil Seal Housing Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-13
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-13
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Lubricating Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Engine Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Oil Filter Adapter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Oil Screen And Pick-up Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Oil Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Oil Pressure Relief Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Engine Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Piston Cooling Jet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5


ENGINE INFORMATION
Specifications
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
General
Cylinder Arrangement In-line

Direction Of Rotation Clockwise From The Front
Combustion System Direct Injection
Nominal Bore 100 (3.937)
Stroke 105 (4.134)
Compression Ratio 17.25:1
Displacement 4 L (243 cm³)
Firing Order 1-3-4-2
Cylinder Head
Head Thickness 117,95 - 118,05 (4.643 - 4.647)

Head Thickness After Machining (Minimum) 117,20 (4.614)
Valve Seat Angle 30°
Leak Test Pressure 200 kPa (2 bar) (29 psi)
Valve Guides
Inside Diameter 8,250 - 8,350 (0.3248 - 0.3287)

Outside Diameter 13,034 - 13,047 (0.5131 - 0.5137)
Valve Guide Bore 13,000 - 13,027 (0.5118 - 0.5129)
Valve Guide Clearance In The Cylinder Head (Interference) 0,007 - 0,047 (0.0003 - 0.00019)
Overall Length:
Intake 128,92 - 129,37 (5.076 - 5.093)
Exhaust 128,92 - 129,37 (5.075 - 5.093)
Protrusion From Bottom 12,35 - 12,65 (0.486 - 0.498)

ENGINE INFORMATION (CONT'D)
Specifications (Cont’d)
parentheses.
Exhaust Valves
Valve Stem Diameter 8,93 - 8,96 (0.3515 - 0.3 528)

Valve Guide Clearance 0,040 - 0,84 (0.0016 - 0.0033)
Maximum 0,15 (0.006)
Valve Head Diameter 41,51 - 41,75 (1.634 - 1.644)
Valve Face Angle 30°
Overall Length 128,92 - 129,37 (5.075 - 5.093)
Seal Type Stem seal with integral seating washer
Valve Clearance 0,45 (0.018)
Exhaust Depth (Production) 1,53 - 1,81 (0.060 - 0.071)
Exhaust Depth (Service) 2,06 (0.081)

Intake Valves
Valve Stem Diameter 8,95 - 8,98 (0.3525 - 0.3535)

Valve Guide Clearance 0,025 - 0,069 (0.0010 - 0.0027)
Maximum 0,13 (0.005)
Valve Head Diameter 46,20 - 46,45 (1.819 - 1.829)
Valve Face Angle 30°
Overall Length 128,92 - 129,37 (5.076 - 5.093)
Seal Type Stem seal with integral seating washer
Valve Clearance 0,20 (0.008)
Intake Depth (Production) 1,58 - 1,84 (0.062 - 0.072)
Intake Depth (Service) 2,09 (0.082)
Valve Springs
Installed Height 34,5 (1.358)

Installed Height Pressure 229 N (51 lb)
Number Of Active Coils 3.8

parentheses.
Rocker Shaft, Rockers And Bushings
Shaft Outside Diameter 24,962 - 24,987 (0.9828 - 0.9837)

Clearance Between Rocker Arm Bushing and Shaft 0,26 - 0,89 (0.0010 - 0.0035)
Maximum 0,17 (0.007)
Pistons And Piston Rings
Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 39,703 - 39,709 (1.5631 - 1.5633)
Piston Projection Above the Block Deck 0,21 - 0,35 (0.008 - 0.0137)
Top Ring Groove Width Tapered
Second Ring Groove Width 2,54 - 2,56 (0.0999 - 0.1007)

Third Ring Groove Width 3,52 - 3,54 (0.1385 - 0.1393)
Top Ring Barrel Face, Molybdenum insert, Keystone
Second Ring Taper Face, Cast Iron, Internal Bottom Step
Oil Control Ring Two Piece Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 2,48 - 2,49 (0.097 - 0.098)
Third Ring Width 3,47 - 3,49 (0.1366 - 0.1374)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0,05 - 0,09 (0.002 - 0.003)
Third Ring Side Clearance 0,03 - 0,07 (0.0011 - 0.0027)
Top Ring End Gap 0,30 - 0,55 (0.011 - 0.021)
Second Ring End Gap 0,70 - 0,95 (0.027 - 0.037)
Third Ring End Gap 0,30 - 0,55 (0.0118 - 0.0216)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 39,694 - 39,700 (1.5628 - 1.5630)
Piston Boss Clearance 0,003 - 0,015 (0.0001 - 0.0006)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 43,66 - 43,84 (1.7190 - 1.7259)
Bushing Inside Diameter (Reamed) 39,723 - 39,738 (1.5638 - 1.5645)
Piston Pin Bushing Clearance 0,023 - 0,044 (0.0009 - 0.0017)

parentheses.
Connecting Rods And Bearings
Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 67,21 - 67,22 (2.6460 - 2.6465)
Piston Pin End 43,01 - 43,03 (1.693 - 1.694)
Length Between Centers 219,05 - 219,10 (8.624 - 8.626)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 31,55 - 31,88 (1.240 - 1.255)
Bearing Thickness At The Center 1,835 - 1,842 (0.0723 - 0.0725)
Bearing Clearance 0,03 - 0,081 (0.0012 - 0.0032)
Bearing Undersize Available -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)
Crankshaft

Main Journals 76,16 - 76,18 (2.998 - 2.999)
Maximum Wear And Out Of Round Of The Journals And 0,04 (0.0016)
Crank Pins
Width Of Center Journal 44,15 - 44,22 (1.738 - 1.741)
Width Of Other Journals 39,24 - 39,34 (1.545 - 1.549)
Crank Pin Diameters 63,47 - 63,49 (2.499 - 2.500)
Width Of Crank Pins 40,35 - 40,42 (1.589 - 1.591)
Crankshaft End Play 0,05 - 0,38 (0.0002 - 0.015)
Thrust Washer Thickness: Std. 2,26 - 2,31 (0.089 - 0.091)
Oversize 2,45 - 2,50 (0.096 - 0.098)
Main Bearing Oil Clearance 0,057 - 0,117 (0.0022 - 0.0046)
Undersize Journals And Crank Pins 0,25 (0.010), 0,50 (0.020), 0,75 (0.030)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0,10 (0.004)
Journal #1 Mounting
Journal #2 0,08 (0.003)
Journal #3 0,15 (0.006)
Journal #4 0,08 (0.003)
Journal #5 Mounting

parentheses.
Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
ITEM 0,25 (0.010) 0,51 (0.020) 0,76 (0.030)

1 75.909 - 75.930 75,649 - 75,670 75,399 - 75,420
(2.9884 - 2.9892) (2.9784 - 2.96792) (2.9684 - 2.9692)
2 63,220 - 63,240 62,962 - 62,982 62,708 - 62,728
(2.488 - 2.4896) (2.4788 - 2.4796) (2.4688 - 2.4696)
3 39,47 (1.554) maximum - -
4 37,44 (1.474) maximum - -
5 44,68 (1.759) maximum - -
6 40,55 (1.596) maximum - -
7 Do not machine this diameter - -
8 Do not machine this diameter - -
9 3,68 - 3,69 (0.1448 - 0.1452) - -
Crankshaft Heat Treatment: 60 Hour Nitride
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0,25 (0.010) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.

parentheses.
Main Bearings
Type Steel Back, 20% Tin Aluminium

All Others 31,62 - 31,88 (1.244 - 1.255)
Bearing Thickness (Center) 2,083 - 2,089 (0.0820 - 0.0823)
Bearing Clearance 0,057 - 0,117 (0.0022 - 0.0046)
Bearing Undersize Available -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)
Thrust Washers
Type Steel back, bearing material

Position Each Side Of Center Mainbearing
Standard 2,26 - 2,31 (0.089 - 0.091)
Oversize 2,45 - 2,50 (0.096 - 0.098)

Camshaft And Thrust Washer
Journal #1 Diameter 50,71 - 50,74 (1.997 - 1.998)

Cam Lift (Intake) 7,03 - 7,13 (0.2768 - 0.2807)
Cam Lift (Exhaust) 7,963 - 8,063 (0.3135 - 0.3174)
Maximum Wear And Out Of Round 0,05 (0.021)
Camshaft End Play (Production) 0,10 - 0,55 (0.004 - 0.022)
Service Limits 0,60 (0.023)
Thrust Washer Type 360°
Thrust Washer Thickness 5,49 - 5,54 (0.216 - 0.218)
Thrust Washer Recess Depth 5,54 - 5,64 (0.218 - 0.222)
Cylinder Block
Cylinder Bore Diameter 105,000 - 105,025 (4.1338 - 4.1348)

Main Bearing Bore Diameter 80,416 - 80,442 (3.166 - 3.167)

parentheses.
Cylinder liners
Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 104,25 - 104,28 (4.105 - 4.106)
Production Liner Clearance 0,03 - 0,08 (0.001 - 0.003)
Production Liner Inside Diameter 100,00 - 100,03 (3.937 - 3.938)
Service Liner Clearance ±0,03 (±0.001)
Inside Diameter Of Service Liner With Flame Ring 100,0 - 100,63 (3.937 - 3.961)
(Installed)
Maximum 0,25 (0.010)
Flange Thickness 3,81 - 3,86 (0.150 - 0.152)
Liner Projection From Deck Surface 0,10 (0.004) Above or 0,10 (0.004) Below

Hose Angle 30 / 35°
Piston Cooling Jets 9 N•m (79.7 in-lb)
Fuel Injection Pump
Type DELPHI DP 210 with locking screw

Rotation From Drive End Clockwise
Fuel System Self Vent
Fuel Injectors
Working Pressure 29,4 MPa (294 bar) (4263 psi)
Fuel Lift Pump
Type Electrically operated

Method of Drive Electric Motor 12V / 24V
Standard Pressure 41 - 69 kPa (0,41 - 0,69 bar) (6 - 10 psi)
Minimum Pressure 26 kPa (0,26 bar) (3.75 psi)

parentheses.
Timing Case And Timing Gears
Camshaft Gear Number Of Teeth 68

Camshaft Gear Bore Diameter 34,93 - 34,95 (1.375 - 1.376)
Camshaft Hub Outside Diameter 34,90 - 34,92 (1.374 - 1.375)
Fuel Pump Gear Number Of Teeth (Electronic) 68
Fuel Pump Gear Bore (Electronic) 29,99 - 30,02 (1.417 - 1.419)
Crankshaft Gear Number Of Teeth 34
Crankshaft Gear Bore Diameter 47,625 - 47,650 (1.875 - 1.8760)
Crankshaft Gear Hub Diameter 47,625 - 47,645 (1.875 - 1.8758)
Crankshaft Gear Clearance -0,020 - +0,020 (-0.0008 - +0.0008)
Idler Gear Number Of Teeth 73
Idler Gear Bore Diameter 57,14 - 57,18 (2.250 - 2.251)

(With Needle Bearings) 72,35 - 72,36 (2.848 - 2.849)
Width Of Idler Gear And Bushing Assembly (Installed) 30,14 - 30,16 (1.186 - 1.187)
Flanged Bushing Inside Assembly (Installed) 50,78 - 50,80 (1.999 - 2.000)
Idler Gear Hub Outside Diameter 50,70 - 50,74 (1.9990 - 1.9999)
Idler Gear Hub Bushing Clearance 0,04 - 0,10 (0.0016 - 0.0039)
Gear End Play (Production Limits) 0,10 - 0,20 (0.004 - 0.008)
Service Limit 0,38 (0.015)
Backlash For All Gears 0,08 (0.003) Minimum

parentheses.
Oil Pump, Gear And Relief Valve
Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 5, Outer 6
Clearance Of Outer Rotor To Body 0,15 - 0,34 (0.006 - 0.013)
End Play
Inner Rotor 0,04 - 0,09 (0.001 - 0.004)
Outer Rotor 0,025 - 0,076 (0.0010 - 0.0029)
Oil Pump Idler Gear Bushing I.D. 16,012 - 16,038 (0.6303 - 0.6314)
Idler Shaft O.D. 15,966 - 15,984 (0.6285 - 0.5292)
Idler Gear Shaft Bushing Clearance 0,028 - 0,072 (0.0011 - 0.0028)
Oil Pump Idler Gear End Play 0,050 - 0,275 (0.0019 - 0.0108)
Relief Valve Plunger Bore Diameter 19,250 - 19,300 (0.7578 - 0.7598)

Relief Valve Plunger Outside Diameter 19,186 - 19,211 (0.7553 - 0.7563)
Clearance 0,039 - 0,114 (0.0015 - 0.0044)
Length Of The Spring (Installed) 59,8 (2.35)
Load On The Spring (Installed) 25 - 36 kPa (0,25 - 0,36 bar) (3.6 - 5.2 psi)
Pressure To Open Pressure Relief Valve 414 - 469 kPa (4,14 - 4,69 bar) (60 - 68 psi)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open Bypass Valve In Oil Filter 55 - 83 kPa (0,55 - 0,83 bar) (8 - 12 psi)
Turbocharger
Type Garrett GT25
Flywheel
Run-Out Less than 0,30 (0.012)

Misalignment 0,03 (0.001) @ 25 (1.0)

parentheses.
Water Pump And Thermostat
Type Centrifugal, Gear Drive

Shaft Outside Diameter 21,425 - 21,438 (0.8435 - 0.8440)
Drive Gear Bore Diameter 21,375 - 21,400 (0.8415 - 0.8425)
Drive Gear Shaft Clearance 0,025 - 0,063 (0.0009 - 0.0024)
Impeller Bore Diameter 11,943 - 11,971 (0.4701 - 0.4712)
Impeller Shaft Outside Diameter 11,997 - 12,008 (0.4723 - 0.4727)
Impeller Clearance On Shaft 0,026 - 0,065 (0.0010 - 0.0025)
Bearing Bore Diameter 39,989 - 40,014 (1.5743 - 1.5753)
Bearing Diameter 39,989 - 40,000 (1.5743 - 1.5747)
Bearing Clearance In Pump Body +0,025 / -0,011 (+0.0009 / -0.0005)
Thermostat Type Wax Pellet, Bypass Blanking

NOMINAL TEMPERATURE
STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BYPASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
82°C (180°F) 77 - 85°C (170 - 185°F) 92 - 98°C (198 - 208°F) 0.35 (9,0)

Engine Torque Component
COMPONENT N•M FT-LB

Bridge Piece To Block 16 12
Camshaft Gear Bolt 95 70
Connecting Rod Nuts
Step 1 18 13
Final 70 52
Crank Pulley Bolts 115 85
Cylinder Head Bolt
Step One 50 37
Step Two 100 74
Step Three 225°
Step Three - Long Bolts 270°
Engine Mounting Bridge To Frame 271 200
Exhaust Manifold Bolts 33 24
Flywheel Cover To Housing 61 45
Flywheel Housing To Cylinder Block 70 52

Flywheel To Crankshaft Bolts 105 77
Fuel Injector Nut 30 22
Fuel Injection Pump Gear Nut 24 18
Fuel Injection Pump Flange Nuts 24 18
Fuel Lift Pump Bolts 22 16
High Pressure Fuel Lines Fittings 30 22
Idler Gear Hub Bolts 44 33
Mainbearing Bolts
Step 1 88 65
Step 2 170 125
Step 3 250 185
Oil Pan Bolts 22 16
Oil Pan Plug 34 25
Oil Pump Cover 22 16
Oil Pump To Front Main Cap 22 16
Oil Transfer Plate Bolts 30 22
Piston Cooling Jets 9 7
Rear Oil Seal Housing Bolts 22 16
Rocker Cover Nuts (With Shim Washer) 9 7
Rocker Shaft Bracket Nuts 27 20
Timing Case To Block 22 16
Timing Case Cover To Timing Case Bolts 22 16
Turbocharger To Manifold Nuts 44 33
Water Pump To Timing Case Bolts And Nuts 22 16

Troubleshooting
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue / white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52

Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45

Troubleshooting (Cont'd)

1. Battery capacity low. 27. Poor boost pressure.
2. Bad electrical connections 28. Fuel leak.
3. Faulty starter motor. 29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil. 30. Sticking valves.
5. Incorrect grade of fuel. 31. Leaking head gasket.
6. Incorrect use of cold starting equipment. 32. Worn valve guides / stems.
7. Faulty cold starting equipment. 33. Faulty thermostat.
8. Insufficient fuel in tank. 34. Incorrect piston height.
9. Faulty stop control. 35. Broken / worn piston rings.
10. Broken fuel injection pump drive. 36. Worn cylinder liners.
11. Air in the fuel system 37. Worn wrist pins.
12. Restricted fuel feed. 38. Excessive camshaft end play.
13. Fuel tank vent blocked. 39. Excessive timing gear backlash.
14. Plugged fuel filters. 40. Oil leaks.

15. Faulty fuel pump. 41. New or rebuilt engine not broken in.
16. Low compression. 42. Plugged breather pipe.
17. Incorrect valve clearance. 43. Glazed cylinder liners.
18. Incorrect valve timing. 44. Worn pistons.
19. Incorrect fuel pump timing. 45. Worn valve stem seals.
20. Faulty injectors. 46. Coolant level low.
21. Faulty fuel injection pump. 47. Faulty water pump.
22. Plugged air filter. 48. Loose or broken blower fan belt.
23. Broken or weak valve springs. 49. Radiator cooling fins plugged.
24. Overheating. 50. Damaged blower fan.
25. Restricted exhaust system. 51. Loose flywheel.
26. Water in fuel. 52. Broken engine mounts.


ENGINE SPEED CONTROL Figure 70-20-3

1
Figure 70-20-1
1 1
S38116
Unscrew and remove the link (Item 1) [Figure 70-20-3].

2 1
Figure 70-20-4
S38084

2
Remove the three bolts (Item 1) and remove the cover 1
cab.
Figure 70-20-2
S38118

1
Remove the nut (Item 2) [Figure 70-20-4] and pull the
cable out through the hole.
S38117
Remove the clip (Item 1) [Figure 70-20-2] from the

pedal.

ENGINE SPEED CONTROL (CONT’D)
Figure 70-20-5
S38119
Remove the engine speed control cable (Item 1) [Figure

70-20-5] from the linkage.

Remove the engine speed control cable from the
mounting bracket (Item 2) [Figure 70-20-5]
Remove any necessary cable ties, carefully remove the

speed control cable.

MUFFLER Figure 70-30-2
Figure 70-30-1
1
1
1 2
S38120
Remove the exhaust mounting bolts (Item 1) [Figure 70-

S38121 30-2].
Remove the muffler and gasket (Item 2) [Figure 70-30-

Open the engine cover. (See Opening And Closing on 2].
Page 10-160-1.)

Installation: Install a new gasket (Item 2) [Figure 70-30-
Remove the muffler mounting bolts (Item 1) [Figure 70- 2].
30-1].


AIR CLEANER
Housing Removal And Installation
Figure 70-40-1
S38122

Page 10-160-1.)

Loosen the clamp (Item 1) [Figure 70-40-1] and remove
the hose from the air cleaner.
NOTE: Cover or plug the air intake hose so no

contamination gets into the engine.
Figure 70-40-2
S38123

2].
Remove the air cleaner housing assembly.


EXPANSION TANK

Figure 70-50-1
1
S38135

Remove the two coolant hoses (Item 1) [Figure 70-50-1].
Lift the tank out of the support clip.
NOTE: The bolts (Item 2) [Figure 70-50-1] do not need

to be removed.
Figure 70-50-2
S39124
Remove the two nuts (Item 1) and bolts and remove the
support (Item 2) [Figure 70-50-2].


OIL COOLER / INTERCOOLER / RADIATOR Figure 70-60-2
Remove the engine cover. (See Opening And Closing on

Page 10-160-1.)

1
Remove the A/C condenser. (See Removal And

Figure 70-60-1 1
S38290
1
Remove the four hydraulic hoses (Item 1) [Figure 70-60-
2] from the fan motor.
NOTE: Mark the hoses for installation.
Figure 70-60-3

2
3
S38280
1 1
Remove the radiator hose (Item 1) [Figure 70-60-1].
Remove the intercooler hose (Item 2) [Figure 70-60-1].
Remove the two hydraulic hoses (Item 3) [Figure 70-60-

1].
NOTE: Install caps or plugs on the hydraulic hoses.

S38281
Remove the two radiator hoses (Item 1) [Figure 70-60-

3].

OIL COOLER / INTERCOOLER / RADIATOR (CONT’D) Figure 70-60-6
Figure 70-60-4
1
1
S38284
Remove the two mounting bolts (Item 1) [Figure 70-60-6]

S38287 and nuts.
Figure 70-60-7
Remove the air inlet hose (Item 1) [Figure 70-60-4] from
the turbo charger. This will facilitate the next step.

NOTE: Cover the air intake hose so no contamination
gets into the engine.
Figure 70-60-5
S38285
Remove the mounting bolt (Item 1) [Figure 70-60-7] and

nut.
1
S38283
Remove the air inlet hose (Item 1) [Figure 70-60-5] from

the intercooler.

OIL COOLER / INTERCOOLER / RADIATOR (CONT’D) Figure 70-60-10
Figure 70-60-8
S38289
With the aid of an assistant, lift and remove the oil cooler
S38286 / radiator assembly from the machine [Figure 70-60-10].
Remove the mounting bolt (Item 1) [Figure 70-60-8] and

nut.

Figure 70-60-9
3 2
1
S38288
Loosen the clamp (Item 2) and remove the hose (Item 3)

[Figure 70-60-9].


ENGINE AND ENGINE MOUNTS Figure 70-70-2
Disconnect the ground (-) cable from the battery. (See 2

Remove the hydrostatic pump. (See Removal And

Remove the oil cooler / radiator. (See Removal And

Remove the expansion tank. (See Removal And 1

Installation on Page 70-50-1.) 3
4
S38075
Remove the air cleaner. (See Housing Removal And
Remove the tie-strap (Item 2) [Figure 70-70-2].
Remove the muffler. (See Removal And Installation on
Page 70-30-1.) Loosen the screw and disconnect the electrical connector
(Item 2) [Figure 70-70-2].
Remove the refrigerant from the A/C system. (See
Reclamation And Charging With Recovery / Charging Remove the nut and ground wires (Item 3) [Figure 70-
70-2].

Unit on Page 80-100-1.)
Figure 70-70-1 Disconnect the ignition connector (Item 4) [Figure 70-70-

2] (red / white cable).
1 Figure 70-70-3
1
1 1
S38137
1
Remove the three bolts (Item 1) [Figure 70-70-1] from S38138

the fuse mounting plate. Place the fuse mounting plate
on the bottom of the engine compartment.
Remove the hose clamps (Item 1) [Figure 70-70-3].
Remove the two tie-straps (Item 2) [Figure 70-70-3]

ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-70-6

1
Figure 70-70-4
S38141
Remove the dual hose clamp (Item 1) [Figure 70-70-6].

S38139
Figure 70-70-7
Remove the radiator hose (Item 1) [Figure 70-70-4] from

the thermostat housing.

Figure 70-70-5
1
S38142
1
Remove the heater hose (Item 1) [Figure 70-70-7] from
the thermostat housing.
S38140
Remove the two hose clamps (Item 1) [Figure 70-70-5].

Figure 70-70-8
S38144
1
Remove the two fuel hoses (Item 1) [Figure 70-70-10].
S38143
NOTE: Mark the hoses for proper assembly.
Remove the A/C hose (Item 1) [Figure 70-70-8] from the Figure 70-70-11
compressor.

Remove the coolant hose (Item 2) [Figure 70-70-8].
Remove the heater hose (Item 3) [Figure 70-70-8].
Figure 70-70-9
1
2 1
S38145

1
S38119

70-70-9] from the linkage.

mounting bracket (Item 2) [Figure 70-70-9]
Remove any necessary cable ties, carefully remove the



1
Figure 70-70-12
1 S38146
Remove the two hose clamps (Item 1) [Figure 70-70-14].

S38148
Figure 70-70-15
Remove the ground wire (Item 1) [Figure 70-70-12].
Figure 70-70-13

1
1
1
S38603
Install a hoist and chain to the lifting brackets (Item 1)

[Figure 70-70-15].
S38147
Remove the hose clamp (Item 1) [Figure 70-70-13].

Figure 70-70-16
1
1
1
S38601
Remove the engine mount bolt (Item 1) [Figure 70-70-

18].
S38149
Installation: Tighten the engine mount bolt to 250 - 271

Remove the three plastic caps (Item 1) [Figure 70-70- N•m (185 - 200 ft-lb) torque.
16].
Figure 70-70-19

Figure 70-70-17
S38146
S38600
Remove the engine mount bolt (Item 1) [Figure 70-70-

Remove the engine mount bolt (Item 1) [Figure 70-70- 19].
17].
Installation: Tighten the engine mount bolt to 250 - 271
Installation: Tighten the engine mount bolt to 250 - 271 N•m (185 - 200 ft-lb) torque.
N•m (185 - 200 ft-lb) torque.

ENGINE AND ENGINE MOUNTS (CONT’D)
Figure 70-70-20
S38602
Lift and remove the engine [Figure 70-70-20].

ENGINE COMPONENTS AND TESTING Figure 70-80-2
Fuel Injection Pump Removal
NOTE: Read and fully understand the following

procedure before removing the fuel injection
pump. Failure to remove the pump correctly
will result in incorrect pump timing and the 2
pump will have to be sent to an authorized
Delphi dealer to be retimed. The internal
adjustment for pump timing is tamper proof.
High and low idle adjustments of the fuel
injection pump are factory set and
adjustments cannot be made to the fuel 1
pump.
P-55774
Set the engine to TDC number one cylinder compression
stroke. (See ENGINE TIMING on Page 70-90-1.)
Loosen the lock bolt (Item 1) and move the washer (Item
Disconnect the ground (-) cable from the battery. (See 2) [Figure 70-80-2] (to the position shown). Retighten
Removing And Installing Battery on Page 60-20-1.) the locking screw to 17 N•m (12 ft-lb) torque.
Figure 70-80-1 Remove the nut and washer (Item 1) [Figure 70-80-1].

Figure 70-80-3
P-55531
P-55529
NOTE: If the fuel pump nut (Item 1) [Figure 70-80-1] is
loosened before the fuel pump timing is set
and the pump locked, the fuel pump timing Using a gear puller, remove the fuel pump gear [Figure
will be lost and the fuel pump will have to be 70-80-3].
sent into the dealer to be reset.
Apply pressure counterclockwise by hand to the fuel

pump gear to remove backlash from the gears.

ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-80-6
Fuel Injection Pump Removal (Cont'd)
Figure 70-80-4
P-55524
Remove the fuel line (Item 1) [Figure 70-80-6] from the

P-55522 front of the pump.
Figure 70-80-7
Remove the harness (Item 1) [Figure 70-80-4].

NOTE: Mark the connectors for correct installation.
Figure 70-80-5
1
P-55525
Remove the fuel line (Item 1) [Figure 70-80-7] from the

rear of the pump.
P-55523
Remove the connector (Item 1) [Figure 70-80-5] from the

top of the pump.

Fuel Injection Pump Removal (Cont'd)
Figure 70-80-8
1
1
P-55533
Disconnect the return spring (Item 1) [Figure 70-80-10]

P-55526 from the pump linkage.
Figure 70-80-11
Remove the four fuel tubelines (Item 1) [Figure 70-80-8].

IMPORTANT
Do not bend the high pressure fuel injection tubes 1
when removing or installing them.
I-2029-0289
Figure 70-80-9
P-55528
Remove the mount bolt (Item 1) [Figure 70-80-11] from

the bracket.
P-55527
Remove the tubeline (Item 1) [Figure 70-80-9] from the

top of the pump.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Installation
Fuel Injection Pump Removal (Cont'd) NOTE: The new fuel pump will be supplied with the
pump shaft in the locked position. Do not
Figure 70-80-12 unlock the shaft of the fuel pump until the fuel
pump gear is installed.
1 The engine must be set to TDC number one cylinder,

1 compression stroke before the pump is installed. (See
ENGINE TIMING on Page 70-90-1.)
Install a new O-ring onto the pump flange.
Figure 70-80-13
1
1
1
P-55532
Remove the three mount bolts (Item 1) [Figure 70-80-12]

and remove the pump.

1
P-55532
Install the fuel pump and tighten the three bolts (Item 1)
[Figure 70-80-13] to 25 N•m (18 ft-lb) torque.
Figure 70-80-14
P-55528
Install the mount bolt (Item 1) [Figure 70-80-14]. Do not

tighten at this time.

Fuel Injection Pump Installation (Cont'd)
Figure 70-80-15
2
1
2
P-55775
Loosen the locking bolt (Item 1) and move the washer

P-55531 (Item 2) [Figure 70-80-17] to the position shown and
tighten the bolt to 12 N•m (9 ft-lb) torque.
Install the gear (Item 1) onto the tapered shaft. Make Retighten the nut (Item 1) [Figure 70-80-16] to 88 N•m
sure the fuel pump gear is correctly in mesh with the idler (65 ft-lb) torque.

gear and install the washer and nut (Item 2) [Figure 70-
80-15]. Do not tighten at this time. Figure 70-80-18
NOTE: The backlash must be removed before the fuel

injection pump is released. Failure to do so
will make the fuel pump timing incorrect.
1
Figure 70-80-16
P-55776
Remove the two timing pins (Item 1) [Figure 70-80-18].
Lightly lubricate each gear with clean engine oil.

P-55530
Install the timing case cover. (See Timing Cover Removal
on Page 70-150-1.)
Apply pressure counterclockwise by hand to the fuel
pump gear to remove the backlash from all the gears. Install the glow plugs. (See Glow Plugs Removal And
Tighten the nut (Item 1) [Figure 70-80-16] to 24 N•m (18 Installation on Page 70-80-14.)
ft-lb) torque.
Install the rocker cover. (See Rocker Cover Removal And

Figure 70-80-19
1
1 1
P-55525
Install the tubelines (Item 1) [Figure 70-80-21] to the

P-55528 pump and tighten to 30 N•m (22 ft-lb) torque.
Do not overtighten.
Tighten the mount bolt (Item 1) [Figure 70-80-19] to 44
N•m (32 ft-lb) torque.

Figure 70-80-20
P-55533
Connect the return spring (Item 1) [Figure 70-80-20] to

the pump linkage.

Figure 70-80-22
P-55522
Install the harness (Item 1) [Figure 70-80-24].

P-55524
Reconnect the ground (-) cable to the battery. (See
Figure 70-80-23
Remove air from the system.

1
2
P-55523
Install the two fuel lines (Item 1) [Figure 70-80-22] and

[Figure 70-80-23].
Install the electrical connector (Item 2) [Figure 70-80-

23].

Fuel Injectors Removal And Installation
WARNING
1
Diesel fuel or hydraulic fluid under pressure can
enters skin or eyes, get immediate medical attention S6895
W-2072-0807
Remove the breather hose (Item 1) [Figure 70-80-26].
Figure 70-80-25 Figure 70-80-27
3 3
1

1 2
1
1
S39192
S6896
Remove the three bolts (Item 1) and remove the fuel Remove the bolt (Item 1) and remove the breather fitting
injector cover (Item 2) [Figure 70-80-25]. (Item 2) [Figure 70-80-27].
Remove the three bolts (Item 3) and remove the fuel filter
assembly (Item 4) [Figure 70-80-27].

Fuel Injector Removal And Installation (Cont'd)
Figure 70-80-28 1
1
1
1
S6897
1
Disconnect the injector tubelines (Item 1) [Figure 70-80-
P-55777 29] from the injectors.
Installation: Tighten the tubelines to 30 N•m (22 ft-lb)

Disconnect the four injector tubelines (Item 1) [Figure torque.
70-80-28] from the injector pump.

Remove the tubelines.
Installation: Tighten the tubelines to 27 N•m (20 ft-lb)
torque.
Figure 70-80-30
IMPORTANT
Do not bend the high pressure fuel injection tubes 1
when removing or installing them.
I-2029-0289 1
2
P-55614
Remove the fuel return hoses (Item 1) and remove the

bolt (Item 2) and clamp (Item 3) [Figure 70-80-30].
Installation: Tighten bolt to 35 N•m (26 ft-lb) torque.

Fuel Injectors Removal And Installation (Cont'd)
Figure 70-80-31
P-55616
Installation: Always replace the copper washer (Item 1)

P-55615 [Figure 70-80-33] at the nozzle. If the washer remains in
the cylinder head, it must be removed.
Remove the injector from the cylinder head [Figure 70- Checking The Fuel Lift Pump
80-31].

Figure 70-80-34
Figure 70-80-32
P-55525
P-55617
Remove the fuel lift pipe (Item 1) [Figure 70-80-34] from

Installation: The roll pin must be in the position shown the injector pump, install a suitable pipe with a pressure
[Figure 70-80-32]. test point and connect a pressure gauge.
Operate the engine at idler for 2 minutes to allow any

trapped air to be removed.
Standard pressure should be 0,04 - 0,07 MPa (0,41 -

0,69 bar) (6 - 10 psi).

ENGINE COMPONENTS AND TESTING (CONT'D) Compression Checking
Fuel Lift Pump Removal And Installation The tools listed will be needed to do the following
procedure:
Figure 70-80-35
MEL10630 - Engine Compression Kit
MEL1352 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Glow Plugs Removal And

1
Figure 70-80-37
S38144
Remove the two fuel lines (Item 1) and electrical harness

(Item 2) [Figure 70-80-35] from the fuel lift pump / filter

assembly.
1
Figure 70-80-36
P-55631
Install the correct compression adapter (Item 1) [Figure

1 70-80-37] into the cylinder head.
Figure 70-80-38
2
S6899
Remove the two fuel lines (Item 1) and three bolts (Item
2) [Figure 70-80-36] and remove the fuel lift pump / filter
assembly.
P-55632
Connect the compression gauge to the adapter [Figure

70-80-38].
Make sure the engine speed control is fully backward

(engine idle).
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200 - 300 rpm.

ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Checking
Compression Checking (Cont’d) Disconnect the ground (-) cable from the battery.
If the measurement is below the allowable limit, inspect Figure 70-80-40

the cylinder, piston ring, top clearance, valve and cylinder
head.
1
Compression Pressure should be 0,2 - 0,3 MPa (2 - 3 2
1
bar) (43.5 - 72.5 psi).
Compression tests should only be used to compare

between the cylinders of an engine. (If one or more
cylinders vary by more than 0,35 MPa (3,5 bar) (51 psi)
then those cylinders can be faulty.
1
Figure 70-80-39
S39192
Remove the three bolts (Item 1) and remove the fuel

injector cover (Item 2) [Figure 70-80-40].

Figure 70-80-41
P-55633 1
Push the button on the compression gauge to release 3

pressure [Figure 70-80-39].
2
Connect the fuel stop solenoid.
S6895
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-80-41].

Glow Plugs Checking (Cont’d)
Figure 70-80-42
1
1 2 1
3
P-55630
Touch one probe to the end of the glow plug and the
S6900 other probe to the body of glow plug [Figure 70-80-44].
The reading must be between 1 and 2 ohm [Figure 70-

Remove the nut (Item 1) [Figure 70-80-42] from the top 80-44]. If the resistance is infinite, the coil of the glow
of each glow plug. plug is broken.

Installation: Tighten to 2 N•m (17.7 in-lb) torque. Repeat the procedure for each glow plug.
Disconnect the engine harness wire (Item 2) [Figure 70-

80-42] from the glow plug.
Remove the glow plug connecting strap (Item 3) [Figure

70-80-42].
Disconnect the glow plug cables and leads.
Figure 70-80-43
P-55629
Use an ohmmeter to check the glow plugs [Figure 70-80-

43].

Glow Plugs Removal And Installation

1
1 2 1
Disconnect the ground (-) cable from the battery.
Figure 70-80-45
1
2
1 3
S6900
1
Remove the nut (Item 1) [Figure 70-80-47] from the top
of each glow plug.
S39192 Installation: Tighten to 2 N•m (17.7 in-lb) torque.
Disconnect the engine harness wire (Item 2) [Figure 70-

Remove the three bolts (Item 1) and remove the fuel 80-47] from the glow plug.
injector cover (Item 2) [Figure 70-80-45].
Remove the glow plug connecting strap (Item 3) [Figure
Figure 70-80-46 70-80-47].
Figure 70-80-48
2
1
1
S6895
S6901
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-80-46].
Loosen and remove the glow plugs (Item 1) [Figure 70-
80-48].
Installation: Tighten the glow plug to 15 N•m (13 ft-lb)

torque.

ENGINE TIMING Figure 70-90-2
Procedure

procedure:
MEL-1638 Camshaft Timing Pin 1

MEL-1639 Crankshaft Timing Pin
Remove the rocker cover. (See Rocker Cover Removal

Remove the glow plugs. (See Glow Plugs Removal And

P-55601
Remove the timing case cover. (See Timing Cover
Removal on Page 70-150-1.) Carefully rotate the crankshaft in the normal direction of
rotation. Align the hole in the crankshaft with the hole in
NOTE: The marks on the timing gears are not to be the cylinder block and timing case and install the
used as timing marks. The marks indicate the crankshaft timing pin (MEL-1639) (Item 1) [Figure 70-90-
front of the gear only. 2]. Push the pin fully into the hole.
Figure 70-90-3
Figure 70-90-1

1
1 2
P-55602
P-55600
Insert the camshaft timing pin (MEL-1638) (Item 1)

[Figure 70-90-3] through the hole in the camshaft gear
To set the number one piston to TDC on the correct
and into the body of the timing case. With the two pins
stroke, rotate the crankshaft in the normal direction of
installed the engine is set at TDC number one on the
rotation until the intake valve (Item 1) of the number four
compression stroke.
cylinder has just opened and the exhaust valve (Item 2)
[Figure 70-90-1] of the same cylinder has not closed
NOTE: The camshaft timing pin is a push fit into the
completely.
timing case. The camshaft gear can rotate a
small amount when the pin is installed. This
allows the assembly of the gears and removal
of the backlash from the gears, with the timing
pins installed.
Install the timing case cover. (See Timing Cover Removal
on Page 70-150-1.)
Install the glow plugs. (See Glow Plugs Removal And
Install the rocker cover. (See Rocker Cover Removal And


ENGINE / HYDROSTAT ASSEMBLY Figure 70-100-2
Remove the engine cover. (See Removal And Installation 1

on Page 50-70-1.)
1
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-100-2.)

2
S38072
Unit on Page 80-100-1.) Remove the four drive shaft mounting bolts (Item 1)
[Figure 70-100-2].
Removing And Installing Battery on Page 60-20-1.) Installation: Apply Loctite® 242 or equivalent to the
threads of the bolts (Item 1) [Figure 70-100-2] and
Remove the operator seat. (See Removal And tighten to 33 - 41 N•m (24.3 - 30.2 ft-lb).

Position the drive shaft (Item 2) [Figure 70-100-2] on the
Figure 70-100-1 frame floor.
Figure 70-100-3
2 2
1
1
3
1
4
3
S38105 1
S38073
Remove the two bolts (Item 1) and the cover (Item 2)
[Figure 70-100-1].
Remove the four drive shaft mounting bolts (Item 1)
Remove the two bolts (Item 3) and the cover (Item 4) [Figure 70-100-3].
[Figure 70-100-1].
Position the drive shaft (Item 2) [Figure 70-100-3] on the
frame floor.

ENGINE / HYDROSTAT ASSEMBLY (CONT'D) Figure 70-100-6
Figure 70-100-4
4 3
2
2
1
S38077
1
3
4 Remove the A/C hose (Item 1) from the drier, and the A/C
S38075 hose (Item 2) [Figure 70-100-6] from the expansion
valve.
Remove the tie-strap (Item 1) [Figure 70-100-4] NOTE: Plug the A/C hoses and component openings
to prevent contamination.

Loosen the screw and disconnect the electrical connector
(Item 2) [Figure 70-100-4]. Remove the heater hoses (Items 3 and 4) [Figure 70-
100-6] from the heater.
Remove the nut and ground wires (Item 3) [Figure 70-
100-4]. Figure 70-100-7
Disconnect the ignition connector (Item 4) [Figure 70-

100-4] (red / white cable).
Figure 70-100-5
1
2
1 3 1
S38107
Remove the tie-straps (Item 1) and loosen the collar

(Item 2) [Figure 70-100-7].
S38076
Disconnect the hose (Item 3) [Figure 70-100-7]
Disconnect the parking brake sensor connector (Item 1)

[Figure 70-100-5].
NOTE: Mark all hoses and electrical connectors, for

correct installation.

Figure 70-100-8
2
1
1
S38081
Loosen the hose clamp (Item 1) [Figure 70-100-10].

S38079

IMPORTANT

hydraulic filter.
Figure 70-100-9 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
1 Figure 70-100-11
S38080
1
hydraulic tank.
S38082

parking brake cylinder.

Figure 70-100-12
1
1
1
1
S38085
1
1 Remove the two hoses (Item 1 and 2) [Figure 70-100-14]
2 from the steering valve.
S39435
Figure 70-100-15
Remove the six hoses (Item 1) from the manifold (Item 2)
[Figure 70-100-12].

Figure 70-100-13
2
1 1
1
S38119
2 1

S38084 70-100-15] from the linkage.

Remove the three bolts (Item 1) and remove the cover mounting bracket (Item 2) [Figure 70-100-15]
cab. Remove any necessary cable ties, carefully remove the
IMPORTANT
damage the system.
I-2003-0888

Figure 70-100-16
1
1
S38106

S38144 18] located inside the front frame compartment.
Figure 70-100-19
Remove the two fuel hoses (Item 1) [Figure 70-100-16].

NOTE: Mark the hoses for proper assembly.
Figure 70-100-17
1
S38107

19] located inside the front frame compartment.
S38145
Support the engine / hydrostat assembly with a fork lift or

suitable lift jack.
NOTE: Make sure the fork tips of the fork lift only
support the engine / hydrostat assembly and
not the machine frame.

Figure 70-100-20
1
S38110
Remove the mounting bolt (Item 1) [Figure 70-100-22] in

S38108 the middle of the engine / hydrostat assembly.
Carefully remove the engine / hydrostat assembly from

Remove the two mounting bolts (Item 1) [Figure 70-100- the machine. Guide the hoses and wire harness out of
20] at the rear of the engine / hydrostat assembly. the frame.

Figure 70-100-21 Pay special attention to route the HVAC hoses out of the
operator cab.
S38109

21] at the front of the engine / hydrostat assembly.

FLYWHEEL AND HOUSING Figure 70-110-3
Remove the hydrostatic pump. (See Removal And

Figure 70-110-1
S39126
Remove the six coupler mounting bolts (Item 1) [Figure

1 70-110-3]. Remove the coupler.

S39164 lb) torque.

Figure 70-110-4
Remove the two bolts (Item 1) and remove the charge
filter (Item 2) [Figure 70-110-1] and its support.
2
Figure 70-110-2 2
1 S39127
2 Remove two of the flywheel mount bolts and install two

S39125 guide studs (Item 1) [Figure 70-110-4] in the flywheel to
prevent the flywheel from falling.
Loosen and remove the ten flywheel housing mount bolts Remove the remainder of the bolts (Item 2) [Figure 70-
(Item 1) [Figure 70-110-2]. 110-4]. Remove the flywheel by sliding outward over the
guide studs.
Inspect the flywheel and ring gear for wear or damage.
Installation: Tighten the bolts to 54 - 61 N•m (40 - 45 ft- Replace as needed.
lb) torque.
Installation: Tighten the flywheel bolts to 115 N•m (85 ft-
lb) torque.

FLYWHEEL AND HOUSING (CONT'D) Figure 70-110-7
Removal And Installation (Cont'd) 3 3
Figure 70-110-5 1
2 2
2
2
1
S39128
If removing the flywheel housing (Item 1) is required,

S39163 loosen and remove the eight mounting bolts (Item 2 and
3) [Figure 70-110-7].
If removal of the flywheel housing is required, loosen the Installation: Tighten the bolts (Item 2) to 63 N•m (46 ft-
three engine mounting bolts. Lift the engine and install lb) and the bolts (Item 3) [Figure 70-110-7] to 75 N•m

blocks under the oil pan. Lower the engine assembly on (55 ft-lb) torque.
the support blocks (Item 1) [Figure 70-110-5].
Figure 70-110-6
1 1
S39136
Remove the eight bolts (Item 1) [Figure 70-110-6] on

both sides of the flywheel housing.

FLYWHEEL AND HOUSING (CONT'D) Ring Gear Removal
Flywheel Inspection Before the ring gear is removed note the position of the
chamfer on the teeth.
Figure 70-110-8
Heat the ring gear enough to expand it and hit it with a
hammer evenly to remove it.
Be careful not to damage the flywheel during this

operation.
Ring Gear Installation
The ring gear is a heat expansion fit on the flywheel.
Do not heat the ring gear to a temperature greater than

250°C (480°F) make sure the ring gear chamfer is in the
correct position.
B-05559
Install a dial indicator to check the flywheel run out

[Figure 70-110-8].

Flywheel run out must be less than 0,30 mm (0.012 in).
Figure 70-110-9
203 mm (8”)
B-05560
Check the alignment of the flywheel face [Figure 70-110-

9].
The misalignment must not be more than 0,03 mm (0.001

in) total indicator reading for every 25 mm (1.0 in) of the
flywheel radius from the crankshaft axis to the dial gauge
plunger.
Example: The misalignment must not be greater than

0,203 mm (0.008 in) at 203 mm (8 in) from the centerline
of the crankshaft toward the outside of the flywheel.
During this check keep the crankshaft pressed toward the

front so crankshaft end play will not affect the reading.


TURBOCHARGER
Turbo Charger Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Too Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Too Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35

Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35

1. Air filter element dirty. 17. Restricted lubricating oil drain pipe.
2. Restricted crankcase breather. 18. Turbine housing damage or restricted.
3. Air filter element missing, leaking or not sealing 19. Leakage from turbocharger seals.
correctly. Loose connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 20. Worn turbocharger bearings.
turbocharger.
5. Damaged / restricted crossover pipe, turbocharger to 21. Excessive dirt in turbocharger housing.
induction manifold.
6. Restriction between air filter and turbocharger. 22. Excessive carbon behind turbine rotor.
7. Restriction in exhaust system. 23. Engine speed raised too rapidly at initial start.
8. Turbocharger loose or clamps / setscrews loose. 24. Insufficient engine idle period.
9. Induction manifold cracked or loose, flanges distorted. 25. Faulty fuel injection pump.
10. Exhaust manifold cracked or loose. 26. Worn or damaged fuel injectors.
11. Restricted exhaust system. 27. Valves burned.
12. Delay of lubricating oil to turbocharger at engine start. 28. Worn piston rings. Flanges distorted.
13. Insufficient lubrication. 29. Lubricating oil leakage from supply pipe.
14. Dirty lubricating oil. 30. Excessive starting fluid (on initial engine start).
15. Incorrect lubricating oil. 31. Excessive engine idle period.
16. Restricted lubricating oil supply pipe. 32. Restriction in turbocharger bearing housing.
33. Restriction in lubricating oil filter.
34. Engine stopped too soon from high load.
35. Insufficient lubricating oil.
36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.

TURBOCHARGER (CONT'D) Turbo Charger Removal And Installation
Turbo Charger Description Figure 70-120-2
Remove the muffler. (See Removal And Installation on

Page 70-30-1.)
2
WARNING 1
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
S39190
Figure 70-120-1
Remove the two bolts (Item 1) and remove the exhaust
elbow (Item 2) [Figure 70-120-2].
Figure 70-120-3

1
2
1
1
S39191
The turbocharger (Item 1) [Figure 70-120-1] is placed

between the exhaust and intake manifolds. It is driven by
S39189
hot exhaust gases and supplies air at more than
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery. Loosen the two intake tube clamps (Item 1) [Figure 70-
120-3].
The oil flows from the filter adapter through the bearing
housing and returns to the engine block. Remove the flexible intake tube (Item 2) [Figure 70-120-
3].
The turbocharger should only be serviced by an
authorized dealer or repair shop.

TURBOCHARGER (CONT'D) Figure 70-120-6
Turbo Charger Removal And Installation (Cont'd)
Figure 70-120-4
1 1
1
P-55624
Remove the four nuts (Item 1) [Figure 70-120-6] for the

P-55623 turbocharger to exhaust manifold flange.
Installation: Apply anti-seize compound to the mounting

Disconnect the oil supply tubeline (Item 1) [Figure 70- studs. Tighten the nuts to 44 N•m (33 ft-lb) torque.
120-4].

Remove the turbocharger and gasket from the exhaust
Installation: Fill the bearing housing with clean oil manifold.
through the oil supply port. Tighten banjo fitting to
22 N•m (16 ft-lb) torque. The turbocharger must only be serviced by an authorized
repair shop.
Figure 70-120-5
Before starting the engine, disconnect the electrical stop
control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.
P-55621
Remove the oil return line (Item 1) [Figure 70-120-5].


FUEL SYSTEM Fuel Injector Cover Removal And Installation
Exhaust Manifold Removal And Installation Figure 70-130-3
Remove the turbocharger. (See Turbo Charger Removal

1
1
Figure 70-130-1
1 1
S39192
Remove the three bolts (Item 1) [Figure 70-130-3] and

remove the cover.
P-55625
Installation: Tighten the bolts to 9 N•m (79.7 in-lb)

torque.
Remove the eight mount bolts (Item 1) [Figure 70-130-
1].
Remove the exhaust manifold and gasket.
Figure 70-130-2
5 2 8
1
4 3 7
6
P-55625
Installation: Tighten the bolts in the sequence shown

[Figure 70-130-2] to 40 N•m (30 ft-lb) torque.

FUEL SYSTEM (CONT'D) Figure 70-130-6
Rocker Cover Removal And Installation
Drain the engine coolant until it is below the thermostat

level.
Figure 70-130-4 1
1 S6895
Remove the breather hose (Item 1) [Figure 70-130-6].
Figure 70-130-7
S39194

Remove the coolant hose (Item 1) [Figure 70-130-4].
Remove the fuel injector cover. (See Fuel Injector Cover

Removal And Installation on Page 70-130-1.)
1
Figure 70-130-5
2
S6896
2 Remove the bolt (Item 1) and remove the breather fitting

1 (Item 2) [Figure 70-130-7].
S39189
Loosen the two intake tube clamps (Item 1) [Figure 70-

130-5].
Remove the flexible intake tube (Item 2) [Figure 70-130-

5].

FUEL SYSTEM (CONT'D)
Rocker Cover Removal And Installation (Cont'd)
Figure 70-130-8
1
1
1
1
S39193
Remove the ten mount bolts (Item 1) [Figure 70-130-8].

Figure 70-130-9
1 10 3 5
8
7
4 9 2
6
S39193
Installation: Tighten the bolts in the sequence shown

[Figure 70-130-9] to 9 N•m (79.7 in-lb) torque.


CYLINDER HEAD Figure 70-140-2
Cylinder Head Removal
Remove the turbo charger. (See Turbo Charger Removal

Remove the exhaust manifold. (See Exhaust Manifold

Remove the alternator. (See Removal And Installation on

Page 60-30-1.)
1
Remove the fuel lift pump. (See Fuel Lift Pump Removal
P-55682
Remove the fuel injectors. (See Fuel Injectors Removal
Disconnect the intake manifold pressure sensor (Item 1)
Remove the glow plugs. (See Glow Plugs Removal And [Figure 70-140-2].
Reposition the harness.
Figure 70-140-1
Figure 70-140-3

1
P-55681
P-55683
Disconnect the engine cooling temperature sensor (Item

1) [Figure 70-140-1]. Remove the tubeline (Item 1) [Figure 70-140-3].
NOTE: Mark wires for correct installation.

CYLINDER HEAD (CONT'D) Figure 70-140-6
Cylinder Head Removal (Cont'd)

8
9 5 1 4
Figure 70-140-4
2
1
10 7
6 2 3
B-23183
1 Release the cylinder head bolts evenly and gradually in

P-55684 the sequence shown [Figure 70-140-6].
Check the head bolts for distortion and damage. Replace

Remove the two bolts (Item 1) and remove the coolant as needed.
bypass tube (Item 2) [Figure 70-140-4].

Lift off the cylinder head and clean the bottom face.
Remove the rocker shaft assembly. (See Rocker Shaft

Disassembly And Assembly on Page 70-140-6.)
Figure 70-140-5
P-8718A
Remove the push rods [Figure 70-140-5].

CYLINDER HEAD (CONT'D) Cylinder Head Installation
Cylinder Head Inspection Make sure the mating surfaces of the head and block are
clean.
Figure 70-140-7
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
1 1 1 1 1 3 Clean any debris out of the cylinder bores.
2 Figure 70-140-8
2 2
1
3 FRONT TOP
B-5564
Put a straight edge on the cylinder head as shown in

[Figure 70-140-7].

Using a feeler gauge between the straight edge and
B-5562
head, check for warping.
Maximum allowed (Item 1) is 0,03 mm (0.0012 in), (Item NOTE: The locating pins (Item 1) are pressed in the
2) is 0,05 mm (0.0019 in) and (Item 3) [Figure 70-140-7] engine block so the head gasket (Item 2)
is 0,05 mm (0.0019 in). [Figure 70-140-8] can be positioned correctly.
The head can be machined removing only a minimum The head gasket is installed with no sealer.
amount. Head thickness must not be less than 117,20
mm (4.614 in). Place the head gasket in position with the Front Top (Item
2) [Figure 70-140-8] marks in the correct position.
Completely clean the rest of the head.
Lower the cylinder head in position.
Inspect for cracks or other damage.

Cylinder Head Installation (Cont'd)

225° 270°
Figure 70-140-9
3
2 6 10 7
EM7513
1 4
5 9 8
If no angle gauge is available make a suitable mark on
B-23183 the head bolt corner. Make another mark on the cylinder
head the correct number of flats away [Figure 70-140-
11]. Turn the head bolt until the lines match.
Tighten the head bolts to 50 N•m (37 ft-lb) in the
sequence shown [Figure 70-140-9]. Figure 70-140-12

Tighten the head bolts to 100 N•m (74 ft-lb) in the
sequence shown [Figure 70-140-9].
Figure 70-140-10
P-8718A
Install the push rods [Figure 70-140-12].
P-8839 Make sure the push rods seat in the tappet sockets.
Install the rocker shaft assembly. (See Rocker Shaft

Additional tightening of the head bolts requires the use of Disassembly And Assembly on Page 70-140-6.)
a torque angle gauge (Item 1) [Figure 70-140-10].
Tighten the short bolts to 225° and long bolts to 270° in Install the rocker cover. (See Rocker Cover Removal And
the same sequence as shown in [Figure 70-140-10]. Installation on Page 70-130-2.)

Cylinder Head Installation (Cont'd)
Figure 70-140-13
1
P-55682
2 Connect the intake manifold pressure sensor (Item 1)

P-55684 [Figure 70-140-15].
Figure 70-140-16
Install the coolant bypass pipe (Item 1) and two screws
(Item 2) [Figure 70-140-13].

Tighten the screws to 22 N•m (16 ft-lb) torque.
Figure 70-140-14
P-55681
Connect the engine cooling temperature sensor (Item 1)

[Figure 70-140-16].
P-55683 Install the glow plugs. (See Glow Plugs Removal And
Install the tubeline (Item 1) [Figure 70-140-14]. Install the fuel injectors. (See Fuel Injectors Removal And
Install the fuel lift pump. (See Fuel Lift Pump Removal
Install the alternator. (See Removal And Installation on

Page 60-30-1.)
Install the exhaust manifold. (See Exhaust Manifold

Install the turbo charger. (See Turbo Charger Removal


CYLINDER HEAD (CONT'D) Valve Removal
Rocker Shaft Disassembly And Assembly NOTE: Mark all components so they can be returned
to the same position.
NOTE: Make an identification mark on each rocker
arm assembly in order to show the location. Figure 70-140-18
Figure 70-140-17
4 5
2 3
3
2 P-8720A
P-8719A
Using a valve spring compressor compress the springs

and remove the retainers (Item 1) [Figure 70-140-18].
Remove the clips (Item 1) [Figure 70-140-17] from both
ends of the shaft. Release the compressor and remove the valve spring
cap (Item 2), spring (Item 3), valve seal / spring seat
Remove the rocker arm (Item 2) and spring (Item 3) washer (Item 4) and valve (Item 5) [Figure 70-140-18].
[Figure 70-140-17].
Clean and inspect all components.
Continue to disassemble the rocker shaft.
Clean and inspect all components for damage and wear.
Check the clearance between the rocker arms and shaft.
Using a press and adapter, remove the old bushing and

press in the new one making sure the oil holes line up.
Shaft O.D. 24,962 - 24,987 mm

(0.9828 - 0.9837 in)
Rocker Arm Bore Dia. 25,013 - 25,051 mm
(0.9848 - 0.9863 in)
Clearance Between Rocker Arm 0,026 - 0,089 mm
and Shaft (0.0010 - 0.0035 in)
If the clearance is more than 0,13 mm (0.005 in) replace

the bushing(s).

CYLINDER HEAD (CONT'D) Valve Depth Checking
Valve Springs Checking Figure 70-140-20
Figure 70-140-19
35,17 mm
(1.3846 in)
N-00533
B-5552
Check the valve depth as shown in [Figure 70-140-20].
Use the following chart [Figure 70-140-19]. The maximum depth is 2,06 mm (0.0811 in) for both
intake and exhaust valves.

Valve Springs
If the valve is below the limits, install a new valve and
Compressed Height 38,17 mm (1.3846 in)
recheck the valve depth. If it is still below limits a new
Installed Pressure 335 N (75 lbf) valve seat insert must be installed.
When the depth is less than 1,53 - 1,81 mm (0.060 -

0.071 in) the seat can be ground to lower the valve depth.

CYLINDER HEAD (CONT'D) Use the following chart to inspect valve guides.
Valve Guides Checking

Inside Diameter
Figure 70-140-21 (Item 1) [Figure 70-140-21] 9,00 - 9,022 mm
(0.3543 - 0.3552 in)
1
4
Outside Diameter (Item 2) [Figure 70-140-21]
Intake and Exhaust 13,034 - 13,047 mm
(0.5131 - 0.5137 in)
3
Interference fit of valve guide to cylinder head: 0,007 -
0,047 mm (0.0003 - 0.0019 in)
2
Overall Diameter (Item 3) [Figure 70-140-21]
Intake and Exhaust 51,00 - 51,50 mm
B-5551
(2.018 - 2.027 in)
Figure 70-140-22

Protrusion from bottom recess for valve spring;
(Item 4) [Figure 70-140-21] 12,35 - 12,65 mm
(0.486 - 0.498 in)
1 3
To inspect the valve guides for wear using a valve.
Set up dial indicator gauge (Item 1) [Figure 70-140-21]

as shown.
Lift the valve (Item 2) 15,0 mm (0.60 in) and move the
2 valve in and away from the gauge (Item 1) [Figure 70-
140-21]. Record this reading.
B-5566A
If the clearance exceeds 0,13 mm (0.005 in) for intake or
0,15 mm (0.006 in) for exhaust (Item 3) [Figure 70-140-
The valve guides can be inspected for wear with either of 22] the valve guide needs to be replaced.
the operations listed in [Figure 70-140-21] or [Figure 70-
140-22].

CYLINDER HEAD (CONT'D) Valve Guide Installation
Valve Guide Removal Figure 70-140-24
Clean the guide bore in the head.
Figure 70-140-23

B-5548
Clean the guide bore in the head.
Lubricate the outer surface of the new guide (Item 1)

B-5549 [Figure 70-140-24] with the engine oil.
Put the guide in position on the valve guide removal /

Install a valve guide removal / installation tool (Item 1) on installation tool (Item 2) [Figure 70-140-24].
the valve guide (Item 2) [Figure 70-140-23].
Pull the guide into the cylinder head.
Pull the guide (Item 2) [Figure 70-140-23] out of the
cylinder head. When correctly positioned the top of the guide should
extend 12,35 - 12,65 mm (0.486 - 0.498 in) above the
valve spring seat [Figure 70-140-21].

CYLINDER HEAD (CONT'D) Cutting A Valve Seat
Valves Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
Figure 70-140-25 Select the correct size cutter.
Valve Seat Angle Intake / 45° / 30°

Exhaust
4 Figure 70-140-26
1
B-5567

Use the following chart [Figure 70-140-25] to inspect the
valve dimensions.
N-00532
Ref. Valve Specifications
1. Intake 128,838 - 129,288 mm
(5.0724 - 5.0901 in) Carefully turn the cutter in a clockwise direction using
Exhaust 128,184 - 128,634 mm even downward pressure. Keep the valve seat as narrow
(5.0466 - 5.0643 in) as possible [Figure 70-140-26].
2. Intake 8,953 - 8,975 mm
Remove any cutting debris.
(0.3525 - 0.3533 in)
Exhaust 8,938 - 8,960 mm
Install the valve and lightly tap.
(0.3519 - 0.3528 in)
3. Intake 46,28 - 46,53 mm Check the valve depth to make sure that it is within limits.
(1.8220 - 1.8319 in) (See Valve Guides Checking on Page 70-140-8.)
Exhaust 41,51 - 41,75 mm
(1.634 - 1.644 in) NOTE: If the valve seat is worn or damaged, a new
4. Intake 1,60 - 1,85 mm valve seat insert can be installed.
(Production) (0.0630 - 0.0728 in)
Intake (Ser- 2,09 mm
vice Maximum) (0.0823 in)
Exhaust (Pro- 1,55 - 1,81 mm
duction) (0.0610 - 0.0713 in)
Exhaust (Ser- 2,06 mm
vice Maximum) (0.0811 in)
Intake / 45° / 30°
Exhaust Valve
Face Angle

CYLINDER HEAD (CONT'D)
Valve Seat Assembly
WARNING
W-2019-0907
Figure 70-140-27
4 5

1
2 3
P-8720A
Lubricate the valve stems (Item 1) [Figure 70-140-27]

with clean engine oil and install them in the respective
guides.
Install new valve seals / spring seat washer (Item 2)

[Figure 70-140-27].
Install the spring (Item 3) [Figure 70-140-27] on the

washer (make sure the larger diameter is against the
cylinder head).
Place the valve cap (Item 4) [Figure 70-140-27] on the

spring.
Using a valve spring compressor compress the springs

and install the retainers (Item 5) [Figure 70-140-27].

Changing Valve Springs (With Cylinder Head

Installed)

Figure 70-140-28
N-00531
Install the valve spring compressor and adapter [Figure

70-140-29].
Compress the valve springs squarely and remove the

retainers.
B-5565

NOTE: Do not rotate the crankshaft while the valve
springs are removed.
Rotate the crankshaft clockwise until the intake valve has
opened and the exhaust valve has not fully closed. In this Release the compressor and remove the valve spring(s).
position the piston (Item 1) [Figure 70-140-28] will be at
approximately T.D.C. Place the new valve springs in position.
Remove the rocker shaft assembly. (See Rocker Shaft Compress the valve springs and install the retainers.
Disassembly And Assembly on Page 70-140-6.)

Valve Clearance Adjustment
Adjust the valve clearance as follows:
Figure 70-140-30
1 2 3 4 5 6 7 8
2 1
B-5569
Figure 70-140-32
3 Cylinder
B-5568 No. 1 2 3 4
Valve No. 1 2 3 4 5 6 7 8
Valve

Loosen the lock nut (Item 1) [Figure 70-140-30]. 1=Intake I E I E I E I E
E=Exhaust
until the correct clearance is obtained. Use the following sequence to set the valves [Figure 70-
140-31] and [Figure 70-140-32].
NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [Figure
70-140-30]. a. With the rocker arm rocking (valves 7 and 8) on No.
4 cylinder set clearance at No. 1 cylinder (valves 1
and 2).
Adjust the valve clearance as follows:
b. With the rocker arm rocking (valves 3 and 4) on No.
0,20 mm (0.008 in) Intake 2 cylinder set clearance at No. 3 cylinder (valves 5
and 6).
0,45 mm (0.018 in) Exhaust
c. With the rocker arm rocking (valves 1 and 2) on No.
and 8).
d. With the rocker arm rocking (valves 5 and 6) on No.
and 4).


CAMSHAFT AND TIMING GEARS Crankshaft Pulley Removal And Installation
Timing Case And Drive Assembly Description Figure 70-150-2
The timing case is made of aluminum and the cover is

made of tin and in most applications, the timing gears are
made of steel. The drive from the crankshaft passes to 1
the idler gear, to the camshaft gear, to the gear on the
fuel injection pump and to the water pump.
The camshaft and fuel injection pump run at half the 1

speed of the crankshaft. 2
Timing Cover Removal
Remove the water pump. (See Water Pump Removal on

Page 70-170-3.)
S6912
Figure 70-150-1
Remove the three bolts (Item 1) and thrust block (Item 2)

[Figure 70-150-2].
Installation: Tighten the bolts to 115 N•m (85 ft-lb)

1 torque.
2
1
Remove the pulley.
Front Oil Seal Removal And Installation

1
Remove the crankshaft pulley. (See Crankshaft Pulley
1 Removal And Installation on Page 70-150-1.)
1 Remove the oil seal using a seal removal tool.

S6911
Do not damage the edge of the seal housing.

Remove the timing cover bolts (Item 1) and remove the Figure 70-150-3
timing cover (Item 2) [Figure 70-150-1].
Timing Cover Installation
Clean the gasket mating surfaces.
Place the gasket and timing cover on the engine.
Remove the timing pins if installed.
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.
1
Install the water pump. (See Water Pump Installation on
P-55686
Page 70-170-3.)
Do not tighten bolts at this time. Install the oil seal (Item 1) [Figure 70-150-3] into the
housing using the special tool.
Tighten the cover bolts and water pump bolts to 22 N•m
(16 ft-lb) torque. Install crankshaft pulley. (See Crankshaft Pulley Removal

CAMSHAFT AND TIMING GEARS (CONT'D) Figure 70-150-6
Timing Case And Gear Removal
Remove the timing cover. (See Timing Cover Removal on 1

Page 70-150-1.)
Remove the crankshaft pulley. (See Crankshaft Pulley

Remove the fuel injection pump. (See Fuel Injection

Pump Removal on Page 70-80-1.)
Figure 70-150-4
P-55689
1
Remove the idler gear (Item 1) [Figure 70-150-6] by
moving the gear assembly forward and lifted over the
front oil seal housing.
NOTE: Do not turn the crankshaft with the idler gear

2
removed.

Figure 70-150-7
1
P-55684
2 1
Remove the two bolts (Item 1) and remove the coolant
bypass tube (Item 2) [Figure 70-150-4].
Figure 70-150-5
3 1
P-55690
Remove the bolt (Item 1) and washer (Item 2) [Figure

70-150-7].
2
1
P-55688
Remove the three bolts (Item 1) and plate (Item 2) from

the idler gear (Item 3) [Figure 70-150-5].

CAMSHAFT AND TIMING GEARS (CONT'D) Timing Case And Gear Installation
Timing Case And Gear Removal (Cont'd) Clean the mating surfaces, if the oil pan was not removed
trim the oil gasket flush with the block.
Figure 70-150-8
Figure 70-150-10
1
1 2
2
2
2
2
P-55691
2 P-55692
Remove the camshaft gear (Item 1) [Figure 70-150-8].

Install the timing case (Item 1) onto the cylinder block and

NOTE: Use care not to lose the key from the key way. hand tighten the bolts (Item 2) [Figure 70-150-10].
Figure 70-150-9 After the cover is correctly aligned, tighten the mount
bolts (Item 2) [Figure 70-150-10] to 22 N•m (16 ft-lb)
torque.
1
1 Figure 70-150-11
1
1
1
2
2
2 P-55692
Remove all the timing case mount bolts (Item 1) and the
four bolts (Item 2) [Figure 70-150-9] from the front of the
P-55691
oil pan.
Remove the timing case from the engine. Install the camshaft gear (Item 1) onto the shaft using
alignment pin (Item 2) [Figure 70-150-11] for correct
alignment.

Timing Case And Gear Installation (Cont'd)
Figure 70-150-12
2
1 P-55688
Install the plate (Item 1) and three bolts (Item 2) [Figure

P-55690 70-150-14].
Tighten the bolts to 44 N•m (33 ft- lb) torque.

Install the washer (Item 1) and bolt (Item 2) [Figure 70-
150-12] and tighten to 95 N•m (70 ft-lb) torque. Figure 70-150-15

Figure 70-150-13
1
2
2
P-55684
P-55689
Install the coolant bypass tube (Item 1) using the two
bolts (Item 2) [Figure 70-150-15].
Install the idler gear (Item 1). Make sure the hole (Item 2)
[Figure 70-150-13] is towards the cylinder head. Install the fuel injection pump. (See Fuel Injection Pump
Install the crankshaft pulley. (See Crankshaft Pulley

Install the timing cover. (See Timing Cover Installation on

Page 70-150-1.)

Camshaft And Tappets Removal
Remove the timing case cover. (See Timing Cover

Removal on Page 70-150-1.)
1
Remove the timing case. (See Timing Case And Gear

Removal on Page 70-150-2.)
Remove the rocker cover, rocker assembly and push

rods. (See Rocker Cover Removal And Installation on
Page 70-130-2.) P-8741
Remove the fuel pump and gasket.

Remove the camshaft thrust washer (Item 1) [Figure 70-
Figure 70-150-16 150-17].
Figure 70-150-18

1
P-8740
P-8742
Turn the engine over and remove the oil pan mounting
bolts [Figure 70-150-16].
Carefully remove the camshaft (Item 1) [Figure 70-150-
Remove the oil pan and gasket. 18].
Installation: Tighten the oil pan mounting bolts to 22

N•m (16 ft-lb) torque.

CAMSHAFT AND TIMING GEARS (CONT'D) Camshaft And Tappets Installation
Camshaft And Tappets Removal (Cont’d) Clean and inspect the camshaft and tappets for
excessive wear and damage.
Figure 70-150-19
Inspect the camshaft bushing for excessive wear and
damage.
NOTE: Only the front camshaft journal bore has a

bushing.
1 Clearance between the camshaft journals, the bushing

1 and camshaft bore is 0,06 - 0,14 mm (0.0025 - 0.0055
in).
Make sure all components are clean and lubricated with

clean engine oil.
Figure 70-150-20
P-8743
Remove the tappets (Item 1) [Figure 70-150-19] from the

block.

1
1
P-08743
Install the tappets (Item 1) [Figure 70-150-20].
Figure 70-150-21
P-8742
Carefully install the camshaft (Item 1) [Figure 70-150-

21].

CAMSHAFT AND TIMING GEARS (CONT'D)
Camshaft And Tappets Installation (Cont’d)
Figure 70-150-22
P-8741
Install the camshaft thrust washer (Item 1). Make sure

that the dowel pin (Item 2) [Figure 70-150-22] lines up

with the hole in the thrust washer.
Install the timing case. (See Timing Case And Gear

Inspect camshaft end play. The end play for a new engine
is 0,10 - 0,55 mm (0.004 - 0.022 in), service limits 0,60
mm (0.023 in).
Install the timing gears. (See Timing Case And Gear

Install the injection pump. (See Fuel Injection Pump

Install the push rods and rocker assembly. (See Rocker

Shaft Disassembly And Assembly on Page 70-140-6.)
Install the timing cover. (See Timing Cover Installation on

Page 70-150-1.)
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-180-2.)


CRANKSHAFT AND PISTONS Pistons And Connecting Rods Removal
Pistons And Connecting Rods Description Figure 70-160-1
The pistons have a Quadram combustion chamber. They

have two compression rings and one oil control ring. The
top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by
snap rings.
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
steel. The connecting rods on the turbocharged engines
have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by 1
serrations and the cap is retained by two bolts.
The pistons used in the 1000 series engines have two P-08744
compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine Remove the cylinder head. (See Cylinder Head Removal
identification number to order new parts. on Page 70-140-1.)
Remove all the carbon from the top of the cylinder liners.

Remove the oil pan. (See Oil Pan Removal And
Remove the oil pick up screen and tube (Item 1) [Figure

70-160-1].
Figure 70-160-2
1 1
1
1
P-08743
Mark and remove the connecting rod caps (Item 1)

[Figure 70-160-2].
NOTE: Do not allow the connecting rods to hit the

cooling jets.

CRANKSHAFT AND PISTONS (CONT'D) Pistons And Connecting Rods Disassembly
Pistons And Connecting Rods Removal (Cont’d) Figure 70-160-5
Figure 70-160-3
1
1 1
4
4
B-05570
P-08745
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-160-5] as shown on the connecting rod.
Turn the connecting rods 90° to prevent contact with the
piston cooling jets (Item 1) [Figure 70-160-3]. Push the Figure 70-160-6

piston and rod assemblies out the top of the cylinder.
Figure 70-160-4 1
4
1 1
1 1
3
P-13999
P-08746 Remove the piston rings (Item 1) [Figure 70-160-6] with

a ring expander.
Inspect the crankshaft journals (Item 1) [Figure 70-160- Remove the snap rings (Item 2) [Figure 70-160-6] which
4] for wear or damage. retain the piston pin.
NOTE: Keep all parts together so they can be Push the piston pin (Item 3) [Figure 70-160-6] out by
replaced in their original position. hand. If the pin doesn't push out easily, heat the piston to
40° - 50°C (100° - 120°F) for easier removal.
NOTE: Before installing the pistons check cylinder
bore for wear or damage. (See Cylinder Liner Remove the connecting rod (Item 4) [Figure 70-160-6].
Inspection on Page 70-190-3.)

CRANKSHAFT AND PISTONS (CONT'D)
Piston Ring End Gap
Figure 70-160-7
B-05571
Place the piston rings in the upper part of the cylinder to

inspect the end gap [Figure 70-160-7].

Top Ring End Gap 0,30 - 0,45 mm
(0.0118 - 0.0117 in)
Second Ring End Gap 0,65 - 0,85 mm
(0.0256 - 0.0335 in)
Third Ring End Gap 0,30 - 0,55 mm
(0.0118 - 0.0216 in)

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-160-9
Piston Ring Installation
Figure 70-160-8 3
B-05575
Install the oil control ring over the spring (Item 1) [Figure
B-05572 70-160-9].
Make sure the ring gap is 180° from the latch pin.
Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring Install the cast iron ring with the tapered face (Item 2)

[Figure 70-160-8]. [Figure 70-160-9] in the second groove with the word
TOP or symbol facing the top of the piston.
Use a ring expander to install the piston rings.
New second rings have a green identification mark,
Install the oil spring on the bottom groove of the piston which must be on the left of the ring gap after the ring is
with the latch pin inside both ends of the spring. installed and the piston is upright.
The second ring has an external step at the bottom of the

tapered face.
Place the chromium ring (Item 3) [Figure 70-160-9] with

the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-160-9] has an internal

step.
New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is upright.
Make sure the ring gaps are 120° apart.

CRANKSHAFT AND PISTONS (CONT'D) Connecting Rod Inspection
Piston Ring Groove Clearance Figure 70-160-11
Figure 70-160-10
127 mm 127 mm
(5”) (5”)
± 0.25 mm ± 0.25 mm
(0.010”) (0.010”)
B-05577
B-05576
Inspecting the connecting rod for distortion [Figure 70-
160-11].
With the piston rings installed, check the groove
clearance [Figure 70-160-10]. NOTE: The large and small end bores must be square

and parallel within the limits of ± 0,25 mm
Top Ring Wedge (± 0.010 in).
Second Ring Side 0,065 - 0,110 mm
Clearance (0.0026 - 0.0043 in) Measure this 127 mm (5.0 in) on each side of the
connecting rod axis on a test fixture.
Third Ring Side Clearance 0,03 - 0,07 mm
(0.0011 - 0.0027 in) With the piston pin bushing installed the limit is reduced
to ± 0,06 mm (± 0.0025 in).
Inspect the pin bushing for wear or damage. Replace as

needed.
Connecting Rod Bushing Replacement
Press out the old bushing. Clean the bore and remove
any burrs.
Press in the new bushing making sure the oil feed holes
line up.
Ream the bushing to get the proper clearance of 0,023 -

0,044 mm (0.0009 - 0.0017 in) between the small end
bushing and piston pin.

CRANKSHAFT AND PISTONS (CONT'D) Piston And Connecting Rod Installation
Piston And Connecting Rod Assembly Apply a light coat of oil to the piston and piston rings.
Figure 70-160-12 NOTE: Make sure the piston ring end gaps are 120°
apart.
Figure 70-160-13
1
P-13999
Install the connecting rod (Item 1), piston pin (Item 2) and
B-05578
two snap rings (Item 3) [Figure 70-160-12] in the piston.

Install the ring compressor over the piston rings [Figure
70-160-13].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.
Figure 70-160-14
FRONT
B-05579
When the piston has cleared the cooling jet, rotate the
piston assembly so that the arrow or FRONT mark is
toward the front of the engine [Figure 70-160-14].

Piston And Connecting Rod Installation (Cont'd)

1 1
Figure 70-160-15 1
1
1 1
1
P-08743
Install the caps (Item 1) [Figure 70-160-17] and nuts.

P-08745 Gradually tighten the nuts to 18 N•m (13 ft-lb) torque.
Tighten to a final torque of 70 N•m (52 ft-lb). The
fasteners must be tightened a further 120°.
Clean the bearing surfaces and crank pin. Lubricate the
crank pin (Item 1) [Figure 70-160-15] with clean engine Rotate the crankshaft. The crankshaft must rotate

oil. smoothly.
Figure 70-160-16 Figure 70-160-18
B-05580
P-08744
Install the upper and lower bearing shells in position Install the oil pick up tube and screen (Item 1) [Figure
making sure the locating tang (Item 1) [Figure 70-160- 70-160-18].
16] is in the correct position.
Install the oil pan. (See Oil Pan Removal And Installation
NOTE: New connecting rod nuts must be installed on Page 70-180-2.)
each time the rod caps are removed.

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings Description
Checking Piston Height The crankshaft is a chrome-moly forging which has five
main journals. End play is controlled by two half thrust
Rotate the crankshaft until the piston is approximately at washers on both sides of the center mainbearing.
top dead center (T.D.C.).
The mainbearings have steel backs with a aluminium / tin
Using a dial indication gauge, pre-load the plunger on the bearing material. The mainbearing caps are made of cast
top surface of the block and zero the gauge. iron.
Carefully move the dial gauge so that the plunger is on The front and rear oil seals are viton lip seals with a dust
top of the piston above the axis of the piston pin. lip to the outside of the main lip.
Rotate the crankshaft to bring the piston to its highest Crankshaft And Bearings Removal
point. Record this gauge reading.
Figure 70-160-19
When installed, the top surface of the piston is slightly
above the surface of the cylinder block.
1
The height above the surface of the block should be 0,21
- 0,35 mm (0.008 - 0.014 in).
Install the cylinder head. (See Cylinder Head Installation

on Page 70-140-3.)

P-08748
Remove the water pump. (See Water Pump Removal on

Page 70-170-3.)
Remove timing case cover. (See Timing Cover Removal

on Page 70-150-1.)

Remove the timing gears and timing case. (See Timing

Case And Gear Removal on Page 70-150-2.)
Remove the flywheel. (See Removal And Installation on

Page 70-110-1.)
Remove the pistons and connecting rods, keeping them

in order. (See Pistons And Connecting Rods Removal on
Page 70-160-1.)
Remove the rear oil seal housing (Item 1) [Figure 70-

160-19].

Crankshaft And Bearings Removal (Cont’d)
Figure 70-160-20
1 1
1 1 1 1
1
P-08750
Remove the mainbearing caps (Item 1) [Figure 70-160-

P-08749 22].
Figure 70-160-23
Remove the two bolts (Item 1) [Figure 70-160-20]
retaining the bridge piece.

Remove the bridge piece.
Figure 70-160-21
1 1 1 1 1
P-08753
Remove the thrust washers from the sides of the center

mainbearing bore [Figure 70-160-23].
P-08746
Mark the mainbearing caps (Item 1) [Figure 70-160-21]

for correct installation.
Remove the mainbearing cap bolts.

CRANKSHAFT AND PISTONS (CONT'D) Inspection Of Crankshaft And Bearings
Crankshaft And Bearings Removal (Cont'd) Figure 70-160-26
Figure 70-160-24
A-02763
P-08751
Inspect the crankshaft for wear [Figure 70-160-26]. The
maximum wear and out of round of the crank journals is
Remove the crankshaft [Figure 70-160-24]. 0,04 mm (0.0016 in).

Figure 70-160-25 The main journals and the crank pins of standard size
can be machined 0,25 mm (0.010 in), 0,50 mm (0.020 in)
or 0,75 mm (0.030 in).
NOTE: (See Specifications on Page 70-10-1.) for more

crankshaft specifications.
Inspect the oil clearance of the bearings.
All Mainbearings 0,057 - 0,117 mm

(0.0022 - 0.0046 in)
Thrust Washer Thickness

Standard 2,26 - 2,31 mm
P-08752
(0.089 - 0.091 in)
Oversize 2,45 - 2,50 mm
(0.096 - 0.098 in)
Remove the crankshaft bearings from the engine block
[Figure 70-160-25].
Keep the bearings with their respective caps for

installation.

Crankshaft And Bearings Installation
Figure 70-160-27
P-08753
Clean and install the upper and lower thrust bearings on

P-08754 each side of the center mainbearing [Figure 70-160-29].
Clean the main caps and install the bearings.

Clean the mainbearing bores and install the upper
bearing shells in position. Lubricate the bearings with Lubricate the bearings with clean engine oil.

clean engine oil [Figure 70-160-27].
Install the main cap bolts and torque in steps working
NOTE: Only the upper half of the bearings has oil from the center outward.
lubrication holes and must be installed in the
cylinder block. Step 1 88 N•m (65 ft-lb)
Figure 70-160-28 Step 2 170 N•m (125 ft-lb)

Step 3 245 N•m (180 ft-lb)
Clean the bridge piece and apply a bead of Loctite® 518

in the corners and around the thread holes on the block.
P-08751
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-160-28].
Make sure the locating pins for the main caps are in
position.

CRANKSHAFT AND PISTONS (CONT'D) Rear Oil Seal Removal
Crankshaft And Bearings Installation (Cont'd) Remove the bolts that retain the seal housing. Remove
the housing.
Figure 70-160-30
Inspect the seal for wear or damage. Replace even if
there is only a small nick or scratch.
Inspect the crankshaft flange for damage.
Clean the block, seal housing, and crankshaft.
P-08755
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-160-30].

Tighten the bridge retaining bolts to 16 N•m (12 ft-lb)
torque.
Figure 70-160-31
P-08756
Inject Loctite® 518 into the groove (Item 1) at each end of

the bridge piece. Continue to inject sealant until it oozes
out of the lower groove (Item 2) [Figure 70-160-31] at the
front and rear of the piece.

CRANKSHAFT AND PISTONS (CONT'D) Rear Oil Seal Installation
Rear Oil Seal Housing Positioning Install the new seal in the housing.
Figure 70-160-34
procedure;
3
MEL1532 - Rear Crankshaft Seal Installation Tool
4
Figure 70-160-32
B-05581
1 Make sure the dowels (Item 1) [Figure 70-160-34] are in

the block correctly.
2
Install the new gasket (Item 2) on the housing (Item 3)

B-05581 [Figure 70-160-34].
Install the seal replacer tool (PD145-3) (Item 4) [Figure
The seal can be installed from flush with the housing face 70-160-34] on the crankshaft.
(Item 1) to 6,86 mm (0.27 in) (Item 2) [Figure 70-160-32]
Lubricate the seal, tool, and crankshaft with clean engine
back from the housing face. Install seal so that the seal
oil.
lip does not line up with any worn areas on the
crankshaft. Carefully push the seal and housing (Item 3) [Figure 70-
160-34] over the tool and crankshaft and into position on
Figure 70-160-33 the dowels. Remove the tool.
Figure 70-160-35
N-00550
P-08748
Install the seal in the seal housing using the seal
installation tool. Seat the seal to the correct depth
[Figure 70-160-33]. Tighten the bolts (Item 1) [Figure 70-160-35] to 22 N•m
(16 ft-lb) torque.

Checking Crankshaft End Play
The axial movement of the crankshaft is controlled by two

half thrust washers placed on both sides of the center
mainbearing.
Figure 70-160-36
B-05583
The end play can also be checked using a feeler gauge

[Figure 70-160-38].
Pry the crankshaft to the rear of the cylinder block and

measure the distance between the thrust washer and
P-08840 crankshaft.

Install a dial indicator on the end of the crankshaft
[Figure 70-160-36].
Pry the crankshaft to the rear of the cylinder block and

set the dial indicator to zero.
Figure 70-160-37
P-08841
Remove the pry bar and record the dial indicator reading
[Figure 70-160-37].
The end play specification is 0,05 - 0,38 mm (0.002 -

0.015 in) maximum.
If end play is excessive there are oversize thrust washers

available to reduce movement.

ENGINE COOLING SYSTEM Figure 70-170-3
Cooling System Description
Figure 70-170-1 1
S39195
The coolant then passes around the cylinders and in the

S6913 cylinder head. The coolant exits the cylinder head at the
front and passes into the thermostat housing (Item 1)
[Figure 70-170-3].
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-170-1], to assist the flow If the thermostat is closed, the coolant goes directly

of the coolant through the system. through a bypass to the inlet side of the water pump. If
the thermostat is open, the thermostat closes the bypass
The water pump is gear driven from the gear off the fuel and the coolant passes to the radiator.
injection pump.
From the water pump, the coolant passes through a

passage in the timing case.
The coolant passes through a passage in the left side of

the cylinder block to the rear of the cylinder block.
Figure 70-170-2
S6914
The oil cooler (Item 1) [Figure 70-170-2] is installed on

the left side of the engine. Coolant from the bypass
connection at the rear of the coolant pump passes
through a pipe to the oil cooler.

ENGINE COOLING SYSTEM (CONT'D) Thermostat Testing
Thermostat Removal and Installation Hang the thermostats in a suitable container filled with
coolant.
Drain the engine coolant until it is below the thermostat
level. Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
Figure 70-170-4 open.
If the thermostat does not operate correctly it must be

replaced.
1 1
NOTE: Identify thermostat temperature by the
stamping on the bypass valve.
Lubricating Oil Cooler Removal And Installation
Figure 70-170-6
1 1
S39195

Remove the bolts (Item 1) [Figure 70-170-4] and 2
thermostat housing.
Installation: Make sure all gasket surfaces are clean.

Replace the gasket before installing the thermostat
housing.
Figure 70-170-5 1 1
P-55782
Remove the eight mounting bolts (Item 1) and remove

the cooler (Item 2) [Figure 70-170-6].
Installation: Check oil level using the dipstick or add oil

as needed.
S39196
Remove the housing and thermostat [Figure 70-170-5].

ENGINE COOLING SYSTEM (CONT'D)
Water Pump Removal
Remove the coolant from the cooling system.
Figure 70-170-7
1
1
S6913

Remove the mounting bolts (Item 1) [Figure 70-170-7]
from the water pump.
Remove the water pump.
Water Pump Installation
Clean the gasket surfaces and replace the gasket.
Install the water pump in the timing cover. The pump is a

tight fit in the cover and is pulled into position by
tightening the bolts evenly.
Install the water pump bolts (Item 1) [Figure 70-170-7]

and tighten to 22 N•m (16 ft-lb) torque.


LUBRICATION SYSTEM Figure 70-180-3
Engine Lubrication System Description
Figure 70-180-1
1 3
S6915
The engine oil passes from the filter (Item 1) [Figure 70-
P-08834 180-3] to the cylinder block.
The oil passes to the mainbearings of the crankshaft and

Pressure lubrication is supplied by a rotor type pump through passages in the crankshaft to the big end
(Item 1) [Figure 70-180-1] which is driven through an bearings. The pistons and the cylinder bores are

idler gear from the crankshaft gear. lubricated by splash and oil mist.
Engine oil from the oil pan sump passes through a Engine oil passes from the mainbearings through
strainer (Item 2) [Figure 70-180-1] and pipe to the passages in the cylinder block to the journals of the
suction side of the pump. camshaft. Engine oil passes from the center journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-180- shaft, at a reduced pressure, to feed the rocker bushing.
1], which is installed in the bottom left side of the cylinder The oil passes through a passage in the rocker shaft to
block. The relief valves opens if the oil pressure is too the bearings of the rocker levers. The valve stems, valve
high; this allows some of the engine oil to return to the springs and the tappets are lubricated by splash and oil
sump. mist.
Figure 70-180-2 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
1 The turbocharger is lubricated by oil after the filter. Oil is

supplied from a connection on the right side of the
cylinder block through an external pipe to the
turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.
S6449
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-180-2].

LUBRICATION SYSTEM (CONT'D) Oil Pan Removal And Installation
Engine Lubrication System Description (Cont'd) Figure 70-180-6
Figure 70-180-4
P-08740
P-08745
Remove the oil pan retaining bolts (Item 1) [Figure 70-
180-6].
Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-180-4]. These jets are connected to the oil Remove the pan and gasket.

pressure rail and spray lubricating oil inside the pistons to
keep them cool. Clean the pan in solvent and dry with compressed air.
Oil Filter Adapter Removal And Installation Clean the block surface.
Figure 70-180-5 Installation: Place a new gasket on the oil pan. Place
two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts (Item 1)
2 [Figure 70-180-6] to 22 N•m (16 ft-lb) torque.
1
1
S6915
Remove the oil filter.
Remove the four bolts (Item 1) and the filter adapter (Item
2) [Figure 70-180-5].
Clean the filter adapter and the block mounting surfaces.
Using a new gasket, install the adapter (Item 2) [Figure

70-180-5] on the block.
Install the oil filter.

LUBRICATION SYSTEM (CONT'D) Oil Pump Removal
Oil Screen And Pick-up Tube NOTE: The oil pump has a channel in the body of the
pump. Oil from the front mainbearing passes
Figure 70-180-7 down the channel of the pump to an oil hole in
the idler shaft for lubrication of the idler shaft
bushing.
2 Remove the oil pan. (See Oil Pan Removal And

4
Figure 70-180-8
1
3
1
P-08834
Remove the bolt (Item 1) that holds the bracket (Item 2)

[Figure 70-180-7] to the mainbearing cap.

Remove the bolts (Item 3) [Figure 70-180-7] from the
pick-up tube flange.
P-08744
Remove the pick-up tube (Item 4) [Figure 70-180-7] and
gasket.
Remove the oil pressure relief valve (Item 1) [Figure 70-
Wash the assembly in solvent and dry with compressed 180-8].
air.
Remove the oil screen and pick-up tube.
Check the tube and strainer for cracks or other damage.
Replace as necessary. The oil pump is installed on the number 1 mainbearing
cap.
Loosely assemble the bracket (Item 2) [Figure 70-180-7]
with the pick-up tube to the mainbearing cap. NOTE: The pump can be removed with the
mainbearing cap if a spanner wrench is
Install the pick up tube gasket and mounting bolts (Item available that will allow the torque to be
3) [Figure 70-180-7]. applied directly to the main cap bolts.
Tighten the mounting bolts to 22 N•m (16 ft-lb) torque. If there is no spanner wrench, the front timing case cover
must be removed. (See Timing Cover Removal on Page
Tighten the bolt (Item 1) [Figure 70-180-7] for the pick-up
70-150-1.)
tube bracket.
Tighten the bolt to 22 N•m (16 ft-lb) torque.

LUBRICATION SYSTEM (CONT'D) Oil Pump Installation
Oil Pump Removal (Cont’d) Figure 70-180-10
Figure 70-180-9
2
1
1
P-08835
P-08835
Fill the pump with engine oil.
Remove the snap ring (Item 1), idler gear (Item 2) If the number 1 main cap was removed, reinstall and
[Figure 70-180-9], and washer. tighten the bolts to 250 N•m (185 ft-lb) torque.

Remove the bolts and oil pump. If the number one main cap was not removed, install the
pump on the main cap and tighten the bolts to 22 N•m
(16 ft-lb) torque.
Install the front timing case cover. (See Timing Cover

Inspect the idler gear and bushing for wear.
Lubricate with clean engine oil and install the washer,

idler gear (Item 1) and snap ring (Item 2) [Figure 70-180-
10].
Check the backlash between oil pump and idler gears.
There must be a minimum of 0,076 mm (0.003 in).

LUBRICATION SYSTEM (CONT'D) Oil Pump Disassembly And Assembly
Oil Pump Installation (Cont’d) Figure 70-180-12
Figure 70-180-11
B-05591
B-05588
NOTE: If any part is worn enough to effect
performance replace the complete oil pump.
Check that there is a minimum of 0,076 mm (0.003 in)
backlash between the idler gear and oil pump gear Remove the cover of the oil pump.

[Figure 70-180-11].
Remove the outer rotor and thoroughly clean. Inspect for
End play for the idler gear should be 0,050 - 0,275 mm cracks or other damage.
(0.0019 - 0.0108 in).
Install the outer rotor and check the outer rotor to body
Install the oil screen and pick-up tube. (See Oil Screen clearance [Figure 70-180-12].
And Pick-up Tube on Page 70-180-3.)
Clearance between the outer rotor and body must be
Install the pressure relief valve. 0,152 - 0,330 mm (0.0059 - 0.0129 in).
Install the oil pan. (See Oil Pan Removal And Installation Figure 70-180-13
on Page 70-180-2.)
B-05592
Check the inner rotor to outer rotor clearance [Figure 70-

180-13].
Clearance between the inner rotor and outer rotor must

be 0,040 - 0,127 mm (0.0015 - 0.005 in).

LUBRICATION SYSTEM (CONT'D) Oil Pressure Relief Valve Disassembly And Assembly
Oil Pump Disassembly And Assembly (Cont’d) Figure 70-180-15
Figure 70-180-14
5
4
1
3
B-05606
B-05593
Press the end plate (Item 1) in the valve body (Item 2)

Check the rotor end play [Figure 70-180-14]. and remove the snap ring (Item 3) [Figure 70-180-15].
Rotor end play must be 0,038 - 0,089 mm (0.0014 - Remove the end plate (Item 1), spring (Item 4), and
0.0035 in) for the inner rotor. plunger (Item 5) from the body (Item 2) [Figure 70-180-

15].
Rotor end play must be 0,025 - 0,076 mm (0.0010 -
0.0029 in) for the outer rotor. Clean the parts in solvent and dry with compressed air.
Install the cover and tighten the bolts to 22 N•m (16 ft-lb) Lubricate the bore of the valve body (Item 2), plunger
torque. (Item 5) and the end plate (Item 1) [Figure 70-180-15]
with clean engine oil before assembly.

ENGINE BLOCK Engine Block Disassembly And Assembly
Engine Block Description Remove the water pump. (See Water Pump Removal on
Page 70-170-3.)
Figure 70-190-1
Remove the oil cooler. (See Removal And Installation on

Page 70-60-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
1
Remove the turbocharger. (See Turbo Charger Removal
Remove the lift fuel pump. (See Fuel Lift Pump Removal
P-08837
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
The cylinder block is made of cast iron and provides full
length support for the dry liners. Remove the cylinder head. (See Cylinder Head Removal

on Page 70-140-1.)
The liners (Item 1) [Figure 70-190-1] are made of cast
iron. Production liners are a press fit and service liners Remove the timing case and gears. (See Timing Case
are a transion fit. Both types of liners are honed with And Gear Removal on Page 70-150-2.)
silicon carbide tools to a specially controlled finish to
ensure long engine life and low oil consumption. Remove the piston and connecting rod assemblies. (See
Pistons And Connecting Rods Removal on Page 70-160-
Figure 70-190-2 1.)
Remove the camshaft and tappets. (See Camshaft And

Tappets Removal on Page 70-150-5.)
Remove the engine mounting bracket and flywheel. (See

1 Removal And Installation on Page 70-110-1.)
Remove the rear oil seal and the crankshaft. (See Rear
Oil Seal Removal on Page 70-160-12.)
P-08842
A bushing (Item 1) [Figure 70-190-2] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.

ENGINE BLOCK (CONT'D) Piston Cooling Jet Alignment
Piston Cooling Jet Removal Figure 70-190-5
Figure 70-190-3
1 1
55,25 mm
(2.2”)
14 mm
(0.55”)
N-00535
P-08754
Insert a 1,70 mm (0.067 in) diameter rod of suitable
length, in the jet.
Remove the piston cooling jet assembly (Item 1) [Figure
70-190-3] from the engine block. The tip of the rod must extend out the top of the cylinder

in an area 55,25 mm (2.2 in) of height and 14 mm (0.55
Figure 70-190-4 in) of width to provide proper cooling jet alignment to cool
the pistons [Figure 70-190-5].
Inspection
Clean all passages of coolant and oil.

2
Inspect the block for cracks or other damage.
NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
3 cylinder block.
1
Inspect the camshaft bushing for wear. If the bushing
P-08836 needs to be replaced, press out old one. Press a new
one in, insuring that the oil holes line up.
Inspect the jet tube (Item 1), mount bolt (Item 2) and
alignment pin (Item 3) [Figure 70-190-4] for damage.
Replace as needed.
Piston Cooling Jet Installation
Install the cooling jet (Item 1) being sure it is seated

correctly on the dowel (Item 3) [Figure 70-190-4] in the
block.
Install the mounting bolt (Item 2) [Figure 70-190-4] and

tighten to 9 N•m (79,7 in-lb) torque.

ENGINE BLOCK (CONT'D) Figure 70-190-7
Cylinder Liner Inspection
Figure 70-190-6
B-04066
Inspect the cylinder liner bore for out of round or wear

P-08837 beyond service limits [Figure 70-190-7]. The inside
diameter of the service liner should be 105,000 - 105,025
mm (4.1338 - 4.1348 in).
The condition of a cylinder liner is decided by:
A flex type hone can be used to clean up small scoring or

• The amount and location of polished areas. pitting.
• Wear. Damaged or worn liners must be replaced.
• Damage to the liner wall.
NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.
Examine the liner surface (Item 1) [Figure 70-190-6] for

cracks, deep scratches and polished areas where the
honed finish is worn away.

ENGINE BLOCK (CONT'D)
Cylinder Liner Removal
Figure 70-190-8

6
B-05556
NOTE: Where several liners are to be removed or a

very tight production liner is found, a press
should be used.
When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.
Rotate the crankshaft (if installed) to provide access to

the liner and protect the crank pin from damage.
Place the tool (Item 1) over the center of the liner (Item
2). Make sure the flat bearing race (Item 3) [Figure 70-
190-8] is against the bottom of the recess.
Install the rod (Item 4) through the handle (Item 5)

[Figure 70-190-8].
Place the adapter (Item 6) [Figure 70-190-8] under the

cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.

ENGINE BLOCK (CONT'D) Place the threaded rod (Item 4) through the handle
(Item 5) and liner (Item 1) [Figure 70-190-9].
Cylinder Liner Installation
Adjust the rod until it is below the bottom of the block
surface.
Install the adapter (Item 6) [Figure 70-190-9] on the rod.

IMPORTANT Center the adapter against the bottom of the block.
For the first five hours after the new liners have been Tighten the nut and washer.
installed:
• Do not operate at full load. Turn the handle and press the liner in the bore, stopping
• Do not operate at high speed. when approximately 50 mm (2 in) remains. Apply
• Do not allow engine to idle for extended periods. Loctite® 603 to the outer surface below the flange and to
I-2117-1196 the flange recess.
Continue to press the liner into position. Remove the tool.

Figure 70-190-9
NOTE: Do Not hit the cylinder liners with a hammer.
4 They will be damaged.
5 Figure 70-190-10
3 2

1 1
2
B-0507
Check liner protrusion with a dial gauge [Figure 70-190-

10].
The liner can have 0,10 mm (0.004 in) protrusion or

recession from the block face.
6 Allow 15 minutes before measuring the bore. The liner

B-05555 will take 6 hours to reach full strength.
The inside diameter of the service liner should be

Clean the cylinder bore and the outside of the liner. 105,000 - 105,025 mm (4.1338 - 4.1348 in).
Lubricate the cylinder bore with engine oil. New piston rings must be used when the cylinder liners
have been replaced.
Start the liner (Item 1) [Figure 70-190-9] in the bore.
Make sure it is started straight. The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2)
With the adapter (Item 2) on the top of the liner, place the [Figure 70-190-10].
bearing (Item 3) [Figure 70-190-9] in the recess at the
top.


HEATING, VENTILATION, AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Filter Element Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Air Conditioning Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . 80-60-1

Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Component Replacement And Refrigeration Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-3
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
TEMPERATURE / PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . 80-100-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-3
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1


PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

AIR CONDITIONING SYSTEM FLOW
Principles
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2.).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the blower fan (Item
6) (See Chart on Page 80-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and produces
cooled air, which is pushed into the cab by the blower fan. The moisture in the air condenses on the evaporator coil and

drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart

COMPONENTS Figure 80-20-3
Identification
Figure 80-20-1
1
1 S38077
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

S38190 20-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-20-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

system. It raises the pressure of the refrigerant for heat Figure 80-20-4
transfer through the condenser and evaporator.
NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5 1
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-20-2
S39158
Pressure Switch: The pressure switch (Item 1) [Figure

80-20-4] is located on the receiver / drier assembly (Item
2) [Figure 80-20-3]. It will disengage the compressor
clutch if the pressure readings are too low or too high,
which indicates loss of refrigerant.
S38191
Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

COMPONENTS (CONT'D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
1 3 2
S38151
1. Blower Fan Switch - This is a three position switch

S38199 (Item 1) [Figure 80-20-7]. When the blower fan switch
is in the OFF position the A/C will not engage.
Evaporator Unit: The evaporator unit (Item 1) [Figure 80- 2. Temperature Control - Turn the knob (Item 3) [Figure
20-5] is located under the operator seat inside the cab. 80-20-7] clockwise to increase cab temperature;

The unit delivers the cold air for the A/C into the cab. The counterclockwise to decrease.
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable. 3. Air Conditioning Switch - Press the top of the switch
(Item 3) [Figure 80-20-7] to turn the Air Conditioning
Figure 80-20-6 ON - Press the bottom of the switch to turn the Air
Conditioning OFF.
S38077
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the
evaporator coil.

SAFETY Figure 80-30-2
Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-30-1
P-16398
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -6°C (21.6°F)
DEGREES "INSTANTLY". If it spills on your skin or in
your eyes you should flood the area with cool water and
SEEK MEDICAL ATTENTION FAST! It is a good idea to

P-16398 wear gloves [Figure 80-30-2] to prevent frost bite if you
should get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-30-
1] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gauge set
connectors. Safety glasses or a transparent face shield
WARNING
are practical safety Items and one or the other is HFC 134A refrigerant can be dangerous if not
absolutely required. properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
WARNING when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
In the event of a leak, wear safety goggles. Escaping even small amounts of 134A in the air.
refrigerant can cause severe injuries to eyes. In Any servicing work that involves release or addition
contact with a flame, R134a refrigerant gives a toxic of 134A to the system must be done by a competent
gas. refrigeration dealer who has the proper equipment,
W-2371-0500 knowledge, and experience to service refrigeration
equipment.
W-2373-0500


REGULAR MAINTENANCE Air Conditioning Belt Adjustment
Filter Element Removal And Installation The air conditioning belt is a special maintenance free
type that is pretensioned over the pulleys. This belt
Figure 80-40-1 eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer
for replacement parts.
Belt Replacement
1 1
Figure 80-40-3
2
S38008
The fresh air filter is located on the side of the operator

cab. Remove the two nuts (Item 1) and filter cover 1

(Item 2) [Figure 80-40-1].
Figure 80-40-2
S38046
1
Remove the two bolts (Item 1) and cover (Item 2) [Figure
80-40-3].
Figure 80-40-4
2
1
S38009
Clean or replace the filter as necessary.

1
S39152
Remove the two bolts (Item 1) and belt cover (Item 2)

[Figure 80-40-4].

REGULAR MAINTENANCE (CONT’D) Figure 80-40-7
Belt Replacement (Cont’d)

1
Figure 80-40-5
S39165
S39386
Use a prybar under the compressor to tension the air

S39386 conditioning belt until the bottom compressor mounting
bolt (Item 1) [Figure 80-40-7] can be installed.
Remove the bottom mounting bolt and nut (Item 1) Install and tighten the bottom compressor mounting bolt
[Figure 80-40-5] from the compressor. (Item 1) [Figure 80-40-7].

Figure 80-40-6 Install the belt cover (Item 2) [Figure 80-40-4].
1 Install the cover (Item 2) [Figure 80-40-3].

3 2
Close the engine cover. (See Opening And Closing on
Page 10-160-1.)
S39153
Loosen the rear compressor mounting bolt (Item 1)

[Figure 80-40-6].
Remove the front compressor mounting bolt (Item 1)

[Figure 80-40-6].
Tilt the compressor until the air conditioning belt can be

removed. Remove the air conditioning belt (Item 3)
[Figure 80-40-6].
Install a new belt.

REGULAR MAINTENANCE (CONT’D) Evaporator / Heater Coil
Cleaning The Condenser Remove the operator seat. (See Removal And
Figure 80-40-8
Figure 80-40-10
2
1
S38023
S39427


Figure 80-40-9
Remove the parking brake lever cover (Item 2) [Figure
80-40-10].
Figure 80-40-11
1
1 1
S38023
Raise the condenser (Item 1) and keep in position by

installing the rod (Item 2) [Figure 80-40-9] in the
S39428
condenser mount.
Use low air pressure or water pressure to clean the Remove the two bolts (Item 1) [Figure 80-40-11].
condenser (Item 1) [Figure 80-40-9].
Lower the condenser and reinstall the nut (Item 1)

[Figure 80-40-8]

Evaporator / Heater Coil (Cont’d)

2
Figure 80-40-12
1
1 4
3 1
S38203
2
Remove the bolts (Item 1) and ground wire (Item 2)

S38202 [Figure 80-40-14].
Figure 80-40-15
Disconnect the connector (Item 1) and the tubes (Items 2
and 3) [Figure 80-40-12].

Remove the fluid reservoir (Item 4) [Figure 80-40-12] by 1
sliding it upward.
Figure 80-40-13
1
1 1
2
S39429
Remove the three bolts (Item 1) [Figure 80-40-15].

2
S38206
Remove the retainer screws (Item 2) and remove the


Evaporator / Heater Coil (Cont’d)

1
Figure 80-40-16
S39214
1 Use low pressure air or water to remove debris from the

S39430 heater coil (Item 1) and evaporator (Item 2) [Figure 80-
40-18].
Remove the frame (Item 1) [Figure 80-40-16].

Figure 80-40-17
S39213
Remove the nine cover screws (Item 1) and remove the



BASIC TROUBLESHOOTING Inspect the A/C condenser for dirt or mud, and clean if
necessary. (See Cleaning The Condenser on Page 80-
Poor A/C Performance 40-3.)
Start the telescopic handler, engage the parking brake. Inspect the sight glass located on the receiver / drier for
Engage the A/C system with the Blower Fan on high. Run air bubbles. (See REGULAR MAINTENANCE on Page
the telescopic handler at full rpm for approximately 15 80-40-1.)
minutes, with the cab door closed.
Figure 80-50-1

S38194
Figure 80-50-2
P-27746
Check the temperature at the louvers (Item 1) [Figure

80-50-1] with a thermometer [Figure 80-50-2].
The louver temperature should be between 2,2 - 11,6°C

(36 - 53°F) depending on the amount of humidity in the
air.
If the louver temperature is too high. (See SYSTEM

TROUBLESHOOTING CHART on Page 80-70-1.)
Inspect the Blower Fan for proper operation or noise, and

replace if necessary. (See EVAPORATOR / HEATER
UNIT on Page 80-150-1.)

BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-5
Checking The Electrical System
Figure 80-50-3 1
S38028
If the compressor clutch does not engage, inspect the

S39152 fuse (Item 1) [Figure 80-50-5]. Replace the fuse if
needed.
Check to see if the compressor clutch (Item 1) is
engaging. The clutch is located inside the pulley which is
protected by the cover (Item 2) [Figure 80-50-3].

Turn the Ignition key switch to the RUN position without
starting the machine.
Figure 80-50-4
S38151
Turn the Blower Fan switch (Item 1) [Figure 80-50-4] to

the first ON - position. The compressor clutch should
make a click sound, which indicates the clutch is
engaging.

Checking The Electrical System (Cont'd)
Figure 80-50-6
S39200
With a multimeter, check the voltage (12V) to the

S39157 compressor clutch at the main harness (Item 1) [Figure
80-50-8].
Disconnect the connector (Item 1) [Figure 80-50-6] from If there is no power at the clutch, check the wiring
the compressor. harness for broken wires.

Figure 80-50-7 If there is power at the clutch, reconnect the wiring
harness to the compressor clutch.

S39197
With a multimeter check the resistance to the compressor

clutch connector (Item 1) [Figure 80-50-7].
If there is no resistance value replace the compressor

clutch. (See Compressor Clutch Disassembly And
Assembly on Page 80-110-3.)

Figure 80-50-9
1
1
2 S39239
Disconnect the thermostat wiring connector (Item 1)

S39199 [Figure 80-50-10] from the machine harness.
Figure 80-50-11
Disconnect the machine harness (Item 1) [Figure 80-50-
9] from the pressure switch.

Using a multimeter, check the terminals (Item 1) [Figure 1
80-50-9] for voltage.
NOTE: The Key switch must still be in the run 2

position (engine off) and the Blower Fan
switch to the first ON position.
The voltage should be around 12 volt.
If there is no voltage at the wiring harness, inspect the

harness for broken wires.
S39240
If there is voltage at the harness, inspect the resistance
at the pressure switch (Item 2) [Figure 80-50-9].
Check the machine harness (Item 1) [Figure 80-50-11]
If there is no resistance value, check for a low refrigerant for voltage. The voltage should be 12 volt.
level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-100-1.) If there is no voltage at the wiring harness, inspect the
If a resistance value is seen, the pressure switch is good.
If there is voltage at the wiring harness, check the
Reconnect the machine harness to the pressure switch. thermostat wire (Item 2) [Figure 80-50-11] for resistance.
The resistance value should be 10 ohm at 20°C (68°F).
If there is no resistance value, replace the thermostat.

(See Removal And Installation on Page 80-170-2.)

Figure 80-50-12
1 1
S38151
Remove the four screws (Item 1) [Figure 80-50-14].

S39239
Remove the panel (Item 2) [Figure 80-50-14].
Disconnect the blower wiring connector (Item 1) [Figure Figure 80-50-15

80-50-12] from the machine harness.

Figure 80-50-13 1
S36341
S39242 Disconnect the main wire harness connector (Item 1)

[Figure 80-50-15] from the switch.
Check the machine harness (Item 1) [Figure 80-50-13]

for voltage (between two outer terminals). The voltage
should be 12 volt.
If there is no voltage at the wiring harness, inspect the

If there is voltage at the wiring harness, check the

resistance to the blower at the blower wiring connector
(Item 2) [Figure 80-50-13].
If there is no resistance value replace the blower.
If there is a resistance value check the climate controls at

the control panel inside the loader cab.


H C
Figure 80-50-16
1 B
M
N-22288
If there is voltage at the main harness check the Blower

S36342 Fan switch [Figure 80-50-17] for resistance.
With the switch in the OFF position, there should be zero

Check the main harness (Item 1) [Figure 80-50-16] for resistance between all terminals.
voltage. The voltage should be 12 volt, if there is no
voltage inspect the harness for broken wires. With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame

[Figure 80-50-17].
With the switch in the 2 position, there should be

also between the C terminal and the M terminal frame
[Figure 80-50-17].
With the switch in the 3 position, there should be

also between the C terminal and the H terminal frame
[Figure 80-50-17].
If any of the above resistance tests fail, replace the

Blower Fan switch.

GENERAL AIR CONDITIONING SERVICE Compressor Oil Check
GUIDELINES
The compressor oil should be checked as follows when
Compressor Oil oil is being added to an in service machine.
Figure 80-60-1 There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-100-1.)
1 Open the cab door and windows.
Run the blower fan at maximum speed.
S39173 Run the compressor for at least 20 minutes at 800 - 1200

rpm.
The compressor (Item 1) [Figure 80-60-1] is factory filled
Remove the compressor from the machine. (See
with 150 - 170 cc's of PAG oil (Poly Alkelene Glycol).

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver / drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any related problems occur in the cooling cycle.
When one of the components (the evaporator, condenser

or receiver / drier) is replaced, 30 cc (1 U.S. fl oz) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a oils.

GENERAL AIR CONDITIONING SERVICE Figure 80-60-4
GUIDELINES (CONT'D)
Compressor Oil Check (Cont'd)
Figure 80-60-2
1
1
S39176
NOTE: After draining the oil through the drain hole

and the connectors, extract the remaining oil
S39174 through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
Figure 80-60-3

Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

1 varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-60-5
S39175
1
Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors (Item 1) [Figure 80-
60-3] and the oil drain hole (Item 1) [Figure 80-60-2].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.
S39175
Add new compressor oil through the suction side

connector (Item 1) [Figure 80-60-5].
Installation: Add 150 - 170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked

with an S and is the large port on the
compressor.

GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Component Replacement And Refrigeration Leaks
Figure 80-60-6
1
S38077
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /

drier (Item 1) [Figure 80-60-6] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.


SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse / wiring. Replace fuse / repair
wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Evaporator /
Blower Unit.
4. Fan Motor switch Check power into and out of the Fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction clean evaporator fins with
air or water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator /

switch (frozen Blower unit.
evaporator).
Insufficient cooling although air flow and compressor operation are normal

1. System low on The high side pressure will be low and bubbles can be present Repair any leaks and
refrigerant. in sight glass on receive / drier. recharge the refrigerant to
the correct level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic
clutch.
5. Oil on the clutch Clutch slips. Replace or clean the
surface. clutch surface.
6. Open coil. Clutch does not engage and there is not reading when a Replace clutch.
circuit tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and connections. Repair.
ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, relay, Check operation.
components. etc.

SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96
°F) and compressor speed of approximately 2000 rpm are:
High pressure side pressure: 1,45 - 1,83 MPa (14.47 - 18,27 bar) (210 - 265 psi)
Low pressure side pressure: 0,10 - 0,23 MPa (1,03 - 2,27 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve opens Frost is present on the suction hose. Replace expansion valve
too far.
2.Defective compressor The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is disengaged.
Low pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge

present in sight glass on receiver / drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve's inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion negative low pressure reading can be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Replace Evaporator / Blower unit.
tion.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the fan.
formance. operating.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil charge The high pressure side will be high. Evacuate system. Remove oil
from condenser and compressor.
Measure oil from compressor
and add correct oil charge back
into compressor. Flush system
with nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.

SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont’d)

High pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge
present in sight glass on receiver / drier. the refrigerant to the correct
level.
System pressures Equal
1. Clutch not operating See magnetic clutch related topics above.
2.Compressor not pump- Equal high and low pressures. Replace compressor.
ing.


TEMPERATURE / PRESSURE
Chart NORMAL CONDENSER RANGE
NORMAL EVAPORATOR RANGE TEMP °C (°F) PSIG

33,9 (93) 110.20
TEMP °C (°F) PSIG
34,4 (94) 112.10
-8,9 (16) 15.69
35 (95) 114.10
-7,8 (18) 17.04
37,8 (100) 124.30
-6,7 (20) 18.43
38,9 (102) 128.50
-5,6 (22) 19.87
40 (104) 132.90
-4,4 (24) 21.35
41,1 (106) 137.30
-3,3 (26) 22.88
42,2 (108) 141.90
-2,2 (28) 24.47
43,3 (110) 146.50
-1,1 (30) 26.10
44,4 (112) 151.30
0 (32) 27.79
45,6 (114) 156.10
1,1 (34) 29.52
46,7 (116) 161.10
2,2 (36) 31.32
47,8 (118) 166.10
3,3 (38) 33.17
48,9 (120) 171.30
4,4 (40) 35.07
50 (122) 176.60
5,6 (42) 37.03
51,1 (124) 182.00
6,7 (44) 39.05

52,2 (126) 187.50
7,2 (45) 40.09
53,3 (128) 193.10
10 (50) 45.48
54,4 (130) 198.90
12,8 (55) 51.27
57,2 (135) 213.70
15,6 (60) 57.47
60 (140) 229.40
18,3 (65) 64.10
62,8 (145) 245.80
21,1 (70) 71.19
65,6 (150) 263.00
23,9 (75) 78.75
68,3 (155) 281.10
26,7 (80) 86.80
71,1 (160) 300.10
29,4 (85) 95.40
73,9 (165) 320.10
32,2 (90) 104.40
76,7 (170) 340.80
32,8 (91) 106.30
33,3 (92) 108.20
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 12,2 - 13,3°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40°F. to the ambient temperature to get
the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
Example: Ambient Temperature= 32,2°C (90°F)

32,2°C (90°F)
+ 4,4°C (40°F)
54,4°C (130°F) condenser temperature=200 psig
Conditions and pressures will vary from system to system.


AIR CONDITIONING SERVICE
Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:


SYSTEM CHARGING AND RECLAMATION Figure 80-100-2

Unit
1
Page 10-160-1.)
Figure 80-100-1
1 N-23024
2 NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-100-2]
S39234 will determine, the kind of refrigerant and any

possible harmful or dangerous substances
that can be present in the system. Thus
Locate the low pressure port (Item 1) and high pressure preventing mixing of dangerous material with
port (Item 2) [Figure 80-100-1] on the back side of the your reclaimed R-134a in your reclaimer, and
compressor. further contamination to other A/C systems
that are reclaimed and charged from your
MEL 1581 Recovery / Recycling / Recharging
Machine.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
NOTE: This procedure is run with the engine off, and

the A/C switch in the OFF position.

SYSTEM CHARGING AND RECLAMATION (CONT'D)

Unit (Cont'd) WARNING
Figure 80-100-3 In the event of a leak, wear safety goggles. Escaping
gas.
W-2371-0500
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
S39234 frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
Remove the protective cap and connect the refrigerant substances.

identifier to the low pressure hose (Item 1) [Figure 80- • NEVER SMOKE when there is the possibility of
100-3]. even small amounts of 134A in the air.
Any servicing work that involves release or addition
Connect the refrigerant identifier to its power source. of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
Follow the steps displayed on the refrigerant identifier knowledge, and experience to service refrigeration
screen [Figure 80-100-2]. equipment.
W-2373-0500
Allow 2 minutes for the refrigerant identifier to display the
type of refrigerant and air content. An alarm will sound if Figure 80-100-4
potentially flammable hydrocarbons are present and will
also indicate on the visual display.
Disconnect the refrigerant identifier from the telescopic

handler A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.
If R134a is found, evacuate the system.
IMPORTANT: Only A/C trained technicians should

perform the reclaiming and recharging
procedure.
N-22291
Use an approved recovery / charging unit [Figure 80-

100-4] to evacuate the system.
Connect the reclaimer to the A/C charge ports.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-7

Unit (Cont'd)
Figure 80-100-5
2
N-22381
1
NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-100-7] to
S39235 follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they can vary
Connect the Red hose (Item 1) [Figure 80-100-5] to the slightly depending on the model and brand of

high pressure port and open the valve. reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-100-5] to the

low pressure port and open the valve.
Figure 80-100-6
N-22292
Turn the reclaimer unit to the ON position and follow the

on screen instructions [Figure 80-100-6].


COMPRESSOR Figure 80-110-3

2
Evacuate the A/C system. (See SYSTEM CHARGING 1
AND RECLAMATION on Page 80-100-1.)

Figure 80-110-1
1
2
S39152
Remove the two bolts (Item 1) and belt cover (Item 2)

[Figure 80-110-3].
1
Figure 80-110-4

S38046
1
Remove the two bolts (Item 1) and cover (Item 2) [Figure
80-110-1].
1
Figure 80-110-2
S39156
Remove the compressor hoses (Item 1) [Figure 80-110-

4].
Installation: Tighten the hoses to 29,8 N•m (22 ft-lb)

torque.
Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
S39157

from the compressor.

COMPRESSOR (CONT'D) Figure 80-110-7
Removal And Installation (Cont’d) 1

Figure 80-110-5
S39165
S39386
Installation: Install the front compressor mounting bolt

S39386 (Item 2) [Figure 80-110-6] and nut. Do not yet tighten.
Then use a prybar under the compressor to tension the
air conditioning belt until the bottom compressor
Remove the bottom mounting bolt and nut (Item 1) mounting bolt and nut (Item 1) [Figure 80-110-7] can be
[Figure 80-110-5] from the compressor. installed.

Figure 80-110-6
3
1
2
S39155
Loosen the rear compressor mounting bolt (Item 1)

[Figure 80-110-6].
Remove the front compressor mounting bolt (Item 2)

[Figure 80-110-6] and nut.
Tilt the compressor until the air conditioning belt can be

removed.
Remove the air conditioning belt (Item 3) [Figure 80-110-

6].
Remove the rear compressor mounting bolt (Item 1)

[Figure 80-110-6] and remove the compressor.

Compressor Clutch Disassembly And Assembly
Figure 80-110-8
8 mm 8 mm
(1.25”) (1.25”)
1
8 mm
(1.25”)
P-27524
1 The armature plate puller (Item 1) [Figure 80-110-10]

P-27519 can be constructed by drilling three 8 mm (0.315 in) holes
in a flat circular plate, located 31,75 mm (1.25 in) apart.
Remove the center armature nut (Item 1) [Figure 80- Figure 80-110-11
110-8].

Assembly: Tighten the armature nut to 12 N•m (8 ft-lb).
Figure 80-110-9
1
P-27522
Attach the armature puller plate (Item 1) to the armature

plate using the three bolts (Item 2) [Figure 80-110-11].
P-27520
To remove the armature plate (Item 1) [Figure 80-110-9]

from the clutch face you must make an armature plate
puller.

COMPRESSOR (CONT'D) The specified clearance for the clutch is 0,3 - 0,6 mm
(0.01 - 0.02 in) adjusting shims are available in the
Compressor Clutch Disassembly And Assembly following thicknesses.
(Cont'd)
0,1 mm (0.0039 in)
Figure 80-110-12 0,3 mm (0.0118 in)
0,5 mm (0.0197 in)
Figure 80-110-14
P-27521
Attach a slide hammer puller to the armature puller tool

P-27525

[Figure 80-110-12].
Figure 80-110-13 Remove the snap ring (Item 1) [Figure 80-110-14] from
the pulley assembly.
Figure 80-110-15
2 1
P-27523
Remove the armature plate (Item 1) [Figure 80-110-13]

P-27526
from the compressor clutch.
Remove the shims (Item 2) [Figure 80-110-13] from the Remove the pulley from the compressor [Figure 80-110-
armature shaft or armature plate. 15].
Assembly: Insure that the clutch has the correct

clearance by adding the shims (Item 2) [Figure 80-110-
13].


(Cont'd)
Figure 80-110-16
1
P-27529
Remove the harness retainer screw assembly (Item 1)

[Figure 80-110-18].
P-27527
Figure 80-110-19
The pulley assembly and bearing [Figure 80-110-16]

must be replaced as a complete unit.
Figure 80-110-17
1
2 1
P-27530
Remove the snap ring (Item 1) [Figure 80-110-19] from

the coil.
P-27528
Remove the lock (Item 1) and connector (Item 2) [Figure

80-110-17] from the compressor harness.

COMPRESSOR (CONT'D)

(Cont'd)
Figure 80-110-20
P-27531
Remove the coil from the compressor [Figure 80-110-

20].
Figure 80-110-21
P-27527
The compressor [Figure 80-110-21] must be replaced as

a complete unit.

CONDENSER Figure 80-120-2
Removal And Installation 1

Unit on Page 80-100-1.) 1
WARNING
contact with a flame, R134a refrigerant gives a toxic S38196
gas.
W-2371-0500
Remove the two bolts and nuts (Item 1) [Figure 80-120-
2] from each side of the condenser.
Figure 80-120-1
Figure 80-120-3

1
2
S38195
S38197
condenser.
Slide the condenser (Item 1) [Figure 80-120-3] forward.
NOTE: Install caps and plugs on all fittings.
condenser.
Remove the condenser (Item 1) [Figure 80-120-3].


RECEIVER / DRIER Figure 80-130-2

Page 10-160-1.)
1
SYSTEM CHARGING AND RECLAMATION on Page 80- 1
100-1.)

Installation on Page 50-20-1.) 2
S38199
WARNING
In the event of a leak, wear safety goggles. Escaping cover (Item 2) [Figure 80-130-2].
contact with a flame, R134a refrigerant gives a toxic Figure 80-130-3
gas.
W-2371-0500 2

Figure 80-130-1
1
1 3
1
S39210
Loosen the screws (Item 1) [Figure 80-130-3] on the

clamps.
S38077
Remove the tubeline (Item 2) [Figure 80-130-3] from the

receiver / drier.
Disconnect the connectors (Item 1) [Figure 80-130-1]
from the pressure switch.
Remove the receiver / drier (Item 3) [Figure 80-130-3].
receiver / drier.
NOTE: Install caps and plugs on all fittings.


PRESSURE SWITCH

Page 10-160-1.)

SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
WARNING
gas.
W-2371-0500
Figure 80-140-1

1
2 2
S38077
S38200
Disconnect the connectors (Item 1) from the pressure

switch (Item 2) [Figure 80-140-1].
Remove the pressure switch (Item 2) [Figure 80-140-1]

from the receiver / drier assembly.


EVAPORATOR / HEATER UNIT Figure 80-150-2

100-1.) 4 3
WARNING
In the event of a leak, wear safety goggles. Escaping 2
refrigerant can cause severe injuries to eyes. In 1
gas. S38077
W-2371-0500
Remove the A/C hose (Item 1) from the drier, and the A/C
Remove the operator seat. (See OPERATOR SEAT on hose (Item 2) [Figure 80-150-2] from the expansion
Page 50-20-1.) valve.
Figure 80-150-1 NOTE: Plug the A/C hoses to prevent contamination.

Remove the heater hoses (Items 3 and 4) [Figure 80-
150-2] from the heater.
Figure 80-150-3
S39211
2
Disconnect the thermostat wiring connector (Item 1) 1
[Figure 80-150-1].
S39427
Remove the parking brake lever cover (Item 2)

[Figure 80-150-3].

EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-150-6

1
Figure 80-150-4
2
1 1
2
S38206

S39428
Figure 80-150-7

Figure 80-150-5
1 4 1
1
2
S38203
S38202

Disconnect the connector (Item 1) and the tubes (Items 2 [Figure 80-150-7].
and 3) [Figure 80-150-5].
Remove the fluid reservoir (Item 4) [Figure 80-150-5] by

sliding it upward.

Figure 80-150-8
1
2 1
1
1
1 1
S38213
Remove the screws (Item 1) and remove the cover (Item

S39429 2) [Figure 80-150-10].
Remove the three bolts (Item 1) [Figure 80-150-8].

Figure 80-150-9
1
S39430
Remove the frame (Item 1) [Figure 80-150-9].

Figure 80-150-11
3 2
1
1
2
S38209
1 S38210
Remove the two bolts (Item 1) [Figure 80-150-13] on the

S38211 left side of the evaporator / blower unit.
Remove the two bolts on the right side of the evaporator /

Remove the screws (Item 1) [Figure 80-150-11]. blower unit (Item 2) [Figure 80-150-13] (Inset).

Loosen the clamp (Item 2) and retract the flexible hose Remove the evaporator / blower unit from the machine.
(Item 3) [Figure 80-150-11].
Figure 80-150-12
S38212
Lift the rubber cover (Item 1) and retract the flexible hose
(Item 2) [Figure 80-150-12].

EXPANSION VALVE Figure 80-160-2

100-1.) 1 1
WARNING
2
gas. S39212
W-2371-0500
Remove the two mount bolts (Item 1) from the expansion

Remove the operator seat. (See OPERATOR SEAT on valve (Item 2) [Figure 80-160-2].
Page 50-20-1.)
Remove the expansion valve (Item 2) [Figure 80-160-2].
Figure 80-160-1
The expansion valve (Item 2) [Figure 80-160-2] is

replaced as a complete unit.
1
1
2
1 1
S38077
S38214
Remove the A/C hoses (Item 1 and Inset) from the

expansion valve (Item 2) [Figure 80-160-1].
NOTE: Plug the A/C hoses to prevent contamination.


THERMOSTAT The EDT has the following protection built in:
Description 1. Over temperature
The Electronic De-icing Thermostat (EDT) is a micro 2. Over current from clutch output
controller based module that measures evaporator coil
temperature and cycles the compressor clutch to 3. Voltage (Above and below operational limits or
maintain a constant evaporator pressure. Onboard circuit reverse voltage)
protection and diagnostics are also built into the module.
4. Short circuit protection (Output shorted to ground)
NOTE: The EDT has a six second delay before start
up to protect the compressor clutch. 5. Temperature sensor open and short detection
The EDT will turn the clutch on when the evaporator coil
DETECTION
temperature is above 2°C (35.6°F). If the EDT does not MALFUNCTION STATUS LED
INTERVAL
detect any malfunction, it will continue to operate and the
status LED will be lit continuously. When the evaporator Temperature Continuous 1x per second
temperature is below -2°C (28.4°F), the EDT will turn off sensor
the clutch and status LED. Temperature At A/C start up 2x per second
sensor open and
Figure 80-170-1 short detection
Compressor Continuous 3x per second
clutch short to

battery
1
P90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [[Figure 80-
170-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

THERMOSTAT (CONT’D) Figure 80-170-4
Remove the operator seat. (See OPERATOR SEAT on

Page 50-20-1.) 1 4
NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
3
evaporator / heater unit from the loader.
Figure 80-170-2
2
S38202
Disconnect the connector (Item 1) and the tubes (Items 2

and 3) [Figure 80-170-4].
Remove the fluid reservoir (Item 4) [Figure 80-170-4] by

2 sliding it upward.
1

Figure 80-170-5
S39427
1
2
Remove the parking brake lever cover (Item 2) [Figure 3

80-170-2].
Figure 80-170-3
S38206
1 1 Remove the bolt (Item 1) [Figure 80-170-5].

S39428

THERMOSTAT (CONT’D) Figure 80-170-8
Figure 80-170-6
1 1
S39241
1
Remove the thermostat probe (Item 1) [Figure 80-170-8]

S38203 from the A/C evaporator coil.
Figure 80-170-9
[Figure 80-170-6].

Figure 80-170-7
1 1 1
1
1
1
2 1
S39211
Remove the thermostat (Item 1) [Figure 80-170-9] from

S38209 the evaporator / heater unit.
Remove the nine screws (Item 1) and remove the cover

(Item 2) [Figure 80-170-7].


SPECIFICATIONS
(TL470) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
MACHINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Drive Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
751 of 770 SPEC-01 TL470(X) Service Manual

752 of 770 SPEC-02 TL470(X) Service Manual

(TL470) TELESCOPIC HANDLER SPECIFICATIONS
Dimensions are given for machine equipped with standard tires and can vary with other tire types.
Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Machine Dimensions

(A) Overall length (with forks) 6074 mm (239.1 in)
(B) Overall length (without attachment carrier) 4869 mm (191.7 in)
(C) Overall length (without attachment; with Quick-Tach attachment carrier) 4763 mm (187.5 in)
(C) Overall length (without attachment; with Mani-Tach attachment carrier) 4822 mm (189.8 in)
(D) Overall length (to front tires) 4145 mm (163.2 in)
(E) Overall height (with rotating beacon) 2561 mm (100.8 in)
(F) Overall height 2374 mm (93.5 in)
(G) Carriage rotation angle 135°
(H) Height to back of the machine 1752 mm (69.0 in)
(I) Ground clearance 430 mm (16.9 in)
(J) Front axle to front carriage 1356 mm (53.4 in)
(K) Wheelbase 2870 mm (113.0 in)
(L) Rear axle to back of machine 643 mm (25.3 in)
(M) Operator cab outside width 1013 mm (39.9 in)
(N) Track width (front & rear) 1895 mm (74.6 in)
(O) Width over standard tires 2300 mm (90.6 in)
(P) External turning radius (with forks spaced 1200 mm [47.3 in] ext.) 4970 mm (195.7 in)
(Q) External turning radius (at tires) 3714 mm (146.2 in)
(R) Internal turning radius 1092 mm (43.0 in)
Operator cab inside width 900 mm (35.4 in)
753 of 770 SPEC-10-1 TL470(X) Service Manual

(TL470) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)
Performance
Crowding force - Tilt 6200 daN (13938 lbf)

Crowding force - Lift 3700 daN (8318 lbf)
Drawbar pull 6700 daN (15062 lbf)
Ground pressure on tires 550 kPa (5,5 bar) (79.8 psi)
Rated load capacity* 3500 kg (7716 lb)
Capacity (at maximum height) 3000 kg (6614 lb)
Capacity (at maximum reach) 1500 kg (3307 lb)
Tipping load (at maximum reach) 1875 kg (4133.7 lb)
Lifting height 6957 mm (273.9 in)
Maximum reach 4002 mm (157.6 in)
Maximum reach (at maximum height) 1143 mm (45.0 in)
Travel Speed in First / Second Gear (TL470)
- Without Two-Speed Control 0 - 6 km/h (0 - 3.7 mph) / 0 - 16 km/h (0 - 9.9 mph)
- With Two-Speed Control 0 - 11 km/h (0 - 6.8 mph) / 0 - 30 km/h (0 - 18.6 mph)
Travel Speed in First / Second Gear (TL470X)
- Without Two-Speed Control 0 - 6 km/h (0 - 3.7 mph) / 0 - 18 km/h (0 - 11.2 mph)
- With Two-Speed Control 0 - 12 km/h (0 - 7.5 mph) / 0 - 40 km/h (0 - 24.9 mph)
* Static and dynamic tests have been carried out and passed according to EN1459.

Weights
Weight (unladen) 7130 kg (15719 lb)

Front axle weight unladen 2910 kg (6415 lb)
Rear axle weight unladen 4220 kg (9303 lb)
Weight with pallet frame and forks 7410 kg (16336 lb)
Front axle weight with pallet frame and forks 3360 kg (7408 lb)
Rear axle weight with pallet frame and forks 4050 kg (8929 lb)
Weight with pallet frame, forks and 3500 kg 10910 kg (24052 lb)
(7716 lb) load
Front axle weight with pallet frame, forks and 9180 kg (20238 lb)
3500 kg (7716 lb) load
Rear axle weight with pallet frame, forks and 1730 kg (3814 lb)
3500 kg (7716 lb) load

Engine
Make / Model PERKINS / 1104D-44TA

Fuel / Cooling Diesel / Liquid
Rated power (DIN 6271) at 2200 rpm 74,5 kW (100 hp)
Maximum torque at 1400 rpm 410 N•m (302.4 ft-lb)
Rated speed 2200 rpm
Low idle speed 900 rpm
Cycle Type 4 cycles
Number of cylinders 4
Displacement 4,4 L (1.16 U.S. gal)
Bore / Stroke 105 mm (4.1 in) / 127 mm (5 in)
Lubrication Gear pump pressurer
Crankshaft ventilation Open breathing
Air Cleaner Dry replaceable cartridge with safety element
Ignition Diesel Compression
Air Induction Turbocharged
Engine Coolant Propylene Glycol Mix -37°C (34.6°F)

Controls
Engine Foot accelerator pedal

Starting Key-type Starter switch and shutdown.
Front auxiliary Variable thumbwheel on joystick
Hydraulics lift and tilt Electronic joystick
Hydraulics telescope in and telescope out Variable thumbwheel on joystick
Service brake Pedal-activated wet multi-disc on front axle
Secondary brake Hand lever activates spring-applied pressure release disk brake
Parking brake Hand lever activates spring-applied pressure release disk brake
Steering Proportional hydraulic steering via a conventional steering wheel
Speed range and reverse selection Switches for hydrostatic motor and gear ratios, and switch on
joystick or lever for F-N-R
4WD / 2WD / parallel drive selection Three-position switch on the right-hand console
Auxiliary pressure release Bobcat coupler
Drive System
Transmission Hydrostatic with electronic regulation

Main drive Hydrostatic motor and 2-speed gearbox
Transmission oil ELF SF3 / TOTAL DYNATRANS FR

Traction
Standard tires DUNLOP 400/80-24 156B T37

(425 kPa [4,25 bar] [62 psi])
Optional tires TITAN 400/70-20 150B/166A2 Lift Rigger II
(400 kPa [4,00 bar] [58 psi])
Optional tires DUNLOP 400/70-20 150B T37
(400 kPa [4,00 bar] [58 psi])
Optional tires DUNLOP 405/70R20 168A2 152J MPT SPT9
(550 kPa [5,50 bar] [80 psi])
Optional tires MICHELIN 400/80-24 162A8 IND TL POWER CL
(425 kPa [4,25 bar] [62 psi])
Optional tires MICHELIN 460/70R24 159A8/159B XMCL IND TL
(340 kPa [3,40 bar] [49.5 psi])
Optional tires MICHELIN 500/70R24 164A8/164B IND TL XMCL
(290 kPa [2,90 bar] [42 psi])
Optional tires DUNLOP 405/70R24 168A2 152J MPT SPT9
(460 kPa [4,6 bar] [67 psi])
Optional tires NOKIAN 460/65R24 156A8/151D TRI STEEL TL
(400 kPa [4,00 bar] [58 psi])

Steering
Steering Pump Gear pump mounted on equipment pump

Steering Mode 2WS / 4WS / CRAB
Brakes
Engine Braking Hydrostatic

Parking and Emergency brake Negative brake with hydraulic command
Service Brake Oil immersed discs
Fluid Capacities
Axle front / rear 9,1 L / 9,1 L (2.4 U.S. gal)

Gear box 1,6 L (0.423 U.S. gal)
Cooling system with heater 15 L (4.0 U.S. gal)
Engine oil with oil filter 8,5 L (2.25 U.S. gal)
Fuel tank 138 L (36.5 U.S. gal)
Hydraulic reservoir 59 L (15.6 U.S. gal)
Hydraulic system plus reservoir 105 L (27.7 U.S. gal)
Hydraulic System
Pump type Gear pump with LS valve

Pump capacity 100 L/min (26.4 U.S. gpm)
Relief valve pressure setting 25,5 MPa (255 bar) (3698 psi)
Control valve type Open center with flow sharing & flow compensators technology
Hydraulic filter specification Full flow filtration
Auxiliary flow 100 L/min (26.4 U.S. gpm)
Hydraulic fluid Superior Hydraulic SH (HPM DB 46)

Electrical System
Alternator 90 A
Battery 110 Ah
Starter 3,2 kW (4.3 hp)
Instrument Panel
The following functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored malfunctions by way of audible and visual indicators.
Gauges
Rev counter
Total operating hours
Job hours
Boom angle
Machine speed
Fuel gauge
Engine coolant temperature gauge
Indicators
Front and rear wheel alignment status

Headlight full beam
Headlight low beam
Position lights
Left and right turn
Trailer turn
Parking brake
Longitudinal stability level
Windscreen wipers
Work lights
Flashing warning lights
Hazard warning lights
Gear Speed Choice
Hydraulic function lock
Rear fog lights
Heater fan
Warning lights
Hydraulic fluid over-temperature
Engine coolant over-temperature
Low oil pressure
Battery not charging
Longitudinal stability alarm
Green - less than 61% of load
Amber - 63 to 68% of load`
Red - over 71% of load
Environmental
Noise level LpA (EU Directive 2000/14/EC) 106 dB(A)

Operator position noise level (EN 12053) 78 dB(A)
Whole body vibration (EN 13059) 1,5 m/s²


MACHINE TORQUE SPECIFICATIONS
Axle
N•M FT-LB
Axle To Frame Mounting Bolts 490 - 550 361 - 405
Brake Housing Hex Bolt 80 59
Brake Housing Spring Bolts 10 7
Brake Housing Stud 120 88
Differential Lock Retainer Bolt 13 10
Fender Mount Bolt 90 - 100 66 - 74
Housing Bolt 320 236
Housing Nut 190 140
Pinion Ring Gear Bolts 13 10
Planetary Cover Bolts 25 18
Planetary Gear Mount Bolts 120 88
Steering Cylinder Bolts 120 88
Tie Rod Jam Nut 250 185
Tie Rod Nut 220 160
Tie Rod Swivel End 406 300
Turn Stop Adjust Jam Nut 150 110

Wheel Nuts 360 266
Boom
N•M FT-LB
Extension Cylinder Base End 180 133
Extension Cylinder Rod End 255 - 285 188 - 210
Wear Pads Front 58 43
Wear Pads Rear 39 29
Drive Box
N•M FT-LB
Cover Bolts 60 44
Inner Housing Bolts 120 88
Mounting Flange Bolts 60 44
Drive Motor
N•M FT-LB
End Cap Bolts 115 85
Mounting Bolts 210 155
Mounting Plate Bolts 63 46

MACHINE TORQUE SPECIFICATIONS (CONT’D)
Engine
N•M FT-.LB
A/C Compressor Mount Bolts 120 88
Alternator Mount Bolts 54 45
Starter Mount Bolts 54 45
Hydraulic Pump
N•M FT-LB
Filter Head 122 90
Flange Adapter 122 90
Guide Post Bolts 23 17
Mounting Bolts 106 78
Retaining Plate 13 10
Servo End Cap 13 10
Side Cover Bolts 32 24

TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9 - 10 13 - 14
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
0.375 34 - 38 48 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 82 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 125 - 135
(65 - 70) (90 - 100)
0.5625 125 - 135 170 - 190
(90-100) (125 - 140)
0.625 170 - 190 240 - 190
(125 - 140) (175 - 190)

0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
N•m 0.875 450 - 490 645 - 710
(ft-lb) (330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size (Dia. x Material

Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M 14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-40-2
IMPORTANT Nut Nut
When repairing hydrostatic and hydraulic systems, Washer

clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, O-ring
O-ring
damage the system.
I-2003-0888
Figure SPEC-40-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
2].

Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-07575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
40-1].

HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it just makes metal to metal contact,
(CONT'D) you can feel the resistance.
Port Seal Fitting Tighten the nut with a wrench no more than one hex flat
maximum.
Figure SPEC-40-3
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE N•M (FT-

Nut Seals THREAD SIZE
WRENCH SIZE LB)
to Fitting
11/16" 9/16" - 18 30 (22)
15/16" 3/4" - 16 54 (40)

1-1/8" 7/8" - 14 81 (61)
Nut Seals
to Port 1-1/4" 1-1/16" - 12 114 (84)
1-1/2" 1-5/16" - 12 160 (118)
Figure SPEC-40-4
Secondary O-ring Seal
P-13008
2
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-3].
1
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Use the following procedure to tighten the port seal P-13571

fitting:
Port seal and nut, washer and O-ring (O-ring Boss) Do not use port seal fittings when a thread in orifice (Item
fittings use the same tightening torque valve chart. 1) [Figure SPEC-40-4] is used in the port. The orifice
can interfere with the fitting and prevent it from sealing.
If a torque wrench cannot be used, use the following
method. Use an O-ring boss fitting (Item 2) [Figure SPEC-40-4]
as shown.

HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
Use Bobcat Axle/Transmission Oil LS (P/N 6987724), for
the transfer case, planetaries and axle housings. During cold weather (0°C [32°F] and below), do not
operate machine until the engine has run for at least
Use Bobcat Superior SH Hydraulic/Hydrostatic Oil (P/N 5 minutes at less than half throttle. This warm-up
6987721). period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
DO NOT use automatic transmission fluids in the period.
machine or permanent damage to the hydraulic /
hydrostatic system will result. When temperatures are below -30°C (-20°F), the
hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
WARNING W-2027-0311
Diesel fuel or hydraulic fluid under pressure can


W-2072-0807
When temperatures below -18°C (0°F) are common, the

machine must be kept in a warm building. Extra warm-up
time must be used each time the machine is started
during cold temperature conditions. Cold fluid will not flow
easily and it makes action on the hydraulic function
slower. Loss of fluid flow to the hydrostatic pump can
cause damage in less than 60 seconds.


CONVERSIONS
Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart


ALPHABETICAL INDEX
(TL470) TELESCOPIC HANDLER ENGINE INFORMATION . . . . . . . . . . . . . 70-10-1

SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1 ENGINE LUBRICATION SYSTEM . . . . . 10-90-1
ACCUMULATOR (IF EQUIPPED) . . . . . 20-180-1 ENGINE SPEED CONTROL . . . . . . . . . . 70-20-1
AIR CLEANER SERVICE . . . . . . . . . . . . 10-60-1 ENGINE TIMING . . . . . . . . . . . . . . . . . . . 70-90-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . 70-40-1 ENGINE / HYDROSTAT ASSEMBLY . . 70-100-1
AIR CONDITIONING SERVICE . . . . . . . 80-90-1 EVAPORATOR / HEATER UNIT . . . . . . 80-150-1
AIR CONDITIONING SYSTEM FLOW . . 80-10-1 EXPANSION TANK . . . . . . . . . . . . . . . . . 70-50-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . 60-30-1 EXPANSION VALVE . . . . . . . . . . . . . . . 80-160-1
APPROVED BOOM STOP EXTENSION CYLINDER . . . . . . . . . . . . 20-40-1
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 10-150-1
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . 20-120-1
ATTACHMENT CARRIER (QUICK-TACH) 50-80-1
FENDER . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
ATTACHMENT CARRIER . . . . . . . . . . . 10-130-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . 1-10
AXLE AND DIFFERENTIAL (FRONT) . . 40-20-1
FIXED BOOM . . . . . . . . . . . . . . . . . . . . . 50-30-1
AXLE AND DIFFERENTIAL (REAR) . . . . 40-21-1
FLYWHEEL AND HOUSING . . . . . . . . . 70-110-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . 40-40-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
AXLES (FRONT AND REAR) . . . . . . . . 10-110-1
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . 40-30-1
BASIC TROUBLESHOOTING . . . . . . . . . 80-50-1

FRONT WIPER MOTOR . . . . . . . . . . . . 60-100-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
FUEL LEVEL SENDER . . . . . . . . . . . . . 60-160-1
BOBCAT TELESCOPIC HANDLER
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 1-14 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10-80-1
BOOM ANGLE SENSOR . . . . . . . . . . . . 60-90-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . 70-130-1
BRAKE VALVE . . . . . . . . . . . . . . . . . . . 20-100-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
CAMSHAFT AND TIMING GEARS . . . . 70-150-1 GEAR BOX . . . . . . . . . . . . . . . . . . . . . . 40-100-1
COMPONENTS . . . . . . . . . . . . . . . . . . . . 80-20-1 GEAR CONTROL CYLINDER . . . . . . . . 20-70-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-110-1 GEAR PUMP . . . . . . . . . . . . . . . . . . . . . 20-110-1
CONDENSER . . . . . . . . . . . . . . . . . . . . 80-120-1 GENERAL AIR CONDITIONING
SERVICE GUIDELINES . . . . . . . . . . . . . 80-60-1
CONVERSIONS . . . . . . . . . . . . . . . . SPEC-60-1
HYDRAULIC / HYDROSTATIC FLUID
COUNTERWEIGHT . . . . . . . . . . . . . . . . 50-90-1 SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-50-1
CRANKSHAFT AND PISTONS . . . . . . . 70-160-1 HYDRAULIC CONNECTION
CYLINDER HEAD . . . . . . . . . . . . . . . . . 70-140-1 SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-40-1
DASH COVER . . . . . . . . . . . . . . . . . . . . 50-120-1 HYDRAULIC CONTROL VALVE . . . . . . 20-150-1
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 1-13 HYDRAULIC RESERVOIR . . . . . . . . . . 20-130-1
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 HYDRAULIC SYSTEM INFORMATION . 20-10-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . 40-70-1 HYDRAULIC/HYDROSTATIC SYSTEM 10-100-1
ELECTRICAL SYSTEM INFORMATION . 60-10-1 HYDROSTATIC DRIVE MOTOR . . . . . . . 30-30-1
EMERGENCY EXIT . . . . . . . . . . . . . . . 10-180-1 HYDROSTATIC PUMP . . . . . . . . . . . . . . 30-40-1
ENGINE AND ENGINE MOUNTS . . . . . . 70-70-1 HYDROSTATIC SYSTEM
ENGINE BLOCK . . . . . . . . . . . . . . . . . . 70-190-1 INFORMATION . . . . . . . . . . . . . . . . . . . . 30-10-1
ENGINE COMPONENTS AND TESTING 70-80-1 INCHING SENSOR . . . . . . . . . . . . . . . . 60-140-1
ENGINE COOLING SYSTEM . . . . . . . . . 10-70-1 INNER BOOM . . . . . . . . . . . . . . . . . . . . . 50-40-1
ENGINE COOLING SYSTEM . . . . . . . . 70-170-1 INSTRUMENT PANELS . . . . . . . . . . . . . 60-80-1
ENGINE COVER . . . . . . . . . . . . . . . . . . 10-160-1 JOYSTICK PANEL . . . . . . . . . . . . . . . . . 50-130-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . 50-60-1 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
769 of 770 INDEX-01 TL470(X) Service Manual

LIFT CYLINDER . . . . . . . . . . . . . . . . . . . 20-20-1 STEERING COLUMN COVER . . . . . . . 50-110-1
LIFTING AND BLOCKING THE STEERING CYLINDER (FRONT/REAR) . 20-60-1
TELESCOPIC HANDLER . . . . . . . . . . . . 10-10-1 STEERING VALVE . . . . . . . . . . . . . . . . 20-140-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 STOPPING THE ENGINE AND
LLMI / LLMC SYSTEM . . . . . . . . . . . . . . 60-180-1 LEAVING THE TELESCOPIC
LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
HANDLER . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 SYSTEM CHARGING AND
LUBRICATION SYSTEM . . . . . . . . . . . . 70-180-1 RECLAMATION . . . . . . . . . . . . . . . . . . . 80-100-1
MACHINE TORQUE SYSTEM TROUBLESHOOTING CHART 80-70-1
SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-20-1 TELESCOPIC HANDLER STORAGE
MAIN RELIEF VALVE . . . . . . . . . . . . . . . 20-80-1 AND RETURN TO SERVICE . . . . . . . . . 10-190-1
MAINTENANCE SAFETY . . . . . . . . . . . . . . . 1-1 TEMPERATURE / PRESSURE . . . . . . . . 80-80-1
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 20-90-1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . 80-170-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . 20-50-1
OIL COOLER / INTERCOOLER / TIRE MAINTENANCE . . . . . . . . . . . . . . 10-140-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 TOP WIPER MOTOR . . . . . . . . . . . . . . . 60-110-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . 30-20-1 TORQUE SPECIFICATIONS FOR
BOLTS . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . 10-20-1
TOWING THE TELESCOPIC HANDLER 10-40-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . 50-10-1

TRACTOR HOMOLOGATED
OPERATOR SEAT . . . . . . . . . . . . . . . . . . 50-20-1 EMERGENCY EXIT . . . . . . . . . . . . . . . . 10-181-1
PARKING BRAKE . . . . . . . . . . . . . . . . . 20-170-1 TRANSPORTING THE TELESCOPIC
PARKING BRAKE . . . . . . . . . . . . . . . . . . 40-50-1 HANDLER ON A TRAILER . . . . . . . . . . . 10-30-1
PEDAL ASSEMBLY . . . . . . . . . . . . . . . . 60-130-1 TROUBLESHOOTING . . . . . . . . . . . . . . . 40-10-1
PORT RELIEF VALVES . . . . . . . . . . . . . 20-160-1 TURBOCHARGER . . . . . . . . . . . . . . . . 70-120-1
PRESSURE SWITCH . . . . . . . . . . . . . . 80-140-1 WEAR PADS (FRONT) . . . . . . . . . . . . . . 50-50-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . 40-90-1 WEAR PADS (REAR) . . . . . . . . . . . . . . . 50-51-1
REAR WIPER MOTOR . . . . . . . . . . . . . 60-120-1
RECEIVER / DRIER . . . . . . . . . . . . . . . 80-130-1
REGULAR MAINTENANCE . . . . . . . . . . 80-40-1
REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 . . . . . . 10-201-1
REMOTE START TOOL
(SERVICE TOOL) KIT - MEL1563 . . . . . 10-200-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . 1-9
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SELF LEVELING CYLINDER
(LOCK VALVE) . . . . . . . . . . . . . . . . . . . . 20-31-1
SELF LEVELING CYLINDER . . . . . . . . . 20-30-1
SERIAL NUMBER LOCATION . . . . . . . . . . . 1-12
SERVICE BRAKE . . . . . . . . . . . . . . . . . . 40-80-1
SERVICE PC (LAPTOP COMPUTER) . 60-150-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . 10-50-1
SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . 60-60-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING ANGLE ADJUSTMENT . . . . 40-60-1
770 of 770 INDEX-02 TL470(X) Service Manual

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Service Manual

TL470(X) Telescopic Handler

S/N ANL711001 & Above

Dealer Copy -- Not for Resale

6990103 (05-11) Printed in Belgium © Bobcat Company 2011

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

NA5434 NA5436 B-6589

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 770 1-3 TL470(X) Service Manual

6 of 770 1-4 TL470(X) Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Dealer Copy -- Not for Resale

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

7 of 770 1-5 TL470(X) Service Manual

8 of 770 1-6 TL470(X) Service Manual

2. Check that ROPS mounting 10. Attachment locking pins must

3. The seat belt must be 11. Safety treads must be in good

Dealer Copy -- Not for Resale

5. Machine signs must be 13. Check hydraulic fluid level,

7. Check for correct function of 15. Lubricate the telescopic

8. The parking brake must 16. Check the condition of the

9 of 770 1-7 TL470(X) Service Manual

19. Inspect for loose or broken 22. Recommend to the owner

Dealer Copy -- Not for Resale

10 of 770 1-8 TL470(X) Service Manual

Dealer Copy -- Not for Resale

WARNING • The operator must know any prohibited uses or work

11 of 770 1-9 TL470(X) Service Manual

Safe Operation Needs A Qualified Operator (Cont’d)

Where overhead power lines are present in the operating

VOLTAGE MINIMUM DISTANCE Maintenance

up to 50 kV 3m The machine and some attachments have components

Dealer Copy -- Not for Resale

All fuels, most lubricants and some coolants mixtures are

Do not use the machine where exhaust, arcs, sparks or

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

12 of 770 1-10 TL470(X) Service Manual

Hydraulic System Always clean the machine and attachment, disconnect

Stop the engine and let it cool before adding fuel. No

Dealer Copy -- Not for Resale

Do not use ether or starting fluids on any engine that has

13 of 770 1-11 TL470(X) Service Manual

Module 1. - Model / Engine