Service Manual: TL35.70 (X) Telescopic Handler

Service Manual
Dealer Copy -- Not for Resale
TL35.70(X) Telescopic Handler

(TL35.70) S/N ANL714000 & Above
(TL35.70) S/N AVM114000 & Above
(TL35.70X) S/N ANMG14000 & Above
(TL35.70X) S/N AVM614000 & Above
7283169enUS (09-20) (D) Printed in Belgium © 2020 Bobcat Company. All rights reserved.
S3A (EC)
1 of 836
2 of 836
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
3 of 836 1-1 TL35.70(X) Service Manual


CONTENTS
SAFETY AND 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


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
Dismantling And Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Telescopic Handler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16


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 all machine fluid

legible and in the correct levels.
location.
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-0617SM

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-0617 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 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 TH EMEA-1015 SM

SAFETY INSTRUCTIONS (CONT’D) Dismantling And Disposal
Safe Operation Needs A Qualified Operator (Cont’d) On the completion of its useful life, the machine and its
parts shall be disposed of in an environmental friendly
Where overhead power lines are present in the operating manner. Please contact your local dealer. Parts of the
area, ensure sufficient clearance between the nearest of machine can be remanufactured like the engine
these lines and any part of the machine. depending on its age and condition, or recycled like
metals, plastics, rubbers and glasses. Respect the
VOLTAGE MINIMUM DISTANCE environment and dispose of waste properly. Worn or
damaged parts shall not be left in the environment. Oils,
up to 50 kV 3 m (10 ft) brake fluid, cooling refrigerants, batteries and cells shall
beyond 50 kV 5 m (16.5 ft) be disposed of in a proper manner through your local
dealer or recycling center.
The operator must survey his / her field of vision when
operating the telescopic handler. Adjust mirrors to obtain
the best visibility. Clean mirrors every day and more often
when necessary. Immediately replace any broken or
damaged mirrors. If a suspended load or the resulting
boom geometry blocks the vision of the operator
alternative carrying means must be considered.
The operator must know the wind speed. Do not use the
telescopic handler with wind speeds over 12,5 m/s (28
mph).

Avoid Silica Dust
Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Use a respirator, water spray or other means to control
dust.
SI TH EMEA-1015 SM

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

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use petrol or diesel fuel
for cleaning parts. Use commercial non-flammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

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

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs. These starting aids can cause explosion and
injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
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 TH EMEA-1015 SM

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

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

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

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

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
Sl TH EMEA-1015 SM

PUBLICATIONS AND TRAINING RESOURCES
The following publications are also available for your

Bobcat telescopic handler. You can order them from your
Bobcat dealer.
For the latest information on Bobcat products and the

Bobcat Company, visit our website at Bobcat.eu.
TL35.70(X)
OPERATION &
MAINTENANCE MANUAL
7283162enGB /
7283163enGB
Complete instructions on the correct operation and the

routine maintenance of the Bobcat telescopic handler.
TL35.70(X)
SERVICE MANUAL
7283169enUS
Complete maintenance instructions for your Bobcat

telescopic handler.
TL35.70(X) / TL38.70(X)
OPERATOR’S
HANDBOOK
7283167enGB
Gives basic operation instructions and safety warnings.

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

P133575
7301313
The telescopic handler serial number plate is located on

the right side of the chassis in front [Figure 1].

SERIAL NUMBER LOCATION (CONT’D) DELIVERY REPORT
Engine Serial Number Figure 3
Figure 2
B-16315
S38000
The delivery report [Figure 3] contains a list of items that
must be explained or shown to the owner or operator by
the dealer when the Bobcat telescopic handler is
delivered.

The delivery report must be reviewed and signed by the
owner or operator and the dealer.
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
18 3 13 20
12 2 2
14
2 4
6
5
1
7 17
11
10
16
9 15
8 19 NA15066
NA13136

ITEM DESCRIPTION ITEM DESCRIPTION
1 Operation & Maintenance Manual and Operator’s 11 Boom Stop [A]
Handbook [F]
2 Mirrors 12 Operator Cab (ROPS and FOPS) [C]
3 Work Lights 13 Rotating Beacon
4 Load Capacity Charts 14 Rear Work Light
5 Front Lights [E] 15 Tail Lights and Direction Signals
6 Telescoping Boom and Boom Extension Indicator 16 Tires [D]
[G]
7 Boom Head 17 Engine Cover
8 Pallet Fork Attachment [B] 18 Front Window Guard [A]
9 Boom and Boom Angle Indicator [G] 19 Carrier Locking Bar Holder
10 Seat Belt 20 Sight Level Gauge [A]
[A] Optional or Field Accessory. (Not Standard Equipment).

[B] Attachments - Several different attachments are available for the Bobcat telescopic handler.
[C] ROPS, FOPS - Roll-Over Protective Structure, per ISO 3471, and Falling-Object Protective Structure 
per ISO 3449, Level II.
[D] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat telescopic
handler.
[E] FRONT LIGHTS - Front lights are available in left or right hand drive version. The correct lights must be installed
depending on the country regulations in which the machine is used.
[F] Only available for models with S/N ANL714000 & Above and ANMG14000 & Above.
[G] Only available for models with S/N AVM114000 & Above and AVM614000 & Above.

SAFETY AND 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

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

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

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-5
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
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4
Fill / Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-5

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 (Gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Removing And Replacing Oil (Gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Front Pads Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Rear Pads Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
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
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
APPROVED BOOM STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
LIFTING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
REMOTE START TOOL (SERVICE TOOL) KIT - 6987761 . . . . . . . . . . . . . . . . . . . . . 10-210-1

Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Telescopic Handler Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-4

LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER
Procedure
Always park the machine on a flat and 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.
W-2718-0208 S39236
STOP the engine. Put a floor jack under the left side of the front axle. Lift the
telescopic handler and install the first jackstand [Figure
Figure 10-10-1 10-10-2].
Figure 10-10-3

2
P122564
S39237
Block the rear axle oscillation using stops (wooden block
or steel plate) (Item 1) between the rear axle oscillation
stops (Item 2) and the axle case (Item 3) (both sides) Put the floor jack under the right side of the front axle. Lift
[Figure 10-10-1]. the telescopic handler and install the second jackstand
[Figure 10-10-3].
Put a block in front and behind the rear wheel.
21 of 836 10-10-1 TL35.70(X) Service Manual

LIFTING AND BLOCKING THE TELESCOPIC
HANDLER (CONT’D)
Procedure (Cont’d)
Figure 10-10-4
S38065
Put the floor jack under the center of the rear axle. Lift the

telescopic handler and install jackstands [Figure 10-10-
4].

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
1
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or
P126565
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

fixate 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 the right (Item 1) to turn the

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


TRANSPORTING THE TELESCOPIC HANDLER ON A
TRAILER
Fastening
Loading And Unloading
Figure 10-30-2
Figure 10-30-1
3
2
4
1 1
EM7143
1 P128178
Fasten the telescopic handler to the transport vehicle to

The telescopic handler must be loaded backward on the prevent it from moving during sudden stops or when

trailer. going up or down slopes.
The rear of the trailer must be blocked or supported • Block the wheels (Item 1) [Figure 10-30-2].
(Item 1) [Figure 10-30-1] when loading or unloading the
telescopic handler to prevent the front end of the trailer • Use chains to fasten the machine frame to the
from raising up. transport vehicle (Items 2 and 3) [Figure 10-30-2].
Use chain binders to tighten the chains.
Be sure the transport and towing vehicles are of
adequate size and capacity. For the weight of telescopic • Attach the forks or bucket attachment to the transport
handler, (See Weights on Page SPEC-10-2.). vehicle (Item 4) [Figure 10-30-2].
Be sure that the contact areas with machine tires are

clean and free from ice, snow, and other slippery
materials.
Inspect visually the tie-down points. If there are signs of

damage or overloading, do not transport the machine.
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 10-40-1
Procedure
The telescopic handler can be towed a short distance

such as removing it from mud or loading onto a transport
vehicle. 1
The towing procedure must be executed in two steps:

• Disengaging the park brake pads (See Disengaging
The Park Brake Pads on Page 10-40-1.)
• Disengaging the transmission (See Disengaging The
Transmission on Page 10-40-2.)
Both steps are mandatory before any towing is

authorized. S38174
Tow the telescopic handler at a slow speed, not

exceeding 5 km/h (3 mph). Do not tow the machine for Remove the cap (Item 1) [Figure 10-40-1]. The cap can
more than three minutes. be accessed from the underside of the machine, through
the oval hole (Item 1) [Figure 10-40-2].
WARNING

UNEXPECTED MACHINE MOVEMENT CAN CAUSE
• 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
Block the wheels to prevent the machine from rolling.

Disengaging The Park Brake Pads
The park brake is engaged by spring pressure and

released by hydraulic pressure. The park brake must be
released manually before towing.
The following procedure describes how to disengage the

park brake pads:
NOTE: Use service wrench 14 to perform this

procedure. Depending on your local
regulation this tool can be available in the net
or container behind the seat.
Release the park brake. (See Operation & Maintenance

Manual.)

TOWING THE TELESCOPIC HANDLER (CONT’D) Disengaging The Transmission
Procedure (Cont’d) NOTE: Use service wrench 10 and 22 to perform this

procedure. Depending on your local
Disengaging The Park Brake Pads (Cont’d) regulation these tools can be available in the
net or container behind the seat.
Figure 10-40-2
Raise the engine cover.
Figure 10-40-4
S39411
2
Figure 10-40-3

S38176
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

1 them three times counterclockwise.
S38175
NOTE: Do not turn more than three times. This can

result in leakage.
This action will bypass the hydraulic fluid flow of the

1
hydrostatic transmission.
S38173
Tow the telescopic handler at a slow speed, not
exceeding 5 km/h (3 mph). Do not tow the machine for
Turn the adjustment screw (Item 1) [Figure 10-40-3] more than three minutes.
counterclockwise until the brake pads no longer make
contact with the brake disc.
The park brake is released manually now for towing the

machine.
WARNING
NOTE: The park brake will not work until the UNEXPECTED MACHINE MOVEMENT CAN CAUSE
adjustment screw is returned to the original SERIOUS INJURY OR DEATH
position. • Block wheels to prevent roll away before
system.
W-2808-0909

TOWING THE TELESCOPIC HANDLER (CONT’D) Engage the parking brake (See Operation &
Maintenance Manual.) and make sure it functions
Procedure (Cont’d) correctly (the engagement between the park brake pads
and the brake disc prevents the machine from moving).
Engaging The Transmission
Towing Points
Figure 10-40-6
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
system.
2
W-2808-0909
After towing is completed, block the wheels to prevent the

machine from rolling. 1
P134811
Tighten the valves (Item 1) [Figure 10-40-4] to 70 N•m

(52 ft-lb) torque to re-engage the hydrostatic pump.
Figure 10-40-7
Engage the park brake pads. (See Engaging The Park
Brake Pads on Page 10-40-3.)
Engaging The Park Brake Pads
Block the wheels to prevent the machine from rolling.

Figure 10-40-5
1
1 S41322
Use the retrieval point (Item 1) or front hitch (Item 2) (if

equipped) [Figure 10-40-6] for towing.
1 NOTE: Keep traction within an angle of 20° with the

longitudinal axis.
S38173
S38175
For models not equipped with the front hitch or retrieval
point, use the two front lifting points (Item 1) [Figure 10-
NOTE: Before re-engaging the park brake pads, make 40-7] for towing.
sure the park brake is released. (See
Operation & Maintenance Manual.)
Turn the adjustment screw (Item 1) [Figure 10-40-5]

clockwise until the park brake pads make contact with the
brake disc.
Turn the adjustment screw counterclockwise for 180°.

TOWING THE TELESCOPIC HANDLER (CONT’D)
Procedure (Cont’d)
Retrieval Point (If Equipped)
Figure 10-40-8
1
P134811
Use the retrieval point (Item 1) [Figure 10-40-8] for

retrieval of machine out of a hole or ditch.
NOTE: The retrieval point is rated for 1,5 times mass
of the machine.
NOTE: Keep traction within an angle of 20° with the

longitudinal axis.

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

WARNING
Failure to do so will result in excessive wear and early
AVOID INJURY OR DEATH
failures.
Instructions are necessary before operating or
servicing machine. Read and understand the
The service schedule is a guide for correct maintenance
Operation & Maintenance Manual, Operator’s
of the Bobcat telescopic handler.
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
Every 10 Hours (Before Starting The Telescopic Handler)
• Engine Oil - Check level and add as needed. Do not overfill. (See page 10-90-1.)
• Engine Air Filters and Air System - Check condition indicator and empty dust extractor. Check for leaks and
damaged components. (See page 10-60-1.)
• Cooling System - Clean debris from radiator, hydraulic fluid cooler and air conditioning condenser (if equipped).

Check coolant level COLD in coolant tank. Add premixed coolant as necessary. Check cooling system for leaks. (See
page 10-70-1.)
• Exhaust System - Check exhaust system and exhaust after-treatment components for leaks.
• Fuel Filter, Primary - Check display panel. Remove the trapped water (See page 10-80-2.)
• Seat Belt, Seat Belt Retractors - Check the condition of seat belt. Clean or replace seat belt retractors as needed.
Clean dirt and debris from moving parts. Check mounting hardware. (See the Operation & Maintenance Manual for
the correct procedure.)
• Front Horn / Back-up Alarm - Check for proper function and repair as needed. (See the Operation & Maintenance
Manual for the correct procedure.)
• Tires - Check for wear or damaged tires. Inflate to correct air pressure. Be sure all tires are inflated to the same
pressure. Use only approved tires. (See page 10-140-1.)
• Wheel Nuts - Perform every 8 hours or daily for the first week, then as scheduled. Check for loose wheel nuts and
tighten to correct torque. (See page 10-140-1.)
• Service Brakes - Check for correct function. Service as necessary. (See page 40-100-1.)
• Parking Brake - Check for correct function. Adjust or service as necessary. (See page 40-60-1.)
• Boom Angle and Extension Indicators (if equipped), Safety Signs (Decals), Safety Treads and Mirrors - Check
for damaged indicators, signs (decals), safety treads and mirrors. Replace any indicators, signs, safety treads or
mirrors that are damaged or worn. (See the Operation & Maintenance Manual for the correct procedure.)
• Hydraulic Fluid - Check fluid level and add as needed. (See page 10-100-1.)
• Tilt Cylinder - Lubricate with multipurpose lithium based grease. (See page 10-120-1.)
• Attachment Carrier Pins - Lubricate with multipurpose lithium based grease. (See page 10-120-1.)
Every 50 Hours
• Cooling System - Clean debris from radiator, air cooler, hydraulic fluid cooler, air conditioning condenser (if
equipped), and grille. (See page 10-70-1.)
• Engine Oil and Filter - Replace oil and filter the first time, then as scheduled. (See page 10-90-2.)
• Hydraulic / Hydrostatic Fluid Filters - Replace the two filter elements for the first time, then as scheduled. Use a
genuine Bobcat filter. (See page 10-100-3.)
• Air Conditioning Belt (if equipped) - Check condition. Replace as needed. (See page 80-20-2.)
• Articulation Pins, Axle Oscillation (Front / Rear), Boom Cylinder, Boom Pivot, Self-Leveling (Compensation)
Cylinder - Lubricate with multipurpose lithium based grease. (See page 10-120-1.)
• Telescopic Boom Wear Pads - Lubricate with multipurpose lithium based grease. (See page 10-120-1.)
• Hydraulic Hoses, Tubelines and Connections - Check for leaks. Repair or replace as needed.
• Harnesses - Check condition. Repair or replace as needed.
• Articulated Steering Links - Check for any damage or cuts on the rubber protection. Replace as needed.

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
Every 100 Hours
• LLMC System - Test the LLMC calibration the first time, then as scheduled. (See page 60-190-5.)
• Wheel Nuts - Check for loose wheel nuts and tighten to correct torque. (See page 10-140-1.)
• Planetary Carriers - Replace the fluid the first time, then as scheduled. (See page 10-110-1.)
• Axle and Differential Fluid- Replace the fluid the first time, then as scheduled. (See page 10-110-2.) And (See page
10-110-3.)
• Gearbox Fluid - Check level. Replace the fluid the first time, then as scheduled. (See page 10-110-4.)
Every 250 Hours Or Every 12 Months
• LLMC System - Test the LLMC calibration (See page 60-190-5.)

• Planetary Carriers - Check level. (See page 10-110-1.)
• Axle and Differential Fluid - Check level. (See page 10-110-2.) And (See page 10-110-3.)
• Fuel Filter, Primary - Replace primary filter element. (See page 10-80-2.)
• Fuel Filter, Secondary - Replace secondary filter element. (See page 10-80-4.)
• Engine Oil and Filter - Replace oil and filter. (See page 10-90-2.)

• Cooling System - Check coolant concentration (with a refractometer). Replace as needed. (See page 10-70-1.)
• Air Conditioning Belt (if equipped) - Check condition. Replace as needed. (See page 80-20-2.)
• Charge Air Cooler - Clean and check entry area.
• Hydraulic / Hydrostatic Fluid Filters - Replace the two filter elements. Use a genuine Bobcat filter. (See page 10-
100-3.)
• Hydraulic Fluid Tank Breather - Replace the hydraulic fluid tank breather. (See page 10-100-5.)
• Gearbox Fluid - Check level. (See page 10-110-4.)
• Telescopic Boom Wear Pads - Check for wear. Replace as necessary. (See page 50-50-1.) and (See page 50-51-1.).
• Service Brake Pedal Spring - Lubricate with multipurpose lithium based grease. (See page 10-120-1.)
• Cab Air Filter and Intake Pipes - Check filter condition. Replace as necessary. Check for damage. (See page 80-
20-1.)
• Planetary Carriers - Replace the fluid. In case of severe duty, half fluid change intervals must be applied. (See page
10-110-1.)
• Axle and Differential Fluid - Replace the fluid. In case of severe duty, half fluid change intervals must be applied.
(See page 10-110-2.) And (See page 10-110-3.)
• Gearbox Fluid - Replace the fluid. In case of severe duty, half fluid change intervals must be applied. (See page 10-
110-4.)
• Battery and Cable Connectors - Check voltage. Check terminals for good contact and presence of protective grease.
(See page 60-20-1.)
• Engine Mounts - Tighten. Replace if damaged. (See page 70-10-14.)
• Engine Air Filter - Replace the outer filter element. (See page 10-60-1.)
• Alternator Belt - Check condition. Replace as needed. (See page 60-30-2.)
• Hydraulic Fluid - Replace the fluid. (See page 10-100-2.)
• Fastenings, Hose Unions and Clips - Replace if damaged.
• Engine Valve Clearance - Check and adjust. (See page 70-90-16.)
• Coolant - Replace the coolant. (See page 10-70-2.)

SERVICE SCHEDULE (CONT’D)
Maintenance Intervals (Cont’d)
• Alternator Belt - Replace the belt. (See page 60-30-2.)

• Alternator - Inspect the alternator. (See page 60-30-1.)


AIR CLEANER SERVICE Figure 10-60-3
Replacing Filter Elements
Outer Filter
Figure 10-60-1
S38013
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. DO NOT use compressed air.

Replace the large (outer) filter element only when the Install a new outer element.
yellow ring has reached the red zone on the condition
indicator (Item 1) [Figure 10-60-1]. Figure 10-60-4
NOTE: Before replacing the filter element, push the 3

button on the condition indicator (Item 2)
[Figure 10-60-1]. Start the engine. If the yellow 1
ring of the condition indicator does not reach
the red zone, do not replace the filter element.
3
Figure 10-60-2
2 3
1 S38012
Install the dust cover (Item 1) with the dust extractor (Item
2) [Figure 10-60-4] facing down.
Fasten the filter housing clamps (Item 3) [Figure 10-60-

4].
1
S38012
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. DO NOT use compressed air.
Figure 10-60-5

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

4].

COOLING SYSTEM Checking Level
Check the cooling system every day to prevent over- Stop the engine and allow the engine to cool. Open the
heating, loss of performance or engine damage. engine cover. (See Opening And Closing on Page 10-
160-1.)
Cleaning
Figure 10-70-3
Stop the engine and open the engine cover. (See
Opening And Closing on Page 10-160-1.)
Figure 10-70-1
S38010

Check coolant level using the level markers (Item 1)
S38023
[Figure 10-70-3] on the tank. Coolant must be between
MIN and MAX level markers when the engine is cold.
Remove the nut (Item 1) [Figure 10-70-1]. NOTE: Always check coolant level before operating
the machine. Lack of engine coolant will
Figure 10-70-2 result in engine damage.
1 NOTE: The cooling system is factory filled with

3 ethylene glycol (EG) coolant. DO NOT mix
ethylene glycol with propylene glycol.
Use a refractometer to check the condition of ethylene

glycol in your cooling system.
2
Add premixed coolant to the tank if the coolant level is
low. (See the Operation & Maintenance Manual for the
correct procedure)
Close the engine cover.
S38134
Raise the condenser (Item 1) (if equipped) and keep in

position by installing the rod (Item 2) [Figure 10-70-2] in
the condenser mount.
Use low air pressure to clean the top and bottom of the
cooler (Item 3) [Figure 10-70-2]. Be careful not to
damage fins.
NOTE: The cooler is a combined radiator, intercooler

and hydraulic fluid cooler.

COOLING SYSTEM (CONT’D) Follow these steps when using concentrated coolant
instead of a ready-to-use premix:
Removing And Replacing The Coolant
• Use a separate container to mix the coolant.
See the SERVICE SCHEDULE for correct service • The correct mixture proportions of coolant to provide
intervals. (See SERVICE SCHEDULE on Page 10-50-1.) a -37°C (-34°F) freeze protection are 50% water and
50% ethylene glycol. For instance, to get 8 L OR
Stop the engine. Open the engine cover. (See Opening 2 U.S. gal of mixture, mix 4 L ethylene glycol with 4 L
And Closing on Page 10-160-1.) of water OR 1 U.S. gal ethylene glycol with 1 U.S. gal
of water.
Figure 10-70-4 • Add premixed coolant to the coolant tank until the
coolant level reaches the lower marker on the tank
(Item 1) [Figure 10-70-3].
1
NOTE: The coolant fill cap must be tightened until the
cap clicks.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level when cool. Add
coolant as needed.
Close the engine cover.

S38010
IMPORTANT
When the engine is cool, remove the coolant fill cap AVOID ENGINE DAMAGE
(Item 1) [Figure 10-70-4]. Always use the correct ratio of water to antifreeze.
Figure 10-70-5 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.
1
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
S38024
Remove the engine block drain plug (Item 1) and drain all
WARNING
of the coolant into a container. Install and tighten the AVOID INJURY OR DEATH
engine block drain plug (Item 1) [Figure 10-70-5]. Wear safety glasses to prevent eye injury when any
Recycle or dispose of used coolant in an environmentally of the following conditions exist:
safe manner. • When fluids are under pressure.
• Flying debris or loose material is present.
Add premixed coolant to the coolant tank until the coolant • Engine is running.
level reaches the MIN marker on the tank. Install the • Tools are being used.
coolant fill cap (Item 1) [Figure 10-70-4]. W-2019-0907

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination which can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.
• Use of biodiesel blend fuel can result in premature
Ultra low sulfur diesel fuel must be used in this machine. failure of fuel system components, such as plugged
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur fuel filters and deteriorated fuel lines.
maximum.
• Shorter maintenance intervals can be required, such
The following is one suggested blending guideline that as cleaning the fuel system and replacing fuel filters
should prevent fuel gelling during cold temperatures: and fuel lines.
• Using biodiesel blend fuel not compliant with the fuel
TEMPERATURE GRADE 2-D GRADE 1-D specifications and standard for approved fuels
Above -9°C (+15°F) 100% 0% described in this manual can affect engine life and
cause deterioration of hoses, tubelines, injectors,
Down to -21°C (-5°F) 50% 50% injector pump and seals.
Below -21°C (-5°F) 0% 100%

Apply the following guidelines if biodiesel blend fuel is
used:
NOTE: Biodiesel blend fuel may also be used in this
machine. Biodiesel blend fuel must contain • Ensure the fuel tank is as full as possible at all times
no more than five percent biodiesel mixed to prevent moisture from collecting in the fuel tank.
with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly • Ensure that the fuel tank cap is securely tightened.
marketed as B5 blended diesel fuel. B5
• Biodiesel blend fuel can damage painted surfaces,
blended diesel fuel must meet ASTM
remove all spilled fuel from painted surfaces
specifications.
immediately.
E.U. Standard (EN590) • Drain all water from the fuel filter daily before
operating the machine.
Use only clean, high quality diesel fuel that meets the
EN590 specifications listed below: • Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10 • Before machine storage; drain the fuel tank, refill with
ppm) sulfur maximum 100% petroleum based diesel fuel, add fuel stabiliser
and run the engine for at least 30 minutes.
• Diesel fuel with cetane number of 51.0 and above.
NOTE: Biodiesel blend fuel does not have long term
NOTE: Biodiesel blend fuel may also be used in this stability and should not be stored for more
machine. Biodiesel blend fuel must contain than three months.
no more than seven percent biodiesel mixed
with ultra low sulfur petroleum based diesel.
This biodiesel blend fuel is commonly
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

FUEL SYSTEM (CONT’D) 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.)
WARNING Removing Water
Stop the engine.

Stop and cool the engine before adding fuel. NO
Place a suitable container under the water separator in
SMOKING! Failure to obey warnings can cause an
order to catch any fuel that might spill. Clean up any
explosion or fire.
W-2063-0807
spilled fuel.
Figure 10-80-2
Figure 10-80-1

1
S39063
S42087
Open the drain valve (Item 1) [Figure 10-80-2] and allow

Remove the fuel fill cap (Item 1) [Figure 10-80-1]. the fluid to drain into the container.
Use a clean, approved safety container to add fuel of the When clean fuel drains from the water separator, hand
correct specifications. Add fuel only in an area that has tighten the drain valve (Item 1) [Figure 10-80-2].
free movement of air and no open flames or sparks. NO
SMOKING! Dispose of drained fluid in an environmentally safe
manner.
Install and tighten the fuel fill cap (Item 1) [Figure 10-80-
1].
IMPORTANT
WARNING AVOID ENGINE DAMAGE
Water in the fuel system can cause serious engine
AVOID INJURY OR DEATH damage. Remove water from the primary fuel filter
Always clean up spilled fuel or oil. Keep heat, flames, daily.
sparks or lighted tobacco away from fuel and oil. I-2354-0112
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Figure 10-80-5
Primary Fuel Filter (Pre-Filter) (Cont’d)

2
Replacing Element
Stop the engine.

3
Figure 10-80-3
S39065
1
Support the filter assembly (Item 1) and remove the
screw and washer (Item 2) [Figure 10-80-5].
2
Remove the filter assembly (Item 1) [Figure 10-80-5]
from the filter housing.
S39064

Remove the old filter element (Item 3) from the filter
assembly (Item 1) [Figure 10-80-5].
Remove the two screws (Item 1) and remove the cover
plate (Item 2) [Figure 10-80-3]. Figure 10-80-6
Place a suitable container under the water separator in

order to catch any fuel that might spill. Clean up any
spilled fuel. Dispose of drained fluid in an environmentally
safe manner. 4 3
Clean the outside of the filter / water separator.
Figure 10-80-4 1
EM9386
Only use filter element supplied with sealing plugs (top

and bottom). Remove plugs just before installing the new
element.
Install the filter element (Item 1) with a new seal (Item 2)

1 onto the glass bowl (Item 3) [Figure 10-80-6].
S39063
Install the new seals (Item 4) onto the filter element
(Item 1) [Figure 10-80-6].
Open the drain valve (Item 1) [Figure 10-80-4] and allow
the fluid to drain into the container.
When fuel stops draining from the water separator, hand

tighten the drain valve (Item 1) [Figure 10-80-4].

FUEL SYSTEM (CONT’D) Figure 10-80-8
Primary Fuel Filter (Pre-Filter) (Cont’d)
Figure 10-80-7
1
S38016
Clean the area around the filter housing.

S39065
Remove the filter element (Item 1) [Figure 10-80-8].
Install the filter assembly (Item 1) [Figure 10-80-7] onto Ensure that dirt can not enter the new filter element. Do
the filter housing. not fill the filter element with fuel before the element is

installed.
Install the screw and washer (Item 2) [Figure 10-80-7].
Use a new seal between washer and filter housing. Install a new filter element with a new seal, and hand
Tighten to 8 N•m (70 in-lb) torque. tighten.
Remove air from the fuel system. (See Removing Air Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-5.) From The Fuel System on Page 10-80-5.)
Secondary Fuel Filter
Stop the engine.

WARNING
See the SERVICE SCHEDULE for the service interval
when to replace the secondary fuel filter. (See SERVICE AVOID INJURY OR DEATH
SCHEDULE on Page 10-50-1.) Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
NOTE: It is important to maintain extreme cleanliness Failure to use care around combustibles can cause
when working on the fuel system, even tiny explosion or fire.
W-2103-0508
particles can cause engine or fuel system
problems.
Only use filter element supplied with sealing plug.

Remove plug just before installing the new element.

FUEL SYSTEM (CONT’D) Ensure the fuel pump is correctly wired as the Electrical
Shut-Off Solenoid must be in the run position during this
Removing Air From The Fuel System phase. This allows the fuel filter, low-pressure fuel pipes
and fuel injection pump to fill with fuel.
After replacing a fuel filter, fixing a leak in the fuel system
or running out of fuel in the fuel tank, the air must be Crank the engine with the throttle lever in the closed
removed from the fuel system before starting the engine. position until the engine starts.
Run the engine at low idle for one minute then cycle the
accelerator pedal rapidly from the low idle position to the
WARNING high idle position three times. The time taken to cycle the
accelerator pedal should be typically one to three
seconds. This will assist in displacing any residual
trapped air in the fuel injection pump.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Check for fuel leaks in the fuel system.
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
To determine whether air is going into the pump,

temporarily replace the standard inlet pipe with a suitable
clear plastic pipe.
Ensure all low-pressure and high-pressure fuel

connections are installed correctly.
Figure 10-80-9
2 2
3 3
1
1
P126571 P126572
Turn the ignition key (Item 1) (if equipped) or starter

switch (Item 1) (if equipped) to the PREHEAT position
(Item 3) [Figure 10-80-9] (this will activate the electrical
pump relay).
Leave the ignition key (if equipped) or starter switch (if

equipped) in the RUN position (Item 2) [Figure 10-80-9]
for three minutes.


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2

ENGINE OIL
Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
engine for the work shift. (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Figure 10-90-1
S38019 TEMPERATURE RANGE ANTICIPATED BEFORE

S6808
NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CI-4 OR BETTER, OR ACEA E7

Open the engine cover and remove the dipstick (Item 1) OR BETTER)
[Figure 10-90-1]. [1] Bobcat Synthetic Oil – 5W-40
Keep the oil level between the marks on the dipstick Bobcat engine oils are recommended for use in this
(Inset) [Figure 10-90-1]. Do not overfill. machine. If Bobcat engine oil is not available, use a good
quality engine oil that meets API Service Classification of
CI-4 or better, or ACEA E7 or better [Figure 10-90-2].
(See the Operation & Maintenance Manual for the correct
procedure.)
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
WARNING
• When fluids are under pressure.
• Flying debris or loose material is present. AVOID INJURY OR DEATH
• Engine is running. Always clean up spilled fuel or oil. Keep heat, flames,
• Tools are being used. sparks or lighted tobacco away from fuel and oil.
W-2019-0907 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Remove the oil filter (Item 1) [Figure 10-90-4].
Removing And Replacing Oil And Filter Put clean oil on the new filter gasket, install the filter and
hand tighten until the gasket contacts the surface, then
See the SERVICE SCHEDULE for the service interval for an additional 1/2 - 3/4 turn.
replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-50-1.) Figure 10-90-5
Run the engine until it is at operating temperature. Stop

the engine. 1
2
Figure 10-90-3
1
S38019
S6808

Remove the oil fill cap (Item 1) [Figure 10-90-5].
S38020 Put oil in the engine. For capacity, (See Fluid Capacities
on Page SPEC-10-5.). For type, (See Engine Oil Chart
on Page 10-90-1.)
Open the engine cover. (See Opening And Closing on
Page 10-160-1.) Install oil fill cap, start the engine and let it run for several
minutes.
Remove the oil drain cap (Item 1) [Figure 10-90-3].
Drain the oil into a container and recycle or dispose of Stop the engine, and check for leaks at the oil filter.
used oil in an environmentally safe manner.
Remove the dipstick (Item 2) [Figure 10-90-5] and check
Install and tighten the oil drain cap (Item 1) [Figure 10- the oil level. Add oil as needed if it is not at the top mark
90-3]. on the dipstick.
Figure 10-90-4
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
1 explosion or fire.
W-2103-0508
S38021
Clean the filter housing surface.

HYDRAULIC / HYDROSTATIC SYSTEM Figure 10-100-3
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system. 4

(See Specifications on Page SPEC-50-1.) 1
3
Completely retract and lower the boom.
Stop the machine on a level surface.

2
Stop the engine.
Hydraulic fluid must be at ambient temperature for this

procedure.
S40582
Figure 10-100-1
Remove the fill / breather cap (Item 1) [Figure 10-100-3].
Add fluid until it is at the center of the sight gauge (Item 1)

[Figure 10-100-1].
Install the fill / breather cap (Item 1) [Figure 10-100-3].

1 Lift the washer (Item 2) against the nut (Item 3),
reposition the cover (Item 4) and tighten the nut (Item 3)
[Figure 10-100-3].
S38033 WARNING
Check the fluid level at the sight gauge (Item 1) [Figure AVOID INJURY OR DEATH
10-100-1]. Always clean up spilled fuel or oil. Keep heat, flames,
Figure 10-100-2 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
S40581
Loosen the nut (Item 1) [Figure 10-100-2].
Rotate the cover (Item 2) [Figure 10-100-2] clockwise.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-4
Removing And Replacing Hydraulic Fluid
See the SERVICE SCHEDULE for the correct service

intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
2
Replace the fluid if it becomes contaminated or after
major repair.
Use only recommended fluid in the hydraulic system.

(See Specifications on Page SPEC-50-1.)
Always replace the hydraulic / hydrostatic filter whenever

the hydraulic fluid is replaced. (See Removing And
Replacing Hydraulic / Hydrostatic Filter on Page 10-100- 1
S38036
3.)
Remove the hydraulic fluid tank drain plug (Item 1)

[Figure 10-100-4] behind the right front wheel and drain
the fluid into a container. Recycle or dispose of the fluid in
WARNING an environmentally safe manner.
AVOID INJURY OR DEATH Put a new seal on the drain plug. Install the drain plug

Diesel fuel or hydraulic fluid under pressure can (Item 1) [Figure 10-100-4] and tighten.
from a doctor familiar with this injury.
W-2072-EN-0909
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic / Hydrostatic
Filter
Removing And Replacing Hydraulic Fluid (Cont’d)
Figure 10-100-5 intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-100-7
1
S40581
S38037

Rotate the cover (Item 2) [Figure 10-100-5] clockwise. Remove the cover (Item 1) [Figure 10-100-7] at the
bottom of the frame.
Figure 10-100-6
Figure 10-100-8
4
1
3
2 1
S40582
S38038
Remove the fill / breather cap (Item 1) [Figure 10-100-6].

Remove the filter housing (Item 1) [Figure 10-100-8].
Add fluid until it is at the center of the sight gauge (Item 1)
[Figure 10-100-1].
Reinstall the fill / breather cap (Item 1) [Figure 10-100-6].
Lift the washer (Item 2) against the nut (Item 3),

[Figure 10-100-6].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Charge Filter
Removing And Replacing Hydraulic / Hydrostatic See the SERVICE SCHEDULE for the correct service
Filter (Cont’d) intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-100-9 Figure 10-100-10
S38295 S38238
Remove the filter element (Item 1) [Figure 10-100-9] and Place a suitable container below the filter housing and

discard. remove the filter housing (Item 1) [Figure 10-100-10]
using a socket wrench.
Install new filter element ensuring that element is fully
seated in the filter base. Figure 10-100-11
Clean the filter housing and lubricate the threads with

aluminum paste P/N 7401526.
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 1
the fluid level in the hydraulic fluid tank and add as
needed. (See Checking And Adding Fluid on Page 10-
100-1.)
Install the cover. S38296
Remove the filter element (Item 1) [Figure 10-100-11]

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

AVOID INJURY OR DEATH seated in the filter base. Install the filter housing and
Always clean up spilled fuel or oil. Keep heat, flames, hand tighten.
Failure to use care around combustibles can cause Start the engine and let the engine run for one minute
explosion or fire. (low idle) before operating the boom hydraulics.
W-2103-0508
Stop the engine and check for leaks at the filter. Check
the fluid level in the hydraulic fluid tank and add as
needed. (See Checking And Adding Fluid on Page 10-
100-1.)

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 10-100-12
S40581

Rotate the cover (Item 2) [Figure 10-100-12] clockwise.
Figure 10-100-13
4
1
3
S40582
Remove the fill / breather cap (Item 1) [Figure 10-100-

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

13].
Lift the washer (Item 2) against the nut (Item 3),

[Figure 10-100-13].


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

[Figure 10-110-2] positioned as shown.
Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-1] positioned as shown. Clean the plug (Item 1) [Figure 10-110-2] and the
surrounding surface.
Clean the plug (Item 1) [Figure 10-110-1] and the
surrounding surface. Remove the plug (Item 1) [Figure 10-110-2] and drain oil
into a container. Recycle or dispose of the used lubricant
Remove the plug (Item 1) [Figure 10-110-1]. The oil level in an environmentally safe manner.
should be at the bottom edge of the plug hole.
Reposition the plug hole as shown in [Figure 10-110-1]
Add oil through the hole if the oil level is below the hole. and add gear lube until the lube level is at the bottom
edge of the plug hole (Item 1) [Figure 10-110-1].
For oil capacity, (See Fluid Capacities on Page SPEC-10-
5.). For oil type, (See Specifications on Page SPEC-50- For oil capacity, (See Fluid Capacities on Page SPEC-10-
1.) 5.). For oil type, (See Specifications on Page SPEC-50-
1.)
Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)
torque. Install and tighten the plug to 35 - 50 N•m (26 - 37 ft-lb)
torque.
Repeat the procedure for the other side.
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 the SERVICE SCHEDULE for the correct service
Figure 10-110-3
1 1
1
S38062
S38041
Put the machine on a level surface.

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

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

is to the bottom of the plug hole.

1.)

torque.

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Front Differential)
Checking And Adding Oil (Front Differential) See the SERVICE SCHEDULE for the correct service
Figure 10-110-6
1 1
S38048
S38043

Figure 10-110-7 Clean the plugs (Item 1) [Figure 10-110-6] and [Figure
10-110-7] and the surrounding surface.
Remove the plugs (Item 1) [Figure 10-110-8] and drain

oil into a container. Recycle or dispose of the used
lubricant in an environmentally safe manner.
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] until it

1
is to the bottom of the plug hole.

S38044 1.)

Put the machine on a level surface. torque.
Clean the plugs (Item 1) [Figure 10-110-6] and [Figure
10-110-7] and the surrounding surface.
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.

1.)

torque.

AXLES (FRONT AND REAR) (CONT’D) Removing And Replacing Oil (Gearbox)
Checking And Adding Oil (Gearbox) See the SERVICE SCHEDULE for the correct service
Figure 10-110-9
2
1
2
S38045
S38097
S38098

Put the machine on a level surface. Clean the plugs (Item 1 and 2) [Figure 10-110-10] and
the surrounding surface.
surrounding surface. Remove the plug (Item 2) [Figure 10-110-10] and drain
oil into a container. Recycle or dispose of the used
Remove the plug (Item 1) [Figure 10-110-9]. The oil level lubricant in an environmentally safe manner.
should be at the bottom edge of the plug hole.
Install and tighten the plug (Item 2) [Figure 10-110-10].
Remove the plug (Item 1) [Figure 10-110-9] and [Figure
For oil capacity, (See Fluid Capacities on Page SPEC-10- 10-110-10] and add oil through the hole.
1.) For oil capacity, (See Fluid Capacities on Page SPEC-10-
Install and tighten the plug. 1.)
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
SCHEDULE on Page 10-50-1.)
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. (See the Operation & Maintenance Manual for
1
more information.) Apply lubricant until extra grease
shows.
S38063
Remove the attachment from the telescopic handler
before lubricating. (See the Operation & Maintenance
Manual for the correct procedure.) Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-2].
Lubricate the following locations on the telescopic Figure 10-120-3

handler:
Figure 10-120-1

1 1
S38100
S38049
Attachment carrier pins - Left and right (Item 1) [Figure
10-120-3].
Axle Pivots - Top and bottom (Item 1) [Figure 10-120-1] Tilt Cylinder Rod End (Item 2) [Figure 10-120-3].
all four wheels.

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

(Compensation) Cylinder Base End (Item 2) [Figure 10-
S38101 120-6].
Figure 10-120-7
Tilt Cylinder Base End (Item 1) [Figure 10-120-4].

1
Figure 10-120-5
2
1
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 Boom and
Self Leveling (Compensation) Cylinders. (See
Installing The Approved Boom Stop on Page
10-150-1.)
Boom Cylinder Rod End (Item 1) and Self Leveling

(Compensation) Cylinder Rod End (Item 2) [Figure 10-
120-5].

LUBRICATING THE TELESCOPIC HANDLER Rear Pads Lubrication
(CONT’D)
Partially extend and lower the boom.
Front Pads Lubrication
Put the Travel Direction Control in NEUTRAL. Make sure
Figure 10-120-8 the parking brake is engaged. (See the Operation &
Maintenance Manual for the correct procedure.) Stop the
engine and exit the telescopic handler. (See STOPPING
THE ENGINE AND LEAVING THE TELESCOPIC
HANDLER on Page 10-170-1.)
Figure 10-120-9
1 1
S39099
Fully extend and lower the boom.

Put the Travel Direction Control in NEUTRAL. Make sure 2
the parking brake is engaged. (See the Operation &
S39070
Maintenance Manual for the correct procedure.) Stop the
engine and exit the telescopic handler. (See STOPPING
THE ENGINE AND LEAVING THE TELESCOPIC Remove the two bolts (Item 1) (both sides) and remove
HANDLER on Page 10-170-1.) the cover (Item 2) [Figure 10-120-9] from the back of the
boom.
Use a brush to lubricate the outside of the inner boom
[Figure 10-120-8]. Figure 10-120-10
S38930
Use a brush to lubricate the inside of the fixed boom

[Figure 10-120-10].


ATTACHMENT CARRIER Figure 10-130-3
Inspection And Maintenance
Figure 10-130-1
S40622
The telescopic handler attachment hydraulic locking pins

S38053 (if 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 hooks (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
1
S40623
S40622 The pins (if equipped) (both sides) must extend through
the holes in the attachment mounting frame (Item 1)
[Figure 10-130-4].
The stop plate (Item 1) [Figure 10-130-2] (both sides)
must not be damaged or worn. Inspect stop plate Lubricate the attachment carrier. (See SERVICE
condition. Replace as needed. SCHEDULE on Page 10-50-1.) (See LUBRICATING THE
TELESCOPIC HANDLER on Page 10-120-1.)


TIRE MAINTENANCE Wheel Replacement
Wheel Nuts Always park the machine on a level surface. STOP the
engine.
See the SERVICE SCHEDULE for the service interval to
check the wheel nuts. (See SERVICE SCHEDULE on
Page 10-50-1.)
WARNING
Figure 10-140-1
MACHINE FALLING OR MOVING CAN CAUSE
machine before running engine for service.
W-2718-0208
Front Wheels
Figure 10-140-2
S38099

The correct wheel nut tightening torque is 360 N•m
(266 ft-lb) with threads M18x1,5mm or 500 N•m (369 ft-
lb) with threads M20x1,5mm [Figure 10-140-1].
Rotating
Check the tires regularly for wear, damage and pressure. S39236
For the correct tire pressure, (See Traction on Page

SPEC-10-4.).
Put the floor jack under the left side of the front axle. Lift
the telescopic handler and install the first jackstand
Rear tires usually wear faster than front tires. To keep the
[Figure 10-140-2].
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

the telescopic handler. If different sizes are used, each
tire will be turning at a different rate and cause excessive
wear. The tread bars of all the tires must face the same
direction.
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.

TIRE MAINTENANCE (CONT’D) Mounting
Wheel Replacement (Cont’d) To change the size of the tires, contact your Bobcat
dealer. Only approved tires can be used. (See Traction on
Figure 10-140-3 Page SPEC-10-4.)
Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

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

S39237
frequently to avoid over inflation.
Put the floor jack under the right side of the front axle. Lift Pressure
the telescopic handler and install the second jackstand
[Figure 10-140-3]. For correct inflation, (See Traction on Page SPEC-10-4.).

Remove the eight wheel nuts and replace the wheel.
Install the wheel nuts and tighten in a crisscross pattern
to 360 N•m (266 ft-lb) torque with threads M18x1,5mm or
500 N•m (369 ft-lb) torque with threads M20x1,5mm.
WARNING
Rear Wheels
Do not inflate tyres above specified pressure. Failure
to use correct tyre mounting procedure can cause an
Figure 10-140-4
explosion which can result in injury or death.
W-2078-EN-0909
IMPORTANT
Inflate tyres to the MAXIMUM pressure shown on the
sidewall of the tyre. DO NOT mix brands of tyres
used on the same machine.
I-2057-EN-1010
S38065
Put the floor jack under the center of the rear axle. Lift the
telescopic handler and install jackstands [Figure 10-140-
4].
Remove the eight wheel nuts and replace the wheel.

Install the wheel nuts and tighten in a crisscross pattern
to 360 N•m (266 ft-lb) torque with threads M18x1,5mm or
500 N•m (369 ft-lb) torque with threads M20x1,5mm.

APPROVED BOOM STOP 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 (if equipped).
Installing The Approved Boom Stop

1
• Put the telescopic handler on a flat, solid and level
surface.
1
• With the operator in the seat, the seat belt fastened, 2
travel direction switch / control lever (if equipped) 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 (Item 1) and secure with lock pins

(Item 2) [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
• Start the engine and raise the boom. Stop the engine.
• Operating from the left back side of the machine,

remove the lock pins, pins and boom stop (Item 1)
[Figure 10-150-2].
S40674
• Reinstall the boom stop in the storage position

(Item 1) [Figure 10-150-1].
• Remove the boom stop (Item 1) [Figure 10-150-1]
from the storage position.
Figure 10-150-2
WARNING
Never work on a machine with the boom up unless
the boom is held by an approved boom stop. Failure
1 to use an approved boom stop can allow the boom to
drop and cause injury or death.
Service boom stop if damaged or if parts are
missing. Using a damaged boom stop or with
missing parts can cause boom to drop causing injury
or death.
W-2899-1210
S40664
• Install the boom stop (Item 1) [Figure 10-150-2]

operating 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 engine cover can be locked.


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

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

S38907MF
• 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.
• Remove the key (if equipped) from the switch to

prevent operation of the telescopic handler by
unauthorized personnel.
• Use grab handles, safety tread and steps when

getting off.
DO NOT JUMP.


EMERGENCY EXIT
Rear Window
Open the rear window. (See Rear Cab Window on Page

10-20-3.)
Figure 10-180-1
S38911

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


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 fluid levels; check
a list of items to perform before storage. coolant level.
• Store the attachments in a dry protected shelter. • Install a fully charged battery.
• Thoroughly clean the telescopic handler including the • Remove grease from exposed cylinder rods.
engine compartment.
• Check all belt tensions.
• Lubricate the telescopic handler.
• Be sure all shields and guards are in place.
• Replace worn or damaged parts.
• Lubricate the telescopic handler.
• Park the telescopic handler in a dry protected shelter.
• Check tire inflation and remove blocks from under
• Lower the boom all the way and put the attachment (if frame.
equipped) flat on the ground.
• Remove cover from exhaust pipe opening.
• Check tire inflation and put blocks under the frame to

remove the weight from the tires. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put grease on any exposed cylinder rods. correct operation.
• Put fuel stabiliser in the fuel tank and run the engine • Operate machine, check for correct function.
a few minutes to circulate the stabiliser to the pump
and fuel injectors. • Stop the engine and check for leaks. Repair as
needed.
If biodiesel blend fuel has been used, perform the
following:
Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabiliser and run the engine for at least
30 minutes.
• Drain and flush the cooling system. Refill with

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

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

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

condition.


LIFTING THE TELESCOPIC HANDLER Figure 10-200-2
Procedure
WARNING
AVOID INJURY OR DEATH 1
• Before lifting, check fasteners on four point lift.
• Never allow riders in the cab or bystanders within
5 m (15 ft) while lifting the machine.
W-2160-0910
Know and do not exceed the maximum rated capacity of S38102

the equipment used to lift and hoist the telescopic
handler.
Take into account the position of the machine’s center of
Before lifting: Remove all attachments, lower boom fully, gravity. (See Lifting on Page SPEC-12-1.)
position wheels straight forward and stop the machine.
Inspect visually the lifting points. If there are signs of

damage or overloading, do not transport the machine.

Attach the lift hooks to the following lifting points (Items 1)
[Figure 10-200-1] and [Figure 10-200-2]:
Figure 10-200-1
P123048


REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-210-2
6987761
2
Remote Start Tool (Service Tool) - 7022042
Tools that will be needed to complete the following steps

5 3
are:
Order from Bobcat Parts P/N: 6987761 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
1
• 7022042 - Remote Start Tool (Service Tool)
• 6689747 - Telescopic Handler Service Tool Harness
• 6689746 - Computer Service Tool Harness
P-76439
• 6689745 - BOSS® Service Tool Harness
• 7023157 - USB - Serial Cable
The Remote Start Tool (Service Tool) (Item 1)
Figure 10-210-1 [Figure 10-210-2] has five buttons.
The STOP button (Item 2) [Figure 10-210-2] is used to

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

The RUN button (Item 3) [Figure 10-210-2] 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 10-210-2] is used to
start the telescopic handler engine.
The PARKING BRAKE button (Item 5) [Figure 10-210-2]

P-76678 is not used for this machine.
The auxiliary button (Item 6) [Figure 10-210-2] is used to

The Remote Start Tool (Item 1) [Figure 10-210-1] 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.

6987761 (CONT'D)
Telescopic Handler Service Tool Harness - 6689747
Figure 10-210-3
1
1
S97029
2
Locate the diagnostic connector (Item 1) [Figure 10-210-

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 10-210-3] to the electrical system on the
telescopic handler.
Figure 10-210-4
S38026
Loosen the retainer screw (Item 1) and remove the fuse

box cover (Item 2) [Figure 10-210-4].

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
6987761 (CONT'D)
Figure 10-210-7
Telescopic Handler Service Tool Harness - 6689747
(Cont’d)
Figure 10-210-6
1
2
P-76450
2 The Computer Service Tool Harness (Item 1) is required

S39238 to connect Remote Start Tool (Service Tool) to the
Service PC (Item 2) [Figure 10-210-7].

Connect the main connector (Item 1) [Figure 10-210-6]
NOTE: Refer to BobcatDealerNET Support for PC
of the Service Tool Harness Control to the diagnostic
requirements and the latest Service Analyzer
connector (Item 1) [Figure 10-210-5].
software.
NOTE: The Remote Start Tool Connection Harness
has two connectors (Item 1) and (Item 2). The
main connector (Item 1) [Figure 10-210-6] is
always used for connection to the telescopic
handler.
The second connector (Item 2) [Figure 10-210-

6] is not used on this model.
WARNING
• Lift and block the machine.
• Check that wheels 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-2938-0612

6987761 (CONT'D)
2
Remote Start Procedure
5 3
WARNING 6 4
UNAUTHORIZED AND UNEXPECTED ENGINE

START-UP 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. P-76439
• Press the RUN button of the Remote Start Tool to
disconnect the operator panel from the start
circuit. The Remote Start Tool (Service Tool) (Item 1)
• Remove the operator panel key (key switch), lock [Figure 10-210-9] has five buttons.
the keypad with a unique password (keyless) or
otherwise disable the starter before working in The STOP button (Item 2) [Figure 10-210-9] is used to
the engine area. stop the Remote Start Tool (Service Tool) from
W-2661-1110 communicating and stop the telescopic handler engine.

The RUN button (Item 3) [Figure 10-210-9] is used to
The tool listed will be needed to do the following
turn the Remote Start Tool (Service Tool) on and
procedure:
activates the telescopic handler ignition power. The
button will illuminate to indicate the service tool is active.
6987761 - Remote Start Tool (Service Tool) Kit
The START button (Item 4) [Figure 10-210-9] is used to
Figure 10-210-8
start the telescopic handler engine.
The PARKING BRAKE button (Item 5) [Figure 10-210-9]

is not used for this machine.
1
The auxiliary button (Item 6) [Figure 10-210-9] 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.
P-76450
The Remote Start Tool (Service Tool) (Item 1)

[Figure 10-210-8] is required when the service
technician needs to turn on the telescopic handler or
start the engine without entering the cab.
Connect the main connector of the Service Tool Harness

Control to the diagnostic connector. (See Telescopic
Handler Service Tool Harness - 6689747 on Page 10-
210-2.)

REMOTE START TOOL (SERVICE TOOL) KIT -
6987761 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-210-10
1 2
P-76441
The gear icon with the left facing arrows (Item 1)

[Figure 10-210-10] will illuminate and blink when the
RUN key is pressed and the telescopic handler is
communicating with the service tool.
The computer icon with the right facing arrows (Item 2)

[Figure 10-210-10] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
NOTE: To relieve the pressure at the rear or

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


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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
BOOM 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 (COMPENSATION) CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-7
EXTENSION (COMPENSATION) 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

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
COLLECTOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
SERVICE BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1


TANDEM GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Parts Identification (Single Speed Version) (Standard) . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Disassembly And Assembly (Single Speed Version) (Standard) . . . . . . . . . . . . . . 20-100-5
Parts Identification (Variable Speed Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
Disassembly And Assembly (Variable Speed Version) . . . . . . . . . . . . . . . . . . . . . . 20-100-9
HYDRAULIC FLUID TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

MAIN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Troubleshooting Chart (Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-2
Troubleshooting Chart (Main Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-7
Main Relief Valve Testing And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-8
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-12
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-14
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-130-15
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-16
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-20
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-130-24
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-130-28
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-32
PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-2
ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Accumulators Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
TRAILER BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
BOOM SUSPENSION AND FLOAT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Boom Suspension Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Boom Float Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-2
Removing And Installing The Boom Suspension Valve . . . . . . . . . . . . . . . . . . . . . 20-170-5

HYDRAULIC/HYDROSTATIC SCHEMATIC
TL35.70 (S/N ANL714000 – ANL716000)
TL35.70 (S/N AVM114000 – AVM116000)
TL35.70X (S/N ANMG14000 – ANMG16000)
TL35.70X (S/N AVM614000 – AVM616000)
(Printed JANUARY 2018)
V-1632legend
1 RESERVOIR: ANTICAVITATION/WORK PORT RELIEF CHECK VALVE - Optional:

22 SOLENOID - Forward Drive 43 62
Reservoir Capacity 59 L (15.6 U.S. gal) VALVE – Tilt Cylinder – Base End: 400 kPa (4,0 bar) (58 psi)
System Capacity 105 L (27.7 U.S. gal) 23 SOLENOID - Reverse Drive 28000 kPa (280 bar) (4061 psi)
63 SOLENOID ACTIVATED DIRECTIONAL
2 ANTICAVITATION/WORK PORT RELIEF
SIGHT GAUGE 24 RELIEF VALVE – Charge: 44 CONTROL VALVE (Optional) –
VALVE – Tilt Cylinder – Rod End:
2400 kPa (24 bar) (348 psi) Trailer Accumulator
3 FILTER – Hydraulic Suction 28000 kPa (280 bar) (4061 psi)
25 RELIEF/REPLENISHING VALVE - HIGH 64 ACCUMULATOR – Park Brake (Optional):
PRESSURE (2): 42000 kPa (420 bar) (6092 psi) 45 LOAD SENSE BLEED VALVE: 1,0 L (0.264 gal) 2000 kPa (20 bar) (290 psi)
4 FILL CAP: With Filterr 1,0 L/m (0.26 gpm)
VARIABLE CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
26 65
5 TEMPERATURE SWITCH BIDIRECTIONAL HYDROSTATIC PUMP 46 BRAKE VALVE: 6000 kPa (60 bar) (870 psi) CONTROL VALVE (Optional) –
Tractor Safety Valve
6 FILTER - Hydraulic 27 CHARGE PUMP
47 PRESSURE SWITCH – Brake
40,5 L/m (10.7 U.S. gpm) @ High Engine Idle 66 RELIEF VALVE – Trailer Brake:
7 SPRING LOADED CHECK VALVE: 28 SERVO PISTON - Swash Plate 13000 kPa (130 bar) (1885 psi)
48 RELIEF VALVE (2):
340 kPa (3,4 bar) (49 psi) 23500 kPa (235 bar) (3408 psi) SOLENOID ACTIVATED DIRECTIONAL
29 PRESSURE SWITCH 67 CONTROL VALVE – Fan Reversing (Optional)
8 PRESSURE SWITCH 49 RELIEF VALVE:
30 FACTORY FILL PORT 17500 kPa (175 bar) (2538 psi)
68 PILOT ACTIVATED DIRECTIONAL
9 SOLENOID ACTIVATED DIRECTIONAL 50 ORIFICE - 0,8 mm (0.031 in)
CONTROL VALVE
CONTROL VALVE – Defeat Valve 31 CHECK VALVE: 300 kPa (3,0 bar) (43 psi)Dealer Copy -- Not for Resale
51 TELESCOPIC CYLINDER LOCK VALVE: 69 RELIEF VALVE:
SOLENOID ACTIVATED DIRECTIONAL 32 17500 kPa (175 bar) (2538 psi)
10 RELIEF VALVE: 1400 kPa (14 bar) (203 psi) 14000 kPa (140 bar) (2031 psi)
CONTROL VALVE – MOTOR
DISPLACEMENT CONTROL SPOOL: 33 ORIFICE - 1,0 mm (0.039 in) 52 TILT CYLINDER LOCK VALVE: 70 SOLENOID ACTIVATED DIRECTIONAL
29000 kPa (290 bar) (4206 psi) 28000 kPa (280 bar) (4061 psi) CONTROL VALVE – Rear Auxiliary (Optional)
11 SHUTTLE VALVE - Drain 53 SELF LEVELING CYLINDER LOC VALVE: 71 SOLEENOID / PILOT ACTIVATED
CONTROL VALVE – System By-Pass
25000 kPa (250 bar) (3626 psi) DIRECTIONAL CONTROL VALVE –
12 RELIEF VALVE: 1600 kPa (16 bar) (232 psi) 35 RELIEF VALVE: 22500 23500 kPa Front / Rear Auxiliary (Optional)
(225 - 235 bar) (3626 - 3771 psi) @ P port 54 ACCUMULATOR - Suspension:
13 SERVO PISTON - Swash Plate 1,0 L (0.264 gal) 2000 kPa (20 bar) (290 psi) SOLENOID ACTIVATED DIRECTIONAL
36 ORIFICE - 1,0 mm (0.039 in) 72 CONTROL VALVE – Power QuickTach (Optional)
14 VARIABLE CAPACITY DISPLACEMENT 55 ACCUMULATOR - Suspension:
BIDIRECTIONAL HYDROSTATIC MOTOR 37 COMPENSATOR 1,0 L (0.264 gal) 5500 kPa (55 bar) (798 psi)
HYDRAULIC PUMP - Gear type 38 SHUTTLE VALVE

15 56 SOLENOID ACTIVATED DIRECTIONAL
105 L/m (27.8 U.S. gpm) @ High Engine Idle CONTROL VALVE – Gear Box
HYDRAULIC PUMP - Gear type VALVE – Telescopic Cylinde – Base Endr: 57 CHECK VALVE: 34,5 kPa (0,35 bar) (5 psi)
16
40,1 L/m (10.6 U.S. gpm) @ High Engine Idle 28000 kPa (280 bar) (4061 psi)
17 PRIORITY VALVE ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL
40 CONTROL VALVE – Park Brake
VALVE – Telescopic Cylinder – Rod End:
18 ORIFICE - 1,3 mm (0.051 in) 28000 kPa (280 bar) (4061 psi) 59 SOLENOID ACTIVATED DIRECTIONAL
19 ORIFICE - 0,6 mm (0.021 in) CONTROL VALVE – Steering (Crab/FWS/4WS)
VALVE – Boom Cylinder – Base End: 60 RELIEF VALVE: 12000 kPa (120 bar) (1740 psi)
20 ORIFICE - 0,75 mm (0.031 in) 28000 kPa (280 bar) (4061 psi)
FILTER ANTICAVITATION/WORK PORT RELIEF 61 FILTER WITH ORIFICE: 0,5 mm (0.019 in) NOTE: Unless otherwise specified springs have NO
21 42
VALVE – Boom Cylinder – Rod End: significant pressure value.
28000 kPa (280 bar) (4061 psi)
Printed in U.S.A. V-1632 (1-17-18)

87 of 836
8 7 6 5 4 3 2 1
SUSPENSION
COUPLER ACCUMULATOR
MACHINE BOOM CYLINDER + SUSPENSION VALVE
FILL
H H
P LS MAINVALVE ACC
C2 C1
B
SELF LEVELING
(COMPENSATION)
U
P CYLINDER
CHARGE
FILTER
BYPASS TRANSM/
TOW VALVE
COUPLER
MACHINE A TILT CYLINDER
FILL T
CF1 EF1 TANDEM PUMP
(St4)
INVERSION FAN
MOTOR V2 V1
(OPTIONAL) LS1 A1
HYDROSTATIC PUMP M4 F E M3 MA BOOM CYLINDER
G IN
CF2
B1
SELF
G
LEVELING
A VALVE
EF2
FORWARD
DRIVE
OUT ENGINE LS2
D
REAR AUXILIARY DRAINED COUPLERS
EXTENSION (OPTIONAL)
A2 CYLINDER
IN TILT CYLINDER
A°
U
FEMALE
B2
COLD START
B BYPASS
REVERSE
DRIVE
TRACTOR
SAFETY REAR AUX
VALVE M5 S L1 L2 MB HYD HOOK
DIVERTER
F N B
TRAILER
VALVE
(OPTIONAL)
FEMALE
F
BRAKE
VALVE
1 OIL COOLER
Y A3
EXTENSION
2 3 CYLINDER
B2
B3 B1
P T A2
A1
C2
C1
L1 M4 M3 MOTOR HYDROSTATIC REAR COUPLERS

DRAIN TANK
B (OPTIONAL)
0.8 MM
0.03 IN A4
0.8 MM MAIN OIL FILTER
B A
0.03 IN
B4 FRONT AUX / REAR OPTIONS
L R DIVERTER VALVE (OPTIONAL)
E
F D E C
A
E
Vg min
A B B
B A L V
REAR HOOK CYLINDER
(OPTIONAL)
PARK GEARBOX
BRAKE
n TEMP
T2
MALE
V L
DRAIN
MALE

HYDRAULIC RESERVOIR
FEMALE
D D
T LS P STEERING
UNIT 2 4
FRONT AUXILIARY
QUICKTACH PWR DRAINED COUPLERS
LOCK / UNLOCK BLOCK
VALVE
(OPTIONAL)
3 1
POWER QUICKTACH CYLINDER

TRAILER BRAKE
(OPTIONAL)
COUPLER
(OPTIONAL)
COLLECTOR BLOCK
A4 L4 TRAILER ACCU
(OPTIONAL)
B4 R4
C P
U C
LS 5 SERVICE BRAKE
T2 2
1 P
U
T
P2
F
3
P
GEAR 1 2
GEAR 2
AXLE FRONT AXLE REAR

MF
P0 A3 B3 T4 T0 1
B GERMAN ACCU B
P
U
(OPTIONAL)
HYDRAULIC / HYDROSTATIC SCHEMATIC
TL35.70 (S/N ANL714000 - ANL716000)

TL35.70X (S/N ANMG14000 - ANMG16000)
TL35.70 (S/N AVM114000 - AVM116000)
TL35.70X (S/N AVM614000 - AVM616000)
A A
(PRINTED JANUARY 2017)
7304863 (B)
Printed In Belgium
88 of 836 8 7 6 5 4 3 2 1
HYDRAULIC/HYDROSTATIC SCHEMATIC
TL35.70 (S/N ANL716001 AND ABOVE)
TL35.70 (S/N AVM116001 AND ABOVE)
TL35.70X (S/N ANMG16001 AND ABOVE)
TL35.70X (S/N AVM616001 AND ABOVE)
(Printed JANUARY 2018)
V-1632legend
1 RESERVOIR: ANTICAVITATION/WORK PORT RELIEF CHECK VALVE - Optional:

22 SOLENOID - Forward Drive 43 62
Reservoir Capacity 59 L (15.6 U.S. gal) VALVE – Tilt Cylinder – Base End: 400 kPa (4,0 bar) (58 psi)
System Capacity 105 L (27.7 U.S. gal) 23 SOLENOID - Reverse Drive 28000 kPa (280 bar) (4061 psi)
SIGHT GAUGE 24 RELIEF VALVE – Charge: 44 CONTROL VALVE (Optional) –
VALVE – Tilt Cylinder – Rod End:
2400 kPa (24 bar) (348 psi) Trailer Accumulator
3 FILTER – Hydraulic Suction 28000 kPa (280 bar) (4061 psi)
25 RELIEF/REPLENISHING VALVE - HIGH 64 ACCUMULATOR – Park Brake (Optional):
PRESSURE (2): 42000 kPa (420 bar) (6092 psi) 45 LOAD SENSE BLEED VALVE: 1,0 L (0.264 gal) 2000 kPa (20 bar) (290 psi)
4 FILL CAP: With Filterr 1,0 L/m (0.26 gpm)
26 VARIABLE CAPACITY DISPLACEMENT 65 PILOT ACTIVATED DIRECTIONAL CONTROL
5 TEMPERATURE SWITCH BIDIRECTIONAL HYDROSTATIC PUMP 46 BRAKE VALVE: 6000 kPa (60 bar) (870 psi) VALVE – Trailer Brake (Optional)
6 FILTER - Hydraulic 27 CHARGE PUMP

47 PRESSURE SWITCH – Brake PILOT ACTIVATED DIRECTIONAL CONTROL
40,5 L/m (10.7 U.S. gpm) @ High Engine Idle 66
VALVE – Pressure Compensating (Optional)
7 SPRING LOADED CHECK VALVE: 28 SERVO PISTON - Swash Plate
48 RELIEF VALVE (2):
340 kPa (3,4 bar) (49 psi) 23500 kPa (235 bar) (3408 psi) SOLENOID ACTIVATED DIRECTIONAL
29 PRESSURE SWITCH 67 CONTROL VALVE – Fan Reversing (Optional)
8 PRESSURE SWITCH 49 RELIEF VALVE:
30 FACTORY FILL PORT 17500 kPa (175 bar) (2538 psi)
68 PILOT ACTIVATED DIRECTIONAL
9 SOLENOID ACTIVATED DIRECTIONAL 50 ORIFICE - 0,8 mm (0.031 in)
CONTROL VALVE
CONTROL VALVE – Defeat Valve 31 CHECK VALVE: 300 kPa (3,0 bar) (43 psi)Dealer Copy -- Not for Resale
51 TELESCOPIC CYLINDER LOCK VALVE: 69 RELIEF VALVE:
SOLENOID ACTIVATED DIRECTIONAL 32 17500 kPa (175 bar) (2538 psi)
10 RELIEF VALVE: 1400 kPa (14 bar) (203 psi) 14000 kPa (140 bar) (2031 psi)
CONTROL VALVE – MOTOR
DISPLACEMENT CONTROL SPOOL: 33 ORIFICE - 1,0 mm (0.039 in) 52 TILT CYLINDER LOCK VALVE: 70 SOLENOID ACTIVATED DIRECTIONAL
29000 kPa (290 bar) (4206 psi) 28000 kPa (280 bar) (4061 psi) CONTROL VALVE – Rear Auxiliary (Optional)
11 SHUTTLE VALVE - Drain 53 SELF LEVELING CYLINDER LOC VALVE: 71 SOLEENOID / PILOT ACTIVATED
CONTROL VALVE – System By-Pass
25000 kPa (250 bar) (3626 psi) DIRECTIONAL CONTROL VALVE –
12 RELIEF VALVE: 1600 kPa (16 bar) (232 psi) 35 RELIEF VALVE: 22500 23500 kPa Front / Rear Auxiliary (Optional)
(225 - 235 bar) (3626 - 3771 psi) @ P port 54 ACCUMULATOR - Suspension:
13 SERVO PISTON - Swash Plate 1,0 L (0.264 gal) 2000 kPa (20 bar) (290 psi) SOLENOID ACTIVATED DIRECTIONAL
36 ORIFICE - 1,0 mm (0.039 in) 72 CONTROL VALVE – Power QuickTach (Optional)
14 VARIABLE CAPACITY DISPLACEMENT 55 ACCUMULATOR - Suspension:
BIDIRECTIONAL HYDROSTATIC MOTOR 37 COMPENSATOR 1,0 L (0.264 gal) 5500 kPa (55 bar) (798 psi) SOLENOID ACTIVATED DIRECTIONAL CONTROL
73 VALVE – Supplementary Line (Optional)
HYDRAULIC PUMP - Gear type 38 SHUTTLE VALVE
15 56 SOLENOID ACTIVATED DIRECTIONAL PILOT ACTIVATED DIRECTIONAL CONTROL
105 L/m (27.8 U.S. gpm) @ High Engine Idle CONTROL VALVE – Gear Box 74
ANTICAVITATION/WORK PORT RELIEF VALVE – Supplementary Line (Optional)
39
HYDRAULIC PUMP - Gear type VALVE – Telescopic Cylinde – Base Endr: 57 CHECK VALVE: 34,5 kPa (0,35 bar) (5 psi) SOLENOID ACTIVATED DIRECTIONAL CONTROL
16 75
40,1 L/m (10.6 U.S. gpm) @ High Engine Idle 28000 kPa (280 bar) (4061 psi) VALVE – Command Line (Optional)
17 PRIORITY VALVE ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL PILOT ACTIVATED DIRECTIONAL CONTROL
40 CONTROL VALVE – Park Brake 76
VALVE – Telescopic Cylinder – Rod End: VALVE – Command Line (Optional)
18 ORIFICE - 1,3 mm (0.051 in) 28000 kPa (280 bar) (4061 psi) 59 SOLENOID ACTIVATED DIRECTIONAL 77 ACCUMULATOR:
19 ORIFICE - 0,6 mm (0.021 in) CONTROL VALVE – Steering (Crab/FWS/4WS) 0,75 L (0.019 gal) 5000 kPa (50 bar) (725 psi)
VALVE – Boom Cylinder – Base End: 60 RELIEF VALVE: 12000 kPa (120 bar) (1740 psi) 78 ACCUMULATOR – German Option Only:
20 ORIFICE - 0,75 mm (0.031 in) 28000 kPa (280 bar) (4061 psi) 1,4 L (0.369 gal) 8100 kPa (81 bar) (1175 psi)
FILTER ANTICAVITATION/WORK PORT RELIEF 61 FILTER WITH ORIFICE: 0,5 mm (0.019 in) NOTE: Unless otherwise specified springs have NO
21 42
VALVE – Boom Cylinder – Rod End: significant pressure value.
28000 kPa (280 bar) (4061 psi)
Printed in U.S.A. V-1632 (1-17-18)

89 of 836
8 7 6 5 4 3 2 1
SUSPENSION
ACCUMULATOR
COUPLER BOOM CYLINDER + SUSPENSION VALVE
MACHINE
FILL
H H
P LS MAINVALVE ACC
C2 C1
B
SELF LEVELING
QTACH ACCU
REVERSE FAN (COMPENSATION)
(OPTIONAL) U
MOTOR P CYLINDER
(OPTIONAL) CHARGE
FILTER
BYPASS TRANSM/
IN
TOW VALVE
COUPLER
MACHINE A TILT CYLINDER
FILL T
CF1 EF1 TANDEM PUMP
(St4)
OUT
V2 V1
LS1 A1
HYDROSTATIC PUMP M4 F E M3 MA BOOM CYLINDER
G D CF2
B1
SELF
G
LEVELING
A VALVE
EF2
FORWARD
DRIVE
TRAILER BRAKE VALVE CL SL SL1
ENGINE LS2
REAR AUXILIARY DRAINED COUPLERS

EXTENSION (OPTIONAL)
A2 CYLINDER
IN TILT CYLINDER
A°
U
FEMALE
B2
COLD START
B BYPASS
REVERSE
DRIVE
REAR AUX
M5 S L1 L2 MB HYD HOOK
T DIVERTER
F VALVE
(OPTIONAL)
FEMALE
F
OIL COOLER
A3
EXTENSION
CYLINDER
B2
B3 B1
A2
A1
C2
LS Y EF P CP C1 REAR COUPLERS
DRAIN TANK
L1 M5 M4 MOTOR HYDROSTATIC (OPTIONAL)
0.8 MM
0.03 IN A4
0.8 MM MAIN OIL FILTER
B A
0.03 IN
B4 FRONT AUX / REAR OPTIONS
L R DIVERTER VALVE (OPTIONAL)
E P
U
F D E C
A
E
Vg min
A B B
B A L V
REAR HOOK CYLINDER
(OPTIONAL)
PARK GEARBOX
BRAKE
n TEMP
T2
MALE
V L
DRAIN
MALE

HYDRAULIC RESERVOIR
FEMALE
D D
T LS P STEERING REDUNDANCY
UNIT PARK BRAKE 2 4
VALVE FRONT AUXILIARY
QUICKTACH PWR DRAINED COUPLERS
LOCK / UNLOCK BLOCK
VALVE
(OPTIONAL)
3 1
POWER QUICKTACH CYLINDER

(OPTIONAL)
COLLECTOR BLOCK
PARK BRAKE
A4 L4
ACCUMULATOR
(OPTIONAL)
B4 R4
C P
U C
LS 5 SERVICE BRAKE
T2 2
1 P
U
T
P2
F
3
P
GEAR 1 2
GEAR 2
AXLE FRONT AXLE REAR

MF
P0 A3 B3 T4 T0 1
(OPTIONAL)
B B
P
U
HYDRAULIC / HYDROSTATIC SCHEMATIC
TL35.70 (S/N ANL716001 - ANL799999)

TL35.70(S/N AVM116001 - AVM199999)
TL35.70X (S/N ANMG16001 - ANMG99999)
TL35.70X (S/N AVM616001 - AVM699999)
(PRINTED JANUARY 2018)
A 7304863 (F) A
Printed In Belgium
90 of 836 8 7 6 5 4 3 2 1
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
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 fluid temperature warning light comes ON when hydraulics are 1, 2
operating.
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine rpm. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9
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 boom cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.
Tightening Procedures
WARNING
IMPORTANT Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
When repairing hydrostatic and hydraulic systems, penetrating the skin. This can cause serious injury
clean the work area before disassembly and keep all and possible death if proper medical treatment by a
parts clean. Always use caps and plugs on hoses, physician familiar with this injury is not received
tubelines and ports to keep dirt out. Dirt can quickly immediately.
damage the system. W-2145-0290
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.

BOOM CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1
S38852
Support the boom 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 boom and self leveling (compensation) cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-20-3]
and lower the boom cylinder onto a block.

BOOM 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 boom cylinder lock valve block on the boom 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 boom cylinder and self leveling When repairing hydrostatic and hydraulic systems,
(compensation) cylinder. clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Installation: Tighten the nut (Item 1) [Figure 20-20-6] tubelines and ports to keep dirt out. Dirt can quickly
until contact with silent-block. Do not apply torque. damage the system.
I-2003-0888

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

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
WARNING
Figure 20-20-10
Hydraulic fluid escaping under pressure can have
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-20-12
S38827
Use the following tools to disassemble the cylinders:

Spanner Wrench
6670026 - Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-10].

S39387
Figure 20-20-11
Carefully peen the two pinches (Item 1) [Figure 20-20-

1
12] in the head gland lock ring until flush.
S38828
Remove the four bolts (Item 1) and remove the boom

cylinder lock valve block (Item 2) [Figure 20-20-11].
NOTE: Hydraulic fluid can still be under pressure.

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

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.

Always replace the seals. Heating is meant to
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:
Spanner Wrench 1
6670026 - Cylinder Wrench
6670009 - 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 fluid 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 2000 N•m (1475 ft-lb) torque.
Clean off any old residue, and apply Loctite® #270 or Figure 20-20-38
equivalent to the threads on the rod [Figure 20-20-35].

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® #270 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 450 N•m (332 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 boom cylinder lock valve block (Item 1) onto

the cylinder and tighten the four bolts (Item 2) [Figure 20-
20-44].

SELF LEVELING (COMPENSATION) CYLINDER Figure 20-30-3
Figure 20-30-1
S38852

[Figure 20-30-3].
S38207

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

1
2
S38853
S38851
(Item 2) [Figure 20-30-4].
Position a wooden block (Item 1) [Figure 20-30-2] under
the boom and self leveling (compensation) cylinders. Slowly loosen the cinch strap (Item 1) [Figure 20-30-3]
and lower the boom cylinder onto a block.

(CONT’D)

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 boom cylinder.

Figure 20-30-6
1
S38858
Remove the self leveling (compensation) cylinder from

the machine.
S38855
Remove the bolt and nut (Item 1) [Figure 20-30-6] and IMPORTANT
separate the boom cylinder and self leveling
(compensation) cylinder. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Installation: Tighten the nut (Item 1) [Figure 20-30-6] parts clean. Always use caps and plugs on hoses,
until contact with silent-block. Do not apply torque. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

SELF LEVELING (COMPENSATION) 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

(CONT'D)
Disassembly
Use the following tools to disassemble the cylinder:
Spanner Wrench
6670022 - 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

(CONT'D)
1
Figure 20-30-13
S39421

piston.
S38835
Figure 20-30-16
Put the rod end of the cylinder in a vise and support the 1

cylinder rod on a wood block [Figure 20-30-13].
Figure 20-30-14
1 2
S39419
Remove the two wear rings (Item 1) and seal (Item 2)

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

rod with a spanner wrench.

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

2
Figure 20-30-18
1
S38843
Remove the back-up ring (Item 1) and two O-rings (Item

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

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

(CONT'D)
Assembly 1
Spanner Wrench
6670009 - 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.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
Figure 20-30-21
S38841
2
Install the head gland (Item 1) and the spacer (Item 2)
[Figure 20-30-23] onto the rod.

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

[Figure 20-30-21] onto the head gland.
Figure 20-30-22
1
2
S38842
Install the dust ring (Item 1), wear ring (Item 2) and wiper
seal (Item 3) [Figure 20-30-22].

(CONT'D)
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 3 minutes [Figure 20-30-27].
S39419
Install the seal (Item 1) and two wear rings (Item 2)

[Figure 20-30-25].

(CONT'D)
Assembly (Cont'd)
Figure 20-30-28
1
P-29887
Apply Loctite® #243 or equivalent to the set screw (Item

1) [Figure 20-30-30].
P-32047
Figure 20-30-31
Clean off any old residue, and apply Loctite® #243 or

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

31].
S39422
Install the piston (Item 1) [Figure 20-30-29] onto the rod.
Tighten the piston to 250 - 300 N•m (184 - 221 ft-lb)

torque.

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

[Figure 20-30-34].
S38834

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

[Figure 20-30-33].

EXTENSION (COMPENSATION) CYLINDER Figure 20-40-3
Cylinder Group Removal And Installation
Figure 20-40-1
1
1 1
1
1
S39098
Disconnect the five fittings (Item 1) [Figure 20-40-3] in

the top opening of the boom head.
P123051
NOTE: Mark the hoses for correct installation.

Remove the two bolts (Item 1) from each cover and
remove metal covers (Item 2) [Figure 20-40-1] from the
boom head.
IMPORTANT

Remove the inner boom. (See Removal And Installation
on Page 50-40-1.)
When repairing hydrostatic and hydraulic systems,
Figure 20-40-2 clean the work area before disassembly and keep all
tubelines and ports to keep dirt out. Dirt can quickly
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 (COMPENSATION) 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
• Engine is running.
• Tools are being used.
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 (COMPENSATION) 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
Installation: Apply Loctite® #242 to the threads of the

Disconnect the two fittings (Item 1) [Figure 20-40-14]. bolts before installation.
Figure 20-40-15 Figure 20-40-17

1
S39105 S39108
Remove the two bolts (Item 1) [Figure 20-40-15] and Install a hoist (Item 1) [Figure 20-40-17] to lift and
nuts. support the extension cylinder.
Installation: Apply Loctite® #242 to the threads of the Slide the extension cylinder through the tubelines
bolts before installation. [Figure 20-40-17] and remove the cylinder.
NOTE: It can be necessary to reposition the lifting

strap.

EXTENSION (COMPENSATION) 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 (COMPENSATION) 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].
Assembly: Apply Loctite® #242 to the threads of the

bolts (Item 1) [Figure 20-40-22] before assembly.
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. Lock 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:
Spanner Wrench
6670022 - 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
6670026 - Cylinder Gland Nut Wrench 2
6670009 - Rod Seal Installation Tool

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

damage. Replace any damaged parts.
S38927
Lubricate all O-rings and seals with hydraulic fluid during
Install the wiper seal (Item 1) and two wear rings (Item 2)
Figure 20-40-36 [Figure 20-40-37] into the head gland.
2 Install the seal (Item 3) [Figure 20-40-37] using the seal

installation tool.
1

NOTE: The groove in the seal must point away from
2 the wiper seal.
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
Clean off any old residue, and apply Loctite® #243 or

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
2
1
S39068
P122536
Install a hoist and lifting strap (Item 1) [Figure 20-50-4] to
the tilt cylinder.
Remove the two bolts (Item 1) and remove the cover
(Item 2) [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 1
2
P133573
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 P133574
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].
Figure 20-50-10

1
1
1
S39098
If needed, disconnect the five fittings (Item 1) [Figure 20-

50-10] in the top opening of the boom head and remove
the hoses.

TILT CYLINDER (CONT’D)
1. Housing
2. Bushing
3. Grease Fitting
4. Rod
5. Wear Ring
6. Seal
7. Set Screw 2
8. Piston 3
1
9. O-ring
10. Back-up Ring
11. Head Gland
13
12. Wiper
13. Lock Valve

5
10
6
10
5
9 8
5 7
2 4
9
10
11
6
12
EM8704S

TILT CYLINDER (CONT'D)
Disassembly
Use the following tool to disassemble the cylinder:
4127913 - Adjustable Gland Wrench

WARNING
Figure 20-50-11
immediately.
W-2145-0290
Figure 20-50-13
1 1
S39076

Figure 20-50-12
S39091
1 Remove the three O-rings and back-up rings (Item 1)

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

Carefully loosen the relief cartridge (Item 1)
[Figure 20-50-12] to allow residual hydraulic
fluid pressure to escape.

TILT CYLINDER (CONT'D) Figure 20-50-16
Figure 20-50-14
P-29906
Tap the head gland several times all around its diameter
P129261 with a hammer as shown in [Figure 20-50-16].
Figure 20-50-17
A chisel tool (Item 1) [Figure 20-50-14] is required to
peen the pinches (Item 1) [Figure 20-50-15] in the head
gland. The tool is available in local aftermarket stores.

1
Figure 20-50-15
S39078
Loosen the head gland (Item 1) [Figure 20-50-17] with a

spanner wrench.
S39390
NOTE: Never tighten or loosen a cylinder under
constraints to avoid damage to the head
Carefully peen the two pinches (Item 1) [Figure 20-50- gland. Both cylinder ends must be moving
15] in the head gland lock ring until flush. freely on their pins or the cylinder must be
completely removed.
If the head gland is still firmly secured, heat the head

gland (Item 1) [Figure 20-50-17] and try to loosen it
again.
NOTE: Heating the head gland can damage the seals.

Always replace the seals. Heating melts the
Loctite® for ease of removal. Always be
careful with hot parts.

Figure 20-50-18
S39081
Support the cylinder rod on a wood block [Figure 20-50-

S39079 20].
Figure 20-50-21
Remove the rod assembly (Item 1) [Figure 20-50-18].
Figure 20-50-19

1
S39082
S39080 Heat and remove the set screw (Item 1) [Figure 20-50-
21].
Put the rod end of the cylinder in a vise [Figure 20-50-

19].

Figure 20-50-22
1
S39084
S39083
Remove the two wear rings (Item 1) [Figure 20-50-24]
from the piston.
Heat the piston (Item 1) [Figure 20-50-22]. Figure 20-50-25
Loosen and remove the piston (Item 1) [Figure 20-50-22] 1 1

from the rod.

NOTE: Heating the piston can damage the seals.
Always replace the seals. Heating melts the
Loctite® for ease of removal. Always be
careful with hot parts.
Figure 20-50-23
S39085
Remove the two back-up rings (Item 1) [Figure 20-50-

1
25].
S39087

inside of the piston.

Disassembly (Cont’d) 2 1
Figure 20-50-26
S39089
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-50-28] from the head gland.
S39086
Figure 20-50-29
Remove the seal (Item 1) [Figure 20-50-26].
Figure 20-50-27

3 1
1 2
S39090
Remove the wiper (Item 1), two wear rings (Item 2) and
S39088 seal (Item 3) [Figure 20-50-29] from the head gland.

the rod.

Assembly
1
Use the following tool to assemble the cylinder:
4127913 - Adjustable Gland Wrench

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

damaged parts.
Lubricate all O-rings and seals with hydraulic fluid during S39088
Install the head gland (Item 1) [Figure 20-50-32] onto the
Figure 20-50-30
rod.
Figure 20-50-33
3 1

2
S39090
Install the wiper seal (Item 1), wear rings (Item 2), and
seal (Item 3) [Figure 20-50-30]. S39087
NOTE: The groove in the seal (Item 3) must point

Install the O-ring (Item 1) [Figure 20-50-33] on the inside
away from the wiper seal (Item 1) [Figure 20-
of the piston.
50-30].
Figure 20-50-31
1 2
S39089
Install the back-up ring (Item 1) and O-rings (Item 2)

[Figure 20-50-31] onto the head gland.

Assembly (Cont'd)
Figure 20-50-34
1
S39084
Install the two wear rings (Item 1) [Figure 20-50-36].

S39086
Figure 20-50-37
Install the O-ring (Item 1) [Figure 20-50-34] onto the

piston.

Figure 20-50-35
1 1
P-32047
Clean off any old residue, and apply Loctite® 270 or

S39085
Install the two back-up rings (Item 1) [Figure 20-50-35].

Assembly (Cont'd)
Figure 20-50-38
1
1
S39082
Install the set screw (Item 1) [Figure 20-50-40].

S39092
Tighten the set screw to 10 N•m (88.5 in-lb) torque.
Install the piston (Item 1) [Figure 20-50-38] onto the rod. Figure 20-50-41
Tighten the piston to 2000 N•m (1475 ft-lb) torque.

Figure 20-50-39
1
S39082
Lock the set screw with a punch (Item 1) [Figure 20-50-

P-29887 41] on the edge of the hole.
Apply Loctite® #243 or equivalent to the set screw

(Item 1) [Figure 20-50-39].

Assembly (Cont'd)
1
Figure 20-50-42
S39390
Peen the lock ring on both locations (Item 1) [Figure 20-

S39079 50-44] in the head gland.
NOTE: To ensure proper locking, peen a notch of

Install the piston / rod assembly (Item 1) [Figure 20-50- 1.0 - 1,5 mm (0.04 - 0.06 in) in the lock ring.
42] into the housing.
Figure 20-50-45

threads of the head (Item 2) [Figure 20-50-42].
Figure 20-50-43
S39077
Before installation, inspect the relief cartridge for

S39093
contamination or visible damage. Clean contaminations
or replace if damaged.
Install the head gland [Figure 20-50-43]. Install the relief cartridge (Item 1) [Figure 20-50-45].
Tighten the head to 450 N•m (332 ft-lb) torque. Tighten the relief cartridge to 45 - 50 N•m (33 - 37 ft-lb)
torque.
NOTE: Never tighten or loosen a cylinder under
constraints to avoid damage to the head
gland. Both cylinder ends must be moving
freely on their pins or the cylinder must be
completely removed.


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

40-110-1.)
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 wheel

alignment 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
Removal (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 Disassembly

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

Installation
Figure 20-60-9
S2523
Apply Loctite® #243 to the thread and install the two tie
S2521 rods [Figure 20-60-11]. Tighten the tie rods to 240 - 270
N•m (177 - 199 ft-Ib) torque.
Lubricate the seats of the seals and install the steering Figure 20-60-12
cylinder (Item 1) [Figure 20-60-9] into its seat.

Figure 20-60-10
2
1 4
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 (Item 4)

[Figure 20-60-12] are intact. If the rubber
boots are damaged, replace them immediately
to avoid further damage to the tie rods.

STEERING CYLINDER (FRONT / REAR) (CONT’D)
Installation (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 wheel alignment sensor for checking piston

centering.
Tighten the bolt (Item 1) [Figure 20-60-14] to 5 - 6 N•m

(44 - 53 in-Ib) torque.

Disassembly
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)
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

beveled 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.

Assembly
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.

Assembly (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.

Assembly (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 (Item 1)

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

Figure 20-60-29
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].


COLLECTOR BLOCK Figure 20-70-1
Removal And Installation 2
WARNING
sufficient force to enter a person’s body by 2 3
immediately. 1
W-2145-0290
1 1 P125400
Disconnect the five electrical connectors (Item 1)

[Figure 20-70-1] on the bottom of the collector block.
IMPORTANT (one is hidden at the back of the left solenoid)
Remove the fifteen hydraulic connections from the

manifold (Item 2) [Figure 20-70-1].

Remove the bolt and bracket (Item 3) [Figure 20-70-1].
damage the system.
I-2003-0888 NOTE: For picture clarity some hydraulic
connectors, electrical connectors and
mounting bracket are removed in [Figure 20-
Relieve hydraulic pressure. 70-1]. Mark the hydraulic and electrical
connectors for correct installation.
Figure 20-70-2
BOTTOM VIEW
S39412
Remove the two bolts (Item 1) [Figure 20-70-2] located

outside of the frame, in front of the hydraulic tank.
Remove the collector block from the machine.

COLLECTOR BLOCK (CONT’D)
4
4
1. Solenoid Valve
2 2. Solenoid
4 2 3. Spacer
4. Nut
5. Coil
3 6. Relief Valve
3
5 7. Check Valve
8. Plug
2
9. Orifice Screen
2 10. Valve Block
11. Seal Kit
1 12. O-ring

1 11
11
11
12
11
11
6
10
9
NA12517S

COLLECTOR BLOCK (CONT’D)
Parts Identification (Cont’d)
Figure 20-70-3
ITEM DESCRIPTION ITEM DESCRIPTION
2 3 1 Relief valve  10 LS Port
12 MPa (120 bar) 11 T4 Port
(1740 psi)
12 L4 Port
4 2 Gearbox valve 13 ‘3’ Port
3 Park brake valve 14 ‘4’ Port
15 R4 Port
4 Steering valve 16 ‘2’ Port
5 Check valve  17 ‘1’ Port
5 35 kPa (0,35 bar) 18 ‘5’ Port
1
(5.1 psi)
6 19 T0 Port
9 8 7 P128064 6 A4 Port 20 P0 Port
7 B4 Port 21 B3 Port
Figure 20-70-4 8 P2 Port 22 A3 Port
11 9 T2 Port

10 12
13
14
15
22
21 16
17
20 19
18 P133760

COLLECTOR BLOCK (CONT’D) Remove the check valve (Item 5) [Figure 20-70-5] from
the manifold.
Disassembly And Assembly
Figure 20-70-7
Figure 20-70-5
1 1
1
2
2
5
4
S39858
P128064
Inspect the O-rings and back-up washer (Item 1)

Remove the three nuts (Item 1) [Figure 20-70-5] from [Figure 20-70-7] for damage.
the solenoid valve stems.

Assembly: Put oil on O-rings and back-up washer.
Remove the four solenoids (Item 2) [Figure 20-70-5] Tighten to 26 - 29 N•m (19 - 21 ft-lb) torque.
from the solenoid valve stems.
Remove the three solenoid valve stems from the collector
Remove the coil (Item 3) [Figure 20-70-5] from the block.
solenoid valve stems.
Figure 20-70-8
Remove the relief valve (Item 4) [Figure 20-70-5] from
the collector block.
Figure 20-70-6
1
S39859
Inspect the O-rings and back-up washers (Item 1)

S39857 [Figure 20-70-8] for damage.
Assembly: Put oil on O-rings and back-up washers.

Inspect the O-rings and back-up washer (Item 1) Tighten the long solenoid valve stem to 33 - 35 N•m (24 -
[Figure 20-70-6] for damage. 26 ft-lb) torque. Tighten the short solenoid valve stem to
26 - 29 N•m (19 - 21 ft-lb) torque.
Assembly: Put oil on O-rings and back-up washer.
Tighten to 26 - 29 N•m (19 - 21 ft-lb) torque.

SERVICE BRAKE VALVE Figure 20-80-3
Remove the steering column cover. (See Removal And

Installation on Page 50-110-1.)
Figure 20-80-1
1
1 1
S39132
Remove the two bolts (Item 1) [Figure 20-80-3] from

inside the operator cab.
2
Remove the service brake valve (Item 4) [Figure 20-80-
S38084 2] from the outer cab.

Remove all fittings (Item 5) from the service brake valve
Remove the three bolts (Item 1) and remove the cover (Item 4) [Figure 20-80-2].
(Item 2) [Figure 20-80-1] from the front of the operator
cab.
Figure 20-80-2
IMPORTANT
3
4 clean the work area before disassembly and keep all
damage the system.
1 I-2003-0888
2
5
1
P125412
Disconnect the two hoses (Item 1), the tubeline (Item 2)

and the service brake pressure sensor (Item 3) from the
service brake valve (Item 4) [Figure 20-80-2].
NOTE: Some additional hoses may need to be

disconnected from the steering unit in order
to disconnect the tubeline.


TANDEM GEAR PUMP Figure 20-90-1
Stop the engine. 1
Relieve the hydraulic pressure. Drain the hydraulic fluid

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

Battery on Page 60-20-3.)
1
WARNING S38066
Hydraulic fluid escaping under pressure can have Loosen the two bolts (Item 1) and remove the cover
sufficient force to enter a person’s body by (Item 2) [Figure 20-90-1] from the front side of the
penetrating the skin. This can cause serious injury engine bay assembly.
physician familiar with this injury is not received Figure 20-90-2
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 20-90-2].

TANDEM GEAR PUMP (CONT'D) Figure 20-90-5
Removal And Installation (Cont'd) 1
Figure 20-90-3 1
1
1
1
2
S39400
Remove the three hoses (Item 1) [Figure 20-90-5] from

S39399 the tandem gear pump assembly.
Figure 20-90-6
Loosen the two fittings (Item 1) and remove the tubeline
(Item 2) [Figure 20-90-3].

1
Figure 20-90-4
2
1 1
1 S39401
2 Install a wooden block under the tandem gear pump

S38070 assembly.
Remove the two mounting bolts (Item 1) [Figure 20-90-6]

Loosen / remove the four bolts (Item 1) and remove the from the tandem gear pump.
fitting (Item 2) [Figure 20-90-4] from the tandem gear
pump. Installation: Tighten the mounting bolts to 50 - 80 N•m
(38 - 59 ft-lb) torque.
Remove the tandem gear pump assembly (Item 2)

[Figure 20-90-6].
NOTE: It can be necessary to reposition any hose or

wires.

TANDEM GEAR PUMP (CONT'D)
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

TANDEM GEAR PUMP (CONT'D) Disassembly And Assembly
Figure 20-90-7
IMPORTANT
2
7 1 When repairing hydrostatic and hydraulic systems,
4 damage the system.
I-2003-0888
Figure 20-90-8
6 1
7 5 3 4
S39437
5
1. LS1 port

2. LS2 port 2
3. CF1 priority port
4. CF2 priority port 3

P129390
5. EF1 excess flow port
6. EF2 excess flow port Mark the pump housing for correct assembly and remove
all fittings [Figure 20-90-8].
7. Priority valve
Assembly: Tighten the fittings [Figure 20-90-8] as
follows:
• Fitting (Item 1): 45 N•m (33 ft-lb)
• Fitting (Item 2): 120 N•m (88.5 ft-lb)
• Fitting (Item 3): 45 N•m (33 ft-lb)
• Fitting (Item 4): 120 N•m (88.5 ft-lb)
• Fittings (Items 5 and 6): 25 N•m (18 ft-lb)

Disassembly And Assembly (Cont'd)
Figure 20-90-9
2
1
1 1
P-25294
1 1
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20-

2
S39437 90-11] from the housing.
Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque.

Remove the four bolts (Item 1) [Figure 20-90-9].

Assembly: Tighten the bolts to 70 N•m (51 ft-lb) torque.
Remove the flow divider (Item 2) [Figure 20-90-9] from

the housing.
Figure 20-90-10
5 4 3 2 1
6
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 20-90-10].
Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque.
NOTE: Always use new O-rings.

Figure 20-90-12 1 2
Cut
14 mm dia.
(0.550” dia.)
P-25295
38 mm Remove the screen (Item 1) from the orifice (Item 2)

(1.500’’) 19 mm
(0.750’’) B-14674 [Figure 20-90-14] and clean.
Figure 20-90-15
Figure 20-90-13
2

1 1
1 1
S39437
P-25296
Remove the four bolts (Item 1) and cover (Item 2)

To remove the orifice assembly (Item 1) [Figure 20-90- [Figure 20-90-15].
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 Assembly: Tighten the bolts to 70 N•m (51 ft-lb) torque.
in wide x 2.0 in long) piece of hardwood. Drill a 14 mm
(0.550 in) hole in the center of the hardwood block. Cut
the block lengthwise [Figure 20-90-12].
Place both halves of the hardwood block around the

spool. Clamp the blocks in a vise [Figure 20-90-13].
NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.


1
Figure 20-90-16
S39252
Remove both O-rings (Item 1) [Figure 20-90-18] from

S39350 the housing.
Figure 20-90-19
Remove the housing / gear assembly (Item 1)
[Figure 20-90-16] from the main housing.

Figure 20-90-17
3
2
1
2 4 P-56453
Remove the back-up ring (Item 1) and seal ring (Item 2)

S39351 [Figure 20-90-19] from the gear holder.
Assembly: The seal ring (Item 2) [Figure 20-90-19] is

Remove the housing (Item 1) from the gear assembly installed onto the gear holder first followed by the back-
(Item 2) [Figure 20-90-17]. up ring.
Assembly: The position of the small opening (Item 3) on

the gear holders will point toward the cut-away (Item 4)
[Figure 20-90-17] on the housing.

Figure 20-90-20
P-25305
Turn the housing over and remove the mount plate

P-25322 [Figure 20-90-22].
Figure 20-90-23
Remove and discard the O-ring (Item 1) [Figure 20-90-
20] from the flange.

Figure 20-90-21
1
1 1
1 1
P-25306
Remove the snap ring (Item 1) [Figure 20-90-23].

P-25304
Remove the four bolts (Item 1) and drive shaft (Item 2)

[Figure 20-90-21].
Assembly: Tighten the bolts to 140 N•m (103 ft-lb)

torque.


2 2
Figure 20-90-24
3 1 3
1
P-25313
Remove the two thrust plates (Item 1), seal ring (Item 2)
P-25307 and back-up ring (Item 3) [Figure 20-90-26] from the
gears.
Remove both shaft seals (Item 1) [Figure 20-90-24]. Assembly: The seal ring (Item 2) will be installed on the
thrust plate (Item 1) first followed by the back-up ring

Assembly: The open part of the first seal goes into the (Item 3) [Figure 20-90-26].
mount plate first. For the second seal the closed side
goes into the mount plate first (reversed orientation).
Figure 20-90-25
4
P-25310
Remove the O-ring (Item 1) and gear assembly (Item 2)

[Figure 20-90-25] from the housing.
Assembly: The position of the V portion (Item 3) on the

thrust plate must point toward the larger port (Item 4)
[Figure 20-90-25] on the housing.


FAN MOTOR
Description
Fan Speed
The maximum fan speed is 2700 rpm at maximum

engine speed (2400 rpm) with hydraulic fluid temperature
at 50°C (122°F).
For machines equipped with the variable speed fan

motor, the fan speed will automatically reach its
maximum speed if the proportional valve (Item 2) [Figure
20-100-18 on Page 9] is disconnected.
Fan Inversion Cycle (Variable Speed Version) (Optional)
Figure 20-100-1
If the switch is pressed during a cycle in progress, it will

have no effect

Fan Inversion switch
Fan_period Fan_period
Minimum fan speed
(@ 1,4 A)
mp1
Fan
Fan
mp1
_ra
_ram
_ra
Fan
_ra
Variable Speed Fan
mp2
p2
Fan
Fan_reverse_period
Maximum fan speed
10 s 5s 10 s 30 s 10 s 5s 10 s
Fan Inversion
relay output
Fan in normal Fan in normal Fan speed is Fan in reverse Fan in reverse rotation Fan in reverse Fan speed is Fan in normal
rotation rotation stopping rotation Maximal speed rotation stopping rotation
@ High speed Speed is Speed is Speed is Speed is
decreasing increasing decreasing increasing
1 Fan Inverter cycle (80 seconds)
NA13898

FAN MOTOR (CONT’D) Figure 20-100-3
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 Hydraulic Oil Cooler / [Figure 20-100-3].
Intercooler / Radiator Removal And Installation on Page
70-60-1.) Installation: Apply Loctite® #242 to the threads of the
bolts.
Figure 20-100-2

Flip the fan assembly around.
2
Figure 20-100-4
1
1
1 S41453
Remove the four bolts and washers (Item 1) [Figure 20- S38796
100-2].
Installation: Tighten the bolts (Item 1) [Figure 20-100-2] Remove the nut and lockwasher (Item 1) [Figure 20-100-
to 15 - 22 N•m (11 - 16 ft-lb) torque. 4].
Remove the fan guard with fan motor (Item 2) [Figure 20- Installation: Apply Loctite® #242 to the thread and
100-2]. tighten the nut to 19 - 20 N•m (14 - 15 ft-lb) torque.

FAN MOTOR (CONT’D)
Figure 20-100-5
S38801
Install the fan assembly onto blocks as shown in [Figure

20-100-5].

Figure 20-100-6
S38797
Tap on the shaft to release the fan motor from the blade
assembly [Figure 20-100-6].
Flip the fan assembly around.
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) Disassembly And Assembly (Single Speed Version)
(Standard)
Parts Identification (Single Speed Version)
(Standard) (Cont’d) Figure 20-100-8
Figure 20-100-7
2
1
1
3 2
4 P-53275
P-53275
Remove the solenoid stem (Item 1) and three fittings
(Item 2) [Figure 20-100-8].
1. INLET Port

Installation: Tighten the fittings (Item 1) to 45 N•m (33 ft-
2. OUTLET Port lb) torque. Tighten the fitting (Item 2) [Figure 20-100-8]
to 12 N•m (9 ft-lb) torque.
3. D port
NOTE: Mark the housing for correct assembly.
4. Relief valve
Figure 20-100-9
4
3
2
1
P-53276
Remove the plug (Item 1), anticavitation check valve

spring (Item 2) and relief valve spring (Item 3) from the
front cover (Item 4) [Figure 20-100-9].
Installation: Tighten the plug (Item 1) [Figure 20-100-

9]to 35 N•m (26 ft-lb) torque.

Disassembly And Assembly (Single Speed Version)

2
(Standard) (Cont’d)
Figure 20-100-10 1
P-53279
1
Remove the front cover (Item 1) from the motor housing

(Item 2) [Figure 20-100-12].
P-53277
Figure 20-100-13

plug. Replace as needed.
Figure 20-100-11
1
1
1
P-53281
1 1
Remove the seal (Item 1) [Figure 20-100-13] from the
housing.
P-53278
Remove the four bolts (Item 1) [Figure 20-100-11] from

the front cover.
Assembly: Tighten bolts to 45 N•m (33 ft-lb) torque.

Disassembly And Assembly (Single Speed Version)

(Standard) (Cont’d)
Figure 20-100-14 2
2
1
1
P-53256
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-100-16].
P-53282
Assembly: The open part of the seal goes into the rear
cover first.
Remove the gear assembly (Item 1) from the motor

housing (Item 2) [Figure 20-100-14]. Figure 20-100-17
Figure 20-100-15
1
P-53285
P-53283
Inspect the gears (Item 1) [Figure 20-100-17] for
damage or wear.
Remove the back-up ring / seal (Item 1) [Figure 20-100-
15] from the gear holder.

Parts Identification (Variable Speed Version)
The variable speed fan motor is optional for this machine.

17
17 6
14
15
11
8
20

18
9
3
11
1 3
1. Seal 2
2. Back-up Ring
3. Plug
4. Solenoid 
(speed control) 3
5. Key
6. Valve (fan reverse)
7. Snap Ring
8. Motor Housing
9. Front Cover
10. Rear Cover
11. Pin
12. Holder 11
13. Gear
14. Bolt
15. Washer 10
16. Ball Bearing
17. Coil (fan reverse)
18. Connector 16
19. Nut
20. Relief /  15 12
Anticavitation 5 13
Check Valve
2 12
1
11
1
19 7 EM8951S

Disassembly And Assembly (Variable Speed Version)
IMPORTANT 1

damage the system.
I-2003-0888
S38804
Figure 20-100-18
Remove the fitting (Item 1) from the “IN” port and the
fitting (Item 2) [Figure 20-100-20] from the “OUT” port.
Assembly: Tighten the fittings to 44 - 45 N•m (32 - 33 ft-

lb) torque.
2

Figure 20-100-21
1
S38802
Remove the nut (Item 1) and speed control solenoid

(Item 2) [Figure 20-100-18].
Mark the housing for correct assembly.
Figure 20-100-19 S38805

“IN” port fitting.
2
S38803
Remove the two O-rings (Item 1) and the washer (Item 2)

[Figure 20-100-19].


(Cont’d)
Figure 20-100-22 1
S38808

fitting.
S38806
Figure 20-100-25

“OUT” port fitting.
Figure 20-100-23
S38809
Remove the speed control solenoid stem (Item 1)

[Figure 20-100-25] from the front cover.
1
S38807
Assembly: Tighten the solenoid stem to 30 N•m (22 ft-
lb) torque.
Remove the fitting (Item 1) [Figure 20-100-23].
Assembly: Tighten the fitting to 11 - 12 N•m (97 - 106 in-

lb) torque.


(Cont’d)
Figure 20-100-26
2
S38812
1 Remove six back-up rings (Item 1) and four O-rings (Item

2) [Figure 20-100-28].
S38810
Figure 20-100-29
Remove the back-up ring (Item 1) and two O-rings (Item

2) [Figure 20-100-26] from the speed control solenoid
stem. 1
Figure 20-100-27
1
1 1 S38813
Remove five plugs (Item 1) [Figure 20-100-29] from the

front cover.
S38811 Assembly: Tighten the plugs to 15 N•m (11 ft-lb) torque.
Remove the fan reverse solenoid stem (Item 1) [Figure

20-100-27] from the front cover.
Assembly: Tighten the solenoid stem to 30 N•m (22 ft-

lb) torque.


(Cont’d)
Figure 20-100-30
P128748

relief / anticavitation check valve.
S38814
Figure 20-100-33
Remove the O-rings (Item 1) [Figure 20-100-30] from the 2

plugs.
Figure 20-100-31
1 S38818
Remove the four bolts and washers (Item 1) and remove

the front cover (Item 2) [Figure 20-100-33].
S38815
Assembly: Tighten the bolts to 45 N•m (33 ft-lb) torque.
Remove the relief / anticavitation check valve (Item 1)

[Figure 20-100-31] from the front cover.
Assembly: Tighten the valve to 30 N•m (22 ft-lb) torque.


(Cont’d)
2
Figure 20-100-34
1
2
1
1
S38821
Remove the two pins (Item 1) and the seal (Item 2)

[Figure 20-100-36] from the motor housing.
S38819
Figure 20-100-37
Remove the two pins (Item 1) and the seal (Item 2)

1

[Figure 20-100-34] from the motor housing. 2
Figure 20-100-35
S38822
Remove the gear assembly (Item 1) from the motor

housing (Item 2) [Figure 20-100-37].
S38820
Remove the rear cover (Item 1) from the motor housing

(Item 2) [Figure 20-100-35].


(Cont’d)
Figure 20-100-38 2
1
1
S38825
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-100-40].
S38823
Assembly: The open part of the seal goes into the cover
first.

38] from the gear holder. Figure 20-100-41
Figure 20-100-39
1
S38826
S38824
Inspect the gears (Item 1) [Figure 20-100-41] for
damage or wear.
39] from the gear holder.

HYDRAULIC FLUID TANK Figure 20-110-3

1 3
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Remove the fuel tank. (See Removal And Installation on

Page 50-70-1.)
2
Drain the hydraulic fluid tank. (See Removing And
Replacing Hydraulic Fluid on Page 10-100-2.)
4
Figure 20-110-1
S38080
2
1 Loosen the hose clamps (Item 1) and remove the hose
(Item 2) [Figure 20-110-3] from the hydraulic fluid tank.
Remove the hose (Item 3) [Figure 20-110-3] from the

hydraulic fluid tank.
1

Disconnect the hydraulic fluid temperature sensor
connector (Item 4) [Figure 20-110-3] from the hydraulic
fluid tank.
S38105
Loosen the two bolts (Item 1) and remove the cover (Item
2) [Figure 20-110-1].
Figure 20-110-2
S38294

the hydraulic fluid tank.

HYDRAULIC FLUID TANK (CONT’D) Figure 20-110-6
Figure 20-110-4
S38292
2
Remove the two mounting bolts (Item 1) [Figure 20-110-
S38798 6] from the hydraulic fluid tank.
Figure 20-110-7
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 20-110-4].

Figure 20-110-5
S38293

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

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

STEERING UNIT

IMPORTANT
Installation on Page 50-110-1.) When repairing hydrostatic and hydraulic systems,
Figure 20-120-1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1 Figure 20-120-3
1
2 1
S38084

Remove the three bolts (Item 1) and remove the cover
cab. S39130
Figure 20-120-2
Remove the four bolts (Item 1) [Figure 20-120-3] and
remove the steering unit.
1
Installation: Tighten the bolts (Item 1) [Figure 20-120-3]
to 44 - 45 N•m (32 - 33 ft-lb) torque.
1
NOTE: The steering unit is not serviceable. If the
1 steering unit is damaged, the entire unit must
be replaced.
S38111
Remove the five hoses (Item 1) [Figure 20-120-2] from

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


MAIN 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
Hydraulic fluid leakage between Faulty seals Replace seal
main valve and solenoid valve

MAIN VALVE (CONT’D)
Valve Section Troubleshooting
Record the serial number of the machine, main valve and

control module.
The following procedure must be done with the main

valve in the machine. The main valve is removed for
photo clarity.
Figure 20-130-1

2
P122916
The joystick lockout function must be disabled (light (Item

1) [Figure 20-130-1] is OFF).
To disable, press the button (Item 2) [Figure 20-130-1] to

turn OFF for all testing procedures.
1. Press the information button (Item 3) to cycle the

display screen (Item 4) [Figure 20-130-1] until the
engine hours, machine speed or engine speed menu
is displayed. 

Press and hold the information button (Item 3)
[Figure 20-130-1] for three seconds until the Service
Codes appear on the display screen. 

When no service code is read, go to step 9. 

If more than one Service Code is present, the codes
will scroll on the display screen.

CODE FUNCTION REF
Valve Section Troubleshooting (Cont’d) W2707 Retract Output Open Circuit 6
W2732 Retract Output Overcurrent 6
2. Locate the valve section and solenoid valve to which
the service code refers [Figure 20-130-2]: D7705 Aux Male Output Short To Battery 7
D7706 Aux Male Output Short To Battery 7
Figure 20-130-2
D7707 Aux Male Output Open Circuit 7
8 D7732 Aux Male Output Overcurrent 7
7
D7605 Aux Female Output Short To Battery 8
6
D7606 Aux Female Output Short To Battery 8
5 4
D7607 Aux Female Output Open Circuit 8
3 2 D7632 Aux Female Output Overcurrent 8
1 3. Disconnect the solenoid valve of the valve which has

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

engine and run the engine at 900 rpm, then run at low
idle rpm. Operate the function which has been
S38679 diagnosed [Figure 20-130-3]. Move forward and
back to see if the function works. Stop the engine.

Figure 20-130-3
CODE FUNCTION REF 1

W2305 Lift Down Output Short To Battery 1 7
W2306 Lift Down Output Short To Ground 1 5
W2307 Lift Down Output Open Circuit 1 3
W2332 Lift Down Output Overcurrent 1

W2205 Lift Up Output Short To Battery 2 4
8
W2206 Lift Up Output Short To Ground 2 6
W2207 Lift Up Output Open Circuit 2
W2232 Lift Up Output Overcurrent 2
W2405 Tilt Out Output Short To Battery 3 2
P133312
W2406 Tilt Out Output Short To Ground 3
W2407 Tilt Out Output Open Circuit 3
W2432 Tilt Out Output Overcurrent 3 REF FUNCTION
W2505 Tilt Back Output Short To Battery 4 1 Lower Boom

W2506 Tilt Back Output Short To Ground 4 2 Raise Boom
W2507 Tilt Back Output Open Circuit 4 3 Tilt Down
W2532 Tilt Back Output Overcurrent 4 4 Tilt Up
W2605 Extend Output Short To Battery 5 5 Extend Telescopic Boom
W2606 Extend Output Short To Ground 5 6 Retract Telescopic Boom
W2607 Extend Output Open Circuit 5 7 Front Auxiliary Hydraulics B4 (Male Coupler)
W2632 Extend Output Overcurrent 5 8 Front Auxiliary Hydraulics A4 (Female Coupler)
W2705 Retract Output Short To Battery 6
W2706 Retract Output Short To Ground 6

MAIN VALVE (CONT’D) Figure 20-130-5
Valve Section Troubleshooting (Cont’d)
1
IMPORTANT
damage the system.
I-2003-0888
S39181
Figure 20-130-4
7. Use an ohmmeter to check the solenoid. The reading

between both electrical connector terminals must be
approximately 4,7 ohm at 20°C (68°F) (Item 1)
2 [Figure 20-130-5].
If the solenoid measurement is correct, the error could be

1

located in wiring / connectors to the solenoid.
8. Reinstall the solenoid valve.
S38678
5. Disconnect the solenoid valve connector (Item 1)

[Figure 20-130-4] which has been diagnosed (“Tilt
Back” solenoid valve shown in picture).
6. Remove the two screws (Item 2) [Figure 20-130-4]

and pull out the solenoid valve (“Tilt Back” solenoid
valve shown in picture).
NOTE: Install a cap on the valve opening to prevent

contamination.

MAIN VALVE (CONT’D) P-Standby Pressure Checking
Valve Section Troubleshooting (Cont’d) Figure 20-130-8
Pilot Pressure Checking

1
Figure 20-130-6
S39398
13. Locate the workgroup pressure test coupler (Item 1)

S39392 [Figure 20-130-8] and remove the cap.
14. Install a 7,0 MPa (70 bar) (1000 psi) test coupler /

9. Locate the hydrostatic charge pressure test coupler gauge assembly on the workgroup pressure test
(Item 1) [Figure 20-130-6] and remove the cap. coupler (Item 1) [Figure 20-130-8] located on the P-
port of the main valve.
Figure 20-130-7
15. Start the engine and run the engine at low idle (900
rpm) until hydraulic fluid temperature reaches
minimum 50°C (122°F). 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) test coupler /
gauge assembly on the hydrostatic charge pressure
test coupler [Figure 20-130-7].
11. Start the engine and run the engine at 2315 rpm until
hydraulic fluid temperature reaches minimum 50°C
(122°F). 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 test coupler / gauge assembly.

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 20-130-9]. Move forward and
1
back to see if the function works. Stop the engine.
Figure 20-130-9
1
7
5 S38678
3
18. Remove the two screws (Item 2) [Figure 20-130-10]

4 and pull out the solenoid valve (“Tilt Back” controller
8
6 shown in picture).
NOTE: Install a cap on the valve opening to prevent

dust penetration.

2
P133312 Figure 20-130-11
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 joystick or switch
(Item 1) [Figure 20-130-9]. The solenoid valve
piston, which can be seen through the valve orifices
(Item 1) [Figure 20-130-11] must be moving
according to the switch movement.
20. If a solenoid valve does not function properly, it must

be replaced.

Troubleshooting Chart (Main 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 Reset to original pressure
adjustment
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 Blockage of individual compensator Remove and clean orifice
controls 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 hydraulic fluid Defective spool seal Replace spool seal
Hydraulic fluid leakage between Defective seals Replace seals
valve section

Main Relief Valve Testing And Adjustment
The following tool will be needed to do the following

procedure:
7313982 - Hydraulic Tester
Figure 20-130-12
2
4 1
P122916
5
Start the engine and run at low idle rpm. Press the front
3 auxiliary hydraulics button (Item 1) [Figure 20-130-13].
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 50°C (122°F) by turning the restrictor
control (Item 5) [Figure 20-130-12] 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 20-130-12]. 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 20-130-12]. There should be 100 L/min (26.4 U.S. gpm) free flow.
Turn the restrictor control (Item 5) [Figure 20-130-12] on
NOTE: When testing the hydraulic flow of a machine, the tester until the main relief opens. The correct
hoses must be at least 19 mm (0.75 in) in pressure should be 25,5 MPa (255 bar) (3698 psi).
diameter and connected directly to the
hydraulic tester without using any type of If adjustment is needed, see [Figure 20-130-14].
quick coupler on the connection to the tester.
Also make sure your hydraulic tester is
capable of at least 190 L/min (50 U.S. gpm).
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

MAIN VALVE (CONT’D) Main Relief Valve Removal And Installation
Main Relief Valve Testing And Adjustment (Cont’d)
The Approved Boom Stop on Page 10-150-1.) IMPORTANT
Figure 20-130-14 When repairing hydrostatic and hydraulic systems,
1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 20-130-16
S39398

Locate the main relief valve (Item 1) on the front upper
side of the main valve [Figure 20-130-14].
Figure 20-130-15
S39398
2
Locate the main relief valve (Item 1) [Figure 20-130-16]
on the front upper side of the main valve.
1
Clean the area around the main valve.
Remove the main relief valve (Item 1) [Figure 20-130-

16].
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 20-130-15] clockwise to increase
the pressure or counterclockwise to decrease the
pressure.
Retest the main relief valve after adjustment.

MAIN VALVE (CONT’D) NOTE: Mark all hoses and harnesses for correct
installation.
Figure 20-130-18
Relieve hydraulic pressure.
2 3
WARNING
Hydraulic fluid escaping under pressure can have 1
sufficient force to enter a person’s body by 4
and possible death if proper medical treatment by a 5
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 20-130-18].
IMPORTANT

Repeat the above step for the bolt (Item 4) [Figure 20-
130-18].
clean the work area before disassembly and keep all Remove the bolt (Item 5) [Figure 20-130-18].
damage the system.
I-2003-0888
Figure 20-130-17
S38604
Remove the thirteen hoses from the main valve

[Figure 20-130-17].
Remove the nine electrical harnesses from the main

valve [Figure 20-130-17].

Figure 20-130-19
1
1
1
S38607
Remove the bolts (Item 1) [Figure 20-130-21].

S38607
Remove the main valve.
Loosen the nuts (Item 1) [Figure 20-130-19] in order to Use care not to damage the tubelines or fittings.
create a gap between the frame and main valve.

Figure 20-130-20
2
S38608
Install a hoist and lifting strap (Item 1) [Figure 20-130-

20] on the main valve.
NOTE: The wire harness (Item 2) [Figure 20-130-20]

which is located below the main 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

1. T2 plug 11. A1 Anti-cavitation / work port relief valve

2. L port 12. A2 Anti-cavitation / work port relief valve
3. T1 port 13. A3 Anti-cavitation / work port relief valve
4. CL plug 14. A4 Plug
5. T port 15. B1 Anti-cavitation / work port relief valve
6. Plug 16. B2 Anti-cavitation / work port relief valve
7. Main relief valve solenoid 17. B3 Anti-cavitation / work port relief valve
8. P port 18. B4 Plug
9. LS port 19. Boom cylinder base port
10. Main relief valve 20. Tilt cylinder base port
21. Telescoping / Extension cylinder base port
22. Auxiliary send port
23. Boom cylinder rod port
24. Tilt cylinder rod port
25. Telescoping / Extension cylinder rod port
26. Auxiliary return port

10
8 18
17
16 15
25 24 23
26
5
2
1 6
21 20
22 19
14 13 12 11
3
S38609
S38611

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
1
S38611
Mark the valve sections for ease of assembly. (See Parts
Identification on Page 20-130-12.)
Remove the three nuts (Item 1) [Figure 20-130-23] from
Figure 20-130-22 the tie rod bolts.
Assembly: Tighten the nuts to 50 N•m (37 ft-lb) torque.

S38610
Remove all hydraulic fittings. Mark the valve sections for

proper assembly [Figure 20-130-22].

Inlet-Outlet Valve Section Disassembly And

Assembly
Figure 20-130-24 2
1 S38614
Remove the valve stem (Item 1) [Figure 20-130-26] from

the inlet-outlet valve section.
S38612
Remove the main pressure relief valve (Item 2)
[Figure 20-130-26] from the inlet-outlet valve section.
Remove the inlet-outlet valve section (Item 1) [Figure 20-

130-24]. Figure 20-130-27
Figure 20-130-25
3
2
2
S38615
1
S38613
Remove the O-ring (Item 1), two back-up rings (Item 2)
and O-ring (Item 3) [Figure 20-130-27] from the safety
Remove the nut (Item 1) and safety valve stem solenoid valve stem.
(Item 2) [Figure 20-130-25] from the inlet-outlet valve
section.

MAIN VALVE (CONT’D) Lifting Valve Section Disassembly And Assembly
Inlet / Outlet Valve Section Disassembly And Figure 20-130-29

Assembly (Cont’d)
Figure 20-130-28
1
S38693
2
S38616 Remove the lifting valve section (Item 1) [Figure 20-130-

29].
Remove the O-ring (Item 1), back-up ring (Item 2) and O- Figure 20-130-30

ring (Item 3) [Figure 20-130-28] from the main pressure
relief valve.
S38694
Remove the seven O-rings (Item 1) [Figure 20-130-30]

from the valve section.

Lifting Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-130-31
1 1
1
S38697
Remove the two screws (Item 1) [Figure 20-130-33] from

1 the controller.
S38695
Remove the two solenoids (Item 2) [Figure 20-130-33]
from the controller.
Remove the screws (Item 1) [Figure 20-130-31] from the

valve section. Figure 20-130-34
Figure 20-130-32
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-130-34]
Remove the three O-rings (Item 1) [Figure 20-130-32]



(Cont’d)
Figure 20-130-35
S38701
Remove the O-ring (Item 1) [Figure 20-130-37].
S38698 Figure 20-130-38
Remove the spool (Item 1) [Figure 20-130-35].

Figure 20-130-36
1
S38702
1 1
S38700
Remove the three screws (Item 1) and remove the cover

(Item 2) [Figure 20-130-36].


(Cont’d)
Figure 20-130-39
1
1
S38705
The relief pressure value (in bar) of the anticavitation /

work port relief valve is indicated on the spool assembly
S38703 (Item 1) [Figure 20-130-41].
Repeat for the other side of the valve section.

Remove the plug (Item 1) [Figure 20-130-39].

Figure 20-130-42
Figure 20-130-40
3
S38705
S38704

Remove the anticavitation / work port relief spool
assembly (Item 1) and spring (Item 2) [Figure 20-130-
40].

plug.

MAIN VALVE (CONT’D) Tilting Valve Section Disassembly And Assembly
Lifting Valve Section Disassembly And Assembly Figure 20-130-44

(Cont’d)
Figure 20-130-43
1
1
2
3
S40001
S38719 Remove the tilting valve section (Item 1) [Figure 20-130-

44].
Remove the spring (Item 1) and flow compensator spools Figure 20-130-45

(Items 2 and 3) [Figure 20-130-43] from the valve
section.
S38694


Tilting Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-130-46
1 1
1
S38697

1 the controller.
S38695

Figure 20-130-47
1
1
S38691
S38696



(Cont’d)
Figure 20-130-50
S38701
S38698 Figure 20-130-53

Figure 20-130-51
1
S38702
1 1
S38700

(Item 2) [Figure 20-130-51].


(Cont’d)
Figure 20-130-54
1
1
S38705

S38703 (Item 1) [Figure 20-130-56].


Figure 20-130-57
Figure 20-130-55
3
S38705
S38704

55].

plug.

MAIN VALVE (CONT’D) Telescoping Valve Section Disassembly And
Assembly
(Cont’d) Figure 20-130-59
Figure 20-130-58
1
1
2
3
S40002
S38719
Remove the telescoping valve section (Item 1)
[Figure 20-130-59].
Remove the spring (Item 1) and flow compensator spools

(Items 2 and 3) [Figure 20-130-58] from the valve Figure 20-130-60
section.
S38694


Telescoping Valve Section Disassembly And

2
Assembly (Cont’d)
Figure 20-130-61
1 1
1
S38697

1 the controller.
S38695

Figure 20-130-62
1
1
S38691
S38696
Clean the filter screen (Item 2) [Figure 20-130-64].



Assembly (Cont’d)
Figure 20-130-65
S38701
Remove the O-ring (Item 1) (both sides) [Figure 20-130-

67].
S38698
Figure 20-130-68

Figure 20-130-66
S38702
1 1

S38700

(Item 2) [Figure 20-130-66].


Assembly (Cont’d)
Figure 20-130-69
1
1
S38705

S38703 (Item 1) [Figure 20-130-71].


Figure 20-130-72
Figure 20-130-70
3
S38705
S38704

70].

plug.

MAIN VALVE (CONT’D) Auxiliary Valve Section Disassembly And Assembly
Telescoping Valve Section Disassembly And Figure 20-130-74

Assembly (Cont’d)
1
Figure 20-130-73
1
2
3
S40003
S38719 Remove the auxiliary valve section (Item 1) [Figure 20-

130-74].
Remove the spring (Item 1) and flow compensator spools Figure 20-130-75

section.
S38694


Auxiliary Valve Section Disassembly And Assembly

2
(Cont’d)
Figure 20-130-76
1 1
1
S38697

1 the controller.
S38695

Figure 20-130-77
1
1
S38691
S38696



(Cont’d)
Figure 20-130-80
S38701
S38698 Figure 20-130-83

Figure 20-130-81
1
S38702
1 1
S38700

(Item 2) [Figure 20-130-81].


(Cont’d)
Figure 20-130-84
1 1
S38705
S38741 Figure 20-130-87
Remove the plug (Item 1) [Figure 20-130-84]. 1

2
Figure 20-130-85
3
4
1
1
2
S38719
Remove the spring (Item 1) and flow compensator spools

S38740 section.
Remove the O-rings (Item 4) [Figure 20-130-87] from

Remove the O-ring (Item 1) and back-up ring (Item 2) the plug.
[Figure 20-130-85] from the plug.

End Housing Disassembly And Assembly
Figure 20-130-88 1
S38744
1
1
Remove the plug (Item 1) [Figure 20-130-90] from the

S38742 valve section.
Figure 20-130-91
Remove the tie rods (Item 1) [Figure 20-130-88] from the
end housing.

1
Figure 20-130-89
S38745
1
S38743 plug.
Remove the nine O-rings (Item 1) [Figure 20-130-89]


End Housing Disassembly And Assembly (Cont’d)
Figure 20-130-92
S38747
Flip the end housing and remove the bleed valve (Item 1)
S38746 [Figure 20-130-94].
Figure 20-130-95

Figure 20-130-93
1 1
S38748
S38745 Remove the two O-rings (Item 1) [Figure 20-130-95].

plug.


PORT RELIEF VALVES Figure 20-140-2
Testing
6
5 4
IMPORTANT 3
2

clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
S38679
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat NOTE: The valve is shown removed from the
hydraulic fluid. machine for photo clarity.
Figure 20-140-1 Boom Port Relief set at:

Rod End (Item 1) [Figure 20-140-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]

Base End (Item 2) [Figure 20-140-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
Tilt Port Relief set at:

[275 - 300 bar] [3988 - 4351 psi]
Base End (Item 4) [Figure 20-140-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
Telescopic Boom Port Relief set at:

[275 - 300 bar] [3988 - 4351 psi]
S39247 Base End (Item 6) [Figure 20-140-2] 27,5 - 30,0 MPa
[275 - 300 bar] [3988 - 4351 psi]
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 20-140-1]. Pressurize this section with the hand
pump until the port relief valve opens and record the
pressure reading.
If the port relief pressure setting is too high / low, release

the hand pump pressure valve and replace the port relief
valve.

PORT RELIEF VALVES (CONT’D) Remove the O-ring (Item 3) [Figure 20-140-4] from the
plug.
Replacement Procedure
Figure 20-140-5
Figure 20-140-3
6 1
5 4
2
3
2
S38679 S38705
REF FUNCTION Replace the port relief valve spool (Item 1) [Figure 20-
140-5]
1 Lower Boom Port Relief Valve (Rod End)

2 Raise Boom Port Relief Valve (Base End) The relief pressure value (in bar) of the port relief valve is
3 Tilt Down Port Relief Valve (Rod End) indicated on the end of the assembly (Item 2) [Figure 20-
140-5].
4 Tilt Up Port Relief Valve (Base End)
5 Retract Telescopic Boom Port Relief Valve (Rod Figure 20-140-6
End)
6 Extend Telescopic Boom Port Relief Valve (Base
End)
1
Remove the port relief valve plug [Figure 20-140-3].
2
3
NOTE: The main valve is shown removed from the
machine for photo clarity.
Figure 20-140-4
2 S38749
1
Install the port relief valve spool (Item 1), spring (Item 2)
and the plug (Item 3) [Figure 20-140-6]
Tighten the plug (Item 3) [Figure 20-140-6] to 24 N•m

(18 ft-lb) torque.
3
S38749
Remove the spring (Item 1) and port relief valve

assembly (Item 2) [Figure 20-140-4] from the main
valve.

ACCUMULATORS Boom Suspension Valve Accumulator
Accumulators Pressure Relief Figure 20-150-2
WARNING
penetrating the skin. This can cause serious injury 1
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210
C201976
IMPORTANT Follow the steps below to release pressure from the

boom suspension valve accumulator (Item 1) [Figure 20-
150-2] (if equipped):

clean the work area before disassembly and keep all • At low idle, raise the boom and install the boom stop
parts clean. Always use caps and plugs on hoses, (See Installing The Approved Boom Stop on Page 10-
tubelines and ports to keep dirt out. Dirt can quickly 150-1.).
damage the system. • Lower the boom against the boom stop.
I-2003-0888 • Move the joystick fully forward for five seconds.
• Stop the engine.
Hydraulic Quick-Tach Accumulator
Figure 20-150-1
S42046
Follow the steps below to release pressure from the

hydraulic quick-tach accumulator (Item 1) [Figure 20-
150-1] (if equipped):
• Stop the engine.

• Wait for at least 1 minute to allow the accumulator to
discharge itself.


TRAILER BRAKE VALVE
The telescopic handler can be equipped with the trailer brake valve. The following procedure is valid for machines with 
S/N 16001 & Above.
Description
The trailer brake pressure is provided by the Control Line (CL)

Supplementary Line (SL) and the Control Line (CL).
Maximum pressure of 13 MPa (130 bar) (1885 PSI) at
Supplementary Line (SL) Control Line (CL) port [Figure 20-160-1] is given by the
brake valve springs and pilot line (they act as the
Supplementary Line (SL) Valve [Figure 20-160-1] is pressure reducer). If only the control line is connected,
supplied as soon as the park brake is disengaged. This there is a mechanical connection in the valve that
supply is managed by the drive controller based on the increases the maximum pressure in the control line to 14
pressure read by the sensor in the park brake line. - 15 MPa (140-150 bar) (2030 - 2176 PSI).
Basically, the valve is supplied with the same pressure
threshold used for the park brake light on the dashboard. Inching triggers the trailer brake, because below 15%
inching, the service brake is not activated. Therefore
there is no pressure generated on the CL Trailer Brake
Port [Figure 20-160-1] while the machine brakes using
the hydrostatic transmission only. In this situation there is
a risk of having a bad behavior of the trailer (wallet
position). As a reference, CL is activated as soon as the

brake lights are ON.
Figure 20-160-1
Trailer Brake Valve
Safety Valve
SL Valve
CL Valve
Brake Valve
To Main Valve To Service From Workgroup To Fan Pump

LS Port Brake Valve Pump CF Port NA15204

TRAILER BRAKE VALVE (CONT’D) Figure 20-160-4

1
Figure 20-160-2
P125594
1
Remove the tie straps (Item 1) [Figure 20-160-4] from
P125592 the hoses.
Figure 20-160-5
Disconnect the four connectors (Item 1) [Figure 20-160-
2] on top of the trailer brake valve.

Figure 20-160-3
P125595
Mark and disconnect the three hoses (Item 1)

P125593 [Figure 20-160-5].
Disconnect the connector (Item 1) [Figure 20-160-3]

from the bottom of the trailer brake valve.


1
Figure 20-160-6
3 2
P133684
Remove the cap (Item 1) [Figure 20-160-8] from the

P125596 coupler.
Remove the two bolts (Item 2) [Figure 20-160-8].

Mark and disconnect the hose (Item 1) [Figure 20-160-
6]. Assembly: Tighten the bolts to 24 N•m (18 ft-lb) torque.

Figure 20-160-7 Remove the plate (Item 3) [Figure 20-160-8] from the
trailer brake valve.
P133682
Loosen the bolt (Item 1) [Figure 20-160-7].
Lift the trailer brake valve assembly (Item 3) up and over

the bolt (Item 1) [Figure 20-160-7] and pull out the
assembly.

Figure 20-160-9
1
3
P125600
2 Remove the hydraulic coupler (Item 1) [Figure 20-160-

1 10].
P133685
Figure 20-160-11
Remove the four hoses from the trailer brake valve
[Figure 20-160-9].

Remove the Y and LS port fittings (Item 1) [Figure 20-
160-9].
2
Assembly: Tighten the fitting to maximum 30 N•m (22 ft-
lb) torque.
Remove the P port fitting (Item 2) [Figure 20-160-9].

1
Assembly: Tighten the fitting to maximum 110 N•m (81
ft-lb) torque. 1
2
Remove the T port fitting (Item 3) [Figure 20-160-9]. P125601
Assembly: Tighten the fitting to maximum 55 N•m (41 ft-

lb) torque. Remove the two nuts (Item 1) and coils (Item 2)
[Figure 20-160-11].
Assembly: Tighten the nuts to maximum 6 N•m (53 in-lb)

torque.

TRAILER BRAKE VALVE (CONT’D)
Figure 20-160-12
1
P125602
Remove the two solenoid valves (Item 1) [Figure 20-160-

11].

Assembly: Tighten the valves to maximum 27 N•m (20
ft-lb) torque.


BOOM SUSPENSION AND FLOAT SYSTEM
Boom Suspension Functional Description
Figure 20-170-1
2
1

4
3
C201975
The Auxiliary controller (Item 1) manages all components used for the boom suspension function through CAN Bus
(Item 2). The boom suspension functions works independently from the stability system. When the boom suspension is
active, the boom suspension valve (Item 3), and the drain valve (Item 4) [Figure 20-170-2] are supplied with 12V.
The boom suspension valve allow the communication between the base side of the boom cylinder and the accumulators.
The drain valve allows the hydraulic fluid to flow both ways between the boom cylinder rod side and the tank to authorize
displacement of the boom cylinder piston.
The float valve (if equipped) is not energized. When the suspension is active, the suspension light indicator on the
dashboard is ON. The boom float cannot be activated. The suspension will automatically deactivate if:
• machine speed < 4 km/h (2.5 mph) (only valid for machine equipped with speed sensor)
• boom angle < -0.7° (machine with 20" tires)
• boom angle < -2° (machine with 24" tires)
TL35.70(X) Service Manual

237 of 836 20-170-1 Service Manual
BOOM SUSPENSION AND FLOAT SYSTEM (CONT'D)
Boom Float Functional Description
Figure 20-170-2
2 1

5
NA15844
The Auxiliary controller (Item 1) manages all components used for the boom float function through CAN Bus (Item 2). It
collects boom angle from the Workgroup controller (Item 3) and stability level from the LLMI / LLMC (Item 4). The Auxiliary
controller then sends the disabling of the boom lift down valve (Item 5) to the Workgroup controller and the float icon status
to the Display Controller (Item 6) [Figure 20-170-2].
NOTE: The boom float function cannot be activated if the instability level given by the LLMS is above 66%.

Boom Float Functional Description (Cont’d)
Boom Lowering
Figure 20-170-3 1. Float Valve - When activated, hydraulic fluid from

boom and self-leveling cylinder (base side) is linked to
tank.
2. Check Valve - Prevents hydraulic fluid from boom

cylinder to go to self-leveling line. Allows fluid from
self-leveling cylinder to be linked to tank when float
mode is activated.
3. Check Valve - Prevents hydraulic fluid from self-

leveling cylinder to go to boom line.
4. Orifice - Controls maximum lowering speed.
When the boom lowers, hydraulic fluid from the base side
NA15847 of boom and self-leveling cylinder is drained to tank.

Figure 20-170-4
BOOM CYLINDER
SELF LEVELING
ON 4 CYLINDER TILT CYLINDER
ON
2
ON
LIFT
DOWN
NA18146

Boom Float Functional Description (Cont’d)
Boom Raising 1. Float Valve - When activated, hydraulic fluid from

boom and self-leveling cylinder (base side) is linked to
Figure 20-170-5 tank.
2. Check Valve - Prevents hydraulic fluid from boom

cylinder to go to self-leveling line. Allows hydraulic
fluid from self-leveling cylinder to be linked to tank
when float mode is activated.
3. Check Valve - Prevents hydraulic fluid from self-

leveling cylinder to go to boom line.
4. Orifice - Controls maximum lowering speed.
When the boom is raising, hydraulic fluid from the rod

side of the boom cylinder is drained to tank.
NA15846 Hydraulic fluid from the rod side of the self-leveling

cylinder is linked to the rod side of the tilt cylinder and tilts
the attachment carrier up.

Figure 20-170-6
BOOM CYLINDER
SELF LEVELING
4 CYLINDER TILT CYLINDER
ON
3 2
ON
ON
LIFT
DOWN
NA15845

BOOM SUSPENSION AND FLOAT SYSTEM (CONT'D) Figure 20-170-9
Removing And Installing The Boom Suspension

Valve
Figure 20-170-7
2
S38852

[Figure 20-170-9].
P133560
Figure 20-170-10
Raise the boom and install on adequate stands
[Figure 20-170-7].

Figure 20-170-8
1 2
1
S38853

(Item 2) [Figure 20-170-10].
S38851
Slowly loosen the cinch strap (Item 1) [Figure 20-170-9]

Position a wooden block (Item 1) [Figure 20-170-8] and lower the boom cylinder onto a block.
under the boom and self leveling (compensation)
cylinders.

BOOM SUSPENSION AND FLOAT SYSTEM (CONT'D) If needed, tighten the set screw lock nut (Item 4)
[Figure 20-170-12] on the load holding valve to 10 N•m
Removing And Installing The Boom Suspension (7.4 ft-lb) torque.
Valve (Cont'd)
Figure 20-170-11
1 WARNING
3 PRESSURIZED FLUID CAN CAUSE
Always release hydraulic pressure from accumulator
3 before service.
W-2984-1113
1 2
IMPORTANT
P119214
Remove the three hoses (Item 1), tubeline (Item 2) and parts clean. Always use caps and plugs on hoses,

two solenoids (Item 3) [Figure 20-170-11] from the boom tubelines and ports to keep dirt out. Dirt can quickly
suspension valve on the boom cylinder. damage the system.
I-2003-0888
NOTE: Mark all hoses and solenoids for correct
installation.
Figure 20-170-12
2 1
4
P145538
Remove the four bolts (Item 1) and the boom suspension

valve (Item 2) [Figure 20-170-12] from the boom
cylinder.
Installation: Tighten the bolts to 30 N•m (22 ft-lb) torque.
If needed, remove the load holding valve (Item 3)

[Figure 20-170-12].
Installation: Tighten the load holding valve to 45 N•m

(33 ft-lb) torque.

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

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Test Coupler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-3
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
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
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
MULTIFUNCTION VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1


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) Figure 30-10-1
Replenishing Valve Function
IMPORTANT
Valve Moves For
damage the system. Function 1
I-2003-0888 Charge Oil
Replacement

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2 B-2804
The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the 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].

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Test Coupler Location
Figure 30-10-2
S39392
The hydrostatic charge pressure test coupler (Item 1) is

located below the fan (Item 2) [Figure 30-10-2].

Figure 30-10-3
2 S39398
The workgroup pressure test coupler (Item 1) is located

on the main valve (Item 2) [Figure 30-10-3].


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

Hydraulic Oil Cooler / Intercooler / Radiator Removal And


HYDROSTATIC DRIVE MOTOR Figure 30-30-3
Remove the engine bay assembly. (See Removal And 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 -
Remove the hose (Item 1) [Figure 30-30-1] from the 210 N•m (140 - 155 ft-lb) torque.
hydrostatic drive motor.
Remove the hydrostatic drive motor from the gearbox
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)
22
23
21
24
20
3 4
18
3
20 18
22 3
23
21
24 1 25
3 14
2
3 4
4 3
4
24 4 3

3 18
13 3 4
25
3 14 26 3
12 4 1
16 6
14
4 5
3
4 3 11
17 5 10
14 19
1. Housing
2. Adjuster 4 3
3. O-ring 3
4. Plug 4
5. Pin 4
6. Gasket 3
7. Shaft 18
8. Cylinder Block
9. Bearing Plate 3 26
3 4
10. Lip Seal 17
11. Retaining Ring 15 22
12. Piston Control
13. Servo Piston Seal
14. Spring 18
15. End Cap
16. Spool 7
17. Valve
18. Screw
19. Socket 27
20. Solenoid
21. Coil 7
22. Cap
23. Ring
24. Seal 8
25. Valve Spool
26. Nut 9
27. Piston Ring NA12516S

HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-7
Disassembly
Clean the outside of the drive motor before disassembly.
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
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
Remove the plug (Item 1) [Figure 30-30-15] from the

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] inward. 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.

1
Figure 30-30-48
P-22462
Inspect the cylinder block assembly for wear or damage.

P-22508 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.
Remove the piston rings (Item 1) [Figure 30-30-48] from
the pistons. If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.
NOTE: If any portion of the shaft assembly, bearings
or races must be replaced, the complete
shaft / bearing assembly must be replaced.
The only serviceable part is the piston rings
(Item 1) [Figure 30-30-48].
Inspection
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of
material can get into the system and cause damage.
Figure 30-30-49
2
1
P-22461
Inspect the running (bronze) surface of the bearing plate

(Item 1) and locating pin holes (Item 2) [Figure 30-30-49]
for wear. Replace if damaged or worn.

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

Using a clamp, compress the spring and spring seat
Inspect all parts for wear or damage. Replace any worn
[Figure 30-30-55].
or damaged parts.
Figure 30-30-56

Figure 30-30-54
1 1
2
P-22441
Install the pin (Item 1) [Figure 30-30-56] as shown.

P-22447
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
1 Press the piston / shaft assembly into the housing

[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 fluid.
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 (80 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 tandem gear pump. (See Removal And
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
clean the work area before disassembly and keep all S38626

Remove the hose (Item 1) [Figure 30-40-3].
damage the system.
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: Apply Loctite® #2701 to the threads and

tighten the bolts (Item 1) [Figure 30-40-4] to 139 -
140 N•m (102 - 103 ft-lb) torque.
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

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.

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.


1
Figure 30-40-37
1
1
S38657
Remove the gasket (Item 1) [Figure 30-40-39] from the

S38655 pump housing.
Remove the two swash plate bearings (Item 1)

[Figure 30-40-37] from the swash plate.

Solenoid Block Disassembly
Figure 30-40-38
1 1
S38656
Remove the six screws (Item 1) [Figure 30-40-38] from

the solenoid block.

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

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 ft-lb) torque.
Figure 30-40-64 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 3 N•m (22 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 14 N•m (10 ft-lb) torque.
Install the three screws (Item 1) [Figure 30-40-78] for

each solenoid. Tighten to 5 N•m (44 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].


CHARGE PRESSURE Testing And Adjusting
Description
Charge pressure is a supply of fluid to the hydrostatic

pump. Charge pressure is regulated by a charge relief
WARNING
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed Hydraulic fluid escaping under pressure can have
from the drive circuit, pump and motor “internal leakage” sufficient force to enter a person’s body by
and from the hydrostatic motor flushing valve. penetrating the skin. This can cause serious injury
Figure 30-50-1 physician familiar with this injury is not received
immediately.
W-2145-0290
1
Figure 30-50-3
2

1
P131007
Remove the two bolts (Item 1) and remove the front

engine cover (Item 2) [Figure 30-50-1]. P131131
Start the engine. Turn the wheels all the way to the left.
Stop the engine. Install a 6895 kPa (69 bar) (1000 psi) test coupler / gauge
assembly (Item 1) [Figure 30-50-3] on the test port.
Figure 30-50-2
Start the engine and warm the hydraulic fluid to a
minimum of 60°C (140°F).
Charge pressure at high idle with the hydraulic fluid at

operating temperature is 3000 kPa (30 bar) (435 psi).
P131132
The charge pressure relief valve (Item 1) [Figure 30-50-

2] is located on the hydrostatic pump.

CHARGE PRESSURE (CONT’D)
Testing And Adjusting (Cont’d)
Figure 30-50-4
P131130
Loosen the locknut (Item 1) and turn the adjustment

screw (Item 2) [Figure 30-50-4] clockwise to increase

pressure and counterclockwise to decrease pressure.
NOTE: 1/2 turn is a approximately 138 kPa (1,4 bar)

(20 psi).
Tighten the locknut (Item 1) [Figure 30-50-4] after the

correct charge pressure of 3000 kPa (30 bar) (435 psi) is
reached.

MULTIFUNCTION VALVES Testing
Description
Figure 30-60-1
IMPORTANT
I-2003-0888
Start the engine and raise the boom.
Install the Approved Boom Stop. (See Installing The

Approved Boom Stop on Page 10-150-1.)
S39399 Place the machine onto stands. (See LIFTING AND

BLOCKING THE TELESCOPIC HANDLER on Page 10-
10-1.)
The multifunction valves (Item 1) [Figure 30-60-1]
provide high pressure relief functions for the forward and
Figure 30-60-2

reverse travel circuits. The valves are also used to
disengage the hydrostatic pump so the machine may be
towed. (See TOWING THE TELESCOPIC HANDLER on
Page 10-40-1.)
P129978
Remove bolts (Item 1) and cover (Item 2) [Figure 30-60-

2].

MULTIFUNCTION VALVES (CONT’D) Figure 30-60-5
Testing (Cont’d)
Figure 30-60-3
P131156
1 Figure 30-60-6
P131195
Remove and plug the hose (Item 1) [Figure 30-60-3]

from the park brake port on the collector block.

Figure 30-60-4
2
1 P131163
Remove the plug on the top (Item 1) [Figure 30-60-5]

and bottom (Item 1) [Figure 30-60-6] of the hydrostatic
pump.
P131007
Remove the bolts (Item 1) and the front access cover

(Item 2) [Figure 30-60-4].

MULTIFUNCTION VALVES (CONT’D) Figure 30-60-9
Testing (Cont’d)
Figure 30-60-7
2
1
1
P131164
Route both hoses out the front of the machine.

P131158
Install 68948 kPa (689 bar) (10000 psi) gauges (Item 1)
[Figure 30-60-9] on both hoses.
Figure 30-60-8
Figure 30-60-10

1
2
P131159
P131165
Install a male fitting (Item 1) [Figure 30-60-7] and

[Figure 30-60-8] into the ports of the hydrostatic pump. Start the engine and engage the forward drive.
Install the hoses (Item 2) [Figure 30-60-7] and [Figure Record the pressure on the top gauge for the forward
30-60-8] onto the fittings. relief valve (Item 1) [Figure 30-60-10].
Press the accelerator pedal to obtain full engine rpm.
Relief pressure at high idle with the hydraulic fluid at a

minimum of 60°C (140°F) will be 45505 - 46884 kPa (455
- 469 bar) (6600 - 6800 psi).
NOTE: The reliefs are non-adjustable and factory set

at 42009 kPa (420 bar) (6092 psi). Due to
system back pressure the reliefs will read
45505 - 46884 kPa (445 - 469 bar) (6600 - 6900
psi).

MULTIFUNCTION VALVES (CONT’D)
Testing (Cont’d)
Figure 30-60-11
P131165
Start the engine and engage the reverse drive.

Record the pressure on the bottom gauge for the reverse
relief valve (Item 1) [Figure 30-60-11].
Press the accelerator pedal to obtain full engine rpm.
Relief pressure at high idle with the hydraulic fluid at a

minimum of 60°C (140°F) will be 45505 - 46884 kPa (455
- 469 bar) (6600 - 6800 psi).
NOTE: The reliefs are non-adjustable and factory set

at 42009 kPa (420 bar) (6092 psi). Due to
system back pressure the reliefs will read
45505 - 46884 kPa (445 - 469 bar) (6600 - 6900
psi).

DRIVE SYSTEM
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-10
Brake Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Differential And Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-16
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-17
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-22
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-25
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-33
Brake Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-39
Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-42

Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-44
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-47
AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Differential And Pinion Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-16
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-19
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-27
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-33
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-36
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Brake Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-2
Brake Cylinder Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-2
Brake Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
Brake Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-12
GEARBOX SHIFTING CONTROL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-6

DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Rear Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Front Driveshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1


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)
Description
For photo clarity, the following axle procedures are done with the complete axle assembly removed from the machine.
However, the planetary carrier, wheel hub, steering knuckle and drive axle procedures can be done with the axle assembly
installed in the machine. For complete axle repair, the following must be done:
• Front Axle Removal (See Removal And Installation on Page 40-30-1.)

• Front Steering Cylinder Removal. (See Removal on Page 20-60-1.)
For more information about the tools used in this chapter, (See Special Drive Tools on Page SPEC-70-4.)
Planetary Carrier And Drive Axle Parts Identification
6 17 1. Seal
6
2 2. Bearing
1
16 3. Wheel Stud
5 21 4. Wheel Hub

5. O-ring
17 6. Snap Ring
22
7. Ring Gear
22 8. Ring Gear Support

1
18 19 9. Locking Plate
20 10. Planet Gear
11. Nut
1
12. Plug
2 4
13. Countersunk Bolt
14. Planet Gear Carrier
5
15. Stud
16. Reduction Bushing
3 17. Drive Axle
18. Thrust Bushing
2
19. Steering Case (Right)
6
7 20. Steering Case (Left)
6 21. Universal Joint
8 10
23 22. Repair Kit
9 23. Bearing Axle
13
5
15
12
11 14 NA16348S
11

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 alternately 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 hub 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 Parts Identification
4
2
7
21
4
6 1. Lock Ring
1
13
2. Jam Nut
3. Seal
4. Tie Rod End
5. O-ring
6. Lock Nut
9
7. Cotter Pin
8. Wheel Positioning
Sensor
9. Screw

8
10. Plug
11. Pivot Pin
12. Grease Fitting
13. Steering Cylinder
4 14. Shim
15. Bushing
2 16 16. Nut
18 17. Washer
22 11 18. Stud
10 19. Steering Case (Right)
12 14
20. Steering Case (Left)
3 21. Bolt
15
1
19
18 20
16
6
7
15
3
11
12
21 10 NA16349S

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 Group Parts Identification
1. Oil-level Plug
7 2. O-ring
10
3. Arm
11
7 4. Screw
5. Washer
6. Plug
9 7. Brake Disc
8 8. Disc Spring
9. Piston
6
2 10. Adjusting Bolt
6 4 11. Spring Piston
2

4
NA16346S

Brake Group Disassembly
Figure 40-20-30
1
1
S37106
Remove the tie rod from the steering case (See Removal
S37103 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
T1
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
[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 Group Disassembly (Cont’d)
Figure 40-20-34
2 1
2
1
S37110
Remove the return springs (Item 1) from the piston

1 S37108 (Item 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 Group Assembly (Cont’d) on Page
switching their position. 40-20-40.)
Extract the drive axle (Item 2) [Figure 40-20-35] (See

Steering Knuckle Disassembly on Page 40-20-8.) and
(See Drive Axle Disassembly on Page 40-20-10.).

Brake Group 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 And Pinion Group Parts Identification
3
4
1
4 7 10
13
18 7 3
1
19
5
9
21 20
1
6
14
2 8
10. Crown Gear

13

11. Disc
17
15 12. Planetary Gear
11 16 13. Differential Carrier
17
12 16 14. Flange
15. Gear Shaft
1. Ring Nut
16 12 16. Planet Wheel Gear
2. Flange Nut
17 17. Thrust Washer
3. Set Screw
4 18. Pinion
4. Bolt
16 19. Internal Bearing
5. Shim Washer
11 20. Shim
6. Seal 17
21. External Bearing
7. Taper Roller Bearing
15 13
8. O-ring
9. Spacer
NA16333S

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).
NOTE: Heating is meant to loosen the Loctite® on the

nut.
WARNING
AVOID BURN INJURY
Parts may be hot, use gloves when handling parts.
W-2762-1108

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 crown 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 crown 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].

Differential Disassembly (Cont’d) T16A

T15
Figure 40-20-51
T14
2 1 2
1
S1422
Remove the press tool T16A and guide bushing T15

S1419 [Figure 40-20-53].
NOTE: In this condition the tool contains the pin.

Insert tool T14 between two planet wheel gears (Item 1)
[Figure 40-20-51]. Figure 40-20-54

NOTE: Make sure that tool T14 is perfectly lined up
with the pins (Item 2) [Figure 40-20-51] when
locked.
Figure 40-20-52
T16A
T15
T16A
1
1
T15 S1423
Remove tool T14 together with the pin (Item 1) [Figure

40-20-54] of the planet wheel gear.
S1421
Place the differential carrier (Item 1) under a press,

position a guide bushing T15 and insert press tool T16A
(Item 3) [Figure 40-20-52]. Press the pin of the upper
planet wheel gear into tool T14 [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 tool T14.

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 tool T14 and remove the planet wheel gears

(Item 1) and any shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-20-56].

Pinion Group 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.
If needed, heat the nut (Item 1) of the flange (Item 2)

[Figure 40-20-57] at 80°C (176°F).

nut.
WARNING
AVOID BURN INJURY
W-2762-1108
Figure 40-20-58
T20A
S37164
Position tool T20A (or T20B), to avoid pinion rotation.

Remove the nut and O-ring (Item 2) [Figure 40-20-58].

Pinion Group Disassembly (Cont’d)
Figure 40-20-60
T23
S37169
Install blocks T23 and, with a puller, push the pinion

S37167 (Item 1) [Figure 40-20-62] inwards with internal bearing,
spacer and shims.
Remove the seal (Item 1) [Figure 40-20-60]. NOTE: The thrust blocks of the bearings remain in
the central body (Item 2) [Figure 40-20-62].

Figure 40-20-61
Figure 40-20-63
T21 1
3
T22
S37168
S37170
Position wrench T22 onto the ring nut and use T21 to
hold the pinion. When loose, hold wrench T22 [Figure Remove the pinion (Item 1), shims (Item 2) and spacer
40-20-61] and rotate the pinion to remove the ring nut. (Item 3) [Figure 40-20-63].
NOTE: If needed, heat the ring nut at approximately

80°C (176°F).
WARNING
AVOID BURN INJURY
W-2762-1108

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].

Pinion Group 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]) [Figure 40-20-67].

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.

Pinion Group Assembly (Cont’d)
Figure 40-20-71 T26A
GB
GB
S1575
Install a depth gauge with long stem into bar T26A

[Figure 40-20-73]; when the bar rests on two gauge
S37178 blocks “GB” of 57 mm (2.24 in) size, reset the indicator.
Preset the indicator to approximately 2 mm (0.08 in). and

Connect the tension rod to the press and move the thrust
zero again.
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.
T26C
Figure 40-20-72
T24
T26C T26B
1
T26A S37181
Place bar T26A on gauged nut T26C [Figure 40-20-74]

and measure the size “A” at about 57 mm (2.24 in)
corresponding to the maximum diameter of arms
S37179 centering.
See [Figure 40-20-75] for a sectional view.

Insert tool T26B complete with external bearing (Item 1),
measurement ring T24 and gauged ring nut T26C
[Figure 40-20-72]. Tighten manually.

Figure 40-20-75
T24 T26B
T26C
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
T26C
1 2 T26B
S37186
1
2 Position tools T26C and T26B complete with tapered

S37184 bearings (Item 1) and (Item 2) [Figure 40-20-81].
Manually tighten until a rolling torque has been obtained.

Insert shim "S" (Item 1) and the thrust block of the
internal bearing (Item 2) [Figure 40-20-79] in the central Figure 40-20-82

body.
NOTE: To hold shim "S" (Item 1) [Figure 40-20-79] in T26C

position, apply grease.
Figure 40-20-80
T25A
S37187
Insert the stem of a depth micrometer in either side hole

T25C
of tool T26C [Figure 40-20-82]. Zero the micrometer with
a presetting of approximately 3 mm (0.118 in).
S37185
Position tool T25A and tension rod T25C [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.

Pinion Group Assembly (Cont’d) S1

Figure 40-20-83
T26C
2 1 3
T26B
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” [Figure 40-20-85] which will be inserted
between the external bearing (Item 3) and the spacer
Remove the micrometer and release tools and bearings (Item 1) [Figure 40-20-83] and subsequently, to
from the central body. determine the preload for the bearings.

Reinstall 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
T26C 2
T26B 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-
20-82].

Figure 40-20-87
1
S1
1
2 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" and spacer (Item 2) Figure 40-20-90
[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
Pinion Group 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 in-lb) in the torque
of the pinion.
Figure 40-20-93
T21
T22 S37196
Apply special wrench T22 to the ring nut and bar-hold

T21 [Figure 40-20-91] to the pinion. Lock the wrench 2
T27

T22 and rotate the pinion using a torque wrench, up to a
minimum required torque setting of 500 N•m (369 ft-lb).
S37198
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
[Figure 40-20-93].
Figure 40-20-94
T21
1 2
S37197
Use the bar-hold T21 [Figure 40-20-92] and a torque

meter to check the pinion torque. Torque: 1,2 - 1,7 N•m
(11 - 15 in-lb).
S37200
NOTE: If torque exceeds the maximum value, then

the size of shim "S1" between the bearing and Install the flange (Item 1) complete with the guard
the spacer needs to be increased. If torque (Item 2) and secure it. For keying the flange (Item 1)
does not reach the set value, increase the [Figure 40-20-94], use a plastic hammer if necessary.
torque setting of the ring nut in different
stages to obtain a maximum value of 570 N•m NOTE: Make sure that the guard (Item 2) [Figure 40-
(420 ft-lb). 20-94] is secured onto the flange and that it is
not deformed.

Figure 40-20-95
T20A
S37201
Apply Loctite® #243 to the threaded part of the pinion.

Position tool T20A (or T20B) [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 (207 - 229 ft-lb) torque.
Figure 40-20-96
T23
S37202
Remove blocks T23 [Figure 40-20-96] (used for

extracting the pinion).

Differential Assembly
1
Figure 40-20-97
2
2
S1534
With the help of another bar, position the second planet

S1532 wheel 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
T16C
1
T16C
S1535
Insert tool T14 between the two planetary gears and line
S1533 up the entire unit by pushing tool T16C [Figure 40-20-
100] all the way through until the other is ejected.
Position the thrust washer (Item 1) and the first planet

wheel gear (Item 2). Temporarily hold them in position
using tool T16C [Figure 40-20-98].

Differential Assembly (Cont’d)

1
T15
Figure 40-20-101
T14
1
1
S40983
Place the differential carrier under the press, position

S1536 guide bushing T15 and insert the planet wheel pin
(Item 1) [Figure 40-20-103].
Lock tool T14 behind the planet wheel gears Figure 40-20-104
(Item 1) [Figure 40-20-101]. Then remove tool T16C.

Figure 40-20-102
2 T16B
1
S1539
S1537 Put a press tool T16B 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].

Figure 40-20-105
1
S1542
1
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 crown gear

S1541 (Item 2) [Figure 40-20-108].
NOTE: In order to hold the thrust washer in position,

Remove the press tool T16B, guide bushing T15 and apply grease to it.
install the snap ring (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 pins.

Figure 40-20-109
1
3
1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races (Item 1) [Figure 40-20-111] in the central body
and in the middle cover.
Position the crown 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 crown gear, so as to increase
S38866 pinion torque up to 1,4 - 2,1 N•m (12 - 19 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 24 - 26 N•m (18 - 20 ft-lb) torque.
Figure 40-20-116
Figure 40-20-114
1
A
T13
S1551
S38864
Install a dial indicator with rotary key “A” through the top
NOTE: If the ring nuts [Figure 40-20-114] are plug hole (Item 1). Position the indicator on the center of
removed, apply some Loctite® #243 to them. one of the teeth of the crown gear (Item 2) [Figure 40-
Tighten ring nut on the crown gear side until 20-116] and pre-set it to 1 mm (0.039 in) and reset it.
clearance between pinion and crown gear is
zero. Lock the crown gear. Turn the ring nut
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 crown gear (Item 1) [Figure 40-20- Tighten the bolts to 24 - 26 N•m (18 - 19 ft-lb) torque.
117] in both directions in order to check the existing
backlash between the pinion and the crown gear. Install the plug in the hole (Item 1) [Figure 40-20-45]

after applying flexible gasket compound for seals to the
Figure 40-20-118 rims.
T13
S38864
Adjust the backlash between the pinion and the crown

gear 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 Group 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 Group 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 - 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 Group Assembly (Cont’d)
Figure 40-20-128
T2
S37121
Check the flatness of the arms using tool T2 [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
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

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
3 UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 oriented as shown in the inset. Lubricate the pivot area
(Item 2) and the seal (Item 1). Install the bottom tie rod
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
oriented as shown in the inset. Lubricate the pivot area cross tightening method, to 140 N•m (103 ft-lb) torque.
(Item 2) and the seal (Item 1). Install the upper tie rod

and shims (Item 3) [Figure 40-20-139], four studs, four Check for the correct assembly side of the seal
washers and four nuts. (Studs, washers and nuts not (Item 1) [Figure 40-20-141].
shown in photo.) Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-20-142
Check the correct assembly side of the seal
(Item 1) [Figure 40-20-139].
Figure 40-20-140
S2568
Install a magnetic based dial indicator on the steering

S38375 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-
Lubricate the group with grease and mount it in the 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
2
3
T10
S1456
1
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the ring gear (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 ring gear (Item 1) into the cover (Item 2) [Figure 40-20-151].
(Item 2) [Figure 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 ring gear 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 alternately 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 ring gear flange (Item 2)
[Figure 40-20-156].
Install the locking plate (Item 1) [Figure 40-20-156].

Figure 40-20-159
2
3
1
S2465A
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.
Figure 40-20-160
S2648
Lock the planetary carrier cover (Item 1) by tightening the

bolts (Item 2) [Figure 40-20-160]. Tighten the bolts to 40
- 50 N•m (30 - 37 ft-lb) torque.


AXLE AND DIFFERENTIAL (REAR)
General Information
For photo clarity, the following axle procedures are done with the complete axle assembly removed from the machine.
However, the planetary carrier, wheel hub, steering knuckle and drive axle procedures can be done with the axle assembly
installed in the machine. For complete axle repair, the following must be done:
• Rear Axle Removal (See Removal And Installation on Page 40-110-1.)

• Rear Steering Cylinder Removal (See Removal on Page 20-60-1.)
For more information about the tools used in this chapter, (See Special Drive Tools on Page SPEC-70-4.)
Planetary Carrier And Drive Axle Parts Identification
6 17 1. Seal
6
2 2. Bearing
1
16 3. Wheel Stud
5 21 4. Wheel Hub

5. O-ring
17 6. Snap Ring
22
7. Ring Gear
22 8. Ring Gear Support

1
18 19 9. Locking Plate
20 10. Planet Gear
11. Nut
1
12. Plug
2 4
13. Countersunk Bolt
14. Planet Gear Carrier
5
15. Stud
16. Reduction Bushing
3 17. Drive Axle
18. Thrust Bushing
2
19. Steering Case (Right)
6
7 20. Steering Case (Left)
6 21. Universal Joint
8 10
23 22. Repair Kit
9 23. Bearing Axle
13
5
15
12
11 14 NA16348S
11

AXLE AND DIFFERENTIAL (REAR) (CONT’D) Figure 40-21-3
Planetary Carrier Disassembly
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 alternately 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 Parts Identification
4
2
7
21
4
6 1. Lock Ring
1
13
2. Jam Nut
3. Seal
4. Tie Rod End
5. O-ring
6. Lock Nut
9
7. Cotter Pin
8. Wheel Positioning
Sensor
9. Screw

8
10. Plug
11. Pivot Pin
12. Grease Fitting
13. Steering Cylinder
4 14. Shim
15. Bushing
2 16 16. Nut
18 17. Washer
22 11 18. Stud
10 19. Steering Case (Right)
12 14
20. Steering Case (Left)
3 21. Bolt
15
1
19
18 20
16
6
7
15
3
11
12
21 10 NA16349S

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 And Pinion Group Parts Identification
3
4
1
4 7 10
13
18 7 3
1
19
5
9
21 20
1
6
14
2 8
10. Crown Gear

13

11. Disc
17
15 12. Planetary Gear
11 16 13. Differential Carrier
17
12 16 14. Flange
15. Gear Shaft
1. Ring Nut
16 12 16. Planet Wheel Gear
2. Flange Nut
17 17. Thrust Washer
3. Set Screw
4 18. Pinion
4. Bolt
16 19. Internal Bearing
5. Shim Washer
11 20. Shim
6. Seal 17
21. External Bearing
7. Taper Roller Bearing
15 13
8. O-ring
9. Spacer
NA16333S

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].
nut.
WARNING
AVOID BURN INJURY
W-2762-1108

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 gear (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 gear
(Item 2) [Figure 40-21-34].

Figure 40-21-37 T14

2 1 1 2
2
S1419
Insert tool T14 between two planet wheel gears (Item 1)

S1417 [Figure 40-21-39].
NOTE: Make sure that tool T14 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
T16A
T15
T16A
1
T15
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 guide bushing T15 and insert press tool T16A
(Item 2) [Figure 40-21-38] of the planet wheel gears. (Item 3) [Figure 40-21-40]. Press the pin of the upper
planet wheel gear into tool T14 [Figure 40-21-39].

Figure 40-21-41
T16A 1
T15 2
S1424
Leave the released planet wheel gear (Item 1) [Figure

S1422 40-21-43] in position and again lock tool T14.
Repeat the operations for the extraction of the pin of the

Remove the press tool T16A and guide bushing T15 second planet wheel gear (Item 2) [Figure 40-21-43].
[Figure 40-21-41].
Repeat the operations for the two remaining pins.

NOTE: In this condition the tool contains the pin.
Figure 40-21-44
Figure 40-21-42
1
S1425
S1423
Remove tool T14 and remove the planet wheel gears

Remove tool T14 together with the pin (Item 1) [Figure (Item 1) and the relative shim washers (Item 2) from the
40-21-42] of the planet wheel gear. differential carrier (Item 3) [Figure 40-21-44].

Pinion Group 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] with 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].
T20A
S37164
Position tool T20A (or T20B), to avoid pinion rotation.

Remove the nut and O-ring (Item 2) [Figure 40-21-46].

Figure 40-21-49
T23
S37169
Install blocks T23 and, with a puller, push the pinion

S37167 (Item 1) [Figure 40-21-51] inwards with internal bearing,
spacer and shims.
Remove the seal (Item 1) [Figure 40-21-49]. NOTE: The thrust blocks of the bearings remain in
the central body (Item 2) [Figure 40-21-51].

Figure 40-21-50
Figure 40-21-52
T21 1
3
T22
S37168
S37170
Position wrench T22 onto the ring nut and use T21 to
hold the pinion. When loose, hold wrench T22 [Figure Remove the pinion (Item 1), shims (Item 2) and spacer
40-21-50] and rotate the pinion to remove the ring nut. (Item 3) [Figure 40-21-52].
NOTE: If needed, heat the ring nut at approximately

80°C (176°F).
WARNING
AVOID BURN INJURY
W-2762-1108

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].

Pinion Group 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].

Preset the indicator to approximately 2 mm (0.08 in).
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 T26A
GB
GB
S1575
Install a depth gauge with long stem into bar T26A

[Figure 40-21-62]; when the bar rests on two gauge
S37178 blocks “GB” of 57 mm (2.24 in) size, reset the indicator.
Preset the indicator to approximately 2 mm (0.08 in). and

Connect the tension rod to the press and move the thrust
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.
T26C
Figure 40-21-61
T24
T26C T26B
1
T26A S37181
Place bar T26A on gauged nut T26C [Figure 40-21-63]

and measure the size “A” at about 57 mm (2.24 in)
corresponding to the maximum diameter of arms
S37179 centering.
See [Figure 40-21-64] for a sectional view.

Insert tool T26B complete with external bearing (Item 1),
measurement ring T24 and gauged ring nut T26C
[Figure 40-21-61]. Tighten manually.

Figure 40-21-64
T26C
T24
T26B
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.
Check 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
T26C
1 2 T26B
S37186
1
2 Position tools T26C and T26B complete with tapered

S37184 bearings (Item 1) and (Item 2) [Figure 40-21-70].
Manually tighten until a rolling torque has been obtained.

Insert shim "S" (Item 1) and the thrust block of the
internal bearing (Item 2) [Figure 40-21-68] in the central Figure 40-21-71

body.
NOTE: To hold shim "S" (Item 1) [Figure 40-21-68] in T26C

position, apply grease.
Figure 40-21-69
T25A
S37187
Insert the stem of a depth micrometer "DDG" in either

T25C
side hole of tool T26C [Figure 40-21-71]. Zero the
comparator with a presetting of approximately 3 mm
S37185 (0.118 in).
Position tool T25A and tension rod T25C [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.

Pinion Group Assembly (Cont’d) S1

Figure 40-21-72
T26C
2 1 3
T26B
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” [Figure 40-21-74] which will be inserted
between the external bearing (Item 3) and the spacer
Remove the micrometer and release tols and bearings (Item 1) [Figure 40-21-72] and subsequently, to
from the central body. determine the preload for the bearings.

Reinstall all and insert the spacer (Item 1) between both Figure 40-21-75
bearings (Item 2 and 3) [Figure 40-21-72]; manually
tighten the whole pack.
Figure 40-21-73
H
DDG
2
T26C 1
T26B S1588
Position the internal bearing (Item 1) and the pinion

S1586 (Item 2) [Figure 40-21-75] under a press. Force 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-
21-71].

Figure 40-21-76
1
S1
1
2 S37194
Connect the pinion (Item 1) [Figure 40-21-78] 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 40-21-79
(Item 2) [Figure 40-21-76] in the main body.

NOTE: The thinner shims must be placed in-between
the thicker ones.
Figure 40-21-77
2
S37195
Apply Loctite® #243 to the thread of the ring nut (Item 1)

and screw the nut onto the pinion (Item 2) [Figure 40-21-
79].
S37193
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
Pinion Group 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 in-lb) in the torque
of the pinion.
Figure 40-21-82
T21
T22 S37196
Apply special wrench T22 to the ring nut and bar-hold

T21 [Figure 40-21-80] to the pinion. Lock the wrench 2
T27

T22 and rotate the pinion using a torque wrench, up to a
minimum required torque setting of 500 N•m (369 ft-lb).
S37198
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
[Figure 40-21-82].
Figure 40-21-83
T21
S37197
Use the bar-hold T21 [Figure 40-21-81] and a torque

meter to check the pinion torque. Torque: 1,2 - 1,7 N•m
(11 - 15 in-lb).
S37199
NOTE: If torque exceeds the maximum value, then

the size of shim "S1" between the bearing and Install the swing support (Item 1) [Figure 40-21-83].
the spacer needs to be increased. If torque
does not reach the set value, increase the NOTE: Inspect that the swing support is properly
torque setting of the ring nut in different oriented.
stages to obtain a maximum value of 570 N•m
(420 ft-lb).

Figure 40-21-84
1 2
T23
S37202
Remove blocks T23 [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
T20A
S37201
Apply Loctite® #243 to the threaded part of the pinion.

Position tool T20A (or T20B) [Figure 40-21-85] and
secure it in order to avoid rotation.
Insert the O-ring and the nut and tighten it to 280 -

310 N•m (207 - 229 ft-lb) torque.

Differential Assembly
1
Figure 40-21-87
2
2
S1534
With the help of another bar, position the second planet

S1532 wheel gear (Item 1) and the relative thrust 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
T16C
1
T16C
S1535
Insert tool T14 between the two planetary gears and line
S1533 up the entire unit by pushing tool T16C [Figure 40-21-
90] all the way through until the other is ejected.
Position the thrust washer (Item 1) and the first planet

wheel gear (Item 2) [Figure 40-21-88]. Temporarily hold
them in position using tool T16C.


1
T15
Figure 40-21-91
T14
1
1
S40983
Place the differential carrier under the press, position

S1536 guide bushing T15 and insert the planet wheel pin
(Item 1) [Figure 40-21-93].
Lock tool T14 behind the planet wheel gears Figure 40-21-94
(Item 1) [Figure 40-21-91]. Then remove tool T16C.

Figure 40-21-92
2 T16B
1
S1539
S1537 Put a press tool T16B on top of the planet wheel pin
(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
1 S1542
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 thrust washer (Item 1) on the crown gear

S1541 (Item 2) [Figure 40-21-98].
NOTE: In order to hold the thrust washer in position,

Remove the press tool T16B, guide bushing T15 and apply grease to it.
install the snap ring (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 pins.

Figure 40-21-99
1
3 1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races (Item 1) [Figure 40-21-101] in the central body
and in the middle cover.
Position the crown gear (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: Tighten 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: Check the position 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 gear, so as to increase
S38866 pinion torque up to 1,4 - 2,1 N•m (12 - 19 in-lb) [Figure
40-21-105].
Lock the middle cover (Item 1) with bolts
NOTE: If bearings are not new, check the static
(Item 2) [Figure 40-21-103].
torque. If bearings are new, check the

continuous torque.
Tighten the bolts to 24 - 26 N•m (18 - 20 ft-lb) torque.
Figure 40-21-106
Figure 40-21-104
1
A
T13
S1551
S38864
Install a dial indicator with rotary key “A” through the top
NOTE: If the ring nuts [Figure 40-21-104] are plug hole (Item 1). Position the indicator on the center of
removed, apply some Loctite® #243 to them. one of the teeth of the crown gear (Item 2) [Figure 40-
Tighten ring nut on the crown gear side until 21-106] and pre-set it to 1 mm (0.039 in) and reset it.
clearance between pinion and crown gear is
zero. Lock the crown gear. Turn the ring nut
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 gear (Item 1) [Figure 40-21- Tighten the bolts to 24 - 26 N•m (18 - 19 ft-lb) torque.
107] in both directions in order to check the existing
backlash between the pinion and the crown gear. Install the plug in the hole (Item 1) [Figure 40-21-33 on

Page 13] after applying flexible gasket compound for
Figure 40-21-108 seals to the rims.
Figure 40-21-110
T13
S38864
S2542
Adjust the backlash between the pinion and the crown

gear by unloosing one of the ring nuts [Figure 40-21-
Reinstall the complete arms (Item 1) [Figure 40-21-110].
108] 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).

Steering Knuckle Assembly
Figure 40-21-111
T7
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 T7. 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 (0.033 in).
To be assembled under the upper tie rod
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
1
2 2
3
1
BOTTOM TIE ROD
S1500
3 UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S38990 oriented as shown in the inset. Lubricate the pivot area
(Item 2) and the seal (Item 1). Install the bottom tie rod
and the six bolts (Item 3) [Figure 40-21-117]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts in sequence using the
oriented as shown in the inset. Lubricate the pivot area cross tightening method, to 140 N•m (103 ft-lb) torque.
(Item 2) and the seal (Item 1). Install the upper tie rod

and shims (Item 3) [Figure 40-21-115], four studs, four Check for the correct assembly side of the seal
washers and four nuts. (Studs, washers and nuts not (Item 1) [Figure 40-21-117].
shown in photo.) Tighten to 140 N•m (103 ft-lb) torque.
Figure 40-21-118
Check the correct assembly side of the seal
(Item 1) [Figure 40-21-115].
Figure 40-21-116
S2568
Install a magnetic based dial indicator on the steering

S38375 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-
Lubricate the group with grease and mount it in the 118].

Figure 40-21-119
S2569
Inspect the torque of the studs, 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

40-21-119].

Planetary Carrier Assembly
Figure 40-21-120
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-21-122] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-21-123
of the external bearing (Item 1) [Figure 40-21-120]
under the press.

Figure 40-21-121
1
2
1
S2587
T9A Install the bearing (Item 1) [Figure 40-21-123] 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 40-21-121] (wide side up).
NOTE: Inspect that the bearing race is correctly

oriented.

Figure 40-21-124
1
2
3
T10
S1456
1
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the ring gear (Item 3) [Figure 40-21-126].
NOTE: Make sure the snap ring (Item 1) [Figure 40-21-

Position tool T10 and press the sealing ring (Item 1) 126] is firmly seated in the groove.
[Figure 40-21-124] into its seat.
Figure 40-21-127

Figure 40-21-125
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 ring gear (Item 2) (Item 1) into the cover (Item 2) [Figure 40-21-127].
[Figure 40-21-125].
Accurately check the orientation.

Figure 40-21-128
S2470A
Install the external bearing (Item 1) [Figure 40-21-130].

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 40-21-128]. edge.
Figure 40-21-129 Figure 40-21-131

1
1
S2471A S2646
Connect the steering bars and install the hub Install the complete ring gear flange (Item 1) [Figure 40-
(Item 1) [Figure 40-21-129]. 21-131].
NOTE: In order to fasten the flange, use a plastic

hammer and alternately hammer on several
equidistant points.

Figure 40-21-132
1
1
2
S2466

S2467
Figure 40-21-135
Apply silicone-based grease to the surface of the locking

plate (Item 1) that touches the ring gear flange (Item 2)
2
[Figure 40-21-132].
3

Install the locking plate (Item 1) [Figure 40-21-132].
Figure 40-21-133
1
S2465A
1
Install the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-21-135].
NOTE: Inspect that the O-ring (Item 3) [Figure 40-21-

135] is in good condition and in position.
S2647
Cross tighten the nuts (Item 1) [Figure 40-21-133] 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.

Figure 40-21-136
S1468
Lock the planetary carrier cover (Item 1) by tightening

the bolts (Item 2) [Figure 40-21-136]. Tighten the bolts
to 40 - 50 N•m (30 - 37 ft-lb) torque.

FRONT AXLE Figure 40-30-2
Fully retract the telescoping boom. Raise the boom and

install the boom stop. (See Installing The Approved 2
Boom Stop on Page 10-150-1.)
3
WARNING 1

P122564
immediately.
Block the rear axle oscillation using stops (wooden block
W-2145-0290
or steel plate) (Item 1) between the rear axle oscillation
stops (Item 2) and the axle case (Item 3) (both sides)
Relieve hydraulic pressure. [Figure 40-30-2].
Figure 40-30-1 Put a block in front and behind the rear wheel.

Figure 40-30-3
S1954
S38617
Loosen the eight lug nuts and washers (Item 1) [Figure
40-30-1] on each front wheel.
Lift the front of the machine and place jack stands
Installation: Tighten the lug nuts (Item 1) [Figure 40-30- (Item 1) [Figure 40-30-3] under the frame as shown.
1] to 360 N•m (266 ft-lb) torque with threads M18x1,5mm
or 500 N•m (369 ft-lb) torque with threads M20x1,5mm. Remove the eight lug nuts and washers (Item 1) [Figure
40-30-1] from each front wheel.
Remove both front wheels.

FRONT AXLE (CONT’D) Figure 40-30-6
Figure 40-30-4
S38618
2
Using a jack, apply upward pressure to lift and support

S1951 the front axle [Figure 40-30-6].
Figure 40-30-7
Remove the four nuts (Item 1) from both front fender
mount brackets (Item 2) [Figure 40-30-4].

Remove the front fenders.
Installation: Tighten the nuts to 90 N•m (66 ft-lb) torque.
Figure 40-30-5
1 1
S38298
1
Remove the four mounting bolts (Item 1) [Figure 40-30-
7] on each side.
Installation: Apply Loctite® #243 or equivalent to the

thread of the mounting bolts (Item 1) [Figure 40-30-7]
S39180 (Both sides). Tighten to 370 - 410 N•m (275 - 300 ft-lb)
torque.
Remove the four drive shaft mounting bolts (Item 1)

[Figure 40-30-5] and remove the two clamps from the
front axle U-joint.

thread of the bolts (Item 1) [Figure 40-30-5] and tighten
to 33 - 41 N•m (24 - 30 ft-lb) torque.

FRONT AXLE (CONT’D) Figure 40-30-10
Figure 40-30-8
2
S38620
Remove the hose (Item 1) and disconnect the wire

S38619 harness (Item 2) [Figure 40-30-10] from the left
(operator’s view) side of the front axle.
Gently lower the front axle [Figure 40-30-8] Figure 40-30-11

approximately 100 mm (4 in).

IMPORTANT
damage the system.
I-2003-0888
1
Figure 40-30-9 S38622

right (operator’s view) side of the front axle.
S38621
Remove the hose (Item 1) [Figure 40-30-9] from the left

(operator’s view) side of the front axle.

FRONT AXLE (CONT’D)
Figure 40-30-12
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 40-30-12].

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
S2056A
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.


STEERING ANGLE ADJUSTMENT Figure 40-50-3
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 40-50-1
37° - 45°
S2062
Turn the steering wheel completely to the other side

[Figure 40-50-3] and repeat above procedure.
S38218

Use an angle gauge, to obtain a reading of the correct
angle [Figure 40-50-1]:
• 45° = Tire sizes 400x20 / 400x24

• 42° = Tire size 460x24
• 37° = Tire size 500x24
Figure 40-50-2
S2061
Adjust the stop (Item 1) [Figure 40-50-2] as needed.

Tighten the lock nut to 150 N•m (110 ft-lb) torque.


PARK BRAKE Figure 40-60-2
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.)
Adjustment
Figure 40-60-1
S38727
2 2
3 4 7. Install the cap (Item 1) [Figure 40-60-2].
WARNING

S38218 UNEXPECTED MACHINE MOVEMENT CAN CAUSE
1. Apply hydraulic pressure of 9 - 20,7 MPa (90 - 207
bar) (1300 - 3000 psi) to the brake (using a hand
system.
pump or portapower).
2. Turn the adjustment screw (Item 1) [Figure 40-60-1] 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 40-60-1] back 90°.
4. Hold the bolt (Item 2) in place while tightening the nut

(Item 3) [Figure 40-60-1] against the inner nut to 41 -
47 N•m (30 - 35 ft-lb).
5. Turn the adjustment screw (Item 1) [Figure 40-60-1]

back 180°.
6. Release the hydraulic pressure and remove the hand

pump or portapower.

PARK BRAKE (CONT'D) Brake Cylinder Disassembly And Assembly
Brake Cylinder Removal Remove the brake cylinder from the machine. (See Brake
Cylinder Removal on Page 40-60-2.)
Figure 40-60-3
Figure 40-60-5
1
2
S38672
S38673
Remove the rubber cap (Item 1) [Figure 40-60-3].

Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-

Figure 40-60-4 60-5].
Figure 40-60-6
2
1
3
S38671
S38674
Remove the pressure sensor (Item 1) [Figure 40-60-4]
and its fittings.
Remove the brake pads (Item 1) [Figure 40-60-6] from
Loosen the inner bolt (Item 2) [Figure 40-60-4] until the the brake cylinder.
brake pads show a gap.
Inspect the brake pads (Item 1) [Figure 40-60-6] for
Loosen the two bolts (Item 3) [Figure 40-60-4] and wear.
remove the brake cylinder.

PARK BRAKE (CONT'D) Figure 40-60-9
Brake Cylinder Disassembly And Assembly (Cont’d)
Figure 40-60-7
1
S38721
Remove the set of springs (Belleville washers) (Item 1)

S38675 [Figure 40-60-9].
Figure 40-60-10
Remove the cylinder cover (Item 1) [Figure 40-60-7].

NOTE: Be careful when removing the cylinder cover
(Item 1) [Figure 40-60-7]. The cover is under TOP
spring pressure.
Figure 40-60-8
S38722
2
Assembly: Verify that the Belleville washers are installed
as shown in [Figure 40-60-10].
S38726
Remove the two O-rings (Items 1 and 2) [Figure 40-60-

8].

PARK BRAKE (CONT'D) Figure 40-60-13
Brake Cylinder Disassembly And Assembly (Cont’d)
Figure 40-60-11
4 1
1
3
2
S38725
Remove the O-ring (Item 1) and back-up ring (Item 2)

S38723 [Figure 40-60-13].
Remove the O-ring (Item 3) and back-up ring (Item 4)

Remove the piston (Item 1) [Figure 40-60-11]. [Figure 40-60-13].

Figure 40-60-12
S38724
Inspect the piston surface for damage (Item 1)

[Figure 40-60-12].

PARK BRAKE (CONT'D) Tighten the adjustment screw (Item 2) clockwise until the
brake pads are clamped onto the disc. Make sure the bolt
Brake Disc Removal And Installation (Item 3) [Figure 40-60-15] does not protrude out far
enough to make contact with the mounting bracket at this
Figure 40-60-14 time.
Figure 40-60-16
2
3
2
1
1
S38251
S38727
Remove the front driveshaft. (See Front Driveshaft
Removal And Installation on Page 40-90-1.)

Tighten the mounting bolts (Item 1) until they make
Remove the brake cylinder. (See Brake Cylinder contact with the urethane springs (Item 2), then tighten
Removal on Page 40-60-2.) 240° more. This puts the proper amount of preload on the
urethane springs (Item 2) [Figure 40-60-16].
Tighten the nuts (Item 3) [Figure 40-60-16] against the
Remove the brake disc (Item 2) [Figure 40-60-14]. mounting bracket. Torque to 271 N•m (200 ft-lb)
Measure the thickness of the brake disc. Replace the The brake is now ready for adjustment. (See Adjustment
brake disc if thickness is below 9,5 mm (0.374 in). on Page 40-60-1.)
Brake Cylinder Installation
Figure 40-60-15
2 3
S38671
Position the brake cylinder on the disc.
Install the mounting bolts (Item 1) [Figure 40-60-15] far

enough to support the brake.


GEARBOX Figure 40-70-3
Remove the engine bay assembly. (See Removal And

2
Remove the brake disc. (See Brake Disc Removal And
Figure 40-70-1
1
S38224
2
Remove the plug (Item 1) [Figure 40-70-3] and drain the

gearbox oil into a container.
Remove the two hoses (Item 1) from the gearbox shifting

control cylinder (Item 2) [Figure 40-70-3].

Figure 40-70-4
S38234
Disconnect the low speed connector (Item 1) [Figure 40- 1

70-1] from the hydrostatic drive motor.

hydrostatic drive motor.
Figure 40-70-2
1 2
S38235
Support the gearbox with a hoist (Item 1) [Figure 40-70-

2
4].
2
S38233
Remove the hydrostatic hoses (Item 1) [Figure 40-70-2]

from the hydrostatic drive motor.

the hydrostatic drive motor.

GEARBOX (CONT’D) Figure 40-70-7

2
Figure 40-70-5 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-
70-7].
Remove the two mounting bolts (Item 1) [Figure 40-70- Remove the four mounting bolts (Item 3) [Figure 40-70-

5]. 7] from the hydrostatic drive motor.
Installation: Apply Loctite® #242 to the threads of the Installation: Tighten the mounting bolts to 190 - 210
bolts (Item 1) [Figure 40-70-5] before installation. N•m (140 - 155 ft-lb) torque.
Figure 40-70-6 Remove the hydrostatic drive motor (Item 2) [Figure 40-
70-7] from the gearbox housing.
Figure 40-70-8
1
S38235
S38247
6].
Installation: Replace the O-ring (Item 1) [Figure 40-70-
Installation: Apply Loctite® #242 to the threads of the 8].
bolts (Item 1) [Figure 40-70-5] before installation.
Remove the gearbox and hydrostatic drive motor

assembly and place it on a bench.

GEARBOX (CONT’D)
12
1. O-ring 2
1
2. Vent 1 8 3
3. Cover 4
13 4
4. Seal 5
6 5
5. Shim 6
3
6. Ball Bearing 12
14 3 12
7. Gear
8. Flange
3
9. Elastic Pin 14
7
10. Pin
27 6
11. Housing 34
12. Bolt
13. Nut
14. Washer 16
15. Plate

20
16. Needle Bearing 19 15 7
16 10 12
17. Shaft 7 14
18. Selector Sleeve 18
24 17 11
19. Magnetic Plug
20. Spacer 23 15 6
1 4 3
21. Switch 12 4 20
12 14
4 8
22. Boot 14 9 12
21 1
23. Spring 22 1 14
25
24. Ball 12
1 1 14
25. Cylinder Bolt 12 13
27 26 31
26. Cylinder 28 1
1 32
27. Plug
29 1
28. Rod 30
29. Piston 10 33
30. Cover Plate
31. Selector Shaft
32. Slide Pin
33. Selector Fork
34. Connector
EM9285

Disassembly
Figure 40-70-9
1
2
2
1 1
S38243
Remove the O-ring (Item 1) and the flange (Item 2)

S36547 [Figure 40-70-11].
Remove the gearbox shifting control cylinder. (See

Remove the four bolts (Item 1) from the motion input Removal on Page 40-80-1.)

Figure 40-70-12
Remove the motion input cover (Item 2) [Figure 40-70-
9].
Figure 40-70-10
S36543
Remove the plug (Item 1) [Figure 40-70-12] with the

washer and the rpm sensor.
S38242
Remove the nut (Item 1) from the flange (Item 2)

[Figure 40-70-10].

Figure 40-70-13
3 2 1
3
S36546
1
Remove the screw (Item 1) and disconnect the connector
(Item 2) to remove the speed sensor cable (Item 3)
S36544
[Figure 40-70-15].
Remove the gear-in-position switch (Item 1), O-ring (Item Figure 40-70-16
2) and washer (Item 3) [Figure 40-70-13].

Figure 40-70-14
1 1
1
3
2
2
S36551
S36546
Remove the four bolts (Item 1) from the cover (Item 2)
[Figure 40-70-16].
Remove the screw (Item 1), spring (Item 2) and neutral
position ball (Item 3) [Figure 40-70-14].

Figure 40-70-17
3 1 1
S36555
Remove the cover (Item 1) [Figure 40-70-19].

S36553
NOTE: Take care not to damage surfaces.
Remove the cover (Item 1) and install the spacers (Item Figure 40-70-20

2) [Figure 40-70-17] onto the cover to keep them in the
correct position until reassembly.
1
NOTE: The notch (Item 3) [Figure 40-70-17] must be
facing upwards. 2
Figure 40-70-18
2
S36556
Pay attention to the position of the pins (Item 2)

1 [Figure 40-70-20].
1
S36554
Remove the fourteen bolts (Item 1) [Figure 40-70-18].

Figure 40-70-21
3 1
S36559
2 Install the bearing (Item 1) [Figure 40-70-23] into the

S36557
gearbox.
Figure 40-70-24
Remove the gear (Item 1), needle bearings (Item 2) and

spacer (Item 3) [Figure 40-70-21] from the gearbox.
Figure 40-70-22
1 2
S36560
Remove the oil shield plate (Item 1) [Figure 40-70-24]

S36558
only if necessary.
NOTE: The oil inlet (Item 2) [Figure 40-70-24] must

Remove the bearing (Item 1) [Figure 40-70-22] if it face upward.
needs replacing.

Figure 40-70-25
2
1
1
S36563
Remove the bolts (Item 1) from the flow regulator plate

S36561
(Item 2) [Figure 40-70-27].
Figure 40-70-28
Install the oil shield plate (Item 1) with oil inlet facing

upward [Figure 40-70-25].
1
Apply Loctite® #510 on the outside [Figure 40-70-25].
3
Figure 40-70-26
S36564
Remove the plate (Item 1) and pull out coupling (Item 2)

and fork (Item 3) [Figure 40-70-28] at the same time.
S36562
Install the oil shield plate into position, 5 - 5,5 mm (0.197

- 0.217 in) from box surface [Figure 40-70-26].

Figure 40-70-29
2 1
1 3
2
S36567
Remove the entire shaft (Item 1) and the flow regulator

S36565
plate (Item 2) [Figure 40-70-31].
Figure 40-70-32
Check sliding blocks (Item 1), pin (Item 2), and sliding

coupling (Item 3) [Figure 40-70-29].
Replace if worn.
Figure 40-70-30
S36568
Disassemble the entire lower shaft [Figure 40-70-32].
S36566
Remove the lower shaft (Item 1) [Figure 40-70-30].

Figure 40-70-33 1
S36571
Remove the upper shaft (Item 1) [Figure 40-70-35].

S36569
NOTE: In case of replacement, the shaft is supplied
already assembled.
Progressive arrangement of parts installed onto the lower

shaft [Figure 40-70-33]. Figure 40-70-36
Figure 40-70-34
S36572
S36570
Pull out the sealing ring (Item 1) [Figure 40-70-36].
Assemble the lower shaft [Figure 40-70-34].

Figure 40-70-37
S36575
Install a new sealing ring [Figure 40-70-39].

S36573
Figure 40-70-40
Install a new sealing ring (Item 1) [Figure 40-70-37].

Figure 40-70-38
1 2
S36576
Remove the sealing ring (Item 1) from the motion input

S36574
Pull out the sealing ring (Item 1) [Figure 40-70-38] of the

cover.

GEARBOX (CONT’D) Assembly
Disassembly (Cont’d) Figure 40-70-42
Figure 40-70-41
2
S36578
S36577
Install the bearing in the cover of the gearbox [Figure 40-
70-42].
Remove the bearing (Item 1) from the cover (Item 2)

[Figure 40-70-41] of the gearbox. Figure 40-70-43
S36579
Install the new sealing ring in the motion input cover

[Figure 40-70-43].

Assembly (Cont’d)
Figure 40-70-44
2
1
S36582
Lubricate the lip of the sealing ring (Item 1) [Figure 40-

S36580
70-46] with grease.
Figure 40-70-47
Apply Loctite® #510 on surfaces and bolts (Item 1).

Install the cover (Item 2) [Figure 40-70-44] on the
gearbox.
Figure 40-70-45
1
1 S36583
Install the motion upper shaft (Item 1) [Figure 40-70-47].
S36581
Tighten the four bolts (Item 1) [Figure 40-70-45] to 49 -

51 N•m (36 - 38 ft-lb) torque.

Figure 40-70-48
1 1
S36586
Temporarily re-assemble the cover (Item 1) [Figure 40-

S36584
70-50] with bolts.
NOTE: Make sure that the recess (Item 2) [Figure 40-

Assemble the entire lower shaft (Item 1) and the flow 70-50] faces upward.

regulator plate (Item 2) [Figure 40-70-48].
Figure 40-70-51
Figure 40-70-49
S36587
S36585
Simultaneously insert fork and sliding blocks (Item 1),

Position the shaft (Item 1) [Figure 40-70-49] so that the coupling (Item 2) and flow regulator plate (Item 3)
bearing protrudes approximately 5 mm (0.197 in) from [Figure 40-70-51].
the cover of the gearbox.

Figure 40-70-52
3 1
1 S36590
Re-assemble needle bearings (Item 1), gear (Item 2) and

S36588
spacer (Item 3) [Figure 40-70-54].
NOTE: Position spacer (Item 3) underneath needle

Install bolts (Item 1) [Figure 40-70-52]. bearings (Item 1) [Figure 40-70-54].

Figure 40-70-53 Figure 40-70-55
1 1
1
1
S36589 S36591
Tighten bolts (Item 1) [Figure 40-70-53] to 25 - 26 N•m Check the insertion of pins (Item 1) [Figure 40-70-55].
(18 - 19 ft-lb) torque.

Assembly (Cont’d)
Figure 40-70-56
1
1
S36594
Tighten the 14 bolts (Item 1) [Figure 40-70-58] in a

S36592
crisscross manner to 49 - 51 N•m (36 - 38 ft-lb) torque.
Figure 40-70-59
Apply Loctite® #510 to the surface and assemble the

Figure 40-70-57
3
1 1
2
S36546
Lubricate components and install ball (Item 1), spring

S36593
(Item 2) and screw (Item 3) [Figure 40-70-59].
Tighten screw to 80 - 100 N•m (59 - 74 ft-lb) torque.

Install the cover (Item 1) [Figure 40-70-57].

Assembly (Cont’d)
Figure 40-70-60
1 1
2 3
2
S36551
1
Remove bolts (Item 1) and remove the temporarily
S36544
assembled cover (Item 2) [Figure 40-70-62].
Figure 40-70-63
Install the gear-in position switch (Item 1) with washer

(Item 2) and O-ring (Item 3) [Figure 40-70-60].
Tighten screw (Item 1) [Figure 40-70-60] to 54 N•m (40

ft-lb) torque.
Figure 40-70-61
S36800
Install the bearing [Figure 40-70-63].
1
S36543
Install the plug (Item 1) [Figure 40-70-61] with washer

and revolution indicator.
Tighten the plug (Item 1) [Figure 40-70-61] to 25 N•m

(18 ft-lb) torque.

Assembly (Cont’d)
Figure 40-70-64
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 40-70-66] facing
upwards.
Measure dimension "A" between the bearing and the box
plane using an depth gauge [Figure 40-70-64].

Figure 40-70-67
NOTE: If parts are not replaced, use disassembled
distance washers.
Figure 40-70-65
B S38250
Install bolts [Figure 40-70-67]. Apply Loctite® #510 or

equivalent to the threads before installation.
S38248
Tighten bolts to 49 - 51 N•m (36 - 38 ft-lb) torque.
Measure dimension "B" on the cover, between the
bearing plane and bearing support [Figure 40-70-65].
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 40-70-68
2
3
S38242
S36546
Install the nut (Item 1) [Figure 40-70-70].
Tighten the nut (Item 1) [Figure 40-70-70] to 260 - 280

Install the connector (Item 1) with the screw (Item 2) to N•m (192 - 207 ft-lb) torque.
install the speed sensor cable (Item 3) [Figure 40-70-

68].
Figure 40-70-69
S38243
Install the flange (Item 1) and the O-ring (Item 2)

[Figure 40-70-69].


GEARBOX SHIFTING CONTROL CYLINDER Figure 40-80-3
Removal
Remove the engine bay assembly. (See Removal And

Figure 40-80-1
1
1
S38227
3
Remove the piston (Item 1) [Figure 40-80-3].
Figure 40-80-4
2
S38224

Remove the two hoses (Item 1) from the gearbox shifting
NOTE: Mark the hoses for installation.
Remove the two bolts (Item 3) from the gearbox shifting

Remove the gearbox shifting control cylinder (Item 2)

[Figure 40-80-1]. 1
S38229
Figure 40-80-2
Remove the cover plate (Item 1) [Figure 40-80-4].
1
2
S38225
Remove the screw (Item 1) from inside the shifting

cylinder rod (Item 2) [Figure 40-80-2].

GEARBOX SHIFTING CONTROL CYLINDER (CONT’D)
Removal (Cont’d)
Figure 40-80-5
1
S38230

GEARBOX SHIFTING 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

GEARBOX SHIFTING CONTROL CYLINDER (CONT’D) Figure 40-80-8
Disassembly
2
Figure 40-80-6
2 S38231
1
Remove the O-ring (Item 1) from the shifting cylinder

S38228 housing (Item 2) [Figure 40-80-8].

Inspect the shifting cylinder rod (Item 2) [Figure 40-80-6]
for nicks and scratches.
Figure 40-80-7
1
2
S38226
Remove the seal (Item 1) from the cylinder housing (Item

2) [Figure 40-80-7].

Assembly
Figure 40-80-9
S38228
Install the O-ring (Item 1) [Figure 40-80-11].

S38231
Figure 40-80-12
Install the O-ring (Item 1) on the shifting cylinder housing

(Item 2) [Figure 40-80-9].

Figure 40-80-10
1
2
1
S38230
Install the O-ring (Item 1) [Figure 40-80-12].
S38226
Install the seal (Item 1) on the cylinder housing (Item 2)

[Figure 40-80-10].

Installation
Figure 40-80-13
1
2
S38225
Install the screw (Item 1) inside the shifting cylinder rod

(Item 2) [Figure 40-80-15]. Apply Loctite® #243 to the
S36809 threads before installation. Torque to 25 - 26 N•m (18 - 19
ft-lb) torque.
Apply Loctite® #510 and install the cover plate (Item 1) Figure 40-80-16

[Figure 40-80-13].
Figure 40-80-14 3
2
1 S38224
S38227 Apply some hydraulic fluid on the control rod and piston
before installing the gearbox shifting control cylinder
(Item 2) [Figure 40-80-16].
Install the piston (Item 1) [Figure 40-80-14].
Install the gearbox shifting control cylinder (Item 2) with
the two bolts (Item 3) [Figure 40-80-16].
Tighten the bolts (Item 3) [Figure 40-80-16] to 49 -

Install the two hoses (Item 1) onto the gearbox shifting


DRIVESHAFT Front Driveshaft Removal And Installation
Rear Driveshaft Removal And Installation Figure 40-90-3
Figure 40-90-1
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 40-90-3] from
Remove the four drive shaft mounting bolts (Item 1) and the park brake disc U-joint.

the rear axle U-joint. Installation: Apply Loctite® #243 or equivalent to the
threads of the bolts (Item 1) [Figure 40-90-3] and tighten
Installation: Apply Loctite® #243 or equivalent to the to 33 - 41 N•m (24.3 - 30.2 ft-lb).
to 33 - 41 N•m (24 - 30 ft-lb) torque. Figure 40-90-4
Figure 40-90-2
1
1
2 1
2
S38222
S38221
Remove the four drive shaft mounting bolts (Item 1)
Remove the four drive shaft mounting bolts (Item 1) and front axle U-joint.
the gearbox U-joint. Installation: Apply Loctite® #243 or equivalent to the
Installation: Apply Loctite® #243 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 Figure 40-100-1
Description
There is a bleed screw located on each side of the front

axle differential housing.
Air trapped in the brake lines can cause a spongy feel

and / or delayed activation of the service brake.
1
Use the following procedure to remove air from the brake
circuit.
WARNING S39118
Figure 40-100-2
immediately. 1

W-2145-0290
WARNING
MACHINE FALLING OR MOVING CAN CAUSE S2014
machine before running engine for service. Remove the caps and loosen the two bleed screws
W-2718-0208 (Items 1) [Figure 40-100-1] and [Figure 40-100-2].
With the aid of an assistant, start the engine and apply

Bleeding The Brake Circuit the service brake until a continuous stream of clean
hydraulic fluid, with no air, flows from the inside bleed
Lift and block the machine. (See Procedure on Page 10- screws (Item 1) [Figure 40-100-1] and [Figure 40-100-
10-1.). 2].
NOTE: Position the jack stands to allow starting the Stop the engine and tighten the two inside bleed screws
machine and driving the wheels. (Item 1) [Figure 40-100-1] and [Figure 40-100-2].
Lower the machine and test for proper brake operation.


REAR AXLE Figure 40-110-2
WARNING
1 1
immediately.
W-2145-0290
S39142

Lift the rear of the machine and place jack stands (Item 1)
Figure 40-110-1 [Figure 40-110-2] under the frame as shown.
Remove the eight lug nuts and washers (Item 1) [Figure

40-110-1] from both rear wheels.
1

Remove both rear wheels.
Figure 40-110-3
S1954
Loosen the eight lug nuts and washers (Item 1) [Figure

40-110-1] on both rear wheels. 2
Installation: Tighten the lug nuts (Item 1) [Figure 40-

110-1] to 360 N•m (266 ft-lb) torque with threads S1951
M18x1,5mm or 500 N•m (369 ft-lb) torque with threads
M20x1,5mm.
Remove the four nuts (Item 1) from both rear fender
mount brackets (Item 2) [Figure 40-110-3].
Remove the rear fenders.

REAR AXLE (CONT’D) Figure 40-110-6
Figure 40-110-4 1
2
2
1
1
1 S39144

S39177 the right hand side of the rear axle.

Remove the tie-straps (Item 1) and disconnect the 6] from the machine.
centering sensor electrical harness (Item 2) [Figure 40-

110-4] from the steering cylinder. NOTE: Remove any tie-straps if needed.
Remove the four drive shaft mounting bolts (Item 3) Figure 40-110-7
rear axle U-joint.
Installation: Apply Loctite® #243 or equivalent to the 1

threads of the bolts (Item 1) [Figure 40-110-4] and
tighten to 33 - 41 N•m (24 - 30 ft-lb) torque.
Figure 40-110-5
S39145
1
the right hand side of the rear axle.
P125340

located on the cab side below the boom.

REAR AXLE (CONT’D) Figure 40-110-10
Figure 40-110-8
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 40-110-10] and
pressure to the rear axle [Figure 40-110-8]. tighten to 33 - 41 N•m (24.3 - 30.2 ft-lb).

Figure 40-110-9 Figure 40-110-11
S39179 S39143
Remove the two bolts (Item 1) [Figure 40-110-9] from Have an assistant balance the axle on the jack and lower
the front mount bracket. the jack slowly while rolling the axle out from under the
frame [Figure 40-110-11].
threads of the bolts (Item 1) [Figure 40-110-9] and
tighten to 33 - 41 N•m (24.3 - 30.2 ft-lb).


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

Boom Wear Pad Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1

Boom Wear Pad Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
P125341
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

Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-1.)
S38084
Disconnect the ground (-) cable from the battery. (See
Removing And Installing Battery on Page 60-20-3.)
cab.

Figure 50-10-4
1
1 1
2
2
2
1
1
P133571
3
1 Remove the four bolts (Item 1) and remove the cover

P125412 (Item 2) [Figure 50-10-5].

Remove all the hoses (Item 1) [Figure 50-10-4] from the bolts (Item 1) [Figure 50-10-5] before installation.
steering unit and the service brake valve.

Figure 50-10-6
Disconnect the two electrical connectors (Item 2) [Figure
50-10-4].
1
Remove the tubeline (Item 3) [Figure 50-10-4] from the 1
service brake valve. 2
1 3
WARNING
P125340
physician familiar with this injury is not received Disconnect the four electrical connectors (Item 1) [Figure
immediately. 50-10-6].
W-2145-0290
Disconnect the red / white cable (Item 2) [Figure 50-10-

6].
Remove the ground wires (Item 3) [Figure 50-10-6].

IMPORTANT NOTE: Mark all hoses and electrical connectors for
correct installation.
damage the system.
I-2003-0888

Figure 50-10-7
1
1
S38128
Remove the two cab mount bolts (Item 1) [Figure 50-10-

S38127 9] from the back of the cab.

Install a hoist to lift and support the cab [Figure 50-10-7]. bolts (Item 1) [Figure 50-10-9] before installation.

Figure 50-10-8 Remove the floor mat.
Figure 50-10-10
S38126
S38128
Remove the cab mount bolt (Item 1) [Figure 50-10-8]
from the front right hand side of the cab.
Remove the cab mount bolt (Item 1) [Figure 50-10-10]
Installation: Apply Loctite® #242 to the threads of the and washer from the cab floor.
bolt (Item 1) [Figure 50-10-8] before installation.
bolt (Item 1) [Figure 50-10-10] before installation.

OPERATOR CAB (CONT’D)
Figure 50-10-11
S38130
Lift and remove the cab [Figure 50-10-11].

OPERATOR SEAT
Figure 50-20-1
1 1
P125380

washers (on each corner of the plate).

bolts before installation.
Remove the seat.


FIXED BOOM Figure 50-30-3
Removal
Remove the boom and self leveling (compensation) 2

cylinders. (See BOOM CYLINDER on Page 20-20-1.)
and (See Removal And Installation 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
1 Remove the two nuts (Item 1) and the retainer bolt (Item
2) [Figure 50-30-3] from the boom pivot pin.
Figure 50-30-4

1
S38102
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 boom and self leveling (compensation)

cylinders. (See BOOM CYLINDER on Page 20-20-1.)
and (See Removal And Installation on Page 20-30-1.)


INNER BOOM Figure 50-40-3
Figure 50-40-1
1 1
P133566
Remove the eight bolts (Item 1) [Figure 50-40-3] and

P133564 remove the four side wear pads. (Both sides).

Position the boom horizontally using wooden blocks tighten the bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.
[Figure 50-40-1].

Figure 50-40-4
Extend the inner boom for approximately 500 mm (20 in).
Figure 50-40-2
1
S39188
P133565 Lift the boom and rest the attachment carrier onto a
suitable stand, such that the lower wear pads become
free of pressure [Figure 50-40-4].
remove the two top wear pads.
NOTE: Mark the original position of each wear pad.

tighten the bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.

INNER BOOM (CONT’D) Figure 50-40-7
Figure 50-40-5
1
1
1 2
P129990
1 Disconnect the ACD harness connector (Item 1)

P133567 [Figure 50-40-7] (if equipped).
Disconnect both retract switch connectors (Item 2)

Remove the six bolts (Item 1) [Figure 50-40-5] and [Figure 50-40-7].
remove the two bottom wear pads.

Figure 50-40-8
NOTE: DO NOT use fingers to remove the bottom 1 1

wear pads.
NOTE: When installing the wear pads, make sure to

install the correct color (same color as was
removed).
Figure 50-40-6
P129993
1 1
Remove the six hoses (Item 1) [Figure 50-40-8] from the
tubelines.
S39070 IMPORTANT
Remove the two bolts (Item 1) and remove the cover When repairing hydrostatic and hydraulic systems,
(Item 2) [Figure 50-40-6] from the back of the boom. clean the work area before disassembly and keep all
Installation: Tighten the bolts (Item 1) [Figure 50-40-6] tubelines and ports to keep dirt out. Dirt can quickly
to maximum 16 N•m (12 ft-lb) torque. damage the system.
I-2003-0888

INNER BOOM (CONT’D) Figure 50-40-11
Figure 50-40-9
P133568
Slide the inner boom from the fixed boom. Before the
S38936 inner boom is completely removed, position a hoist and
lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-11].
Remove the bolt (Item 1) [Figure 50-40-9] from the
cylinder. NOTE: Support the attachment carrier with a pallet

and pallet truck.
Installation: Tighten the mounting bolt (Item 1)
[Figure 50-40-9] to 760 N•m (560 ft-lb) torque. Figure 50-40-12
Figure 50-40-10
S39171
S38937
Install the inner boom on adequate stands [Figure 50-
40-12].
Install a wooden block (120 x 80 x 55 mm) (Item 1)
[Figure 50-40-10] under the extension cylinder (as
shown).


WEAR PADS (FRONT)
Boom Wear Pad Checking
Figure 50-50-1
11 mm
(0.43 in)
FRONT
(FROM REAR VIEW)

11 mm 11 mm
(0.43 in) (0.43 in)
(both sides)
P141517
Measure the thickness of the front boom wear pads.
Replace the wear pad if the thickness is below the values

shown in [Figure 50-50-1]. (See Removal And

WEAR PADS (FRONT) (CONT’D) Installation: Apply Loctite® #2700 to the threads and
Figure 50-50-4
(See SERVICE SCHEDULE on Page 10-50-1.) for the
service interval when to check the wear pads.
Extend the inner boom for approximately 500 mm (20 in).
Figure 50-50-2
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 50-50-4].

P133565
Figure 50-50-5

remove the two top wear pads from in between the inner 1
and fixed boom.
Installation: Apply Loctite® #2700 to the threads and 1

NOTE: Mark the original position of each wear pad.

1
Figure 50-50-3
1
P133567
Remove the six bolts (Item 1) [Figure 50-50-5] and

1 1 remove the two bottom wear pads.

NOTE: DO NOT use fingers to remove the bottom

wear pads.
P133566
NOTE: When installing the wear pads, make sure to
Remove the eight bolts (Item 1) [Figure 50-50-3] and removed).
remove the four side wear pads from in between the inner
and fixed boom. (Both sides)

WEAR PADS (REAR)
Boom Wear Pad Checking
Figure 50-51-1
11 mm
(0.43 in)
REAR
(FROM REAR VIEW)

11 mm
11 mm (0.43 in)
(0.43 in) (both sides)
P141516
Measure the thickness of the rear boom wear pads.
Replace the wear pad if the thickness is below the values

shown in [Figure 50-51-1]. (See Removal And

WEAR PADS (REAR) (CONT’D) Figure 50-51-3
(See SERVICE SCHEDULE on Page 10-50-1.) for the

service interval when to check the wear pads. 3
1
2
Remove the inner boom. (See Removal And Installation
on Page 50-40-1.) 4
4
3
Figure 50-51-2 3
1
2
5
S39161
Remove the two screws (Item 1) and remove the side

wear pad (Item 2) [Figure 50-51-3].
1 Repeat for the other three side wear pads (Item 3)

[Figure 50-51-3].
Remove the six screws (Item 4) and remove the bottom

wear pads (Item 5) [Figure 50-51-3].

S39162

With the inner boom supported, remove the six screws screws.
(Item 1) and remove the two top wear pads (Item 2)
[Figure 50-51-2]. NOTE: Make sure that the surface of the boom is
cleaned before installing the pads.
screws. NOTE: When installing the wear pads, make sure to
NOTE: Make sure that the surface of the boom is removed).
cleaned before installing the pads.

ENGINE COVER
Gas Cylinder Removal And Installation

WARNING
Page 10-160-1.) Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
Add a support to prevent the cover from closing when the death.
gas cylinder is removed. W-2113-0288
Figure 50-60-1 Removal And Installation
Remove the gas cylinder. (See Gas Cylinder Removal

1 And Installation on Page 50-60-1.)
Figure 50-60-3

S38113
Figure 50-60-2
1
S38115
Remove the two hinge mounting bolts (Item 1) [Figure

50-60-3].
1 Installation: Apply Loctite® #242 to the threads of the

bolts (Item 1) prior to assembly. Tighten the bolts (Item 1)
[Figure 50-60-3] to 10 - 12 N•m (7 - 9 ft-lb) torque.
S38114 Remove the engine cover.
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
plate (Item 2) [Figure 50-70-2]. 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
S40653
Remove the two screws (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
2
1
1
S40654
2
Remove the filter (Item 1) [Figure 50-70-8].

S38086
Remove the four bolts (Items 1 and 2) [Figure 50-70-6].

threads of the bolts.
Tighten the two rear bolts (Item 1) [Figure 50-70-6] to
25 - 30 N•m (18 - 22 ft-lb) torque. 
Tighten the two front bolts (Item 2) [Figure 50-70-6] to
5 - 6 N•m (44 - 53 in-lb) torque.

FUEL TANK (CONT'D) Figure 50-70-11
Figure 50-70-9
1
S38090
Disconnect the fuel level sensor connector (Item 1)

S38087 [Figure 50-70-11].
Figure 50-70-12

threads of the bolt. Tighten the bolt (Item 1) [Figure 50-
70-9] to 25 - 30 N•m (18 - 22 ft-lb) torque.
1
Figure 50-70-10
S38095
Remove the fuel return hose (Item 1) [Figure 50-70-12]

1 from the fuel tank.

S38088

threads of the bolt. Tighten the bolt (Item 1) [Figure 50-
70-10] to 25 - 30 N•m (18 - 22 ft-lb) torque.
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 approximately 855 kg
(1885 lb). Use a fork lift rated for this mass.
NOTE: Make sure the fork tips of the fork lift only
support the counterweight. Stay clear from
the rear axle.
Figure 50-90-2
S39141
Lower the counterweight and remove it from under the

1
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 nuts (Item 1) from the fender mount

bracket (Item 2) [Figure 50-100-1].

Remove the fender.


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.

Installation: Tighten the screws to 2 - 4 N•m (13 - 35 in-
lb) torque.
Figure 50-110-2
1
1
P125389
Remove the four screws (Item 1) [Figure 50-110-2] from

the steering column cover.

lb) torque.
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-

P125390 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
S39051
P125391

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.

lb) torque.
Figure 50-120-6 1
S39055
1
1 Loosen the clamp (Item 1) [Figure 50-120-8] and

remove the blower hose from the blower.
S39053

from the dash cover.

lb) torque.

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

P125390 from the steering column cover.

Remove the cap (Item 1) [Figure 50-130-1] from the lb) torque.
steering wheel.

Figure 50-130-4
Figure 50-130-2
1
1
1
1
2
P125389
P125391
Remove the four screws (Item 1) [Figure 50-130-4] from

Remove the nut (Item 1) [Figure 50-130-2] from the the steering column cover.
steering wheel.
Remove the steering wheel (Item 2) [Figure 50-130-2]. lb) torque.
Remove the signal lever. (See Removal And Installation Lower the steering column cover.
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

P125392 joystick panel.

Remove the screws (Item 1) [Figure 50-130-6] from the lb) torque.
dash cover.
Lift the joystick panel.
lb) torque. NOTE: Slightly lift the dash cover for easier removal
of the joystick panel.
Remove the joystick. (See Removal And Installation on
Page 60-180-1.) Mark and remove all harnesses from the joystick panel.
Remove the joystick panel.

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Engine Bay Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
Fuses And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Belt Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Rear Work Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
FRONT WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1


TOP WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
REAR WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

SERVICE BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

INCHING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
EMERGENCY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Connecting Remote Start Tool (Service Tool) - 6987761 . . . . . . . . . . . . . . . . . . . . 60-160-1
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1


JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
LLMI / LLMC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1

System Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Longitudinal Load Moment Indicator (LLMI) Description . . . . . . . . . . . . . . . . . . . . 60-190-2
Longitudinal Load Moment Controller (LLMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-4
Longitudinal Load Moment Controller (LLMC) Override Switch . . . . . . . . . . . . . . . 60-190-4
LLMC Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-5
LLMI / LLMC Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-7
System Failure Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-10
LLMS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-12
LLMS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-13
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
CONTROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Gateway Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Drive Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Workgroup Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Display Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
LLMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
LLMC Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2

RETRACT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-2
AUTOMATIC PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-1
Calibrating The Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-1
Calibrating The Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-8
Calibrating The Inching Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-10
Calibrating The LLMC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-12
LLMC Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-15
LLMI / LLMC System Failure Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-240-17


8 7 6 5 4 3 2 1
HARNESSES OVERVIEW SCHEMATIC INDEX

H MACHINE SPECIFICATION PAGE 1 H
DESIGNATION PN
FUSES RELAYS OVERVIEW PAGE 2
ELECTRICAL SCHEMATIC HARNESS ENGINE
HARNESS FRAME
7299431
7257484
CONNECTORS ASSIGNMENT
CONTROLLERS CONNECTION
PAGE 3
PAGE 4, 5
NxG TLS HARNESS LOWER CAB 7257479 POWER

GROUND
PAGE 6
PAGE 7
PF2 St3a 100HP ENGINE

HARNESS UPPER CAB 7162048
CAN BUS PAGE 8 G
G
HARNESS BOOM 6M 7162054 IGNITION & ENGINE PAGE 9
HARNESS BOOM 7M 7162055 LOWER CAB PAGE 10
LOWER CAB, UPPER CAB PAGE 11
HARNESS BOOM WORK LIGHT 6M 7179216
14 July 2016
TRANSMISSION PAGE 12
HARNESS BOOM WORK LIGHT 7M 7178823 BRAKES PAGE 13
HARNESS BLUE WL LEFT 7178982 STEERING PAGE 14
F WORKGROUP PAGE 15 F
HARNESS BLUE WL RIGHT 7179236
WORKGROUP PAGE 16
LLM SYSTEM PAGE 17
AUXILIARY HYDRAULIC PAGE 18
STANDARD LIGHTS PAGE 19
Machines Serial Number (n° de série machines): WORK LIGHTS PAGE 20
E E
TL35.70 30kph : From ANL7
TL35.70 40kph : From ANMG
TL35.70 30kph : From AVM1
TL35.70 40kph : From AVM6 Dealer Copy -- Not for Resale
D D
TH.7035 30kph : From AR39
TH.7035 40kph : From AR3D
TH.7035 30kph : From B3C4
TH.7035 40kph : From B3C5
C C
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 1 of 20
A (PRINTED OCTOBER 2016)
A
Printed In Belgium 7299587 (0)
503 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
FUSES FUNCTION
H FUSE LOCATION SIZE(A) CIRCUIT FUNCTION 1 FUNCTION 2 FUNCTION 3 FUNCTION 4 FUNCTION 5 WIRE CATEGORIES FOR COLORS AND NUMBER RANGE H
RADIO, DOME LIGHT
F1 FRC1 (CAB) 20 BATTERY GATEWAY CONTROLLER IGNITION SWITCH DIAG. CONNECTOR BATT WARNING LIGHTS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
POWER SUPPLY
F2 FRC1 (CAB) 7,5 IGNITION DISPLAY CONTROLLER LLMI DIAG. CONNECTOR IGN SHUNT KEY SWITCHES BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
F3 FRC1 (CAB) 10 IGNITION FRONT WIPER WASHERS FNR LEVER BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
F4 FRC1 (CAB) 20 IGNITION REAR/ROOF WIPER LLMC RADIO IGNITION BEACON
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
F5 FRC1 (CAB) 25 IGNITION HVAC HEATER/BLOWER FAN INVERTER
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
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
G F8 FRC1 (CAB) 7,5 IGNITION SUSPENSION SEAT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL G
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
F9 FRC1 (CAB) 7,5 LIGHTS POSITION LIGHTS LEFT FOG LIGHT
CONTROLLER SUPLY
F10 FRC1 (CAB) 7,5 LIGHTS POSITION LIGHTS RIGHT (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
F11 FRC1 (CAB) 20 IGNITION CAB WORK LIGHTS LIGHTS 6000 THROUGH 6999 PINK PNK
F12 FRC1 (CAB) 20 IGNITION BOOM WORK LIGHTS BLUE WORK LIGHTS OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
F21 FRC2 (FRAME) 15 IGNITION DRIVE CONTROLLER ENGINE 8000 THROUGH 8999 TAN TAN
F22 FRC2 (FRAME) 15 IGNITION WORKGROUP CONTROLLER COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
F23 FRC2 (FRAME) 10 BATTERY ACD BATTERY SUPPLY
F F24 FRC2 (FRAME) 10 IGNITION ACD IGNITION SUPPLY
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
F
F25 FRC2 (FRAME) 7,5 IGNITION LOW SPEED DEFEAT HYD MOTOR RELAYS FUNCTION
F26 FRC2 (FRAME) 5 IGNITION JOYSTICK WHEELS ALIGNMENT RETRACT SWITCH REAR SHAFT SENSOR IGNITION SIGNAL RELAY LOCATION FUNCTION 1
FRC2 (FRAME) R1 FRC1 (CAB) LOW BEAM

F27 15 IGNITION REAR DIVERTER 2 BOOM DRAIN VALVE
FRC2 (FRAME) R2 FRC1 (CAB) HIGH BEAM

F28 10 IGNITION STOP LIGHTS REVERSE LIGHT BACK UP ALARM
TRACTOR TRAILER BRAKE R3 FRC1 (CAB) BLUE WORK LIGHTS
F29 FRC2 (FRAME) 5 IGNITION
VALVE
ALTERNATOR R4 FRC1 (CAB) CAB WORK LIGHTS
F41 FC3 (ENGINE) 25 IGNITION STARTER
EXCITATION
E F42 FC3 (ENGINE) 10 IGNITION FUEL SOLENOID FUEL PUMP TEMP. SWITCH
R5 FRC1 (CAB) BOOM WORK LIGHTS E
R6 FRC1 (CAB) FAN INVERTOR
F50 MEGAFUSE 100 IGNITION MAIN IGNITION POWER GLOW PLUGS
R9 FRC2 (FRAME) LOW SPEED
R10 FRC2 (FRAME) REVERSE & BACKUP ALARM
R11 FRC2 (FRAME) STOP LIGHTS
R12 FRC2 (FRAME) TRACTOR TRAILER BRAKE
R13 FRC2 (FRAME) DEFEAT HYD MOTOR

Dealer Copy -- Not for Resale FRC2 (FRAME)
R14 BOOM DRAIN VALVE
D R16 FRC2 (FRAME) REAR DIVERTER

D
R21 ENGINE STARTER RELAY
R22 ENGINE GLUW PLUGS RELAY
R24 ENGINE FUEL SOLENOID PUMP
FRC 1 R25 ENGINE FUEL PUMP
FC 3
C C
STOP
WIRING SCHEMATIC
B FRC 2
B
TL35.70 (S/N ANL714000 - ANL7999999)
STOP
TL35.70X (S/N ANMG14000 - ANMG99999)
R TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 2 of 20
A
504 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
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
H C100 ENGINE TO FRAME 29
6,8,12,13,
C400 HYDRAULIC OIL TEMPERATURE 2 15 C200 ICON DISPLAY CLUSTER 8 14,18,19 C280 SUSPENSION SEAT MOTOR 2 10
CONNECTOR DESCRIPTION PINS SHEET
H
14 C302 FRONT LIGHTS LEFT 6 19
C103 FUEL PUMP 2 9 C401 BACKUP ALARM 2 19 C205 REAR AUX/HYD HOOK SWITCH 10 18 C281 FRONT WIPER MOTOR 6 10
C303 REAR LIGHTS LEFT 6 19
C105 FUEL SOLENOID 2 9 C402 GEAR 1 VALVE 2 12 C210 IGNITION KEY SWITCH 6 9 C282 SEAT SWITCH 2 10
C304 FRONT LIGHTS RIGHT 6 19
C109 ELECTRONIC BATTERY DISC. 2 6 C403 GEAR 2 VALVE 2 12 C211 AC SWITCH 3 10 C284 QUICKTACH POWER SWITCH 10 18 C305 REAR LIGHTS RIGHT 6 19
C110 ALTERNATOR 2 9 C412 BOOM UP 2 15 C212 BLOWER SPEED SWITCH 5 10 C290 DIAGNOSTIC CONNECTOR 7 8, 16
C306 LICENSE PLATE LIGHT 2 20
C113 GLOW PLUGS 1 9 C413 BOOM DOWN 2 15 C213 HEATER AND BLOWER MOTOR 5 10 T26 LOWER CAB GND 1 7 C307 TRAILER PLUG 7 19
C115 VARIABLE FAN SPEED 2 9 C414 TILT UP 2 15 C214 THERMOSTAT MODULE 3 10 T50, T51 AC PRESSURE SWITCH 1 10 C332 LIGHTS TO BOOM 2 20
G C116 FAN INVERTER 2 9 C415 TILT DOWN 2 15 C215 EMREGENCY STOP SWITCH 4 9 T59, T60 CAB BUZZER 1 10 C333 FRAME TO BLUE LIGHT LEFT 2 20 G
C117 SWASH PLATE SENSOR 4 12 C416 BOOM EXTEND 2 15 C216 FAN INVERTER SWITCH 10 9 C601 REAR WIPER MOTOR 2 11 C334 FRAME TO BLUE LIGHT RIGHT 2 20
C120 DRIVE PUMP FORWARD 2 12 C417 BOOM RETRACT 2 15 C218 SHUNT KEY 2 17 C602 ROOF WIPER MOTOR 3 11 T70, T71 BLUE WORK LIGHT LEFT 1 20
C121 DRIVE PUMP REVERSE 2 12 C418 AUX A4 VALVE 2 15 C219 GEAR SELECT SWITCH 10 12 C603 CAR RADIO SUPPLY 8 11 T72, T73 BLUE WORK LIGHT RIGHT 1 20
C123 AC COMPRESSOR CLUTCH 2 10 C419 AUX B4 VALVE 2 15 C221 FLASHER RELAY 6 19 C604 CAR RADIO SPEAKERS 8 11
10,12,13,
C130 LOW SPEED 2 12 C420 RETRACT SWITCH 4 15 C224 LEFT LEVER 12 C605 FRONT LEFT WORK LIGHT 2 20
19
C131 DEFEAT VALVE 2 12 C421 CRAB STEER VALVE 2 14 C225 FNR LEVER 6 12 C606 FRONT RIGHT WORK LIGHT 2 20
C141 1ST/2ND GEAR SWITH 2 12 C422 4 WHEEL STEER 2 14 C227 12V SOCKET 2 10 C607 REAR WORK LIGHT 2 20
F C143 STEERING PRESSURE SENSOR 3 14 C423 SAFETY VALVE 2 16 C229 CAB TO LLMI SENSOR 8 17 C608 DOME LIGHT 3 11 F
C150 TRACTOR TRAILER BRAKE VALVE 2 13 C424 HORN 2 10 8,10,12, C620 ROOF WIPER SWITCH 10 11
C230 CAB TO FRAME 40 14,16,17,
C158 ENGINE OIL PRESSURE 2 9 C425 STEERING PRESSURE SENSOR 3 14 18,19,20 C621 BEACON SWITCH 10 11
C235 IGNITION TO CAB 1 6 C427 RETRACT SWITCH 2 4 15 C232 CAB TO UPPER CAB 4 11,20 T32 UPPER CAB GND 1 7
6,8,9,10,
BOOM CONNECTORS ASSIGNMENT
T1, T2 MEGAFUSE F50 1 6 C431 REAR DIVERTER 1 2 18 C233 CAB TO ENGINE 24 T78, T79 BEACON 1 11
20 CONNECTOR DESCRIPTION PINS SHEET
T5,T6,T7,T8 GLOW PLUGS RELAY 1 9 C432 REAR DIVERTER 2 2 18 C235 CAB TO IGNITION 1 6 T84, T85 SPEAKER RIGHT 1 11
C433 BOOM ACD TO FRAME 8 8, 16
T10,T11,T12 ELECTRONIC BATTERY DISC. 1 6 C433 FRAME TO BOOM ACD 8 8,16 C237 LLMI 6 8, 17 T86, T87 SPEAKER LEFT 1 11
C501 ACD CONNECTOR 7 8, 16
T16 ALTERNATOR B+ 1 9 8, 17
E T43 ALTERNATOR EXCITATION 1 9
C435 FRONT/REAR DIVERTER SWITCH 2 18 C238 LLMC 6
8,10,12,
C504 BOOM WORK LIGHT LEFT 2 20 E
C436 BOOM ANGLE SENSOR 8 15 C240 DISPLAY (BLACK CONNECTOR) 12
19 C505 BOOM WORK LIGHT RIGHT 2 20
T18, T19 STARTER B 1 9 C451 REAR SHAFT SPEED SENSOR 2 12 DISPLAY (GRAY CONNECTOR) 9,12,13,
C241 12
19
T20 STARTER S 1 9 C452 REAR WHEELS ALLIGNMENT 3 14 C242 WIPER SWITCH 10 10
T23 ENGINE GND 1 6, 7 C453 FRONT WHEELS ALLIGNMENT 3 14 C243 FUEL LEVEL SENSOR 2 10
T29 ECU CASE GND 1 7 C455 GERMAN BRAKE RESERVE PRESSURE 3 13 C244 CAB TO FUEL LEVEL SENSOR 3 10
T30, T31 BATTERY 1 6 C456 PARK BRAKE PRESSUE SWITCH 2 13 C247 LLMI TO SENSOR 4 17
T44, T45 ENGINE SPEED SENSOR 1 9 C458 PARK BRAKE VALVE 2 13 C248
Dealer Copy 4-- Not
LLMC TO SENSOR 17
for Resale
T55, T56 ENGINE COOLANT TEMPERATURE 1 9 C459 SERVICE BRAKE PRESSURE SENSOR 3 13 C250 KEYLESS PAD (KSS) 6 8, 9
D C460 QUICTACH POWER VALVE 2 18 C251 BRAKE INCHING POTENTIOMETER 3 12
D
TRAILER PRESSURE RELEASE
C467 10 13 C253 SMART HANDLING SYSTEM SWITCH 10 16
SWITCH
C701 BOOM DRAIN VALVE 2 18 C254 CREEP ENABLE SWITCH 10 12
C703 BOOM SUSPENSION VALVE 2 18 C256 JOYSTICK 4 8, 15
T35 FRAME GND 1 7 C257 ACD LH SKI SWITCH 10 18

HYDRAULIC FILER 1
T80, T81 1 15 C259 ACD RH SKI SWITCH 18
(CLOGGING INDICATOR 1)
HYDRAULIC FILER 2 C260 STEER MODE SWITCH 10 14
T82, T83 1 15
(CLOGGING INDICATOR 2)
C261 PARK BRAKE SWITCH 10 13
C C265 FRONT WASHER MOTOR 2 10
C
C267 WASHER SWITCH 10 10
C270 WARNING SWITCH 10 19
C272 FOG LIGHT SWITCH 10 19

BRAKE FAIL PRESSURE LAMP
C273 4 13
BRAKE FAIL ELECTRIC LAMP
C275
4W STEER LAP
CRAB STEER LAMP
4 14 WIRING SCHEMATIC
C276 TRAILER INDICATOR LAMP 4 19
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 3 of 20
A
505 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
J1 CONNECTOR ASSIGNMENT (GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENT (DRIVE CONTROLLER) J3 CONNECTOR ASSIGNMENT (WORKGROUP CONTROLLER)
H H
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 BRAKE FAIL ELECTRIC LAMP B-1 ENGINE OIL PRESSURE A-1 DRIVE PUMP FORWARD RETURN B-1 P.B.ACCU VALVE RELAY FDBK A-1 BOOM EXTEND RETURN B-1 SPARE
A-2 SAFETY VALVE RETURN B-2 POWER SUPPLY A-2 SPARE 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 SPARE B-3 POWER SUPPLY
A-4 FRONT ALIGNMENT LAMP B-4 CRAB STEER VALVE A-4 DEFEAT HYD MOTOR 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 P.B.ACCU VALVE RELAY B-5 DRIVE PUMP REVERSE A-5 SPARE B-5 BOOM RETRACT
A-6 REAR ALIGNMENT LAMP B-6 VARIABLE FAN SPEED A-6 DEF COOLING FAN RELAY B-6 AUX A4 VALVE A-6 SPARE B-6 BOOM UP
G 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
G
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 CAB BUZZER B-10 INCHING POTENTIOMETER A-10 DRIVE PUMP REVERSE RETURN B-10 SWASH PLATE SENSOR 1 A-10 TILT UP RETURN B-10 BOOM ANGLE 2
A-11 SPARE B-11 IVS SWITCH (ST4) A-11 DEFEAT HYD MOTOR RELAY FDBK B-11 PARK BRAKE PRESSURE SENSOR A-11 SPARE B-11 SPARE
A-12 PARK BRAKE SW (NO) B-12 FUEL LEVEL HYDRAULIC FILTER CLOGGING
A-12 STOP LIGHT RELAY FDBK B-12 A-12 SPARE B-12 SPARE
INDICATOR
A-13 CRANKING POSITION B-13 SPARE A-13 RETRACT SWITCH 1 (NO) B-13 TILT UP
A-13 HIGH/LOW SPEED SWITCH B-13 GEAR 1 VALVE
F A-14 CRAB STEER SWITCH B-14 CAN HI 2
A-14 GEAR SELECTOR SWITCH B-14 SPARE A-14 SHUNT KEY POSITION B-14 SPARE F
A-15 ENGINE SPEED (ST3A) B-15 GND A-15 SPARE B-15 GND
A-15 REAR SHAFT SPEED B-15 GND
A-16 EMERGENCY STOP SWITCH B-16 GND A-16 SPARE B-16 GND
A-16 SPARE B-16 GND
A-17 FUEL PUMP RELAY B-17 SENSOR GND
A-17 TRACTOR TRAILER BRAKE VALVE B-17 SENSOR GND A-17 SPARE B-17 SENSOR GND
A-18 BRAKE FAIL PRESSURE LAMP B-18 ANALOG THROTTLE PEDAL (ST4) GERMAN RESERVE BRAKE
A-18 AUX B4 RETURN B-18 A-18 BOOM RETRACT RETURN B-18 HYDRAULIC OIL TEMPERATURE
PRESSURE
A-19 FRONT ALIGNMENT STATUS B-19 SAFETY VALVE
A-19 SPARE B-19 GEAR 2 VALVE A-19 SPARE B-19 TILT DOWN
A-20 SPARE B-20 CAN LO 2
A-20 LS PUMP INLET PRESSURE (ST3A) B-20 SPARE A-20 SPARE B-20 SPARE
E A-21 ACD LH SKI SWITCH UP B-21 ATTACHMENT RUN
A-21 POSITION LIGHTS STATUS B-21 IGNITION SIGNAL A-21 RETRACT SWITCH 1 (NC) B-21 IGNITION SIGNAL E
A-22 ACD RH SKI SWITCH UP B-22 IGNITION POSITION TRACTOR TRAILER BRAKE
A-22 B-22 FNR LEVER A-22 RETRACT SW 2 (NO) B-22 QUICKTACH POWER SWITCH
A-23 B-23 RELAY FDBK
REAR ALIGNMENT STATUS SENSOR SUPPLY 5V
A-23 SPARE B-23 SENSOR SUPPLY 5V A-23 SPARE B-23 SENSOR SUPPLY 5V
A-24 ACD LH SKI SWITCH DOWN B-24 SMART HANDLING SYSTEM
A-24 SPARE B-24 BOOM ANGLE 1
A-24 SPARE B-24 SWASH PLATE SENSOR 2
A-25 SPARE B-25 BATTERY DISCONNECT
A-25 SPARE B-25 QUICKTACH POWER
A-25 STEERING PRESSURE SENSOR B-25 SPARE
A-26 VARIABLE FAN SPEED FDBK B-26 SPARE
A-26 BOOM UP RETURN B-26 SPARE
A-26 PARK BRAKE VALVE RETURN B-26 PARK BRAKE VALVE
A-27 SPARE Dealer Copy -- Not for Resale A-27 TILT DOWN RETURN
A-27 AUX A4 RETURN
A-28 ACD ATTACH SKI SWITCH RIGHT
D A-29 4 WHEEL STEER SWITCH
A-28 FNR LEVER REVERSE
A-28 SPARE
D
A-29 SPARE
A-29 SPARE
A-30 ACD RH SKI SWITCH DOWN
A-30 SPARE
A-30 TRAILER PRESSURE RELEASE SWITCH
A-31 ACD ATTACH SKI SWITCH LEFT
A-31 RETRCAT SW 2 (NC)
A-32 ENGINE COOLANT TEMPERATURE A-31 FNR LEVER FORWARD
A-32 SPARE
A-33 SEAT SWITCH A-32 SERVICE BRAKE PRESSURE
A-33 SPARE
A-34 IGNITION FDBK A-33 1ST/2ND GEAR SWITCH
A-34 SPARE
A-34 LOW SPEED RELAY FDBK
C C
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 4 of 20
A
506 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
J6 CONNECTOR ASSIGNMENT (AUXILIARY CONTROLLER)
H PIN FUNCTION PIN FUNCTION H
A-1 BOOM SUSPENSION RETURN B-1 SPARE
A-2 SPARE B-2 POWER SUPPLY
A-3 BOOM DRAIN VALVE RELAY B-3 POWER SUPPLY

Connector C241 Connector C240
C240, C241 CONNETCOR ASSIGNMENT (DISPLAY CONTROLLER)
A-4 SPARE B-4 SPARE
PIN FUNCTION PIN FUNCTION
A-5 BOOM SUSPENSION LAMP B-5 REAR DIVERTER 1
C240-1 POWER SUPPLY C241-1 FAN INVERTER SWITCH
A-6 REAR DIVERTER 2 B-6 BOOM SUSPENSION
C240-2 GND C241-2 ECO MODE STATUS (ST4)
G A-7 SPARE B-7 SPARE

C240-3 CAN HI C241-3 ACTIVE DESOX STATUS (ST4) G
A-8 SPARE B-8 CAN LO 1 INHIBIT DESOX STATUS (ST4)
C240-4 CAN LO C241-4
A-9 SPARE B-9 CAN HIGH 1 C240-5 IGNITION INPUT C241-5 SPARE
LP PUMP CONTROL VALVE
A-10 B-10 SPARE C240-6 SPARE C241-6 SPARE
RETURN(ST4)
A-11 SPARE B-11 SPARE C240-7 CREEP SWITCH C241-7 SPARE
C240-8 HIGH BEAM STATUS C241-8 SPARE

A-12 SPARE B-12 SPARE
C240-9 FORCED DESOX SWITCH (ST4) C241-9 PARK BRAKE SW (NC)
A-13 SPARE B-13 LS PUMP CONTROL VALVE (ST4)
C240-10 SPARE C241-10 SPARE
A-14 BOOM DRAIN VALVE RELAY FEEDBACK B-14 CAN HIGH 2
F C240-11 TURN SIGNAL STATUS C241-11 SPARE F
A-15 SPARE B-15 GND
C240-12 SPARE C241-12 ECO MODE ENABLE SWITCH (ST4)
A-16 SPARE B-16 GND
A-17 SPARE B-17 SENSOR GND
A-19 SPARE B-19 SPARE COMPONENTS SUPPLIED BY 5 VDC

LS PUMP INLET PRESSURE SENSOR J1B-23, POWER SUPPLY 5 VDC J1B-17, GROUND 0 VDC
A-20 B-20 CAN LO 2
(ST4) CONNECTOR DESCRIPTION SHEET CONNECTOR DESCRIPTION SHEET
E A-21 REAR AUX SW B-21 IGNITION SIGNAL
GATEWAY CONTROLLER J1 E
A-22 SPARE B-22 SPARE C251-C INCHING POTENTIOMETER 12 C251-A INCHING POTENTIOMETER 12
A-23 SPARE B-23 SENSOR SUPPLY 5V C222-F THROTTLE PEDAL 20, 12 C222-C, D THROTTLE PEDAL 12,12
LS PUMP OUTLET RESSURE C457-B FUEL LEVEL SENSOR 10

A-24 SPARE B-24
SENSOR (ST4)
DRIVE CONTROLLER J2
A-27 SPARE
C117-4 SWASH PLATE SENSOR
Dealer
12
Copy
C117-1
-- Not SWASH
for Resale
PLATE SENSOR 12
C144-A INLET PRESSURE SENSOR 12,15 C144-B INLET PRESSURE SENSOR 15
D A-28 SPARE
C425-B STEERING PRESSURE SENSOR 12,14 C425-A STEERING PRESSURE SENSOR 12,14 D
A-29 SPARE 13,12 13,12
C455-B GERMAN BRAKE RESERVE PRESSURE C455-A GERMAN BRAKE RESERVE PRESSURE
A-30 REAR HOOK SW C456-B PARK BRAKE PRESSURE 13,12 C456-A PARK BRAKE PRESSURE 13,12
A-31 REAR DIVERTER 2 FDBK C459-B SERVICE BRAKE PRESSURE 13,12 C459-A SERVICE BRAKE PRESSURE 13,12
Connector A
A-32 SPARE C451-4 REAR SHAFT SPEED 12 C451-5 REAR SHAFT SPEED 12 Connector B
A-33 REAR DIVERTER SWITCH WORKGROUP CONTROLLER J3
A-34 SPARE C436-1,4 BOOM ANGLE SENSOR 15 C436-7,8 BOOM ANGLE SENSOR 15
C400-B HYDRAULIC OIL TEMPERATURE 15
C ACRONYMS DESCRIPTION C
AC AIR-CONDITIONING
ACD ATTACHMENT CONTROL DEVICE
DRV DRIVE CONTROLLER
EMEA EUROPE, MIDDLE EAST, AFRICA
FORWARD, NEUTRAL, REVERSE

FNR
WIRING SCHEMATIC
GTW GATEWAY CONTROLLER
HVAC HEATING VENTILATION AIR-CONDITIONING

B B
KSS KEYLESS START SYSTEM
TL35.70 (S/N ANL714000 - ANL7999999)
LLMI LONGITUDINAL LOAD MOMENT INDICATOR
LLMC LONGITUDINAL LOAD MOMENT CONTROLLER

TL35.70X (S/N ANMG14000 - ANMG99999)
LS LOAD SENSING TL35.70 (S/N AVM114000 - AVM199999)
RSS RUN, START, STOP
TL35.70X (S/N AVM614000 - AVM699999)
WGP WORKGROUP CONTROLLER
Sheet 5 of 20
A
507 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
POWER H
G G
C235
C100
F F
E E
D D
C C233 C
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 6 of 20
A
508 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
GROUND H
G G
T35
F F
T26
E E
LOWER CAB GROUNDS Dealer

FRAME Copy
GROUNDS -- Not for Resale
D D
T23
C T32
C
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
UPPER CAB GROUNDS TL35.70 (S/N AVM114000 - AVM199999)
T35 TL35.70X (S/N AVM614000 - AVM699999)
Sheet 7 of 20
A ENGINE GROUNDS
(PRINTED OCTOBER 2016)
A
509 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
LOWER CAB
H
CAN BUS H
G G
FRAME
F F
C290
VEHICLE
DIAGNOSTIC
E CONNECTOR E
C100
ENGINE
C233
D D
C230 C100
C C
C169
ENGINE WIRING SCHEMATIC

DIAGNOSTIC
B CONNECTOR B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 8 of 20
A
510 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H ENGINE, H
IGNITION
G G
GATEWAY CONTROLLER
F F
DISPLAY
CONTROLLER
E E
C233
D D
C158
C114
C116
C115
C C
P
T16 T18 T19 T20
C105
C103
C113
C110
B+ B S
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
T
TL35.70X (S/N ANMG14000 - ANMG99999)

TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
HARNESS ENGINE
Sheet 9 of 20
A
511 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H LOWER CAB H
INTERNALLY CONNECTED
WITH PIN 1 - SEE SHEET 18/G5
G G
GATEWAY CONTROLLER
F M
F
E E
P
C244-B C244-A
C230
C233 Dealer Copy -- Not for Resale
D D
HARNESS FRAME
C243
C282
C424
C C
C280
C227
C123
C281
C265
12V SOCKET
15 Amps max.
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
HARNESS ENGINE TL35.70X (S/N AVM614000 - AVM699999)
Sheet 10 of 20
A
512 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS FRAME
H UPPER CAB H
G G
F F
C232
E E

D D
C604
C603
C602
C608
C601
RADIO
SUPPLY
- -
C + +
C
HARNESS UPPER CAB
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 11 of 20
A
513 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H
TRANSMISSION H
WITH PIN 1 - SEE SHEET 18/G5
G G
C230
HARNESS FRAME
DRIVE CONTROLLER GATEWAY

CONTROLLER
F F
DISPLAY
CONTROLLER
E E
D D
C100
C251
C451
C402
C403
C C
WIRING SCHEMATIC
C117
C141
C131
C121
C130
C120
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 12 of 20
A HARNESS ENGINE (PRINTED OCTOBER 2016)
A
514 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER
H BRAKES H
G G
F F
DRIVE CONTROLLER
DISPLAY
GATEWAY
CONTROLLER
E E
D D
C100
C C
C150
C458
C456
C455
C459
WIRING SCHEMATIC
B B
P P P TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
EMEATRACTOR
TL35.70 (S/N AVM114000 - AVM199999)
GERMAN
OPTION OPTION TL35.70X (S/N AVM614000 - AVM699999)
HARNESS ENGINE HARNESS FRAME
Sheet 13 of 20
A
515 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H STEERING H
G G
GATEWAY DRIVE
CONTROLLER CONTROLLER
F F
E E
C230 C100
D D
HARNESS ENGINE
C425
C143
C P P
C
TRACTOR TRACTOR
C421
C452
C453
C422
LS PUMP GEAR PUMP
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
HARNESS FRAME TL35.70X (S/N AVM614000 - AVM699999)
Sheet 14 of 20
A
516 of 836
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS FRAME
H
LS PUMP
WORKGROUP H
P P
G G
WORKGROUP CONTROLLER DRIVE CONTROLLER
F F
E E
D D
C C
C419
C436
C414
C418
C420
C427
C412
C413
C416
C400
C415
C417
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
HYDRAULIC BLOCK TL35.70X (S/N AVM614000 - AVM699999)
Sheet 15 of 20
A
517 of 836
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
HARNESS LOWER CAB
WORKGROUP H
G G
C290
GATEWAY
CONTROLLER
F F
VEHICLE
DIAGNOSTIC
CONNECTOR
E E
C230
D D
C423
C C
HARNESS ENGINE
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 16 of 20
A
518 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H LLM SYSTEM H
(EMEA ONLY)
G G
C238 C237 C230
F F
LLMC CONTROLLER LLMI DISPLAY WORKGROUP

CONTROLLER
E E
HARNESS FRAME
C248
C247
C229
D D
C C
LLMI & LLMC
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 17 of 20
A
519 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
H
HARNESS LOWER CAB
AUXILIARY H
HYDRAULIC
G G
C230
F F
AUXILIARY CONTROLLER
WORKGROUP
CONTROLLER
E E
D D
C433
C460
HARNESS BOOM 7M
C C
C501
ACD CONNECTOR
C431
C432
C435
C701
C703
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
REAR AUXILIARY TL35.70 (S/N AVM114000 - AVM199999)
BOOM OPTION
OPTION TL35.70X (S/N AVM614000 - AVM699999)
HARNESS FRAME Sheet 18 of 20
A
520 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H STD H
SEE SHEET 12/H7 AND

SHEET 10/G2
LIGHTS
WITH PIN 1
G G
DISPLAY DRIVE CONTROLLER

CONTROLLER
F F
E E

C230
D D
C C
WIRING SCHEMATIC
C303
C302
C305
C304
B B
TL35.70 (S/N ANL714000 - ANL7999999)
C307
TL35.70X (S/N ANMG14000 - ANMG99999)

TRAILER
PLUG TL35.70 (S/N AVM114000 - AVM199999)
HARNESS FRAME TL35.70X (S/N AVM614000 - AVM699999)
Sheet 19 of 20
A
521 of 836 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
HARNESS LOWER CAB
H WORK H
LIGHTS
G G
GATEWAY CONTROLLER
F F
E E
C232 C230
D D
HARNESS FRAME
C333 C334 C332
C C
C607
C606
C605
C504
C505
WIRING SCHEMATIC
B B
TL35.70 (S/N ANL714000 - ANL7999999)
TL35.70X (S/N ANMG14000 - ANMG99999)
TL35.70 (S/N AVM114000 - AVM199999)
HARNESS UPPER CAB HARNESS BLUE LIGHTS HARNESS BOOM WK LIGHTS
TL35.70X (S/N AVM614000 - AVM699999)
Sheet 20 of 20
A
522 of 836 8 7 6 5 4 3 2 1
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Key - Multi position switch 0.5 ohm A the solenoid coils are listed next to
B
to activate various start functions at the component [if available]). The pull
ST different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch.
BUZZER - Audible alarm. Sounds at a

1
SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3700 3710 SPLICE (•) - Used to show when

3110
multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000 ohm
ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A
SPEED SENSOR - magnetic pickup -
detects rpm.
B

Cab Harness Connectors
T84 C620 C608 C601 C602

C605 T85 C621 C603
C227
C210 C200 C606 C604
C218-3 C270
C218-4
C219 C607
C242
C254
T78
C260
T79
C263
C267
T32
C272
C273
C275 T86
C276 T87

C240
C241 C232
C205 C232
C206
C216
C237
C252 C211
C253 C212
C261
C257
C262
C259
C284
C288 C280
C215 C282
J1A
C225
J1B
C230 C214
C233
C235 T50
T26 T51
C244-A C265
C244-B
C238
C251 C169
C222-ST3A C213
T59 C221
C222-ST4
T60 C290
C224 C243
C250
Cab Harness Lower 7405975 FRC1
Cab Harness UPPER 7326339
NA13896

CONNECTOR CONNECTS TO
Cab Harness Connectors (Cont’d) C260 STEER MODE CRAB / 4 WHEEL
C261 PARK BRAKE SWITCH
C262 E.G. CONTROL SWITCH
C169 ENGINE DIAGNOSTIC CONNECTOR C263 PRESSURE GAUGE
C200 ICON CLUSTER FRONT / REAR C265 FRONT / REAR WASHER MOTOR
ALIGN. LAMP
C267 WASHER SWITCH
C205 REAR AUX / HOOK SWITCH
C270 WARNING SWITCH
C206 BOOM SUSPENSION SWITCH
C272 FOG LIGHT SWITCH
C210 IGNITION SWITCH OR RSS
C273 BRAKE LAMPS
C211 AC SWITCH
C275 4 WHEEL / CRAB STEER LAMP
C212 BLOWER SPEED
C276 TRAILER LAMP
C213 HEATER AND BLOWER
C280 SUSPENSION SEAT
C214 THERMOSTAT MODULE
C282 SEAT SWITCH
C215 ERMERGENCY STOP SWITCH
C284 POWER QUICKTACH SWITCH
C216 FAN INVERTER
C288 DESOX SWITCH
C218-3,  SHUNT KEY
C218-4 C290 VEHICLE DIAGNOSTIC CONNECTOR
C601 REAR WIPER MOTOR

C219 GEAR SELECTOR
C221 FLASHER RELAY C602 ROOF WIPER MOTOR
C222-ST3A THROTTLE PEDAL SENSOR ST3A C603 RADIO SUPPLY
C222-ST4 THROTTLE PEDAL SENSOR ST4 C604 RADIO SPEAKERS
C224 LEFT LEVER (HORN SWITCH) C605 FRONT LEFT WORK LIGHT
C225 FNR LEVER C606 FRONT RIGHT WORK LIGHT
C227 12V SOCKET C607 REAR WORK LIGHT
C230 HORN C608 DOME LIGHT
C232 LOWER CAB TO UPPER CAB C620 ROOF WIPER SWITCH
C233 CAB TO ENGINE C621 BEACON SWITCH
C235 CAB TO IGNITION FRC1 CAB FUSE BOX
C237 LLMI DISPLAY J1A, J1B GATEWAY CONTROLLER
C238 LLMC CONTROLLER T26 LOWER CAB GND
C240 DISPLAY CONTROLLER (BLACK) T32 UPPER CAB GND
C241 DISPLAY CONTROLLER (GRAY) T50, T51 PRESSURE SWITCH
C242 WIPER SWITCH T59, T60 CAB BUZZER
C243 FUEL GAUGE T78, T79 BEACON
C244-A CAB TO FUEL SENSOR T84, T85 RADIO RIGHT SPEAKER
C244-B FUEL SENSOR TO CAB T86, T87 RADIO LEFT SPEAKER
C250 KSS
C251 INCHING POTENTIOMETER
C252 ECO MODE SWITCH
C253 SMART HANDLING SYSTEM SWITCH
C254 CREEP ENABLE SWITCH
C257 ACD LH SKI SWITCH
C259 ACD RH SKI SWITCH

Mainframe Harness Connectors
C433 C432 C306

C305
C332
C420 C436
C335 C427
C730 C307
C401 C308
C431 C309
C463
C460
C423
C425 C464
C467
C452
T80
T81 J6A
T82 J6B
T83
J3A
C256
J3B

C230
T35 C303
J2A C435
J2B
C100
C101
C412
C413
C414
C304 C415
C416
C520 C417
C418
C424
C419
C400
C451
FRC2
C461
C462 C402
C453 C302 C403 C455 C459 C333
C421 C334
C422
C456
Frame Harness 7333154 C458
NA15151

Mainframe Harness Connectors (Cont’d) C452 REAR WHEELS ALIGNMENT
C453 FRONT WHEELS ALIGNMENT
C455 GERMAN BRAKE RES. PRESSURE
C100, C101 FRAME TO ENGINE C456 PARK BRAKE PRESSURE
C230 FRAME TO CAB C458 PARK BRAKE VALVE
C256 JOYSTICK C459 SERVICE BRAKE PRESSURE
C302 FRONT LEFT LIGHTS C460 HYD. QUICKTACH VALVE
C303 REAR LEFT LIGHTS C461 PARK BRAKE ACCU VALVE
C304 FRONT RIGHT LIGHTS C462 REDUNDANCY PARK BRAKE VALVE
C305 REAR RIGHT LIGHTS C463 TRAILER SUPPLEMENTARY LINE
C306 LICENSE PLATE LIGHTS VALVE
C307 TRAILER LIGHT PLUG C464 TRAILER COMMAND LINE VALVE
C308 COMMAND TRAILER BRAKE PLUG C467 TRAILER PRESSURE RELEASE
C309 PWR TRAILER BRAKE PLUG SWITCH
C332 FRAME TO WORK LIGHT C520 FRAME TO AIRBRAKE
C333 LEFT BLUE WOPRK LIGHT C730 FRAME TO BOOM SUSPENSION
C334 RIGHT BLUE WORK LIGHT FRC2 FRAME FUSE BOX

C335 FRAME WORK LIGHT J2A, J2B DRIVE CONTROLLER
C400 HYDRAULIC OIL TEMP J3A, J3B WORKGROUP CONTROLLER
C401 BACK UP ALARM J6A, J6B AUXILIARY CONTROLLER
C402 GEAR 1 T35 FRAME GND
C403 GEAR 2 T80 HYD. FILTER 1
C412 BOOM UP T81 HYD FILTER 1 GND
C413 BOOM DOWN T82 HYD. FILTER 2
C414 TILT UP T83 HYD. FILTER 2 GND
C415 TILT DOWN

C416 BOOM EXTEND
C417 BOOM RETRACT
C418 AUX A4
C419 AUX B4
C420 RETRACT SENSOR 1
C421 CRAB STEER
C422 4 WHEELS
C423 SAFETY VALVE
C424 HORN
C427 RETRACT SENSOR 2
C431 REAR DIVERTER 1
C432 REAR DIVERTER 2
C433 FRAME TO BOOM ACD
C435 FRONT / REAR DIVERTER SWITCH
C436 BOOM ANGLE SENSOR
C451 REAR SHAFT SPEED SENSOR

Engine Bay Harness Connectors
T54
C105
T55
T56
C113
C103
C123
T18
C115 T19
C117 T20
C121 C158

C120
T23
C116
C110
T16
C109
T11 C114
C143 C130
C131
C150 C233
C235
T35
FC3
T1 C100
T5
T6 T2 C141
T7 R21
T8 R24
R25
Engine Harness 7343662
NA15149

Engine Bay Harness Connectors (Cont’d)
C100 ENGINE TO FRAME
C103 FUEL PUMP
C105 FUEL SHUTOFF VALVE
C109 BATTERY DISCONNECT
C110 ALTERNATOR
C113 GLOW PLUGS
C114 SPEED SENSOR
C115 VARIABLE FAN SPEED
C116 REVERSE FAN
C117 SWASH PLATE SENSOR
C120 DRIVE PUMP FWD
C121 DRIVE PUMP REV
C123 AC CLUTCH
C130 LOW SPEED SOLENOID

C131 DEFEAT VALVE
C141 1ST / 2ND GEAR SWITCH
C143 STEERING PRESSURE SENSOR
C150 TRACTOR TRL BRAKE VALVE
C158 ENGINE OIL PRESSURE
C233 ENGINE TO CAB
C235 IGNITION TO CAB
FC3 FUSE BOX
R21 STARTER RELAY
R24 FUEL SOLENOID RELAY
R25 FUEL PUMP RELAY
T1, T2 FUSE F50
T11 BATTERY DISCONNECT
T16 ALTERNATOR B+
T18 STARTER B
T19 STARTER TO MEGAFUSE
T20 STARTER S
T23 STARTER GND
T35 FRAME GND
T5, T6, T7, T8 GLOW PLUGS RELAY
T54 ENGINE TEMP. SWITCH
T55, T56 ENGINE COOLANT TEMP.

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) Fuses And Relay Location / Identification
Description The electrical system is protected by fuses and relays on

three locations:
The telescopic handler has a 12 volt, negative ground
alternator charging system. The electrical system is • in the cab below the dashboard. (See Cab on Page
protected by fuses on three locations. (See Fuses And 60-10-12.)
Relay Location / Identification on Page 60-10-11.) • on the front frame left of the boom. (See Frame on
Page 60-10-13.)
The fuses will protect the electrical system when there is • in the front left corner of the engine compartment.
an electrical overload. The reason for the overload must (See Engine Compartment on Page 60-10-14.)
be found before starting the engine again.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Fuses And Relay Location / Identification (Cont’d)

5 9 11 13 15
Cab 1 6 17
Figure 60-10-1 2 18
3 19
4 20
7 10 12 14 16
1 8
S38028
2
The location and description are shown below and in
[Figure 60-10-3].
REF DESCRIPTION AMP REF DESCRIPTION AMP

S38026
1 A/C and Heater / 25 11 Blue Worklights R
ACD Switches

Loosen the retainer screw (Item 1) and remove the / Fan Inverter
console cover (Item 2) [Figure 60-10-1]. 2 Headlights / 15 12 Fan Inverter R
Direction Lights /
Figure 60-10-2 Horn
3 Low/High Beam 15 13 High Beam R
4 Ignition feedback 7,5 14 Not Used R
1 on Gateway
controller /
Suspension Seat
(If equipped)
5 Cab light / 20 15 Low Beam R
Gateway
Controller /
Ignition Key
2 Switch / Radio /
Warning Lights
1
6 Display Panel / 7,5 16 Not Used R
LLMI / Shunt key /
S38027 Switches
7 Front Wiper / 10 17 Park Lights Left / 7,5
Washers / Fog Light
Remove retainer screws (Item 1) and remove the cover
Emergency Stop /
(Item 2) [Figure 60-10-2] to check or replace fuses or Travel Direction
relays. Lever
8 Rear and Roof 20 18 Park Lights Right 7,5
Wiper / LLMC /
Radio Ignition /
Beacon
9 Cab Work Lights R 19 Cab Work Lights 20
10 Boom Worklight R 20 Boom and Blue 20
Work Lights
R - Relay

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-6
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 Defeat Valve R

Remove the three bolts (Item 1) and remove the cover 2 Not Used — 12 Trailer Brake R
(Item 2) [Figure 60-10-4]. Valve (Tractor)
3 Not Used — 13 Ignition Power 10
Installation: Tighten the bolts (Item 1) [Figure 60-10-4] Supply
to maximum 16 N•m (12 ft-lb) torque.
4 Trailer Brake 5 14 Battery Power 10
Valve Supply
Figure 60-10-5
5 Rear Diverter R 15 Work Group 15
Controller
6 Low Speed R 16 Drive Controller 15
7 Not Used — 17 Stop Lights / 10
2 Reverse Light /
Back Up Alarm
8 Back-up Alarm / R 18 Boom Drain Valve 15
Reverse Light / Rear Diverter 2
9 Boom Drain Valve R 19 Joystick / Wheels 5
Alignment /
Retract Switch /
Rear Shaft
1
Sensor / Ignition
Signal
S38059 10 Brake Light R 20 Low Speed 7.5
/ Defeat Valve
Remove the two retainer screws (Item 1) (both sides) and

R - Relay
remove the cover (Item 2) [Figure 60-10-5] to check or
replace fuses or relays.

Engine Compartment
Figure 60-10-7
1 3
2 4
6 7
5

8 9
S38030
P120494
S38061

[Figure 60-10-7].
REF DESCRIPTION AMP

1 Starter / Alternator 25
2 Not Used —
3 Fuel Shutoff / Fuel Pump / Engine Temperature 10
Switch
4 Not Used —
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 Using A Booster Battery (Jump Starting)
Battery Maintenance If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
Figure 60-20-1 operator’s seat and one person to connect and
disconnect the battery cables.
The key switch (if equipped) or start switch (if equipped)
must be OFF. The booster battery must be 12 volt.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
P-09589 P-09590
Do not jump start or charge a frozen or damaged

battery. Warm battery to 16°C (60°F) before
The battery cables must be clean and tight [Figure 60- connecting to a charger. Unplug charger before
20-1]. Check electrolyte level in the battery. Add distilled
connecting or disconnecting cables to battery. Never

water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and lean over battery while boosting, testing or charging.
water solution. W-2066-0910
Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.
The battery must be kept charged.
The battery must be kept warm because temperature
affects the cranking power. If the battery is too cold, the
IMPORTANT
battery will not crank the engine.
Damage to the alternator can occur if:
When the engine is not run for long periods of time or if • Engine is operated with battery cables
the engine is run for short periods, the battery may not
fully charge. A battery with a low charge will freeze more disconnected.
easily than a battery with a full charge. • Battery cables are connected when using a fast
charger or when welding on the Telescopic
Handler. (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
WARNING I-2345-0311

Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY (CONT’D) Remove the cable from the positive (+) terminal (Item 1)
[Figure 60-20-3].
Using A Booster Battery (Jump Starting) (Cont’d)
Install the battery cover (Item 2) with the three bolts
Figure 60-20-2 (Item 1) [Figure 60-20-2].
1
1 2
IMPORTANT
Damage to the alternator can occur if:
1 • Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the Telescopic
Handler. (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
S38031
I-2345-0311
Remove the three bolts (Item 1) and remove the battery For Battery With Cold Start (If Equipped):

Figure 60-20-4
For Standard Battery (If Equipped):
Figure 60-20-3
1
2
S39416
P117974 Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
Connect the end of the first cable to the positive (+) [Figure 60-20-4] of the telescopic handler battery.
the same cable to the positive (+) terminal (Item 1)
[Figure 60-20-3] of the telescopic handler battery.
Connect the end of the second cable to the ground (-)

the same cable to the ground (-) terminal (Item 2)
[Figure 60-20-3] of the telescopic handler battery.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 2) [Figure 60-20-3] first.

BATTERY (CONT’D) Removing And Installing Battery
Using A Booster Battery (Jump Starting) (Cont’d)
Figure 60-20-5
WARNING

minutes.
1
S39417
W-2065-0807
Connect the end of the second cable to the ground (-) Figure 60-20-6

the same cable to the ground (-) terminal (Item 1)
1 1
[Figure 60-20-5] on the telescopic handler starter.
Keep cables away from moving parts. Start the engine. 2

After the engine has started, remove the ground (-) cable
(Item 1) [Figure 60-20-5] first.
1
Remove the cable from the positive (+) terminal (Item 1)
[Figure 60-20-4].
Install the battery cover (Item 2) with the three bolts

(Item 1) [Figure 60-20-2].
S38031
Remove the three bolts (Item 1) and remove the battery


BATTERY (CONT’D) Remove the battery.
Removing And Installing Battery (Cont’d) If needed, remove the two bolts (Item 4) and remove the
battery disconnect switch (Item 3) [Figure 60-20-8] from
For Standard Battery (If Equipped): the hold-down plate.
Figure 60-20-7 Installation: Install the bolts (Item 4) and move the
battery disconnect switch (Item 3) [Figure 60-20-8] to the
far right of the slots in the hold-down plate. Tighten the
bolts to 9 - 11 N•m (80 - 97 in-lb) torque.
For Battery With Cold Start (If Equipped):
Figure 60-20-9
2 2
P117972

Always disconnect the ground (-) cable (Item 1)
[Figure 60-20-7] first to prevent sparks.
1
Remove the positive (+) battery cable (Item 2)
[Figure 60-20-7].
S38032
Installation: Tighten the bolts to 5 - 10 N•m (44 - 88 in-

lb) torque. Always disconnect the ground (-) cable (Item 1)
[Figure 60-20-9] first to prevent sparks.
Figure 60-20-8
Remove the positive (+) battery cable (Item 2)
2 [Figure 60-20-9].
4
4 Installation: Tighten the bolts to 5 - 10 N•m (44 - 88 in-
lb) torque.
3
P117973
Remove the bolt securing the hold-down plate (Item 2)

[Figure 60-20-8] to the frame bottom.
Move the hold down plate (Item 2) including the battery

disconnect switch (Item 3) [Figure 60-20-8] out of the
way.

BATTERY (CONT’D) Figure 60-20-11
Removing And Installing Battery (Cont’d)
Figure 60-20-10 1
2
1
4
6
1
2
3
S38032
3
5 If needed, remove the two bolts (Item 1) and remove the
S38032 battery disconnect switch (Item 2) from the hold-down
plate (Item 3) [Figure 60-20-11].
Disconnect the connector (Item 1) and remove the cables Installation: Tighten the bolts to 9 - 11 N•m (80 - 97 in-
from the battery disconnect switch terminals (Item 2) lb) torque.

[Figure 60-20-10].
Installation: Tighten the nuts (Item 2) [Figure 60-20-10]

to 11 - 17 N•m (8 - 12 ft-lb) torque.

WARNING
Remove the bolt (Item 4) located at the back end of the
hold-down plate (Item 5) [Figure 60-20-10].
Remove the hold-down plate (Item 5) including the
battery disconnect switch (Item 6) [Figure 60-20-10].
Remove the battery.
minutes.

W-2065-0807

BATTERY (CONT’D)
Removing And Installing Battery (Cont’d)
For All Batteries:

DANGER
Figure 60-20-12
Be aware that vehicle batteries contain gases that are
flammable and can explode violently. The following
precautions should be taken before making battery
connection:
• Wear eye protection.
• Remove all jewelry.
• Keep spectators away.
In the event of a battery explosion, acid should be

flushed away immediately. Seek medical help as
soon as possible.
D-1032-1210
P-09589 P-09590

Always clean the battery terminals and cable ends when
installing a new or used battery [Figure 60-20-12].
When installing the battery, do not touch any metal parts

with the battery terminals.
Install the battery hold-down plate and tighten the nuts.
Connect and tighten the battery cables. Connect the

ground (-) cable last to prevent sparks.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
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

ALTERNATOR Figure 60-30-2
Inspection
• Inspect the alternator for loose connections and

correct battery charging.
• Check the battery voltage during engine operation 3

(See the Operation & Maintenance Manual for the
correct procedure.) in order to ensure correct battery
performance and correct performance of the electrical
2
system. Repair as needed.
1
• Check the alternator for correct operation. If the
battery is correctly charged, the battery voltage
should read approximately 12 volts. S38683

Remove the bolt (Item 1) [Figure 60-30-2] and loosen
Stop the engine and open the engine cover. (See both mounting bolts (Item 3) [Figure 60-30-3].
NOTE: The nut side of the bolt is also used to ground
Figure 60-30-1 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].
1 1
Figure 60-30-3
3 3
2
1
S38684
Remove the two bolts (Item 1) and cover (Item 2) [Figure

60-30-1].
2
S38685
Remove the engine oil filter (Item 1) [Figure 60-30-3].
Remove the connector and charge cable (Item 2) [Figure

60-30-3] from the back of the alternator.
Remove both mounting bolts (Item 3) [Figure 60-30-3].

Remove the alternator.

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 Checking
Check the whole belt drive visually for damage. Replace 1

damaged parts. (See Belt Replacement on Page 60-30-
2.).
S38738
Belt Replacement
Figure 60-30-6
Stop the engine and open the engine cover (See
Opening And Closing on Page 10-160-1.).
Remove the air conditioning belt. (See Belt Replacement

on Page 80-20-2.)

Figure 60-30-4
2 2
2
S38683
1
Remove the lower alternator mounting bolt (Item 1)
[Figure 60-30-5] and loosen the two top alternator
mounting bolts (Item 2) [Figure 60-30-6].
S38046
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.
60-30-4].
Apply Loctite® #242 to the threads and install the two top
alternator mounting bolts (Item 2) [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 Belt Replacement on

Page 80-20-2.)
Install the cover (Item 2) [Figure 60-30-4]. Close the

engine cover.

STARTER
Testing
Figure 60-40-1
Bat
S
M
Cranking
Motor
A-1992
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

tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-2
Bat
S
M
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
Turn the Starter switch OFF and remove the key.

1
Page 10-160-1.)

1
Figure 60-40-3
S39233
2
Remove the three bolts (Item 1) [Figure 60-40-4] and
remove the starter.
1 3 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.
S39232
Disconnect the three wires from the starter ground

terminal (Item 1) [Figure 60-40-3].
Installation: Tighten the nut to 11 - 13 N•m (97 - 115 in-

lb) torque.
Disconnect the three wires from the starter positive

terminal (Item 2) [Figure 60-40-3].
Installation: Tighten the nut to 7 - 10 N•m (62 - 88 in-lb)

torque.
Disconnect the wire from the start signal terminal (Item 3)

[Figure 60-40-3].
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.

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 2) [Figure 60-50-4].

tighten the nuts (Item 2) [Figure 60-50-4] to 6 - 8 N•m
(53 - 71 in-lb) torque.

LIGHTS (CONT'D) Figure 60-50-7
Front Light Removal And Installation
Figure 60-50-5
LEFT FRONT LIGHT 1
P133569
1 Pull the cable (Item 1) [Figure 60-50-7] out of the front

S38256 light support.
Remove the nut (Item 2) and remove the front light

RIGHT FRONT LIGHT

Installation: Tighten the nut (Item 2) [Figure 60-50-7] to
1
S38257

50-5] and [Figure 60-50-6].

LIGHTS (CONT'D) Figure 60-50-10
Rear Work Light Removal And Installation
Figure 60-50-8
2
20°
1
NA15127
Installation: Install the rear work light (Item 1) at a 20°

P134785 angle from frame (Item 2) [Figure 60-50-10], in the
horizontal plane.
Disconnect the connector (Item 1) [Figure 60-50-8].

Figure 60-50-9
P134784
Remove the nut and washer (Item 1) and remove the rear
work light (Item 2) [Figure 60-50-9].


SIGNAL LEVER Figure 60-60-2
Figure 60-60-1
P125396
Figure 60-60-3
P133313
2
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
P125395
Remove the four screws (Item 1) [Figure 60-60-2] and

[Figure 60-60-3].
Remove both halves of the cover (Item 2) [Figure 60-60-

3].

SIGNAL LEVER (CONT’D) Figure 60-60-6
Figure 60-60-4 2
1
1
2
P125388
Remove the screw (Item 1) and cover (Item 2)

P125389 [Figure 60-60-6] from the signal lever.
Figure 60-60-7
Loosen the retainer screw (Item 1) and remove the
console cover (Item 2) [Figure 60-60-4].

Figure 60-60-5
P125387

S38297 the signal lever.
Route the harness out of the cowling and remove the

Disconnect the signal control wire connector (Item 1) signal lever.
[Figure 60-60-5].

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 60-20-3.)
Disconnect the ground (-) cable from the battery. (See Figure 60-80-3
Figure 60-80-1 1
1 1
1 1
P126557
P133289 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]. Disconnect the harness connectors from the back of the
left instrument panel.
Figure 60-80-2
NOTE: Mark all connectors for ease of installation.
Remove the left instrument panel.
P125386
Disconnect the harness connectors from the back of the

right instrument and indicator panel (Item 1) [Figure 60-
80-2].
NOTE: Mark all connectors for ease of installation.
Remove the right instrument and indicator panel (Item 1)

[Figure 60-80-2].


BOOM ANGLE SENSOR Figure 60-90-2
Description
2
The boom angle sensor has two redundant outputs:
boom angle 1 and boom angle 2. The voltage supply is
5V provided by the Workgroup controller. The typical
voltage values are as follows, depending on the boom
position:
1
• Boom angle 1: from 0,5V to 4,5V
• Boom angle 2: from 4,5V to 0,5V
The boom angle value is displayed in the boom angle

menu (maximum angle 60.8° / minimum angle -4°). (See
the Operation & Maintenance Manual for more S39396
information.)
The boom angle sensor has two different purposes. It is Disconnect the electrical connector (Item 1) from the
used to manage the stability of the machine together with boom angle sensor (Item 2) [Figure 60-90-2].
the LLM system and it is also used to manage the boom
lifting / lowering speed reduction when approaching the Figure 60-90-3
end of the boom cylinder stroke, to avoid shocks. As soon
as the boom approaches maximum or minimum angle 2

values, the current sent to the lifting / lowering coils is 1
reduced to provide a cushioning effect.
Figure 60-90-1
1 1
S39433
Remove the nut (Item 1) from the connecting rod (Item 2)

and remove the rod from the boom angle sensor (Item 3)
[Figure 60-90-3].
2 Remove the two screws (Item 4) from the boom angle
S39070
sensor (Item 3) [Figure 60-90-3].
Remove the boom angle sensor (Item 3) [Figure 60-90-

Remove the two bolts (Item 1) (both sides) and remove 3].
the cover (Item 2) [Figure 60-90-1] from the back of the
boom.


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 [Figure 60-120-4].
(Item 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.


SERVICE BRAKE PEDAL ASSEMBLY Figure 60-130-3

Figure 60-130-1 1
2 2
1 1
S39148
2 Remove the three fittings (Item 2) [Figure 60-130-3].
S38084 Figure 60-130-4

cab.
Figure 60-130-2
1
1 S39061

2 inside the operator cab.
5
1
P125412
Disconnect the two hoses (Item 1), the tubeline (Item 2)

and the pressure sensor (Item 3) from the service brake
valve (Item 4) [Figure 60-130-2].
NOTE: Some additional hoses may need to be

disconnected from the steering unit in order
to disconnect the tubeline.

SERVICE BRAKE PEDAL ASSEMBLY (CONT’D)
Figure 60-130-5
1
S39132

inside the operator cab.

Remove the service brake pedal assembly.
Figure 60-130-6
S39151
Remove the two bolts (Item 1) and remove the service

brake valve (Item 2) [Figure 60-130-6].

INCHING SENSOR
Description
The inching function reduces the current through the Inching Position
pump forward or reverse coils using a potentiometer
sensor (5V) located under the brake pedal of the The inching position is divided into the inching zone and
telescopic handler. This inching sensor provides the the brake zone [Figure 60-140-1].
inching position proportionally to the brake pedal angle.
Pressing the brake pedal slows down the vehicle speed Inching Zone: The inching function is active during the
while still maintaining high engine rpm. The inching first part of the brake pedal stroke [Figure 60-140-1].
sensor also controls the brake lights of the telescopic
handler. Brake Zone: The brake function is active during the
second part of the brake pedal stroke [Figure 60-140-1].
The inching sensor readings are also used to monitor the
brake system: the controllers expect a certain level of
service brake pressure according to the position of the
brake pedal. If the values are irrelevant, the controllers
will activate the emergency brakes and raise error codes.
(See EMERGENCY BRAKE on Page 60-150-1.)
Figure 60-140-1

Pe
da
l C
D
Po
sit
ion Pe (%
da o
Pedal Up
lL fp
oc ed
Inc
a t al
hin
g io po
n s
Zo
E n iti
ne
d on
In )
ch
in
g
e High
p
own
ng U
Br
Out Of Rang
al d
Inchi
ak
e
in it i
Zo
ne
ing
Inch
C a li b
Dyna Range
CD
r a t io
p
it i al u
m ic
n
g in
n
chi wn
In in g Do
CD Inc h
Low
u t O f R a ng e
O
Pedal Down
NA15203

INCHING SENSOR (CONT’D) Figure 60-140-4

Figure 60-140-2
1 S39062
Remove the screws (Item 1) [Figure 60-140-4].
Installation: Perform the adjustment procedure after

installation. (See Calibrating The Inching Sensor on Page
S39060 60-240-10.)

Remove the switch.
Remove the cover (Item 1) [Figure 60-140-2] from the
inching sensor.
Figure 60-140-3
S39061
Disconnect the connector (Item 1) [Figure 60-140-3].

EMERGENCY BRAKE
Description
The service brake pressure is constantly monitored and As soon as Emergency Brake mode is active, the park
compared to the service brake pedal angle. When a brake valve is supplied proportionally to the inching pedal
failure is detected, the following actions take place: position [Figure 60-150-1]:
• An error code is generated. BRAKE ZONE PARK BRAKE SUPPLY

• Three beeps sound in the cab.
• The Brake Failure light is turned ON. Start 100%
• The emergency (secondary) brake is engaged. End 0%
In Emergency Brake mode, the cab buzzer sounds

continuously.
Figure 60-150-1
C
D
Pe (%
da o
Pe
lL fp
da
oc ed
lP
os
at al
it
io po
Pedal Up
ion
n s

En iti
Inc
d on
hin
In )
g
ch
Zo
in
ne
g
Pa
rk
Br
ak
e High
eS
p
own
ng U
up
Br
Out Of Rang
ply
al d
ak
Inchi
e
in it i
Zo
n
ing
e
Inch
Calib
CD
Dyna Range
r a t io
ia l up
init
mic
ng
n
chi
In Dow
n
CD ch ing
In
Low
Range
Out Of
Pedal Down
NA15202

EMERGENCY BRAKE (CONT’D)
Description (Cont’d)
Service Brake Pressure Status
The service brake input is monitored by the inching sensor on the service brake pedal. At a certain brake pedal position,
a certain pressure is supplied to the service brake. This output is monitored by a pressure sensor.
The service brake pressure has been assigned an ideal theoretical value (P in table below), dependent on the service
brake pedal position. Within a range of this theoretical pressure, the service brake output is proportional to the input and
the park brake valve stays fully energized. See [Figure 60-150-2] and [Figure 60-150-3] for service brake pressure
ranges.
PRESSURE
PRESSURE RANGE RESULT
STATUS
Normal Tractor P - 0,9 MPa (9 bar) (130.5 PSI) Service brake output proportional to service
through P + 1,1 MPa (11 bar) (159.5 PSI) brake pedal angle
Non-Tractor P - 1,6 MPa (16 bar) (232 PSI)  Park brake valve is fully energized
through P + 2 MPa (20 bar) (290 PSI)
High* Tractor > P + 1,1 MPa (11 bar) (159.5 PSI) Error code
Non-Tractor > P + 2 MPa (20 bar) (290 PSI) Yellow Brake Failure light ON

Low Tractor < P- 0,9 MPa (9 bar) (130.5 PSI) Error code
Non-Tractor < P - 1,6 MPa (16 bar) (232 PSI) Red Brake Failure light ON
Park brake valve is de-energized, proportional
to service brake pedal angle
Extremely Low Tractor < P - 1,35 MPa (13,5 bar) (196 PSI) Error code
Non-Tractor < P - 2,4 MPa (24 bar) (348 PSI) Red Brake Failure light ON
Park brake valve is de-energized, proportional
to service brake pedal angle
Transmission reduced
* Service brake high pressure status has the same results as when an electrical failure (short-circuit or open-circuit) is
detected.

Figure 60-150-2
Service Brake Pressure (bar)
Non-Tractor Homologation: maximum service brake pressure 10 MPa (100 bar) (1450 PSI)
Theoretical
Low Pressure
High Pressure
Extremely Low
Pressure

Pedal Position (%)
NA15245

Figure 60-150-3
Service Brake Pressure (bar)
Tractor Homologation: maximum service brake pressure 5 MPa (50 bar) (725 PSI)
Theoretical
Low Pressure
High Pressure
Extremely Low
Pressure

Pedal Position (%)
NA15246

SERVICE PC (LAPTOP COMPUTER) Connect the Remote Start Tool (Service Tool) to the
telescopic handler. (See REMOTE START TOOL
Connecting Remote Start Tool (Service Tool) - (SERVICE TOOL) KIT - 6987761 on Page 10-210-1.)
6987761
NOTE: Refer to BobcatDealerNET.com for PC
Figure 60-160-1 requirements and the latest Service Analyzer
software.
3
1
P-76450
The tools listed will be needed to do the following

procedure:

Order from Bobcat Parts P/N: 6987761 - Remote Start
Tool (Service Tool) Kit.
Kit Includes:
7022042 - Remote Start Tool (Service Tool)

6689747 - Telescopic Handler Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
7023157 - USB - Serial Cable
NOTE: Make all connections with the key in the OFF

position.
The Service PC (Item 1) with the Remote Start Tool

(Service Tool) (Item 2) [Figure 60-160-1]. When
connected to the telescopic handler, the Service PC is
used to monitor, conduct diagnostics, and upgrade
software.
Connect the Remote Start Tool (Service Tool) Computer

Service Tool Harness (Item 3) [Figure 60-160-1] 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
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the Remote

Start Tool (Service Tool).


FUEL LEVEL SENDER Figure 60-170-3
Figure 60-170-1
S39067
1
Remove the two fuel lines (Item 1) [Figure 60-170-3]

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 60-170-4

[Figure 60-170-1].
Remove the drain plug (Item 1) [Figure 60-170-1]. 1 1
Figure 60-170-2
2
1
S39137
Remove the bolts (Item 1) and remove the step (Item 2)

[Figure 60-170-4].
S39064
plate (Item 2) [Figure 60-170-2]. NOTE: Support the step while removing the bolts.
Remove the operator cab floor mat.

FUEL LEVEL SENDER (CONT'D) Figure 60-170-7
Figure 60-170-5
1 1
S40653
Remove the two screws (Item 1) and filter cover (Item 2)

S38291 [Figure 60-170-7].
Figure 60-170-8
Fully support the fuel tank using an appropriate lifting
device [Figure 60-170-5].

Figure 60-170-6
1
1
1
1
S40654
1
Remove the filter (Item 1) [Figure 60-170-8].

S38086

threads of the bolts. Tighten the two rear bolts (Item 1) to
25 - 30 N•m (18 - 22 ft-lb) torque. Tighten the two front
bolts (Item 2) [Figure 60-170-6] to 5 - 6 N•m (44 - 53 in-
lb) torque.

FUEL LEVEL SENDER (CONT'D) Figure 60-170-11
Figure 60-170-9
1
S38090
Disconnect the fuel level sensor connector (Item 1)

S38087 [Figure 60-170-11].
Figure 60-170-12

Figure 60-170-10
1 S39810
S38088 Remove the fuel level sender (Item 1) [Figure 60-170-

12].

thread of the bolt. Tighten the bolt (Item 1) [Figure 60-
170-10] to 25 - 30 N•m (18 - 22 ft-lb) torque.
Lower the fuel tank for approximately 200 mm (8 in).

FUEL LEVEL SENDER (CONT'D)
Figure 60-170-13
P-85716
Inspect the fuel level sender and replace if worn or

damaged [Figure 60-170-13].

JOYSTICK Figure 60-180-3
1
Figure 60-180-1
1
1
P125385
2 Raise up the dust cover (Item 1) [Figure 60-180-3]
Figure 60-180-4
P133571

Remove the four bolts (Item 1) and remove the cover
(Item 2) [Figure 60-180-1]
1
Figure 60-180-2
1
P125384
Remove the four bolts (Item 1) [Figure 60-180-4] from

each corner of the joystick.
1
Remove the joystick.
P125383

180-2].


LLMI / LLMC SYSTEM Figure 60-190-3
System Components Identification
Figure 60-190-1
1
S39246
The LLMS (Longitudinal Load Moment Sensor) (Item 1)

P125409 [Figure 60-190-3] 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 60-190-1] 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 60-190-2
Figure 60-190-4
S39395
S39424
The LLMC (Longitudinal Load Moment Controller) (Item

1) [Figure 60-190-2] which is located under the The safety valve (Item 1) [Figure 60-190-4] 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.

LLMI / LLMC SYSTEM (CONT’D) Longitudinal Load Moment Indicator (LLMI)
Description
System Components Identification (Cont’d)
The LLMI warns the operator about inadequate stability
Figure 60-190-5 in the longitudinal plane (forward direction).
The LLMI is intended to warn for tipping over in the case

of:
• The machine is stationary on solid, stable and level

ground
1 • The machine is performing load picking, carrying,
loading and unloading
• The telescopic boom is not fully retracted.
The LLMI is not intended to warn for tipping over in the

case of:
2
• A sudden overload
S39396 • Traveling with a lifted load
• Traveling on rough terrain or on grounds with
The boom angle sensor (5°) (Item 1) [Figure 60-190-5] obstacles and holes
measures the boom angle. If the boom angle is higher • Traveling across a slope or turning on a slope
than five degrees and the machine is in unstable • Turning corners too fast or too sharp.

condition, every boom movement except retract and lift is
reduced. Figure 60-190-7
The boom retracted sensor (Item 2) [Figure 60-190-5] 4

3
detects if the boom is fully retracted. When the boom is
retracted all boom movements will be fully operational at 5
any angle. The internal LLMI buzzer is deactivated with
retracted boom. 2
Figure 60-190-6 6
1
P125409
1 The indicator lights (Items 1, 2 and 3) [Figure 60-190-7]

sequentially illuminate as the machine’s longitudinal
stability decreases. They identify three zones of the
machine's longitudinal stability level:
NOTE: All hydraulic movements are functional if the

P133289 boom is fully retracted, regardless of the
machine's stability level.
The LLMC Override Switch (Item 1) [Figure 60-190-6] NOTE: For New Zealand and Australian machines,
can be used to override the LLMC. the LLMI / LLMC system setting is different.
All hydraulic movement are functional if the
Turned clockwise (unstable position), the switch (Item 1) boom is fully retracted and the boom angle
[Figure 60-190-6] overrides the LLMC. The switch below 5°, regardless of the machine's stability
returns to the original position as soon as the switch is level.
released and the LLMC becomes active again.

LLMI / LLMC SYSTEM (CONT’D) Critical zone:
Longitudinal Load Moment Indicator (LLMI) Red indicator light (Item 3) [Figure 60-190-7 on Page
Description (Cont’d) 60-190-2] (one light). The machine's longitudinal
stability reaches a critical level. A warning horn is
NOTE: When the longitudinal stability level reaches a activated along with the red indicator light.
critical level (Critical zone) with the boom not
fully retracted and the boom angle below 5°, In this zone, the following machine functions are
only hazardous movements are disabled (tilt reduced in speed or disabled:
and boom lowering are reduced in speed). It is
still possible to retract and lift the boom. • Boom lowering (disabled with boom angle above 5°,
reduced in speed when below 5°).
Secure zone: • Boom extend (disabled).
• Tilt (disabled with boom angle above 5°, reduced in
Green indicator lights (Item 1) [Figure 60-190-7 on speed when below 5°).
Page 60-190-2] (four lights). The operator works in a • Auxiliary hydraulic functions (disabled).
secure zone.
Use the remaining active functions to bring the
In this zone, the following machine functions are machine back to a safe level of stability. If necessary,
progressively reduced in speed as the machine's activate the LLMC override switch or mode to enable
longitudinal stability decreases: a disabled function such that the machine can be
brought back to a safe level of stability. (See
• Boom lowering Longitudinal Load Moment Controller (LLMC)
• Boom extend Override Switch on Page 60-190-4.)

• Tilting of attachment
• Auxiliary hydraulic functions. NOTE: The LLMC override switch or mode should
only be activated when necessary and is
Warning zone: automatically deactivated after a running
period of 60 seconds.
Orange indicator lights (Item 2) [Figure 60-190-7 on
Page 60-190-2] (two lights). The longitudinal stability NOTE: The warning horn cannot be deactivated.
level gets close to the critical zone.
Test Button:
In this zone, the following machine functions are
progressively reduced in speed as the machine's The test button (Item 4) [Figure 60-190-7 on Page 60-
longitudinal stability decreases: 190-2] has two functions:
• Boom lowering • Testing the correct functioning of the LLMI and the
• Boom extend LLMC. (See LLMC Calibration Test on Page 60-190-
• Tilting of attachment 5.)
• Auxiliary hydraulic functions. • Calibrating the LLMI / LLMC system. (See LLMI /
LLMC Calibration on Page 60-190-7.)
The test indicator light (RED) (Item 5) [Figure 60-190-7

on Page 60-190-2] is used for the test procedure and the
LLMI / LLMC system calibration. The light flashes when
the LLMC is in fault mode.
The control indicator light (ORANGE) (Item 6)

[Figure 60-190-7 on Page 60-190-2] indicates that the
machine is under control of the LLMC. The light flashes
when the LLMC override switch is activated. (See
Longitudinal Load Moment Controller (LLMC) Override
Switch on Page 60-190-4.)

LLMI / LLMC SYSTEM (CONT’D) Longitudinal Load Moment Controller (LLMC)
Override Switch
Longitudinal Load Moment Controller (LLMC)
Figure 60-190-8
The LLMC disables or limits the following movements
when the machine stability level is critical:
• lowering of the boom,

• extending the telescopic boom,
• forward tilt of attachment,
• backward tilt of attachment,
• auxiliary hydraulic functions.
P133289

2
P125409
Turn the LLMC override switch (Item 1) [Figure 60-190-

8] clockwise to override the LLMC.
The control indicator light (ORANGE) (Item 2)

[Figure 60-190-8] flashes when the LLMC override
switch is activated.
The switch returns to the original position as soon as the

switch is released and the LLMC becomes active again.
NOTE: The LLMC override switch should only be

activated when necessary and is
automatically deactivated after a running
period of 60 seconds.

LLMI / LLMC SYSTEM (CONT’D) Figure 60-190-10
LLMC Calibration Test
The Longitudinal Load Moment Control (LLMC) system

calibration can be tested by performing the following
procedure:
Park the machine on flat level ground and align the front
and rear wheels straight ahead.
NOTE: A load will be needed to topple the machine.
WARNING EM9626
TIPPING CAN CAUSE SERIOUS INJURY OR DEATH Without attachment and with the attachment carrier fully
tilted up, fully retract and raise the boom [Figure 60-190-
Keep the boom low, only raise the load 500 mm (20 10].
in) when testing or calibrating the LLMI / LLMC
system. Figure 60-190-11
W-2929-1012

1
Figure 60-190-9
S41197
1. Push and hold the TEST button (Item 1) [Figure 60-

S39203
190-11] during the complete procedure. All the LEDs
(Item 2 and 3) light up, and the buzzer sounds
Using the LLMC override switch, decrease the rear axle discontinuously during 3 seconds.
load pressure by picking up a load and extending the
boom until the machine topples over (rear wheels off the NOTE: Keep holding the test button for default test
ground) [Figure 60-190-9]. result confirmation.
NOTE: Do not move or reposition the machine after

decreasing the rear axle load pressure.
Retract the boom and place the load on the ground.

LLMC Calibration Test (Cont’d)
Two test results are possible:
Figure 60-190-12 1
1 S41234
• The orange and red LEDs (Item 1) [Figure 60-190-

13] light up, calibration is out of range. Please redo
calibration of the LLMI / LLMC system. (See LLMI /
S41233 LLMC Calibration on Page 60-190-7.)
2. Release the TEST button (Item 1) [Figure 60-190-11

• The four green LEDs (Item 1) [Figure 60-190-12] on Page 60-190-5].
light up, calibration is OK;
The calibration test is finished.
NOTE: After pressing the TEST button (Item 1)

[Figure 60-190-11 on Page 60-190-5] 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 60-190-
11 on Page 60-190-5] is released during the
procedure.

LLMI / LLMC Calibration
Figure 60-190-14
S39203
Using the LLMC override switch, decrease the rear axle

S39205
boom until the machine topples over (rear wheels off the
ground) [Figure 60-190-15].
Before calibration, drive the machine for a while in order
to warm the axles, then check tightening torque of the NOTE: Do not move or reposition the machine after
two bolts (Item 1) of the LLMS (Longitudinal Load decreasing the rear axle load pressure.

Moment Sensor) (Item 2). Torque value should be
65 N•m (48 ft-lb). When torque value is adjusted, drive Retract the boom and place the load on the ground. Then
the machine for a while and check a second time retract the boom and turn off the engine.
tightening torque of the two bolts (Item 1) [Figure 60-
190-14]. Follow the procedure below to calibrate the LLMI / LLMC
system:
and rear wheels straight ahead. NOTE: Calibration must be performed within a time
span of 5 minutes. If longer, the LLMI / LLMC
NOTE: A load will be needed to topple the machine. system will return to its original settings.
NOTE: During the procedure below, the buzzer will

be activated whenever the TEST button is
pushed.
WARNING
TIPPING CAN CAUSE SERIOUS INJURY OR DEATH
Keep the boom low, only raise the load 500 mm (20
system.
W-2929-1012

LLMI / LLMC Calibration (Cont’d)
Figure 60-190-16
EM9626
3. Without attachment and with the attachment carrier

S41197 fully tilted up, fully retract and raise the boom
[Figure 60-190-18].
Figure 60-190-17
4. Press and release the TEST button (Item 1)
[Figure 60-190-16] to record the first calibration

point.
5. The orange and red LEDs (Item 3) [Figure 60-190-

16] light up to indicate the system is ready to record
the second calibration point.
WARNING
S0007 Keep the boom low, only raise the load 500 mm (20
1. Push and hold the TEST button (Item 1) [Figure 60- system.
W-2929-1012
190-16] while turning the key switch to START
[Figure 60-190-17] then quickly press the TEST
button (Item 1) [Figure 60-190-16] for 3 times within
the first 4 seconds after the key switch back to RUN /
PREHEAT.
NOTE: To indicate that the system enters calibration

mode, the LED bar (Items 2 and 3) [Figure 60-
190-16] will be blinking and the buzzer sounds
intermittent for 3 seconds.
2. The green LEDs (Item 2) [Figure 60-190-16] light up

to indicate the system is ready to record the first
calibration point.

LLMI / LLMC SYSTEM (CONT’D)
LLMI / LLMC Calibration (For Dealer) (Cont’d)
Figure 60-190-19
S39203
6. Pick up the load and extend the boom until the

machine topples over (rear wheels off the ground)

[Figure 60-190-19].
7. Press and release the TEST button (Item 1)

[Figure 60-190-16 on Page 60-190-8] to record the
second calibration point.
8. To indicate the calibration has been validated, the

LED bar (Items 2 and 3) [Figure 60-190-16 on Page
60-190-8] lights up for 3 seconds and the buzzer
sounds two times.
NOTE: If the buzzer sounds and LEDs light up in a

particular configuration, a calibration failure
has occurred. (See System Failure Reports on
Page 60-190-10.)
Calibration is finished. The LLMI / LLMC system

automatically returns to normal mode.
Always perform the LLMC calibration test after system

calibration. (See LLMC Calibration Test on Page 60-190-
5.)

System Failure Reports
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
ERROR MACHINE
DISPLAY FUNCTION CAUSE SOLUTION
CODE BEHAVIOR
I3018 Sensor No The speed of The LLMI sensor input is Check the harness between
Communication the aggravating disconnected. the sensor and the LLMI.
motions is The sensor linked to the Replace the LLMS on the
decreased LLMI has stopped rear axle and redo the
(50%). sending CAN frame. calibration.
I3014 Sensor OOR Low No aggravating Sensor shifted toward the Recalibrate the system.
(after 30 seconds) motions stability If the error remains: Replace
possible. the LLMS on the rear axle
Shunt is and redo the calibration.
I3015 Sensor OOR High allowed. Sensor shifted toward the Recalibrate the system.
(after 1 second) instability If the error remains: Replace
the LLMS on the rear axle
and redo the calibration.
I3016 Sensor In Error Sensor is out of order Replace the LLMS on the

(after 8 seconds) rear axle and redo the
calibration.
I3017 Sensor Not No motion Sensor has never been Calibrate the system.
Calibrated allowed calibrated.
Or either LLMI, LLMS or
both have been replaced.
I3113 OOR Calibration No aggravating Calibration has been Redo the calibration
Values motions done with out of range correctly within 5 minutes.
possible. values
I3121 Backwards Shunt is Calibration has been
Calibration Values allowed. done backwards.
I3122 Calibration Values Calibration has been
Too Close done with points too
close.
I3123 Calibration Calibration lasted more
Timeout than 5 minutes.
I3901 Internal Error No impact. LLMI internal memory Replace the LLMI and redo
I3903 failure. the calibration.
I3904
I3905
I3909 Test Membrane Test switch has been on Release the test switch.
Switch Failure. for more than 10s after
the system was started. If the error remains:
Replace the LLMI and redo
the calibration.
Test switch has been on Release the test switch.
for more than 60s during
the calibration verification If the error remains:
procedure. Replace the LLMI and redo
the calibration.

System Failure Reports (Cont’d)
ERROR MACHINE
CODE BEHAVIOR
I0314 Battery Voltage No impact. Battery voltage is lower
OOR Low than 9V
I0315 Battery Voltage Battery voltage is higher
OOR High than 16V —
C3018 Sensor No The speed of The LLMC sensor input is Check the harness
Communication the aggravating disconnected. between the sensor and
motions is the LLMC.
decreased The sensor linked to the Replace the LLMS on the
(50%). LLMC has stopped rear axle and redo the
sending CAN frame. calibration.
C3014 Sensor OOR Low No aggravating Sensor shifted toward the Recalibrate the system.
(after 30 seconds) motions stability If the error remains:
possible. Replace the LLMS on the

Shunt is rear axle and redo the
allowed. calibration.
C3015 Sensor OOR High Sensor shifted toward the Recalibrate the system.
(after 1 second) instability If the error remains:
Replace the LLMS on the
rear axle and redo the
calibration.
C3016 Sensor In Error Sensor is out of order Replace the LLMS on the
calibration.
C3113 OOR Calibration Calibration has been done Redo the calibration
Values with out of range values correctly within 5 minutes.
C3121 Backwards Calibration has been done
Calibration Values backwards.
C3122 Calibration Values Calibration has been done
Too Close with points too close.
C3123 Calibration Calibration lasted more
C0314 Battery Voltage Battery voltage is lower
OOR Low than 9V
—
C0315 Battery Voltage Battery voltage is higher
OOR High than 16V
C3017 Sensor Not No motion Sensor has never been Calibrate the system.
Or either LLMC, LLMS or
C3801 Internal Error No motion LLMC internal failure. Replace the LLMC and
C3803 allowed redo the calibration.
C3804
C3805

LLMS Removal
2
Raise the boom and install the approved boom stop (See
Installing The Approved Boom Stop on Page 10-150-1.) 1
Figure 60-190-20
1
S39246
Remove the two bolts (Item 1) and remove the LLMS

(Item 2) [Figure 60-190-22]
P125340

located on the cab side below the boom.
Figure 60-190-21
S39144

21] 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 60-190-23
S39144
Route the electrical harness (Item 1) [Figure 60-190-25]

into the machine.
Figure 60-190-26
S39355

Clean the axle sensor area (Item 1) [Figure 60-190-23]
to remove rust and / or dirt.
1
Figure 60-190-24
2
1
P125340
Plug the connector (Item 1) [Figure 60-190-26] located

on the cab side below the boom.
Attach the harness with tie-straps.
S39246 To avoid errors caused by position shifts of the LLMS,

perform the following actions:
Position the LLMS (Item 1) and install the two bolts (Item 1. Drive the rear axle over crossties in order to settle the
2) [Figure 60-190-24]. position of the LLMS on the rear axle.
NOTE: Apply Loctite® #242 to the bolts. 2. Calibrate the LLMS. (See LLMI / LLMC Calibration on
Page 60-190-7.)
Tighten the two bolts (Item 2) [Figure 60-190-24] 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).


MAINTENANCE CLOCK Setup
The Maintenance Clock alerts the operator when the next

service interval is due. EXAMPLE: The maintenance
clock can be set to a 500 hour interval as a reminder for 3
the next 500 hour planned maintenance. 2
Figure 60-200-1
2
1
1
3
P128475
NA3086
In the left window pane, click the “Maintenance Clock” tab

During machine operation, a 2 beep alarm will sound (Item 1) [Figure 60-200-2] to view the maintenance clock
when there are less than 10 hours until the next planned menu.

maintenance.
Click Turn On / Set Length (Item 2) [Figure 60-200-2] to
The remaining hours before maintenance is required turn the maintenance clock on.
(Item 1) will appear in the data display for 10 seconds
while the service icon (Item 3) and the hourmeter icon Click Turn Clock Off (Item 3) [Figure 60-200-3] to turn
(Item 2) [Figure 60-200-1] flash. the maintenance clock off.
NOTE: The display will show negative numbers after Figure 60-200-3
counting down to zero.
The display will revert to the previous display and will

3 1
appear for 10 seconds every time the machine is started
until the maintenance clock is reset.
2
P128476
The default Interval (Item 1) is 250 hours, it can also be

changed by placing the cursor in the box and typing the
new interval. Click Set Length (Item 2) [Figure 60-200-3]
to reset and set the maintenance clock.

MAINTENANCE CLOCK (CONT’D) Reset
Setup (Cont’d) Figure 60-200-6
Figure 60-200-4
1
3
2
2 1
P128747
P128746
Press the Information button (Item 2) [Figure 60-200-6]

until the display screen shows the maintenance clock.
The current maintenance clock Length (Interval) (Item 1)
and Hours (Time Reset) (Item 2) will be displayed. This
Press and hold the Information button (Item 2) for three
screen will display the most recent 20 entries of history.

seconds until [RESET] (Item 1) [Figure 60-200-6]
Once an entry is added, it cannot be changed. If an entry
appears in the display screen.
is made and the interval is not correct, make another
entry and click Set Length (Item 3) [Figure 60-200-4].
NOTE: If the maintenance clock is deactivated, the
maintenance clock menu is not shown on the
NOTE: If the interval is set to 10 hours or less, the
display screen.
maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
The maintenance clock can also be reset by clicking Set
service icon will NOT be removed from the
Length (Item 2) [Figure 60-200-5] in service analyzer.
display screen.
NOTE: If the interval is set to 10 hours or less, the
Figure 60-200-5
maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
2 service icon will NOT be removed from the
display screen.
P128746
After the maintenance clock has been activated, the

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-5]. If past
the interval, the number will reflect negative hours.

CONTROLLERS Gateway Controller
Description Location
There are six controllers installed on the machine: Figure 60-210-1
1. Gateway controller. (See Gateway Controller on

Page 60-210-1.)
1
2. Drive controller. (See Drive Controller on Page 60-
210-1.)
3. Workgroup controller. (See Workgroup Controller on

Page 60-210-2.)
4. Display controller. (See Display Controller on Page

60-210-2.)
5. LLMI controller.(See LLMI Controller on Page 60-

210-2.) P125386
6. LLMC controller. (See LLMC Controller on Page 60-

210-2.) The gateway controller is located behind the right
instrument panel (Item 1) [Figure 60-210-1].

NOTE: If equipped with the boom suspension option
or rear auxiliary / rear hook option, an Drive Controller
Auxiliary controller is installed at the same
location as the Workgroup controller Location
Figure 60-210-2
P133571
The drive controller is mounted on the main frame under

the cover (Item 1) [Figure 60-210-2].

CONTROLLERS (CONT’D) LLMI Controller
Workgroup Controller Location
Location Figure 60-210-5
Figure 60-210-3
P125356
P125548
The LLMI controller (Item 1) [Figure 60-210-5] is located
on the right side of the instrument panel.

The workgroup controller (Item 1) [Figure 60-210-3] is
located at the back of the machine, left of the boom. LLMC Controller
Display Controller Location
Location Figure 60-210-6
Figure 60-210-4
1 1
S38027
S39050
The LLMC controller is located behind the operator cab
fuses and relays housing (Item 1) [Figure 60-210-6].
The display controller is integrated in the display (Item 1)
[Figure 60-210-4].

RETRACT SENSOR Figure 60-220-3
Figure 60-220-1
2
1 1
1
P129992
2 Remove the two nuts / bolts (Item 1) [Figure 60-220-3].
S39070
NOTE: Hoses are removed for photo clarity.
Remove the two bolts (Item 1) and remove the cover Remove the sensor / bracket assembly (Item 2)
(Item 2) [Figure 60-220-1] from the back of the boom. [Figure 60-220-3].

Installation: Tighten the bolts (Item 1) [Figure 60-220-1]
to maximum 16 N•m (12 ft-lb) torque.
Figure 60-220-2
P129990
Disconnect both retract switch connectors (Item 1)

[Figure 60-220-2].

RETRACT SENSOR (CONT’D)
Adjustment
Figure 60-220-4
1 6 mm
(0.24 in)
NA15132
With the sensors / bracket installed, loosen the jam nuts

(Item 1), set the clearance of 6 mm (0.24 in) between the

sensor and the inner boom. Tighten the jam nuts (Item 1)
[Figure 60-220-4].

AUTOMATIC PARK BRAKE
Description
The automatic park brake is managed by a proportional, negative, electrically powered valve. It is activated by the park
brake switch. (See the Operation & Maintenance Manual for the correct procedure.)
Figure 60-230-1
Service brake valve

equipped with
pedal angle sensor
Service
brake
port Service brake
pressure sensor

Park
brake
port
Park brake
pressure sensor Park brake valve
(Proportional
electric valve)
NA15201
Park Brake Pressure Sensor Park Brake Valve
The park brake pressure is constantly monitored by the The park brake valve is proportionally controlled:
park brake pressure sensor to determine the park brake
status: CURRENT STATUS
0A Park brake fully applied
PRESSURE STATUS RESULT
Maximum Park brake fully released
< 0.7 MPa  Park brake Drive disabled
(7 bar)  applied Park Brake light ON
The park brake pressure is constantly compared to the
(102 PSI)
park brake valve command in order to detect over or
> 2,4 MPa  Park brake Drive enabled under pressure issues.
(24 bar)  released Park Brake light OFF
(348 PSI)


CALIBRATION Figure 60-240-2
Calibrating The Hydrostatic Pump
This calibration is used to adjust the start of forward and

reverse movement of the telescopic handler.
NOTE: A Service Tool must be connected to the

telescopic handler and the engine must be
running and the travel mode must be in
NEUTRAL in order to perform this procedure.
Connect the service tool to the telescopic handler. (See

6987761 on Page 10-210-1.)
NA15841
Put the Travel Direction Switch or the Travel Direction
Lever (if equipped) in the NEUTRAL position.
Press the AUX button (Item 3) [Figure 60-240-1] for 3
Figure 60-240-1 seconds until the drive pump calibration mode [Figure
60-240-2] appears on the display screen.
Travel Direction Switch

2

Figure 60-240-3
1 3
3
1
3
P122914 2
Press the information button (Item 1) to cycle the display

screen (Item 2) [Figure 60-240-1] until the engine speed
menu is displayed. (See Operation & Maintenance P133312
Press the top of the switch (Item 1) [Figure 60-240-3] for

forward travel calibration (display is showing [DF])
[Figure 60-240-5].
Press the bottom of the switch (Item 2) [Figure 60-240-3]

for reverse travel calibration (display is showing [DR])
[Figure 60-240-6].

CALIBRATION (CONT’D) Figure 60-240-5
Calibrating The Hydrostatic Pump (Cont’d)
Travel Direction Lever (If Equipped)
Figure 60-240-4
NA15834
Figure 60-240-6
P126555

Move the lever (if equipped) forward (Item 1) [Figure 60-
240-4] for forward travel calibration (display is showing
[DF]) [Figure 60-240-5].
Move the lever (if equipped) backward (Item 2) [Figure

60-240-4] for reverse travel calibration (display is
showing [DR]) [Figure 60-240-6].
NA15835
Press the “+” and “-” buttons (Item 3) [Figure 60-240-3]

to adjust the value within a range of 60 ± 5.
Press the AUX button (Item 3) [Figure 60-240-1] once to

validate and finish the procedure.
NOTE: The machine must be set to start advancing at

engine speed of 1080 - 1150 RPM with cold
hydraulic fluid temperature (20°C [68°F]) or
1100 - 1200 RPM with warm hydraulic fluid
temperature (50°C [122°F]).

CALIBRATION (CONT’D)
Figure 60-240-7
EM8037
If calibration is successful, [STORE] [Figure 60-240-7]

appears on the display screen. The three calibration

points have now been saved.
Figure 60-240-8
NA15826
If an error occurred during calibration, [FAIL] [Figure 60-

240-8] appears on the display screen. Redo the
calibration procedure until the calibration is successful.
Press the information button (Item 1) [Figure 60-240-1]

once to return to the engine speed menu.

Swash Plate Calibration - Neutral Range
The swash plate calibration for neutral range is available

if error code D9199 is active. This calibration records the
swash plate positions which will be used in the Safe Start
/ Stop function.

running in order to perform this procedure.
Connect the service tool to the telescopic handler. (See NA15836

6987761 on Page 10-210-1.)
Press the AUX button (Item 3) [Figure 60-240-9] for
Start the engine. Make sure that the following conditions three seconds until the swash plate calibration mode
exist (See the Operation & Maintenance Manual for more [Figure 60-240-10] appears on the display screen.
information):
Figure 60-240-11
• The inching pedal must be calibrated.

• The hydrostatic pump must be calibrated.
• The creep function must be disabled.
• Low speed must be activated.
• Gear 1 must be engaged.
Figure 60-240-9
NA15837
After two seconds, the neutral range calibration menu

[Figure 60-240-11] will appear on the display screen.
1
3
P122916

screen (Item 2) [Figure 60-240-9] until the creep menu is
displayed. (See Operation & Maintenance Manual for the
correct procedure.)

Swash Plate Calibration - Neutral Range (Cont’d)
Figure 60-240-12
NA15833
6. Put the Travel Direction Control in REVERSE. [REV]

will appear on the display screen (Item 1) [Figure 60-
240-13]. Apply low speed (turtle) (if equipped).
NA15838
7. Slowly back up the machine with engine rpm between
1100 - 1200 rpm until [REV] disappears.

Press the AUX button (Item 3) [Figure 60-240-9] until
[FWD] [Figure 60-240-12] appears on the display 8. The neutral REVERSE point is automatically stored.
screen.
9. Stop the machine and put the Travel Direction Control
1. Put the Travel Direction Control in FORWARD and in NEUTRAL.
apply low speed (turtle) (if equipped)
When the calibration is fully performed, the error code
2. Release the parking brake by pressing the Parking D9199 should be cleared from the display panel.
Brake switch.
3. Slowly move the machine forward with engine rpm

between 1100 - 1200 rpm until [FWD] disappears.
4. The neutral FORWARD point is automatically stored.

in NEUTRAL.

Swash Plate Calibration - Maximum Range
The swash plate calibration for maximum range is

available if error code D9299 is active. This calibration
records the swash plate positions which will be used in
the Safe Start / Stop function.

running and gear 1 must be engaged in order
to perform this procedure.
NA15836
Connect the service tool to the telescopic handler. (See
6987761 on Page 10-210-1.) Press the AUX button (Item 3) [Figure 60-240-14] for
three seconds until the swash plate calibration mode
Start the engine. Make sure that the following conditions [Figure 60-240-15] appears on the display screen.
exist (See the Operation & Maintenance Manual for more
information): After two seconds, the neutral range calibration menu will
appear on the display screen.

• The inching pedal must be calibrated.
• The creep function must be disabled. Figure 60-240-16
• Low speed must be activated.
• Gear 1 must be engaged.
Figure 60-240-14
NA15827
1
3 Press the AUX button (Item 3) [Figure 60-240-14] quickly
P122916
to enter the maximum range calibration menu (Item 1)
[Figure 60-240-16].

screen (Item 2) [Figure 60-240-14] until the creep menu
is displayed. (See Operation & Maintenance Manual for
the correct procedure.)

CALIBRATION (CONT’D) NOTE: In the display panel, FNR is blinking when
FNR is not in NEUTRAL. (P) is blinking when
Calibrating The Hydrostatic Pump (Cont’d) parking brake is not applied.
Swash Plate Calibration - Maximum Range (Cont’d) The maximum REVERSE point is automatically stored
from the maximum FORWARD point (display showing
Figure 60-240-17 [PASS]).
Figure 60-240-19
NA15838
NA15833

Press the AUX button (Item 3) [Figure 60-240-14] until
[FWD] appears on the display screen (Item 1) [Figure
60-240-17]. 5. Put the Travel Direction Control in REVERSE [Figure
60-240-19].
1. Put the Travel Direction Control in FORWARD.
6. Drive the machine backward to maximum rpm and
2. Drive the machine forward at maximum rpm and maintain for minimum two seconds.
maintain for minimum 2 seconds.
7. The maximum REVERSE point is automatically
Figure 60-240-18 stored.

in NEUTRAL.
When the calibration is fully performed, the error code

D9299 should be cleared from the display panel.
NA15832
3. The maximum FORWARD point is automatically

stored when the display shows [WAIT] [Figure 60-
240-18].

in NEUTRAL. The parking brake is applied
automatically.

Calibrating The Boom Angle Sensor
Park the telescopic handler on level ground.
Connect the service tool to the telescopic handler. 

See “REMOTE START TOOL (SERVICE TOOL) KIT -
6987761” on page 10-210-1
Figure 60-240-20
2
NA15839
Fully lower the boom (display is showing [DOWN°])

[Figure 60-240-2].
Press the joystick lockout button (Item 3) [Figure 60-240-

1] once to validate and move to the next step.
1

3 Figure 60-240-22
P126178

screen (Item 2) [Figure 60-240-1] until the boom angle
menu is displayed. (See Operation & Maintenance

1] for 3 seconds until the boom angle calibration mode
[Figure 60-240-2] appears on the display screen.
NOTE: A service tool must be connected to the

telescopic handler in order to perform this
procedure. NA15840
Fully raise the boom (display is showing [UP°]) [Figure

60-240-22].

1] once to validate and finish the procedure.
BOOM LENGTH BOOM ANGLE

7 m (22.97 ft) -4°; 60.8°

Calibrating The Boom Angle Sensor (Cont’d)
Figure 60-240-23
EM8037

appears on the display screen. The two calibration points

have now been saved.
Figure 60-240-24
NA15826

240-8] appears on the display screen. Redo the
Press the information button (Item 1) [Figure 60-240-1]

once to return to the engine hour menu.

Calibrating The Inching Sensor
Connect the service tool to the telescopic handler. 

See “REMOTE START TOOL (SERVICE TOOL) KIT -
6987761” on page 10-210-1
Figure 60-240-25
NA15823
Fully release the service brake pedal (display is showing

[UP]) [Figure 60-240-2].
1 Press the AUX button (Item 3) [Figure 60-240-1] once to

3 validate and move to the next step.
P126177

Figure 60-240-27

screen (Item 2) [Figure 60-240-1] until the engine hours
menu is displayed. (See Operation & Maintenance
Press the AUX button (Item 3) [Figure 60-240-1] for 3

seconds until the inching calibration mode [Figure 60-
240-2] appears on the display screen.
NOTE: A service tool must be connected to the

telescopic handler in order to perform this
procedure.
NA15824
Position the service brake pedal at the brake point (end of

inching) (display is showing [BR]) [Figure 60-240-5].
NOTE: The brake point is the pedal position where

the service brake pedal first touches the
service brake valve.
NOTE: Approximately the first half of the total service

brake pedal travel is for inching control.

validate and move to the next step.

INCHING SENSOR (CONT’D) Figure 60-240-30
Calibrating The Inching Sensor (Cont’d)
Figure 60-240-28
NA15826

NA15825 240-8] appears on the display screen. Redo the
Fully press the service brake pedal (display is showing Press the information button (Item 1) [Figure 60-240-1]
[DN]) [Figure 60-240-28]. once to return to the engine hour menu.

validate and finish the procedure.
Figure 60-240-29
EM8037

appears on the display screen. The three calibration
points have now been saved.

Calibrating The LLMC System
Figure 60-240-31
S39203

S39205
Before calibration, drive the machine for a while in order
to warm the axles, then check tightening torque of the NOTE: Do not move or reposition the machine after
two bolts (Item 1) of the LLMS (Longitudinal Load decreasing the rear axle load pressure.

Moment Sensor) (Item 2). Torque value should be
65 N•m (48 ft-lb). When torque value is adjusted, drive Retract the boom and place the load on the ground. Then
the machine for a while and check a second time retract the boom and turn off the engine.
tightening torque of the two bolts (Item 1) [Figure 60-
240-31]. Follow the procedure below to calibrate the LLMI / LLMC
system:
and rear wheels straight ahead. NOTE: Calibration must be performed within a time
span of 5 minutes. If longer, the LLMI / LLMC
NOTE: A load will be needed to topple the machine. system will return to its original settings.
NOTE: During the procedure below, the buzzer will

be activated whenever the TEST button is
WARNING pushed.

system.
W-2929-1012

Calibrating The LLMC System (Cont’d)
Figure 60-240-33
EM9626
3. Without attachment and with the attachment carrier

S41197 fully tilted up, fully retract and raise the boom [Figure
60-240-35].
Figure 60-240-34
4. Press and release the TEST button (Item 1) [Figure
60-240-33] to record the first calibration point.

5. The orange and red LEDs (Item 3) [Figure 60-240-
33] light up to indicate the system is ready to record
the second calibration point.
WARNING
S0007 in) when testing or calibrating the LLMI / LLMC
system.
W-2929-1012
1. Push and hold the TEST button (Item 1) [Figure 60-
240-33] while turning the key switch to START
[Figure 60-240-34] then quickly press the TEST
button (Item 1) [Figure 60-240-33] for 3 times within
the first 4 seconds after the key switch back to RUN /
PREHEAT.
NOTE: To indicate that the system enters calibration

mode, the LED bar (Items 2 and 3) [Figure 60-
240-33] will be blinking and the buzzer sounds
intermittent for 3 seconds.
2. The green LEDs (Item 2) [Figure 60-240-33] light up

to indicate the system is ready to record the first
calibration point.

Calibrating The LLMC System (Cont’d)
Figure 60-240-36
S39203
6. Pick up the load and extend the boom until the

machine topples over (rear wheels off the ground)

[Figure 60-240-36].
7. Press and release the TEST button (Item 1) [Figure

60-240-33 on Page 13] to record the second
calibration point.
8. To indicate the calibration has been validated, the

LED bar (Items 2 and 3) [Figure 60-240-33 on Page
13] lights up for 3 seconds and the buzzer sounds two
times.
NOTE: If the buzzer sounds and LEDs light up in a

particular configuration, a calibration failure
has occurred. (See LLMI / LLMC System
Failure Reports on Page 60-240-17.)
Calibration is finished. The LLMI / LLMC system

automatically returns to normal mode.
Always perform the LLMC calibration test after system

calibration. (See LLMC Calibration Test on Page 60-240-
15.)

LLMC Calibration Test
The Longitudinal Load Moment Control (LLMC) system

calibration can be tested by performing the following
procedure:
and rear wheels straight ahead.
NOTE: A load will be needed to topple the machine.
WARNING EM9626
TIPPING CAN CAUSE SERIOUS INJURY OR DEATH Without attachment and with the attachment carrier fully
tilted up, fully retract and raise the boom [Figure 60-240-
Keep the boom low, only raise the load 500 mm (20 38].
system. Figure 60-240-39
W-2929-1012

1
Figure 60-240-37
S41197
Push and hold the TEST button (Item 1) [Figure 60-240-

S39203 39] during the complete procedure. All the LEDs (Item 2
and 3) light up, and the buzzer sounds discontinuously
during 3 seconds.
NOTE: Keep holding the test button for default test
result confirmation.
NOTE: Do not move or reposition the machine after

decreasing the rear axle load pressure.
Retract the boom and place the load on the ground.

CALIBRATION (CONT’D) NOTE: The system always returns to normal mode
when the TEST button (Item 1) [Figure 60-240-
LLMC Calibration Test (Cont’d) 39] is released during the procedure.
Two test results are possible:
Figure 60-240-40
S41233

• The four green LEDs (Item 1) [Figure 60-240-40] light
up, calibration is OK;
Figure 60-240-41
S41234
• The orange and red LEDs (Item 1) [Figure 60-240-

41] light up, calibration is out of range. Please redo
calibration of the LLMI / LLMC system.
Release the TEST button (Item 1) [Figure 60-240-39].
The calibration test is finished.
NOTE: After pressing the TEST button (Item 1)

[Figure 60-240-39] longer than 60 seconds,
the procedure will automatically end and the
system will return to normal mode.

LLMI / LLMC System Failure Reports
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
ERROR MACHINE
CODE BEHAVIOR
I3018 Sensor No The speed of The LLMI sensor input is Check the harness between
Communication the aggravating disconnected. the sensor and the LLMI.
motions is The sensor linked to the Replace the LLMS on the
decreased LLMI has stopped rear axle and redo the
(50%). sending CAN frame. calibration.
I3014 Sensor OOR Low No aggravating Sensor shifted toward the Recalibrate the system.
(after 30 seconds) motions stability If the error remains: Replace
possible. the LLMS on the rear axle
Shunt is and redo the calibration.
I3015 Sensor OOR High allowed. Sensor shifted toward the Recalibrate the system.
(after 1 second) instability If the error remains: Replace
the LLMS on the rear axle
and redo the calibration.
I3016 Sensor In Error Sensor is out of order Replace the LLMS on the

calibration.
I3017 Sensor Not No motion Sensor has never been Calibrate the system.
Or either LLMI, LLMS or
I3113 OOR Calibration No aggravating Calibration has been Redo the calibration
Values motions done with out of range correctly within 5 minutes.
possible. values
I3121 Backwards Shunt is Calibration has been
Calibration Values allowed. done backwards.
I3122 Calibration Values Calibration has been
Too Close done with points too
close.
I3123 Calibration Calibration lasted more
I3901 Internal Error No impact. LLMI internal memory Replace the LLMI and redo
I3903 failure. the calibration.
I3904
I3905
I3909 Test Membrane Test switch has been on Release the test switch.
Switch Failure. for more than 10s after
the system was started. If the error remains:
Replace the LLMI and redo
the calibration.
Test switch has been on Release the test switch.
for more than 60s during
the calibration verification If the error remains:
procedure. Replace the LLMI and redo
the calibration.

LLMI / LLMC System Failure Reports (Cont’d)
ERROR MACHINE
CODE BEHAVIOR
I0314 Battery Voltage No impact. Battery voltage is lower
OOR Low than 9V
I0315 Battery Voltage Battery voltage is higher
OOR High than 16V —
C3018 Sensor No The speed of The LLMC sensor input is Check the harness
Communication the aggravating disconnected. between the sensor and
motions is the LLMC.
decreased The sensor linked to the Replace the LLMS on the
(50%). LLMC has stopped rear axle and redo the
sending CAN frame. calibration.
C3014 Sensor OOR Low No aggravating Sensor shifted toward the Recalibrate the system.
(after 30 seconds) motions stability If the error remains:
possible. Replace the LLMS on the

Shunt is rear axle and redo the
allowed. calibration.
C3015 Sensor OOR High Sensor shifted toward the Recalibrate the system.
(after 1 second) instability If the error remains:
Replace the LLMS on the
rear axle and redo the
calibration.
C3016 Sensor In Error Sensor is out of order Replace the LLMS on the
calibration.
C3113 OOR Calibration Calibration has been done Redo the calibration
Values with out of range values correctly within 5 minutes.
C3121 Backwards Calibration has been done
Calibration Values backwards.
C3122 Calibration Values Calibration has been done
Too Close with points too close.
C3123 Calibration Calibration lasted more
C0314 Battery Voltage Battery voltage is lower
OOR Low than 9V
—
C0315 Battery Voltage Battery voltage is higher
OOR High than 16V
C3017 Sensor Not No motion Sensor has never been Calibrate the system.
Or either LLMC, LLMS or
C3801 Internal Error No motion LLMC internal failure. Replace the LLMC and
C3803 allowed redo the calibration.
C3804
C3805

ENGINE SERVICE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-19
ENGINE BAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Hydraulic Oil Cooler / Intercooler / Radiator Removal And Installation . . . . . . . . . . . 70-60-1
Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Lubricating Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
Expansion Tank Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Engine Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Oil Filter Adapter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Oil Screen And Pick-up Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Oil Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Oil Pressure Relief Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Injectors Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Checking The Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-10
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Exhaust Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Fuel Injector Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Rocker Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Glow Plugs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-10
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-10
Valve Guide Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-12
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-12
Valve Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-14
Changing Valve Springs (With Cylinder Head Installed) . . . . . . . . . . . . . . . . . . . . . 70-90-15
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-16
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-17
Engine Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-17
Engine Block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-18

Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-18
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-19
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-20
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Pistons And Connecting Rods Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Pistons And Connecting Rods Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Pistons And Connecting Rods Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Piston Cooling Jet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Connecting Rod Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-7
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-7
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Crankshaft And Bearings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-13
Rear Oil Seal Housing Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-15

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Engine Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Timing Case And Drive Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Crankshaft Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Front Oil Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-3
Timing Case And Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-6
Camshaft And Tappets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-7
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Flywheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3
Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3

Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3


ENGINE
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 (CONT'D)
Specifications (Cont’d)
parentheses.
Exhaust Valves
Valve Stem Diameter 8,93 - 8,96 (0.3515 - 0.3528)

Valve Guide Clearance 0,040 - 0,084 (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

ENGINE (CONT'D)
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)

ENGINE (CONT'D)
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

ENGINE (CONT'D)
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.

ENGINE (CONT'D)
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)

ENGINE (CONT'D)
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)

ENGINE (CONT'D)
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

ENGINE (CONT'D)
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)

ENGINE (CONT'D)
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 (CONT'D)
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

ENGINE (CONT'D)
Troubleshooting
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue / white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52

Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45

ENGINE (CONT'D)
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 (CONT'D) Figure 70-10-2
Engine Removal And Installation
Disconnect the ground (-) cable from the battery. (See 4 2

Remove the hydrostatic pump. (See Removal And 3

1
Remove the hydraulic oil cooler / radiator. (See Hydraulic
Oil Cooler / Intercooler / Radiator Removal And
Remove the expansion tank. (See Expansion Tank

Removal And Installation on Page 70-60-6.) P125340
Remove the air cleaner. (See Housing Removal And

Installation on Page 70-50-1.) Remove the tie-strap (Item 2) [Figure 70-10-2].
Remove the muffler. (See Removal And Installation on Loosen the screw and disconnect the electrical connector
Page 70-40-1.) (Item 2) [Figure 70-10-2].
Remove the refrigerant from the A/C system. (See Remove the nut and ground wires (Item 3) [Figure 70-

Reclamation And Charging With Recovery / Charging 10-2].
Unit on Page 80-40-1.)
Disconnect the ignition connector (Item 4) [Figure 70-10-
Figure 70-10-1 2] (red / white cable).
Figure 70-10-3
1
1 1
S38137 1
S38138
Remove the three bolts (Item 1) [Figure 70-10-1] from
the fuse mounting plate. Place the fuse mounting plate
on the bottom of the engine compartment. Remove the hose clamps (Item 1) [Figure 70-10-3].
Remove the two tie-straps (Item 2) [Figure 70-10-3]

Engine Removal And Installation (Cont’d)

1
Figure 70-10-4
S38141
Remove the dual hose clamp (Item 1) [Figure 70-10-6].

S38139
Remove the radiator hose (Item 1) [Figure 70-10-4] from
the thermostat housing. Figure 70-10-7

Figure 70-10-5
1 1
S38142
S38140
Remove the heater hose (Item 1) [Figure 70-10-7] from
the thermostat housing.
Remove the two hose clamps (Item 1) [Figure 70-10-5].
Installation: Apply Loctite® pipe sealant to the insert
Installation: Apply Loctite® #242 to the threads of the before installation.

Figure 70-10-8
S38144
1
Remove the two fuel hoses (Item 1) [Figure 70-10-10].
S38143
NOTE: Mark the hoses for proper assembly.
Remove the A/C hose (Item 1) [Figure 70-10-8] from the Figure 70-10-11
compressor.

Remove the coolant hose (Item 2) [Figure 70-10-8].
Remove the heater hose (Item 3) [Figure 70-10-8].
Installation: Apply Loctite® pipe sealant to the insert of

the heater hose before installation. 1
Figure 70-10-9
1
2
S38145
Remove the hose clamps (Item 1) [Figure 70-10-11].

1
S38119
Remove the engine speed control cable (Item 1) [Figure

70-10-9] from the linkage.
Remove the engine speed control cable from the

mounting bracket (Item 2) [Figure 70-10-9]
Remove any necessary cable ties, carefully remove the

speed control cable.


1
Figure 70-10-12
1 S38146
Remove the two hose clamps (Item 1) [Figure 70-10-14].

S38148
Remove the ground wire (Item 1) [Figure 70-10-12].
Figure 70-10-15

Figure 70-10-13
1
1
S38603
S38147
Install a hoist and chain to the lifting brackets (Item 1)

Remove the hose clamp (Item 1) [Figure 70-10-13]. [Figure 70-10-15].

bolt before installation.

Figure 70-10-16
1
1
1
S38601
Remove the engine mount bolt (Item 1) [Figure 70-10-

S38149 18].

Remove the three plastic caps (Item 1) [Figure 70-10- tighten the engine mount bolt to 250 - 271 N•m (185 -
16]. 200 ft-lb) torque.

Figure 70-10-17 Figure 70-10-19
S38600 S38146
Remove the engine mount bolt (Item 1) [Figure 70-10- Remove the engine mount bolt (Item 1) [Figure 70-10-
17]. 19].
Installation: Apply Loctite® #242 to the threads and Installation: Apply Loctite® #242 to the threads and
tighten the engine mount bolt to 250 - 271 N•m (185 - tighten the engine mount bolt to 250 - 271 N•m (185 -
200 ft-lb) torque. 200 ft-lb) torque.

ENGINE (CONT'D) Compression Checking
Engine Removal And Installation (Cont’d) The tools listed will be needed to do the following
procedure:
Figure 70-10-20
6671177 - Engine Compression Test Kit
6671358 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Glow Plugs Removal And

Figure 70-10-21
S38602
Lift and remove the engine [Figure 70-10-20].

1
P-55631
Install the correct compression adapter (Item 1) [Figure

70-10-21] into the cylinder head.
Figure 70-10-22
P-55632
Connect the compression gauge to the adapter [Figure

70-10-22].
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 (CONT'D)
Compression Checking (Cont’d)
If the measurement is below the allowable limit, inspect

the cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 0,2 - 0,3 MPa (2 - 3

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.
Figure 70-10-23

P-55633
Push the button on the compression gauge to release

pressure [Figure 70-10-23].
Connect the fuel stop solenoid.

ENGINE BAY ASSEMBLY Figure 70-20-2
The Approved Boom Stop on Page 10-150-1.) 1
Remove the engine cover. (See Removal And Installation

on Page 50-70-1.)
1
Drain the hydraulic fluid tank. (See Removing And
Replacing Hydraulic Fluid on Page 10-100-2.) 2

P133571
Remove the refrigerant from the A/C system. (See
Unit on Page 80-40-1.) Remove the four bolts (Item 1) and remove the bolts
(Item 2) [Figure 70-20-2].
Removing And Installing Battery on Page 60-20-3.) Figure 70-20-3

Figure 70-20-1
1
1
2
1
3
1 2
S38072
4
3 Remove the four drive shaft mounting bolts (Item 1)
[Figure 70-20-3].
S38105
Remove the two bolts (Item 1) and the cover (Item 2) to 33 - 41 N•m (24 - 30 ft-lb) torque.
[Figure 70-20-1].
Position the drive shaft (Item 2) [Figure 70-20-3] on the
Remove the two bolts (Item 3) and the cover (Item 4) frame floor.
[Figure 70-20-1].

ENGINE BAY ASSEMBLY (CONT'D) Figure 70-20-6
Figure 70-20-4
1
1
S38076
1
Disconnect the park brake sensor connector (Item 1)
S38073 [Figure 70-20-6].
NOTE: Mark all hoses and electrical connectors, for

Remove the four drive shaft mounting bolts (Item 1) correct installation.
[Figure 70-20-4].

Figure 70-20-7
Position the drive shaft (Item 2) [Figure 70-20-4] on the
frame floor.
Figure 70-20-5
4 3
4 2
1 2
1
P125341
P125340 hose (Item 2) [Figure 70-20-7] from the expansion valve.
NOTE: Plug the A/C hoses and component openings

Remove the tie-strap (Item 1) [Figure 70-20-5] to prevent contamination.
Loosen the screw and disconnect the electrical connector Remove the heater hoses (Items 3 and 4) [Figure 70-20-
(Item 2) [Figure 70-20-5]. 7] from the heater.
Remove the nut and ground wires (Item 3) [Figure 70-

20-5].
Disconnect the ignition connector (Item 4) [Figure 70-20-

5] (red / white cable).

Figure 70-20-8
1
2
S38080

3 1
S38107 hydraulic tank.
Figure 70-20-11
Remove the tie-straps (Item 1) and loosen the collar
(Item 2) [Figure 70-20-8].

Disconnect the hose (Item 3) [Figure 70-20-8]
Figure 70-20-9
2
1 S38081
1
Loosen the hose clamp (Item 1) [Figure 70-20-11].
S38079
IMPORTANT
Remove the hose (Item 2) [Figure 70-20-9] from the clean the work area before disassembly and keep all
hydraulic filter. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888

Figure 70-20-12
1 1
2 1
1 S38084

S38082 (Item 2) [Figure 70-20-14] from the front of the operator
cab.

park brake cylinder.

Figure 70-20-13 IMPORTANT
1
I-2003-0888
Figure 70-20-15
1
1
2 1
S39435
Remove the six hoses (Item 1) from the manifold (Item 2)

[Figure 70-20-13].
S38085
Remove the two hoses (Item 1 and 2) [Figure 70-20-15]

from the steering unit.


1
Figure 70-20-16
2 1
1 S38145
Remove the hose clamps (Item 1) [Figure 70-20-18].

S38119
Support the engine bay assembly with a fork lift or
suitable lift jack.
70-20-16] from the linkage. NOTE: Make sure the fork tips of the fork lift only

support the engine bay assembly and not the
Remove the engine speed control cable from the machine frame.
Figure 70-20-19
Figure 70-20-17
1
1
S38106

S38144 19] located inside the front frame compartment.

Remove the two fuel hoses (Item 1) [Figure 70-20-17]. bolts (Item 1) [Figure 70-20-19] before installation.
NOTE: Mark the hoses for proper assembly.

Figure 70-20-20
1
S38109
Remove the two mounting bolts (Item 1 and 2) [Figure

S38107 70-20-22] at the front of the engine bay assembly.

Remove the two mounting bolts (Item 1) [Figure 70-20- bolt (Item 2) and tighten the mounting bolts (Item 1 and 2)
20] located inside the front frame compartment. [Figure 70-20-22] to 195 - 225 N•m (144 - 166 ft-lb)

torque.
bolts (Item 1) [Figure 70-20-20] before installation. Figure 70-20-23
Figure 70-20-21
1
1
S38110
S38108
Remove the mounting bolt (Item 1) [Figure 70-20-23] in
the middle of the engine bay assembly.
Remove the two mounting bolts (Item 1 and 2) [Figure
70-20-21] at the rear of the engine bay assembly. Carefully remove the engine bay assembly from the
machine. Guide the hoses and wire harness out of the
Installation: Apply Loctite® #242 to the threads of the frame.
bolt (Item 2) and tighten the mounting bolts (Item 1 and 2)
[Figure 70-20-21] to 195 - 225 N•m (144 - 166 ft-lb) Pay special attention to route the HVAC hoses out of the
torque. operator cab.

ENGINE SPEED CONTROL Figure 70-30-3

1
Figure 70-30-1
1 1
S38116
Unscrew and remove the link (Item 1) [Figure 70-30-3].

2 1
Figure 70-30-4
S38084

2
Remove the three bolts (Item 1) and remove the cover 1
cab.
Figure 70-30-2
S38118

1
Remove the nut (Item 2) [Figure 70-30-4] and pull the
cable out through the hole.
S38117
Remove the clip (Item 1) [Figure 70-30-2] from the

pedal.

ENGINE SPEED CONTROL (CONT’D)
Figure 70-30-5
S38119

70-30-5] from the linkage.

Remove the engine speed control cable from the


MUFFLER Figure 70-40-2
Figure 70-40-1
1
1
1 2
S38120
Remove the exhaust mounting bolts (Item 1) [Figure 70-

S38121 40-2].
Remove the muffler and gasket (Item 2) [Figure 70-40-

Open the engine cover. (See Opening And Closing on 2].
Page 10-160-1.)

Installation: Install a new gasket (Item 2) [Figure 70-40-
Remove the muffler mounting bolts (Item 1) [Figure 70- 2].
40-1].
Installation: Apply Loctite® #242 to the threads before
Installation: Apply Loctite® #242 to the threads before tightening the bolts (Item 1) [Figure 70-40-2].
tightening the bolts (Item 1) [Figure 70-40-1].


AIR CLEANER
Housing Removal And Installation

Page 10-160-1.)
Figure 70-50-1
S38122

Loosen the clamp (Item 1) [Figure 70-50-1] and remove
the hose from the air cleaner.
NOTE: Cover or plug the air intake hose so no

contamination gets into the engine.
Figure 70-50-2
S38123

2].

Remove the air cleaner housing assembly.


COOLING SYSTEM Figure 70-60-2
Hydraulic Oil Cooler / Intercooler / Radiator Removal

And Installation
Remove the engine cover. (See Opening And Closing on

Page 10-160-1.)
1
Remove the A/C condenser. (See Removal And

Installation on Page 80-60-1.) 1
Figure 70-60-1
S38290
Remove the four hydraulic hoses (Item 1) [Figure 70-60-

1
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].
S38281
NOTE: Install caps or plugs on the hydraulic hoses.
Remove the two radiator hoses (Item 1) [Figure 70-60-

3].

COOLING SYSTEM (CONT'D) Figure 70-60-6

And Installation (Cont’d)
Figure 70-60-4
1 1
S38284
Remove the two mounting bolts (Item 1) [Figure 70-60-6]

and nuts.
S38287
Remove the air inlet hose (Item 1) [Figure 70-60-4] from

the turbo charger. This will facilitate the next step. Figure 70-60-7
NOTE: Cover the air intake hose so no contamination

gets into the engine.
Figure 70-60-5
S38285
1
Remove the mounting bolt (Item 1) [Figure 70-60-7] and
nut.
S38283
Remove the air inlet hose (Item 1) [Figure 70-60-5] from
the intercooler.


And Installation (Cont’d)
Figure 70-60-8
S38289
With the aid of an assistant, lift and remove the oil cooler
/ radiator assembly from the machine [Figure 70-60-10].
S38286
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].

Cooling System Description
Figure 70-60-11 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 70-60-13].
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-60-11], 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 70-60-12
S6914
The oil cooler (Item 1) [Figure 70-60-12] 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.

COOLING SYSTEM (CONT'D) Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
Thermostat Removal And Installation open.
Drain the engine coolant until it is below the thermostat If the thermostat does not operate correctly it must be
level. replaced.
Figure 70-60-14 NOTE: Identify thermostat temperature by the

stamping on the bypass valve.
Lubricating Oil Cooler Removal And Installation

1 1
Figure 70-60-16
1 1
S39195

Remove the bolts (Item 1) [Figure 70-60-14] and
thermostat housing.
1 1
P-55782
Installation: Make sure all gasket surfaces are clean.
Replace the gasket before installing the thermostat
housing. Remove the eight mounting bolts (Item 1) and remove
the cooler (Item 2) [Figure 70-60-16].
Figure 70-60-15
Installation: Check oil level using the dipstick or add oil
as needed.
S39196
Remove the housing and thermostat [Figure 70-60-15].
Thermostat Testing
Hang the thermostats in a suitable container filled with

coolant.

COOLING SYSTEM (CONT'D) Expansion Tank Removal And Installation
Water Pump Removal Drain the radiator. (See Removing And Replacing The
Remove the coolant from the cooling system.
Figure 70-60-18
Figure 70-60-17
1
1
1
1
2
1
1
S38135
S6913
Remove the two coolant hoses (Item 1) [Figure 70-60-

Remove the mounting bolts (Item 1) [Figure 70-60-17] 18].
from the water pump.
Lift the tank out of the support clip.
Remove the water pump.
NOTE: The bolts (Item 2) [Figure 70-60-18] do not
Water Pump Installation need to be removed.
Clean the gasket surfaces and replace the gasket. Figure 70-60-19
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.
2
Install the water pump bolts (Item 1) [Figure 70-60-17]
and tighten to 22 N•m (16 ft-lb) torque.
1
S39124
Remove the two nuts (Item 1) and bolts and remove the
support (Item 2) [Figure 70-60-19].


LUBRICATION SYSTEM Figure 70-70-3
Engine Lubrication System Description
Figure 70-70-1
1 3
S6915
The engine oil passes from the filter (Item 1) [Figure 70-
P-08834 70-3] to the cylinder block.
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 70-70-1] which is driven through an idler bearings. The pistons and the cylinder bores are

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 70-70-1] and pipe to the suction passages in the cylinder block to the journals of the
side of the pump. camshaft. Engine oil passes from the center journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-70-1], shaft, at a reduced pressure, to feed the rocker bushing.
which is installed in the bottom left side of the cylinder The oil passes through a passage in the rocker shaft to
block. The relief valves opens if the oil pressure is too the bearings of the rocker levers. The valve stems, valve
high; this allows some of the engine oil to return to the springs and the tappets are lubricated by splash and oil
sump. mist.
Figure 70-70-2 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
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 70-70-2].

LUBRICATION SYSTEM (CONT'D) Oil Pan Removal And Installation
Engine Lubrication System Description (Cont'd) Figure 70-70-6
Figure 70-70-4
P-08740
P-08745
Remove the oil pan retaining bolts (Item 1) [Figure 70-
70-6].
Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-70-4]. These jets are connected to the oil Remove the pan and gasket.

pressure rail and spray lubricating oil inside the pistons to
keep them cool. Clean the pan in solvent and dry with compressed air.
Oil Filter Adapter Removal And Installation Clean the block surface.
Figure 70-70-5 Installation: Place a new gasket on the oil pan. Place
two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts (Item 1)
2 [Figure 70-70-6] to 22 N•m (16 ft-lb) torque.
1
1
S6915
Remove the oil filter.
Remove the four bolts (Item 1) and the filter adapter (Item
2) [Figure 70-70-5].
Clean the filter adapter and the block mounting surfaces.
Using a new gasket, install the adapter (Item 2) [Figure

70-70-5] 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 70-70-7 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 70-70-8
1
3
1
P-08834
Remove the bolt (Item 1) that holds the bracket (Item 2)

[Figure 70-70-7] to the mainbearing cap.

Remove the bolts (Item 3) [Figure 70-70-7] from the
pick-up tube flange.
P-08744
Remove the pick-up tube (Item 4) [Figure 70-70-7] and
gasket.
Remove the oil pressure relief valve (Item 1) [Figure 70-
Wash the assembly in solvent and dry with compressed 70-8].
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 70-70-7]
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 70-70-7]. 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 70-70-7] for the pick-up 70-110-2.)
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 70-70-10
Figure 70-70-9
2
1
1
P-08835
P-08835
Fill the pump with engine oil.
Remove the snap ring (Item 1), idler gear (Item 2) If the number 1 main cap was removed, reinstall and
[Figure 70-70-9], and washer. tighten the bolts to 250 N•m (185 ft-lb) torque.

Remove the bolts and oil pump. If the number one main cap was not removed, install the
pump on the main cap and tighten the bolts to 22 N•m
(16 ft-lb) torque.
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 70-70-
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 70-70-12
Figure 70-70-11
B-05591
B-05588
NOTE: If any part is worn enough to effect
performance replace the complete oil pump.
Check that there is a minimum of 0,076 mm (0.003 in)
backlash between the idler gear and oil pump gear Remove the cover of the oil pump.

[Figure 70-70-11].
Remove the outer rotor and thoroughly clean. Inspect for
End play for the idler gear should be 0,050 - 0,275 mm cracks or other damage.
(0.0019 - 0.0108 in).
Install the outer rotor and check the outer rotor to body
Install the oil screen and pick-up tube. (See Oil Screen clearance [Figure 70-70-12].
And Pick-up Tube on Page 70-70-3.)
Clearance between the outer rotor and body must be
Install the pressure relief valve. 0,152 - 0,330 mm (0.0059 - 0.0129 in).
Install the oil pan. (See Oil Pan Removal And Installation Figure 70-70-13
on Page 70-70-2.)
B-05592
Check the inner rotor to outer rotor clearance [Figure 70-

70-13].
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 70-70-15
Figure 70-70-14
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 70-70-14]. and remove the snap ring (Item 3) [Figure 70-70-15].
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 70-70-

15].
Rotor end play must be 0,025 - 0,076 mm (0.0010 -
0.0029 in) for the outer rotor. Clean the parts in solvent and dry with compressed air.
Install the cover and tighten the bolts to 22 N•m (16 ft-lb) Lubricate the bore of the valve body (Item 2), plunger
torque. (Item 5) and the end plate (Item 1) [Figure 70-70-15]
with clean engine oil before assembly.

FUEL SYSTEM 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 Procedure on Page 70-110-
1.) Loosen the lock bolt (Item 1) and move the washer
(Item 2) [Figure 70-80-2] (to the position shown).
Disconnect the ground (-) cable from the battery. (See Retighten the locking screw to 17 N•m (12 ft-lb) torque.
Remove the nut and washer (Item 1) [Figure 70-80-1].
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 Using a gear puller, remove the fuel pump gear [Figure
and the pump locked, the fuel pump timing 70-80-3].
will be lost and the fuel pump will have to be
sent into the dealer to be reset.
Apply pressure counterclockwise by hand to the fuel

pump gear to remove backlash from the gears.

FUEL SYSTEM (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.

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
when removing or installing them. 1
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.

Figure 70-80-12
1
1
P-55528
1 Install the mount bolt (Item 1) [Figure 70-80-14]. Do not

P-55532 tighten at this time.
Remove the three mount bolts (Item 1) [Figure 70-80-12]

and remove the pump.

Fuel Injection Pump Installation
NOTE: The new fuel pump will be supplied with the

pump shaft in the locked position. Do not
unlock the shaft of the fuel pump until the fuel
pump gear is installed.
The engine must be set to TDC number one cylinder,

compression stroke before the pump is installed. (See
Engine Timing Procedure on Page 70-110-1.)
Install a new O-ring onto the pump flange.
Figure 70-80-13
1
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.

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 70-110-2.)
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 70-90-3.)
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

3 3
WARNING 4
AVOID INJURY OR DEATH 1

death. Fluid leaks under pressure may not be visible. 2
S6896
from a physician familiar with this injury.
W-2072-0807
Remove the bolt (Item 1) and remove the breather fitting

Remove the three bolts (Item 3) and remove the fuel filter
1 assembly (Item 4) [Figure 70-80-27].
1 2

1
S39192
Remove the three bolts (Item 1) and remove the fuel

injector cover (Item 2) [Figure 70-80-25].
Figure 70-80-26
S6895
Remove the breather hose (Item 1) [Figure 70-80-26].

FUEL SYSTEM (CONT'D) Installation: Tighten the tubelines to 30 N•m (22 ft-lb)
torque.
Fuel Injector Removal And Installation (Cont'd)
Remove the tubelines.
Figure 70-80-28
Figure 70-80-30
1
1
2
3
P-55777
P-55614
Disconnect the four injector tubelines (Item 1) [Figure

70-80-28] from the injector pump. Remove the fuel return hoses (Item 1) and remove the

bolt (Item 2) and clamp (Item 3) [Figure 70-80-30].
Installation: Tighten the tubelines to 27 N•m (20 ft-lb)
torque. Installation: Tighten bolt to 35 N•m (26 ft-lb) torque.
Figure 70-80-31
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-80-29
1
1
P-55615
1
Remove the injector from the cylinder head [Figure 70-
80-31].
S6897
Disconnect the injector tubelines (Item 1) [Figure 70-80-

29] from the injectors.

FUEL SYSTEM (CONT'D) Checking The Fuel Lift Pump
Fuel Injectors Removal And Installation (Cont'd) Figure 70-80-34
Figure 70-80-32
1
P-55525
P-55617
Remove the fuel lift pipe (Item 1) [Figure 70-80-34] from
the injector pump, install a suitable pipe with a pressure
Installation: The roll pin must be in the position shown test point and connect a pressure gauge.
[Figure 70-80-32].

Operate the engine at idler for 2 minutes to allow any
Figure 70-80-33 trapped air to be removed.
Standard pressure should be 0,04 - 0,07 MPa (0,41 -

0,69 bar) (6 - 10 psi).
P-55616
Installation: Always replace the copper washer (Item 1)

[Figure 70-80-33] at the nozzle. If the washer remains in
the cylinder head, it must be removed.

FUEL SYSTEM (CONT'D) Exhaust Manifold Removal And Installation
Fuel Lift Pump Removal And Installation Remove the turbocharger. (See Removal And Installation
on Page 70-120-2.)
Figure 70-80-35
Figure 70-80-37
1 1
S38144
P-55625
Remove the two fuel lines (Item 1) and electrical harness

(Item 2) [Figure 70-80-35] from the fuel lift pump / filter Remove the eight mount bolts (Item 1) [Figure 70-80-

assembly. 37].
Figure 70-80-36 Remove the exhaust manifold and gasket.
Figure 70-80-38
1 5 2 1 8
4 3 7
6
S6899
P-55625
Remove the two fuel lines (Item 1) and three bolts (Item
2) [Figure 70-80-36] and remove the fuel lift pump / filter
assembly. Installation: Tighten the bolts in the sequence shown
[Figure 70-80-38] to 40 N•m (30 ft-lb) torque.

FUEL SYSTEM (CONT'D) Rocker Cover Removal And Installation
Fuel Injector Cover Removal And Installation Drain the engine coolant until it is below the thermostat
level.
Figure 70-80-39
Figure 70-80-40
1
1
1
1
S39192
S39194
Remove the three bolts (Item 1) [Figure 70-80-39] and

remove the cover. Remove the coolant hose (Item 1) [Figure 70-80-40].

Installation: Tighten the bolts to 9 N•m (80 in-lb) torque. Remove the fuel injector cover. (See Fuel Injector Cover
Figure 70-80-41
2
1
S39189
Loosen the two intake tube clamps (Item 1) [Figure 70-

80-41].
Remove the flexible intake tube (Item 2) [Figure 70-80-

41].

Rocker Cover Removal And Installation (Cont'd)

1
Figure 70-80-42 1
1
1
1
1
S39193
Remove the ten mount bolts (Item 1) [Figure 70-80-44].

S6895
Figure 70-80-45
Remove the breather hose (Item 1) [Figure 70-80-42].

1 10 3 5

Figure 70-80-43 8
1
7
4 9 2
2 6
S39193
Installation: Tighten the bolts in the sequence shown

S6896 [Figure 70-80-45] to 9 N•m (80 in-lb) torque.
Remove the bolt (Item 1) and remove the breather fitting

(Item 2) [Figure 70-80-43].


CYLINDER HEAD Figure 70-90-3
Glow Plugs Checking

1
1 2 1
Disconnect the ground (-) cable from the battery.
Figure 70-90-1
1
2
1 3
S6900
1
Remove the nut (Item 1) [Figure 70-90-3] from the top of
each glow plug.
S39192 Installation: Tighten to 2 N•m (18 in-lb) torque.
Disconnect the engine harness wire (Item 2) [Figure 70-

Remove the three bolts (Item 1) and remove the fuel 90-3] from the glow plug.
Remove the glow plug connecting strap (Item 3) [Figure
Figure 70-90-2 70-90-3].
Disconnect the glow plug cables and leads.
Figure 70-90-4
S6895
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-90-2].
P-55629
Use an ohmmeter to check the glow plugs [Figure 70-90-

4].

CYLINDER HEAD (CONT'D)
Glow Plugs Checking (Cont’d)
Figure 70-90-5
P-55630
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-90-5].

The reading must be between 1 and 2 ohm [Figure 70-
90-5]. If the resistance is infinite, the coil of the glow plug
is broken.
Repeat the procedure for each glow plug.

CYLINDER HEAD (CONT'D) Figure 70-90-8
Glow Plugs Removal And Installation

1
1 2 1
Disconnect the ground (-) cable from the battery.
Figure 70-90-6
1
2
1 3
S6900
1
Remove the nut (Item 1) [Figure 70-90-8] from the top of
each glow plug.
S39192 Installation: Tighten to 2 N•m (18 in-lb) torque.
Disconnect the engine harness wire (Item 2) [Figure 70-

Remove the three bolts (Item 1) and remove the fuel 90-8] from the glow plug.
Remove the glow plug connecting strap (Item 3) [Figure
Figure 70-90-7 70-90-8].
Figure 70-90-9
2
1
1
S6895
S6901
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-90-7].
Loosen and remove the glow plugs (Item 1) [Figure 70-
90-9].
Installation: Tighten the glow plug to 15 N•m (13 ft-lb)

torque.

Removal
Remove the turbo charger. (See Removal And

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
And Installation on Page 70-80-11.)
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 70-90-11].
Reposition the harness.
Figure 70-90-10
Figure 70-90-12

1
P-55681
P-55683
Disconnect the engine cooling temperature sensor (Item

1) [Figure 70-90-10]. Remove the tubeline (Item 1) [Figure 70-90-12].
NOTE: Mark wires for correct installation.

Removal (Cont'd)
8
9 5 1 4
Figure 70-90-13
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 70-90-15].
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 70-90-13].

Lift off the cylinder head and clean the bottom face.
Remove the rocker cover. (See Rocker Cover Removal
Remove the rocker shaft assembly. (See Rocker Shaft

Disassembly And Assembly on Page 70-90-9.)
Figure 70-90-14
P-8718A
Remove the push rods [Figure 70-90-14].

Inspection
Figure 70-90-16 2
1
FRONT TOP
1 1 1 1 1 3
2
B-5562
3
NOTE: The locating pins (Item 1) are pressed in the
B-5564 engine block so the head gasket (Item 2)
[Figure 70-90-17] can be positioned correctly.
Put a straight edge on the cylinder head as shown in The head gasket is installed with no sealer.
[Figure 70-90-16].

Place the head gasket in position with the Front Top (Item
Using a feeler gauge between the straight edge and 2) [Figure 70-90-17] marks in the correct position.
head, check for warping.
Lower the cylinder head in position.
Maximum allowed (Item 1) is 0,03 mm (0.0012 in), (Item
2) is 0,05 mm (0.0019 in) and (Item 3) [Figure 70-90-16]
is 0,05 mm (0.0019 in).
The head can be machined removing only a minimum

amount. Head thickness must not be less than 117,20
mm (4.614 in).
Completely clean the rest of the head.
Inspect for cracks or other damage.
Installation
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
Clean any debris out of the cylinder bores.

Installation (Cont'd)
225° 270°
Figure 70-90-18
3
2 6 10 7
EM7513
1 4
5 9 8
If no angle gauge is available make a suitable mark on
B-23183 the head bolt corner. Make another mark on the cylinder
head the correct number of flats away [Figure 70-90-20].
Turn the head bolt until the lines match.
Tighten the head bolts to 50 N•m (37 ft-lb) in the
sequence shown [Figure 70-90-18]. Figure 70-90-21

Tighten the head bolts to 100 N•m (74 ft-lb) in the
sequence shown [Figure 70-90-18].
Figure 70-90-19
P-8718A
Install the push rods [Figure 70-90-21].
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 70-90-9.)
a torque angle gauge (Item 1) [Figure 70-90-19]. Tighten
the short bolts to 225° and long bolts to 270° in the same Install the rocker cover. (See Rocker Cover Removal And
sequence as shown in [Figure 70-90-19]. Installation on Page 70-80-12.)

Installation (Cont'd)
Figure 70-90-22
1
P-55682
2 Connect the intake manifold pressure sensor (Item 1)

P-55684 [Figure 70-90-24].
Figure 70-90-25
Install the coolant bypass pipe (Item 1) and two screws
(Item 2) [Figure 70-90-22].

Tighten the screws to 22 N•m (16 ft-lb) torque.
Figure 70-90-23
P-55681
Connect the engine cooling temperature sensor (Item 1)

[Figure 70-90-25].
P-55683 Install the glow plugs. (See Glow Plugs Removal And
Install the tubeline (Item 1) [Figure 70-90-23]. 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 Removal And Installation

on Page 70-120-2.)

Rocker Shaft Disassembly And Assembly
NOTE: Make an identification mark on each rocker

arm assembly in order to show the location. 4 5
Figure 70-90-26
1
2 3
P-8720A
Using a valve spring compressor compress the springs

3 and remove the retainers (Item 1) [Figure 70-90-27].
2
Release the compressor and remove the valve spring
P-8719A cap (Item 2), spring (Item 3), valve seal / spring seat
washer (Item 4) and valve (Item 5) [Figure 70-90-27].

Remove the clips (Item 1) [Figure 70-90-26] from both Clean and inspect all components.
ends of the shaft.
Remove the rocker arm (Item 2) and spring (Item 3)

[Figure 70-90-26].
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).
Valve Removal
NOTE: Mark all components so they can be returned

to the same position.

CYLINDER HEAD (CONT'D) 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.
Valve Springs Checking
Figure 70-90-28
35,17 mm
(1.3846 in)
B-5552
Use the following chart [Figure 70-90-28].

Valve Springs
Compressed Height 38,17 mm (1.3846 in)
Installed Pressure 335 N (75 lbf)
Valve Depth Checking
Figure 70-90-29
N-00533
Check the valve depth as shown in [Figure 70-90-29].
The maximum depth is 2,06 mm (0.0811 in) for both

intake and exhaust valves.
If the valve is below the limits, install a new valve and

recheck the valve depth. If it is still below limits a new
valve seat insert must be installed.

CYLINDER HEAD (CONT'D) Interference fit of valve guide to cylinder head: 0,007 -
0,047 mm (0.0003 - 0.0019 in)
Valve Guide Checking
Overall Diameter (Item 3) [Figure 70-90-30]
Figure 70-90-30
Intake and Exhaust 51,00 - 51,50 mm
1 (2.018 - 2.027 in)
Protrusion from bottom recess for valve spring;

(Item 4) [Figure 70-90-30] 12,35 - 12,65 mm
3 (0.486 - 0.498 in)
To inspect the valve guides for wear using a valve.
2 Set up dial indicator gauge (Item 1) [Figure 70-90-30] as

shown.
B-5551
Lift the valve (Item 2) 15,0 mm (0.60 in) and move the
valve in and away from the gauge (Item 1) [Figure 70-90-
Figure 70-90-31 30]. Record this reading.
If the clearance exceeds 0,13 mm (0.005 in) for intake or

0,15 mm (0.006 in) for exhaust (Item 3) [Figure 70-90-
31] the valve guide needs to be replaced.
1 3
B-5566A
The valve guides can be inspected for wear with either of

the operations listed in [Figure 70-90-30] or [Figure 70-
90-31].
Use the following chart to inspect valve guides.
Inside Diameter
(Item 1) [Figure 70-90-30] 9,00 - 9,022 mm
(0.3543 - 0.3552 in)
Outside Diameter (Item 2) [Figure 70-90-30]

Intake and Exhaust 13,034 - 13,047 mm
(0.5131 - 0.5137 in)

Valve Guide Removal
Clean the guide bore in the head.
Figure 70-90-32
2 B-5548

Clean the guide bore in the head.
Lubricate the outer surface of the new guide (Item 1)

[Figure 70-90-33] with the engine oil.
B-5549 Put the guide in position on the valve guide removal /

installation tool (Item 2) [Figure 70-90-33].
Install a valve guide removal / installation tool (Item 1) on Pull the guide into the cylinder head.
the valve guide (Item 2) [Figure 70-90-32].
When correctly positioned the top of the guide should
Pull the guide (Item 2) [Figure 70-90-32] out of the extend 12,35 - 12,65 mm (0.486 - 0.498 in) above the
cylinder head. valve spring seat [Figure 70-90-30].
Valve Guide Installation

CYLINDER HEAD (CONT'D) Cutting A Valve Seat
Valve Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
Figure 70-90-34 Select the correct size cutter.
Valve Seat Angle Intake / 45° / 30°

Exhaust
4 Figure 70-90-35
1
B-5567

Use the following chart [Figure 70-90-34] 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 70-90-35].
2. Intake 8,953 - 8,975 mm
Remove any cutting debris.
(0.3525 - 0.3533 in)
Exhaust 8,938 - 8,960 mm Install the valve and lightly tap.
(0.3519 - 0.3528 in)
3. Intake 46,28 - 46,53 mm Check the valve depth to make sure that it is within limits.
(1.8220 - 1.8319 in) (See Valve Guide Checking on Page 70-90-11.)
Exhaust 41,51 - 41,75 mm
(1.634 - 1.644 in) NOTE: If the valve seat is worn or damaged, a new
4. Intake 1,60 - 1,85 mm valve seat insert can be installed.
(Production) (0.0630 - 0.0728 in)
Intake (Ser- 2,09 mm
vice Maximum) (0.0823 in)
Exhaust (Pro- 1,55 - 1,81 mm
duction) (0.0610 - 0.0713 in)
Exhaust (Ser- 2,06 mm
vice Maximum) (0.0811 in)
Intake / 45° / 30°
Exhaust Valve
Face Angle

Valve Seat Assembly
WARNING
• Engine is running.
• Tools are being used.
W-2019-0907
Figure 70-90-36
4 5

1
2 3
P-8720A
Lubricate the valve stems (Item 1) [Figure 70-90-36] with

clean engine oil and install them in the respective guides.
Install new valve seals / spring seat washer (Item 2)

[Figure 70-90-36].
Install the spring (Item 3) [Figure 70-90-36] on the

washer (make sure the larger diameter is against the
cylinder head).
Place the valve cap (Item 4) [Figure 70-90-36] on the

spring.
Using a valve spring compressor compress the springs

and install the retainers (Item 5) [Figure 70-90-36].

CYLINDER HEAD (CONT'D) NOTE: Do not rotate the crankshaft while the valve
springs are removed.
Changing Valve Springs (With Cylinder Head
Installed) Release the compressor and remove the valve spring(s).
Remove the rocker cover. (See Rocker Cover Removal Place the new valve springs in position.
Compress the valve springs and install the retainers.
Figure 70-90-37
B-5565

Rotate the crankshaft clockwise until the intake valve has
opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [Figure 70-90-37] will be at
approximately T.D.C.
Remove the rocker shaft assembly. (See Rocker Shaft

Disassembly And Assembly on Page 70-90-9.)
Figure 70-90-38
N-00531
Install the valve spring compressor and adapter [Figure

70-90-38].
Compress the valve springs squarely and remove the

retainers.

Valve Clearance Adjustment Cylinder

No. 1 2 3 4
Adjust the valve clearance as follows:
Valve No. 1 2 3 4 5 6 7 8
Valve
Figure 70-90-39
1=Intake I E I E I E I E
E=Exhaust
Use the following sequence to set the valves [Figure 70-

90-40] and [Figure 70-90-41].
2 1 a. With the rocker arm rocking (valves 7 and 8) on No.

4 cylinder set clearance at No. 1 cylinder (valves 1
and 2).
b. With the rocker arm rocking (valves 3 and 4) on No.
2 cylinder set clearance at No. 3 cylinder (valves 5
and 6).
c. With the rocker arm rocking (valves 1 and 2) on No.
3 1 cylinder set clearance at No. 4 cylinder (valves 7
B-5568
and 8).
d. With the rocker arm rocking (valves 5 and 6) on No.

Loosen the lock nut (Item 1) [Figure 70-90-39]. 3 cylinder set clearance at No. 2 cylinder (valves 3
and 4).
Turn the adjustment screw (Item 2) [Figure 70-90-39]
until the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
70-90-39].
Adjust the valve clearance as follows:
0,20 mm (0.008 in) Intake

0,45 mm (0.018 in) Exhaust
Figure 70-90-40
1 2 3 4 5 6 7 8
B-5569

CYLINDER HEAD (CONT'D) Engine Block Disassembly And Assembly
Engine Block Description Remove the water pump. (See Water Pump Removal on
Page 70-60-6.)
Figure 70-90-42
Remove the fuel injection pump. (See Fuel Injection
Pump Removal on Page 70-80-1.)
Remove the oil cooler. (See Hydraulic Oil Cooler /

Intercooler / Radiator Removal And Installation on Page
70-60-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
1 And Installation on Page 70-70-2.)
Remove the turbocharger. (See Removal And Installation

on Page 70-120-2.)
Remove the lift fuel pump. (See Fuel Lift Pump Removal
P-08837 And Installation on Page 70-80-11.)
Remove the starter. (See Removal And Installation on

The cylinder block is made of cast iron and provides full Page 60-40-2.)
length support for the dry liners.

Remove the cylinder head. (See Removal on Page 70-
The liners (Item 1) [Figure 70-90-42] are made of cast 90-4.)
iron. Production liners are a press fit and service liners
are a transion fit. Both types of liners are honed with Remove the timing case and gears. (See Timing Case
silicon carbide tools to a specially controlled finish to And Gear Removal on Page 70-110-3.)
ensure long engine life and low oil consumption.
Remove the piston and connecting rod assemblies. (See
Figure 70-90-43 Pistons And Connecting Rods Removal on Page 70-100-
1.)
Remove the camshaft and tappets. (See Camshaft And

Tappets Removal on Page 70-110-6.)
1 Remove the engine mounting bracket and flywheel. (See

Remove the rear oil seal and the crankshaft. (See Rear
Oil Seal Removal on Page 70-100-13.)
P-08842
A bushing (Item 1) [Figure 70-90-43] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.

Engine Block Inspection
Clean all passages of coolant and oil.
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
cylinder block.
Inspect the camshaft bushing for wear. If the bushing

needs to be replaced, press out old one. Press a new
one in, insuring that the oil holes line up. B-04066
Cylinder Liner Inspection

Inspect the cylinder liner bore for out of round or wear
Figure 70-90-44 beyond service limits [Figure 70-90-45]. The inside
diameter of the service liner should be 105,000 - 105,025
mm (4.1338 - 4.1348 in).
A flex type hone can be used to clean up small scoring or

pitting.
Damaged or worn liners must be replaced.
P-08837
The condition of a cylinder liner is decided by:
• The amount and location of polished areas.
• Wear.
• 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 70-90-44] for

cracks, deep scratches and polished areas where the
honed finish is worn away.

Cylinder Liner Removal
Figure 70-90-46

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-
90-46] is against the bottom of the recess.
Install the rod (Item 4) through the handle (Item 5)

[Figure 70-90-46].
Place the adapter (Item 6) [Figure 70-90-46] under the

cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.

CYLINDER HEAD (CONT'D) Place the threaded rod (Item 4) through the handle
(Item 5) and liner (Item 1) [Figure 70-90-47].
Cylinder Liner Installation
Adjust the rod until it is below the bottom of the block
surface.
IMPORTANT Install the adapter (Item 6) [Figure 70-90-47] on the rod.

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
I-2117-1196
to the flange recess.
Figure 70-90-47 Continue to press the liner into position. Remove the tool.
NOTE: Do Not hit the cylinder liners with a hammer.

4 They will be damaged.
5
Figure 70-90-48
3
1 2

1
2
B-0507
Check liner protrusion with a dial gauge [Figure 70-90-

48].
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 70-90-47] in the bore.
Make sure it is started straight.
The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2)
With the adapter (Item 2) on the top of the liner, place the
[Figure 70-90-48].
bearing (Item 3) [Figure 70-90-47] in the recess at the
top.

CRANKSHAFT AND PISTONS Pistons And Connecting Rods Removal
Pistons And Connecting Rods Description Figure 70-100-1
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 Removal on Page 70-
identification number to order new parts. 90-4.)
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

70-100-1].
Figure 70-100-2
1 1
1
1
P-08743
Mark and remove the connecting rod caps (Item 1)

[Figure 70-100-2].
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 70-100-5
Figure 70-100-3
1
1 1
4
4
B-05570
P-08745
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-100-5] as shown on the connecting rod.
Turn the connecting rods 90° to prevent contact with the
piston cooling jets (Item 1) [Figure 70-100-3]. Push the Figure 70-100-6

piston and rod assemblies out the top of the cylinder.
Figure 70-100-4 1
4
1 1
1 1
3
P-13999
P-08746 Remove the piston rings (Item 1) [Figure 70-100-6] with

a ring expander.
Inspect the crankshaft journals (Item 1) [Figure 70-100- Remove the snap rings (Item 2) [Figure 70-100-6] which
4] for wear or damage. retain the piston pin.
NOTE: Keep all parts together so they can be Push the piston pin (Item 3) [Figure 70-100-6] out by
replaced in their original position. hand. If the pin doesn't push out easily, heat the piston to
40° - 50°C (100° - 120°F) for easier removal.
NOTE: Before installing the pistons check cylinder
bore for wear or damage. (See Cylinder Liner Remove the connecting rod (Item 4) [Figure 70-100-6].
Inspection on Page 70-90-18.)

CRANKSHAFT AND PISTONS (CONT'D)
Piston Ring End Gap
Figure 70-100-7
B-05571
Place the piston rings in the upper part of the cylinder to

inspect the end gap [Figure 70-100-7].

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) New second rings have a green identification mark,
which must be on the left of the ring gap after the ring is
Piston Ring Installation installed and the piston is upright.
Figure 70-100-8 The second ring has an external step at the bottom of the
tapered face.
Place the chromium ring (Item 3) [Figure 70-100-9] with

the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-100-9] 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.
B-05572
Install the spring of the oil control ring in the bottom

groove with the latch pin inside both ends of the spring

[Figure 70-100-8].
Use a ring expander to install the piston rings.
Install the oil spring on the bottom groove of the piston

with the latch pin inside both ends of the spring.
Figure 70-100-9
B-05575
Install the oil control ring over the spring (Item 1) [Figure
70-100-9].
Make sure the ring gap is 180° from the latch pin.
Install the cast iron ring with the tapered face (Item 2)
[Figure 70-100-9] in the second groove with the word
TOP or symbol facing the top of the piston.

CRANKSHAFT AND PISTONS (CONT'D) Piston Cooling Jet Removal
Piston Ring Groove Clearance Figure 70-100-11
Figure 70-100-10
1 1
P-08754
B-05576
Remove the piston cooling jet assembly (Item 1) [Figure
70-100-11] from the engine block.
With the piston rings installed, check the groove
clearance [Figure 70-100-10]. Figure 70-100-12

Top Ring Wedge
Second Ring Side 0,065 - 0,110 mm
Clearance (0.0026 - 0.0043 in)
Third Ring Side Clearance 0,03 - 0,07 mm
(0.0011 - 0.0027 in) 2
3
1
P-08836
Inspect the jet tube (Item 1), mount bolt (Item 2) and
alignment pin (Item 3) [Figure 70-100-12] for damage.
Replace as needed.
Piston Cooling Jet Installation
Install the cooling jet (Item 1) being sure it is seated

correctly on the dowel (Item 3) [Figure 70-100-12] in the
block.
Install the mounting bolt (Item 2) [Figure 70-100-12] and

tighten to 9 N•m (80 in-lb) torque.

CRANKSHAFT AND PISTONS (CONT'D) Connecting Rod Inspection
Piston Cooling Jet Alignment Figure 70-100-14
Figure 70-100-13
127 mm 127 mm
(5”) (5”)
± 0.25 mm ± 0.25 mm
(0.010”) (0.010”)
55,25 mm
(2.2”)
B-05577
14 mm
(0.55”)
N-00535
Inspecting the connecting rod for distortion [Figure 70-
100-14].
Insert a 1,70 mm (0.067 in) diameter rod of suitable
length, in the jet. NOTE: The large and small end bores must be square

and parallel within the limits of ± 0,25 mm
The tip of the rod must extend out the top of the cylinder (± 0.010 in).
in an area 55,25 mm (2.2 in) of height and 14 mm (0.55
in) of width to provide proper cooling jet alignment to cool Measure this 127 mm (5.0 in) on each side of the
the pistons [Figure 70-100-13]. connecting rod axis on a test fixture.
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) Figure 70-100-17
Piston And Connecting Rod Assembly
Figure 70-100-15
FRONT
2
B-05579
3
When the piston has cleared the cooling jet, rotate the
P-13999 piston assembly so that the arrow or FRONT mark is
toward the front of the engine [Figure 70-100-17].
Install the connecting rod (Item 1), piston pin (Item 2) and
two snap rings (Item 3) [Figure 70-100-15] in the piston.

Piston And Connecting Rod Installation
Apply a light coat of oil to the piston and piston rings.
NOTE: Make sure the piston ring end gaps are 120°
apart.
Figure 70-100-16
B-05578
Install the ring compressor over the piston rings [Figure

70-100-16].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.

Piston And Connecting Rod Installation (Cont'd)

1 1
Figure 70-100-18 1
1
1 1
1
P-08743
Install the caps (Item 1) [Figure 70-100-20] 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 70-100-18] with clean engine Rotate the crankshaft. The crankshaft must rotate

oil. smoothly.
Figure 70-100-19 Figure 70-100-21
B-05580 P-08744
Install the upper and lower bearing shells in position Install the oil pick up tube and screen (Item 1) [Figure
making sure the locating tang (Item 1) [Figure 70-100- 70-100-21].
19] is in the correct position.
Install the oil pan. (See Oil Pan Removal And Installation
NOTE: New connecting rod nuts must be installed on Page 70-70-2.)
each time the rod caps are removed.

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings Removal
Checking Piston Height Figure 70-100-22
Rotate the crankshaft until the piston is approximately at

top dead center (T.D.C.). 1
Using a dial indication gauge, pre-load the plunger on the

top surface of the block and zero the gauge.
Carefully move the dial gauge so that the plunger is on

top of the piston above the axis of the piston pin.
Rotate the crankshaft to bring the piston to its highest

point. Record this gauge reading.
When installed, the top surface of the piston is slightly

above the surface of the cylinder block. P-08748
The height above the surface of the block should be 0,21

- 0,35 mm (0.008 - 0.014 in). Remove the water pump. (See Water Pump Removal on
Page 70-60-6.)
Install the cylinder head. (See Installation on Page 70-90-
6.) Remove timing case cover. (See Timing Cover Removal

on Page 70-110-2.)
Crankshaft And Bearings Description
The crankshaft is a chrome-moly forging which has five Pump Removal on Page 70-80-1.)
main journals. End play is controlled by two half thrust
washers on both sides of the center mainbearing. Remove the timing gears and timing case. (See Timing
Case And Gear Removal on Page 70-110-3.)
The mainbearings have steel backs with a aluminium / tin
bearing material. The mainbearing caps are made of cast Remove the flywheel. (See Removal And Installation on
iron. Page 70-130-1.)
The front and rear oil seals are viton lip seals with a dust Remove the pistons and connecting rods, keeping them
lip to the outside of the main lip. in order. (See Pistons And Connecting Rods Removal on
Page 70-100-1.)
Remove the rear oil seal housing (Item 1) [Figure 70-

100-22].

Crankshaft And Bearings Removal (Cont’d)
Figure 70-100-23
1 1
1 1 1 1
1
P-08750
Remove the mainbearing caps (Item 1) [Figure 70-100-

P-08749 25].
Figure 70-100-26
Remove the two bolts (Item 1) [Figure 70-100-23]
retaining the bridge piece.

Remove the bridge piece.
Figure 70-100-24
1 1 1 1 1
P-08753
Remove the thrust washers from the sides of the center

mainbearing bore [Figure 70-100-26].
P-08746
Mark the mainbearing caps (Item 1) [Figure 70-100-24]

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 70-100-29
Figure 70-100-27
A-02763
P-08751
Inspect the crankshaft for wear [Figure 70-100-29]. The
maximum wear and out of round of the crank journals is
Remove the crankshaft [Figure 70-100-27]. 0,04 mm (0.0016 in).

Figure 70-100-28 The main journals and the crank pins of standard size
can be machined 0,25 mm (0.010 in), 0,50 mm (0.020 in)
or 0,75 mm (0.030 in).
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 70-100-28].
Keep the bearings with their respective caps for

installation.

Crankshaft And Bearings Installation
Figure 70-100-30
P-08753
Clean and install the upper and lower thrust bearings on

P-08754 each side of the center mainbearing [Figure 70-100-32].
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 70-100-30].
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 70-100-31 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 70-100-31].
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 70-100-33
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 70-100-33].

Tighten the bridge retaining bolts to 16 N•m (12 ft-lb)
torque.
Figure 70-100-34
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 70-100-
34] 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.
The tool listed will be needed to do the following Figure 70-100-37

procedure;
6674154 - Rear Crankshaft Seal Installation Tool 3
4
Figure 70-100-35
B-05581
1
Make sure the dowels (Item 1) [Figure 70-100-37] are in
2 the block correctly.

B-05581
Install the new gasket (Item 2) on the housing (Item 3)
[Figure 70-100-37].
The seal can be installed from flush with the housing face
(Item 1) to 6,86 mm (0.27 in) (Item 2) [Figure 70-100-35] Install the seal replacer tool (PD145-3) (Item 4) [Figure
back from the housing face. Install seal so that the seal 70-100-37] on the crankshaft.
lip does not line up with any worn areas on the
crankshaft. Lubricate the seal, tool, and crankshaft with clean engine
oil.
Figure 70-100-36
Carefully push the seal and housing (Item 3) [Figure 70-
100-37] over the tool and crankshaft and into position on
the dowels. Remove the tool.
Figure 70-100-38
N-00550
Install the seal in the seal housing using the seal

installation tool. Seat the seal to the correct depth
[Figure 70-100-36].
P-08748
Tighten the bolts (Item 1) [Figure 70-100-38] 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 70-100-39
B-05583
The end play can also be checked using a feeler gauge

[Figure 70-100-41].
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 70-100-39].
Pry the crankshaft to the rear of the cylinder block and

set the dial indicator to zero.
Figure 70-100-40
P-08841
Remove the pry bar and record the dial indicator reading
[Figure 70-100-40].
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.


CAMSHAFT AND TIMING GEARS Figure 70-110-2
Engine Timing Procedure
The tool listed will be needed to do the following

procedure:
6689597 - Camshaft Timing Pins 1
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 70-110-2.)
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 long
used as timing marks. The marks indicate the
camshaft timing pin (6689597) (Item 1) [Figure 70-110-
front of the gear only.
2]. Push the pin fully into the hole.
Figure 70-110-1
Figure 70-110-3

1
1 2
P-55602
P-55600
Insert the short camshaft timing pin (6689597) (Item 1)
[Figure 70-110-3] 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 70-110-1] 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 70-110-2.)
Install the glow plugs. (See Glow Plugs Removal And

Install the rocker cover. (See Rocker Cover Removal And


CAMSHAFT AND TIMING GEARS (CONT'D) Crankshaft Pulley Removal And Installation
Timing Case And Drive Assembly Description Figure 70-110-5
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 70-60-6.)
S6912
Figure 70-110-4
Remove the three bolts (Item 1) and thrust block (Item 2)
[Figure 70-110-5].
Installation: Tighten the bolts to 115 N•m (85 ft-lb)

torque.

1
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 70-110-2.)
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
timing cover (Item 2) [Figure 70-110-4]. Figure 70-110-6
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.
Install the water pump. (See Water Pump Installation on 1 P-55686

Page 70-60-6.)
Install the oil seal (Item 1) [Figure 70-110-6] into the
Do not tighten bolts at this time.
housing using the special tool.
Tighten the cover bolts and water pump bolts to 22 N•m
Install crankshaft pulley. (See Crankshaft Pulley Removal
(16 ft-lb) torque.

CAMSHAFT AND TIMING GEARS (CONT'D) Figure 70-110-9
Timing Case And Gear Removal
Remove the timing cover. (See Timing Cover Removal on 1

Page 70-110-2.)
Remove the crankshaft pulley. (See Crankshaft Pulley


Figure 70-110-7
P-55689
1
Remove the idler gear (Item 1) [Figure 70-110-9] by
moving the gear assembly forward and lifted over the
front oil seal housing.
NOTE: Do not turn the crankshaft with the idler gear

2
removed.

Figure 70-110-10
1
P-55684
2 1
Remove the two bolts (Item 1) and remove the coolant
bypass tube (Item 2) [Figure 70-110-7].
Figure 70-110-8
3 1
P-55690
Remove the bolt (Item 1) and washer (Item 2) [Figure

70-110-10].
2
1
P-55688
Remove the three bolts (Item 1) and plate (Item 2) from

the idler gear (Item 3) [Figure 70-110-8].

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 70-110-11
Figure 70-110-13
1
1 2
2
2
2
2
P-55691
2 P-55692
Remove the camshaft gear (Item 1) [Figure 70-110-11].

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 70-110-13].
Figure 70-110-12 After the cover is correctly aligned, tighten the mount
bolts (Item 2) [Figure 70-110-13] to 22 N•m (16 ft-lb)
torque.
1
1
Figure 70-110-14
1
1
1
2
2
2 P-55692
Remove all the timing case mount bolts (Item 1) and the
four bolts (Item 2) [Figure 70-110-12] from the front of
P-55691
the oil pan.
Remove the timing case from the engine. Install the camshaft gear (Item 1) onto the shaft using
alignment pin (Item 2) [Figure 70-110-14] for correct
alignment.

Timing Case And Gear Installation (Cont'd)
Figure 70-110-15
2
1 P-55688
Install the plate (Item 1) and three bolts (Item 2) [Figure

P-55690 70-110-17].
Tighten the bolts to 44 N•m (33 ft- lb) torque.

Install the washer (Item 1) and bolt (Item 2) [Figure 70-
110-15] and tighten to 95 N•m (70 ft-lb) torque. Figure 70-110-18

Figure 70-110-16
1
2
2
P-55684
P-55689
Install the coolant bypass tube (Item 1) using the two
bolts (Item 2) [Figure 70-110-18].
Install the idler gear (Item 1). Make sure the hole (Item 2)
[Figure 70-110-16] is toward the cylinder head. Install the fuel injection pump. (See Fuel Injection Pump
Install the crankshaft pulley. (See Crankshaft Pulley

Install the timing cover. (See Timing Cover Installation on

Page 70-110-2.)

Camshaft And Tappets Removal
Remove the timing case cover. (See Timing Cover

1
Remove the timing case. (See Timing Case And Gear

Remove the rocker cover, rocker assembly and push

rods. (See Rocker Cover Removal And Installation on
Page 70-80-12.) P-8741
Remove the fuel pump and gasket.

Remove the camshaft thrust washer (Item 1) [Figure 70-
Figure 70-110-19 110-20].
Figure 70-110-21

1
P-8740
P-8742
Turn the engine over and remove the oil pan mounting
bolts [Figure 70-110-19].
Carefully remove the camshaft (Item 1) [Figure 70-110-
Remove the oil pan and gasket. 21].
Installation: Tighten the oil pan mounting bolts to 22

N•m (16 ft-lb) torque.

Camshaft And Tappets Removal (Cont’d)
Figure 70-110-22
1
1
1
1
P-08743
Install the tappets (Item 1) [Figure 70-110-23].

P-8743
Figure 70-110-24
Remove the tappets (Item 1) [Figure 70-110-22] from the

block.

Camshaft And Tappets Installation
Clean and inspect the camshaft and tappets for 1

excessive wear and damage.
Inspect the camshaft bushing for excessive wear and

damage.
NOTE: Only the front camshaft journal bore has a

bushing.
P-8742
Clearance between the camshaft journals, the bushing
and camshaft bore is 0,06 - 0,14 mm (0.0025 - 0.0055
in). Carefully install the camshaft (Item 1) [Figure 70-110-
24].
Make sure all components are clean and lubricated with
clean engine oil.

CAMSHAFT AND TIMING GEARS (CONT'D)
Camshaft And Tappets Installation (Cont’d)
Figure 70-110-25
P-8741
Install the camshaft thrust washer (Item 1). Make sure

that the dowel pin (Item 2) [Figure 70-110-25] 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 70-90-9.)
Install the timing cover. (See Timing Cover Installation on

Page 70-110-2.)
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-70-2.)

TURBOCHARGER
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 fueled starting aid.
37. Crack in back plate of compressor.

TURBOCHARGER (CONT'D) Removal And Installation
Remove the muffler. (See Removal And Installation on

Page 70-40-1.)
WARNING 2
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
hot exhaust gases and supplies air at more than S39189
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
Loosen the two intake tube clamps (Item 1) [Figure 70-
The oil flows from the filter adapter through the bearing 120-3].
housing and returns to the engine block.
Remove the flexible intake tube (Item 2) [Figure 70-120-
The turbocharger should only be serviced by an 3].
authorized dealer or repair shop.

TURBOCHARGER (CONT'D) Figure 70-120-6
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].


FLYWHEEL AND HOUSING Figure 70-130-3
Remove the hydrostatic pump. (See Removal And

Figure 70-130-1
S39126
Remove the six coupler mounting bolts (Item 1) [Figure

1 70-130-3]. Remove the coupler.
Installation: Apply Loctite® #242 to the bolts and tighten

S39164 the bolts to 47 - 51 N•m (35 - 38 ft-lb) torque.

Figure 70-130-4
Remove the two bolts (Item 1) and remove the charge
filter (Item 2) [Figure 70-130-1] and its support.
2
Installation: Apply Loctite® #242 to the threads and 2
1
Figure 70-130-2
1
S39127
Remove two of the flywheel mount bolts and install two

1 guide studs (Item 1) [Figure 70-130-4] in the flywheel to
prevent the flywheel from falling.
2 Remove the remainder of the bolts (Item 2) [Figure 70-
S39125 130-4]. Remove the flywheel by sliding outward over the
guide studs.
Loosen and remove the ten flywheel housing mount bolts Inspect the flywheel and ring gear for wear or damage.
(Item 1) [Figure 70-130-2]. Replace as needed.
Remove the cover (Item 2) [Figure 70-130-2]. Installation: Tighten the flywheel bolts to 115 N•m (85 ft-
lb) torque.

FLYWHEEL AND HOUSING (CONT'D) Figure 70-130-7
Removal And Installation (Cont'd) 3 3
Figure 70-130-5 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 70-130-7].
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 70-130-7] to 75 N•m

blocks under the oil pan. Lower the engine assembly on (55 ft-lb) torque.
the support blocks (Item 1) [Figure 70-130-5].
Figure 70-130-6
1 1
S39136
Remove the eight bolts (Item 1) [Figure 70-130-6] on

both sides of the flywheel housing.
Installation: Apply Loctite® #242 to the bolts before

installation.

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 70-130-8
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 70-130-8].

Flywheel run out must be less than 0,30 mm (0.012 in).
Figure 70-130-9
203 mm (8”)
B-05560
Check the alignment of the flywheel face [Figure 70-130-

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.


HEATING, VENTILATION, AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-5
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Air Conditioning Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-5
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1

The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-5
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-6
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-5
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1


THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1


AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2.).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the blower fan (Item
6) (See Chart on Page 80-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and produces
cooled air, which is pushed into the cab by the blower fan. The moisture in the air condenses on the evaporator coil and

drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1
1
1 P125341
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

S38190 10-3] 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 80-10-1] 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 80-10-4
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 80-10-2
S39158
Pressure Switch: The pressure switch (Item 1)

[Figure 80-10-4] is located on the receiver / drier
assembly (Item 2) [Figure 80-10-3]. 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 80-10-2] 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 80-10-5
1 3 2
S38151
1. Blower Fan Switch - This is a three position switch

P125381 (Item 1) [Figure 80-10-7]. 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)
10-5] is located under the operator seat inside the cab.
[Figure 80-10-7] clockwise to increase cab

The unit delivers the cold air for the A/C into the cab. The
temperature; 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 80-10-7] to turn the Air Conditioning
Figure 80-10-6
ON - Press the bottom of the switch to turn the Air
Conditioning OFF.
P125341
Expansion Valve: The expansion valve (Item 1)

[Figure 80-10-6] controls the amount of refrigerant
entering the evaporator coil.

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 80-10-8
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 80-10-9] 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 80-10-
8] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gauge set
WARNING
connectors. Safety glasses or a transparent face shield
are practical safety Items and one or the other is HFC R-134a refrigerant can be dangerous if not
absolutely required. properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-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 R-134a in the air.
refrigerant can cause severe injuries to eyes. In Any servicing work that involves release or addition
contact with a flame, R-134a refrigerant gives a toxic of R-134a to the system must be done by a
gas. competent refrigeration dealer who has the proper
W-2371-0611 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611


REGULAR MAINTENANCE Recirculation Filter
Filters Figure 80-20-3
Fresh Air Filter

2
Figure 80-20-1
1
1
1
S38736
The recirculation filter is located below the operator’s seat

S40653 inside the operator cab. Remove the two screws (Item 1)
and remove the filter cover (Item 2) [Figure 80-20-3].

The fresh air filter is located on the side of the operator Figure 80-20-4
cab. Remove the two screws (Item 1) and filter cover
(Item 2) [Figure 80-20-1].
Figure 80-20-2
1
S38737
Shake the filter (Item 1) [Figure 80-20-4] or use a

S40654 vacuum to clean. This can be done several times before
replacement is required.
Remove the filter (Item 1) [Figure 80-20-2]. Install the filter (Item 1) [Figure 80-20-4] onto the filter
cover (Item 2) [Figure 80-20-3] and install the filter cover
Clean or replace the filter as necessary. with the two screws (Item 1) [Figure 80-20-3].

REGULAR MAINTENANCE (CONT’D) Belt Replacement
Air Conditioning Belt Adjustment Stop the engine and open the engine cover. (See
The air conditioning belt is a special maintenance free
type that is pretensioned over the pulleys. This belt Figure 80-20-5
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer
for replacement parts.
P115128
A belt tool (Item 1) [Figure 80-20-5] is required to install

the new air conditioning belt. See your Bobcat dealer.
Figure 80-20-6
S38046

80-20-6].

REGULAR MAINTENANCE (CONT’D) Figure 80-20-9
Belt Replacement (Cont’d) 1

3 2
Figure 80-20-7
2
1
S39153
1
Loosen the rear compressor mounting bolt (Item 1)
S39152 [Figure 80-20-9].
Remove the front compressor mounting bolt (Item 1)

Remove the two bolts (Item 1) and belt cover (Item 2) [Figure 80-20-9].
[Figure 80-20-7].
Tilt the compressor until the air conditioning belt can be

removed. Remove the air conditioning belt (Item 3)
Figure 80-20-8
[Figure 80-20-9].
Install a new belt.
Figure 80-20-10
1 1
S39386
Remove the bottom mounting bolt and nut (Item 1)

S39165
[Figure 80-20-8] from the compressor. S39386
Use a prybar under the compressor to tension the air

conditioning belt until the bottom compressor mounting
bolt (Item 1) [Figure 80-20-10] can be installed.
Install and tighten the bottom compressor mounting bolt

(Item 1) [Figure 80-20-10].
Install the belt cover (Item 2) [Figure 80-20-7].
Install the cover (Item 2) [Figure 80-20-6].
Close the engine cover. (See Opening And Closing on

Page 10-160-1.)

REGULAR MAINTENANCE (CONT’D) Air Conditioning Lubrication
Cleaning The Condenser Run the air conditioning for about 5 minutes every week
to lubricate the internal components.
Figure 80-20-11
S38023

Figure 80-20-12
S38023
Raise the condenser (Item 1) and keep in position by

installing the rod (Item 2) [Figure 80-20-12] in the
condenser mount.
Use low air pressure or water pressure to clean the

condenser (Item 1) [Figure 80-20-12]. Be careful not to
damage fins.
Lower the condenser and reinstall the nut (Item 1)

[Figure 80-20-11].

REGULAR MAINTENANCE (CONT’D)
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:

Evaporator / Heater Coil

1
2
Figure 80-20-13 3
2
1
S38206

2
Remove the retainer screws (Item 2) and remove the
1 cover (Item 3) [Figure 80-20-15].
P125381
Figure 80-20-16

Remove the two screws (Item 1) [Figure 80-20-13].
2
Figure 80-20-14
1
1
2
S38203
1
Remove the bolts (Item 1) and ground wire (Item 2)
P125371 [Figure 80-20-16].
Disconnect the connector (Item 1) and the tubes (Items

2) [Figure 80-20-14].
Remove the fluid tank (Item 3) [Figure 80-20-14] by

sliding it upward.

Evaporator / Heater Coil (Cont’d)

1
Figure 80-20-17
2
1
S39214
1
Use low pressure air or water to remove debris from the
P125382 heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-19]. Be careful not to damage fins.

Remove the frame (Item 2) [Figure 80-20-17].
Figure 80-20-18
S39213
Remove the nine cover screws (Item 1) and remove the



TROUBLESHOOTING
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 Repair any leaks and recharge the
refrigerant. can be present in sight glass on receive / drier. 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 circuit Replace clutch.
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.

TROUBLESHOOTING (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.

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.

TROUBLESHOOTING (CONT'D) Inspect the A/C condenser for dirt or mud, and clean if
necessary. (See Cleaning The Condenser on Page 80-
Poor A/C Performance 20-4.)
Start the telescopic handler, engage the parking brake. Inspect the sight glass (Item 2) [Figure 80-30-3] located
Engage the A/C system with the Blower Fan on high. Run on the receiver / drier for air bubbles. (See REGULAR
the telescopic handler at full rpm for approximately 15 MAINTENANCE on Page 80-20-1.)
minutes, with the cab door closed.
HVAC Repair And Leaks
Figure 80-30-1
Figure 80-30-3
1
2

P126565
1
P125341
Figure 80-30-2
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 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.
P-27746
Check the temperature at the louvers (Item 1)

[Figure 80-30-1] with a thermometer [Figure 80-30-2].
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

TROUBLESHOOTING on Page 80-30-1.)
Inspect the Blower Fan for proper operation or noise, and

replace if necessary. (See EVAPORATOR / HEATER
UNIT on Page 80-90-1.)

TROUBLESHOOTING (CONT'D) Figure 80-30-6
Electrical System
Figure 80-30-4 1
S38028
If the compressor clutch does not engage, inspect the

S39152 fuse (Item 1) [Figure 80-30-6]. Replace the fuse if
needed.
Check to see if the compressor clutch (Item 1) is
Figure 80-30-7
engaging. The clutch is located inside the pulley which is
protected by the cover (Item 2) [Figure 80-30-4].

Turn the Ignition key switch to the RUN position without 1
starting the machine.
Figure 80-30-5
2
1
S39157
Disconnect the connector (Item 1) [Figure 80-30-7] from

the compressor.
S38151
Press the top of the switch (Item 1) [Figure 80-30-5] to

activate the air conditioning.
Turn the Blower Fan switch (Item 2) [Figure 80-30-5] to

the first ON - position. The compressor clutch should
make a click sound, which indicates the clutch is
engaging.

Electrical System (Cont'd)
Figure 80-30-8
1
P125341
Disconnect the machine harness (Item 1) [Figure 80-30-

S39197 10] from the pressure switch.
Using a multimeter, check the terminals (Item 1) [Figure

With a multimeter check the resistance to the compressor 80-30-10] for voltage.
clutch connector (Item 1) [Figure 80-30-8].

NOTE: The Key switch must still be in the run
If there is no resistance value replace the compressor position (engine off) and the Blower Fan
clutch. (See Clutch Disassembly And Assembly on Page switch to the first ON position.
80-50-5.)
The voltage should be around 12 volt.
Figure 80-30-9
If there is no voltage at the wiring harness, inspect the
harness for broken wires.
If there is voltage at the harness, inspect the resistance

at the pressure switch (Item 2) [Figure 80-30-10].
If there is no resistance value, check for a low refrigerant

level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-40-1.)
1
If a resistance value is seen, the pressure switch is good.
Reconnect the machine harness to the pressure switch.
S39200
With a multimeter, check the voltage (12V) to the

compressor clutch at the main harness (Item 1) [Figure
80-30-9].
If there is no power at the clutch, check the wiring

If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.



1
Figure 80-30-11
1
2
P125341
Disconnect the blower wiring connector (Item 1) [Figure

P125341 80-30-12] from the machine harness.
Figure 80-30-13
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-30-11] from the machine harness.

1
Check the machine harness (Item 1) [Figure 80-30-11]
for voltage. The voltage should be 12 volt.

If there is voltage at the wiring harness, check the

thermostat wire (Item 2) [Figure 80-30-11] for resistance.
The resistance value should be 10 ohm at 20°C (68°F).
If there is no resistance value, replace the thermostat. S42166

(See Removal And Installation on Page 80-100-2.)
Check the machine harness (Item 1) [Figure 80-30-13]

for voltage (between two outer terminals). The voltage
should be 12 volt.

If there is voltage at the wiring harness, check the

resistance to the blower at the blower wiring connector
(Item 2) [Figure 80-30-13].
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.


1
Figure 80-30-14
S36342
1 1
Check the main harness (Item 1) [Figure 80-30-16] for
2 voltage. The voltage should be 12 volt, if there is no
voltage inspect the harness for broken wires.
S38151
Figure 80-30-17
Remove the four screws (Item 1) [Figure 80-30-14].

H C

Installation: Tighten screws (Item 1) [Figure 80-30-14]
to 2 N•m (18 in-lb) torque.
Remove the panel (Item 2) [Figure 80-30-14]. B

M
Figure 80-30-15
L
1
N-22288
If there is voltage at the main harness check the Blower

Fan switch [Figure 80-30-17] for resistance.
With the switch in the OFF position, there should be zero

resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And
S36341 also between the C terminal and the L terminal frame
[Figure 80-30-17].
Disconnect the main wire harness connector (Item 1) With the switch in the 2 position, there should be
[Figure 80-30-15] from the switch. resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-17].
With the switch in the 3 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-30-17].
If any of the above resistance tests fail, replace the

Blower Fan switch.


SYSTEM CHARGING AND RECLAMATION Figure 80-40-2

Unit
1
Page 10-160-1.)
Figure 80-40-1
1 N-23024
2 NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the refrigerant that
is in the A/C system and if it is pure enough to
use. The Refrigerant Identifier (Item 1) [Figure
80-40-2] will determine the kind of refrigerant
S39234 and any possible harmful or dangerous

substances that can be present in the system.
Thus preventing mixing of dangerous
Locate the low pressure port (Item 1) and high pressure material with your reclaimed R-134a in your
port (Item 2) [Figure 80-40-1] on the back side of the reclaimer, and further contamination to other
compressor. A/C systems that are reclaimed and charged
from your 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, R-134a refrigerant gives a toxic
gas.
W-2371-0611
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 80-40-3 In the event of a leak, wear safety goggles. Escaping
gas.
W-2371-0611
1
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
S39234
when it contacts open flame or very hot
substances.
Remove the protective cap and connect the refrigerant • NEVER SMOKE when there is the possibility of

identifier to the low pressure hose (Item 1) [Figure 80- even small amounts of R-134a in the air.
40-3]. Any servicing work that involves release or addition
of R-134a to the system must be done by a
Connect the refrigerant identifier to its power source. competent refrigeration dealer who has the proper
equipment, knowledge, and experience to service
Follow the steps displayed on the refrigerant identifier refrigeration equipment.
screen [Figure 80-40-2]. W-2373-0611
Allow 2 minutes for the refrigerant identifier to display the Figure 80-40-4
type of refrigerant and air content. An alarm will sound if
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 N-22291
procedure.
Use an approved recovery / charging unit [Figure 80-40-

4] to evacuate the system.
Connect the reclaimer to the A/C charge ports.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-7

Unit (Cont'd)
Figure 80-40-5
2
N-22381
1
NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
S39235 follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they can vary
Connect the Red hose (Item 1) [Figure 80-40-5] to the slightly depending on the model and brand of

high pressure port and open the valve. reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-40-5] to the

low pressure port and open the valve.
Figure 80-40-6
N-22292
Turn the reclaimer unit to the ON position and follow the

on screen instructions [Figure 80-40-6].
NOTE: The A/C system holds 1,13 kg (1.98 lb) of

refrigerant (R134a).


COMPRESSOR Figure 80-50-3

2
Evacuate the A/C system. (See SYSTEM CHARGING 1
AND RECLAMATION on Page 80-40-1.)
Stop the engine and open the engine cover. (See

Figure 80-50-1
1
2
S39152
Remove the two bolts (Item 1) and belt cover (Item 2)

[Figure 80-50-3].
1
Figure 80-50-4

S38046
2
80-50-1].
1
Figure 80-50-2
S39156
Remove the compressor hoses (Item 1 and 2) [Figure

80-50-4].
Installation: Tighten the hose (Item 1) to 27 - 41 N•m (20

- 30 ft-lb) torque. Tighten the hose (Item 2) [Figure 80-
50-4] to 20 - 27 N•m (15 - 20 ft-lb) torque.
Cap and plug the hoses and fittings with the proper A/C
S39157
caps and plugs.
Disconnect the connector (Item 1) [Figure 80-50-2] from

the compressor.

COMPRESSOR (CONT'D) Remove the rear compressor mounting bolt (Item 1)
[Figure 80-50-6] and remove the compressor.
Figure 80-50-5 bolt before installation.
Figure 80-50-7
1
1
S39386
S39165
S39386
Remove the bottom mounting bolt and nut (Item 1)
[Figure 80-50-5] from the compressor.

Installation: Apply Loctite® #242 to the threads of the install the front compressor mounting bolt (Item 2)
bolt before installation. [Figure 80-50-6] and nut. Do not yet tighten. Then use a
prybar under the compressor to tension the air
Figure 80-50-6 conditioning belt until the bottom compressor mounting
bolt and nut (Item 1) [Figure 80-50-7] can be installed.
3
1
2
S39155
Loosen the rear compressor mounting bolt (Item 1)

[Figure 80-50-6].
Remove the front compressor mounting bolt (Item 2)

[Figure 80-50-6] and nut.
Tilt the compressor until the air conditioning belt can be

removed.
Remove the air conditioning belt (Item 3) [Figure 80-50-

6].

COMPRESSOR (CONT'D) Oil Check
Oil The compressor oil should be checked as follows when

oil is being added to an in service machine.
Figure 80-50-8
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 80-40-1.)
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 80-50-8] is factory filled
with 150 - 170 cc's of PAG oil (Poly Alkelene Glycol). Remove the compressor from the machine. (See

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.

COMPRESSOR (CONT'D) Figure 80-50-11
Oil Check (Cont'd)
Figure 80-50-9
1
S39176
NOTE: After draining the oil through the drain hole

S39174 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-10 11] several times by hand.

Measure the drained oil in a measuring cylinder.
1 Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-50-12
S39175
Remove the oil drain plug (Item 1) [Figure 80-50-9] and 1

drain the oil through the connectors (Item 1) [Figure 80-
50-10] and the oil drain hole (Item 1) [Figure 80-50-9].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9 -

11 ft-lb) torque.
S39175
Add new compressor oil through the suction side

connector (Item 1) [Figure 80-50-12].
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.

Clutch Disassembly And Assembly
Figure 80-50-13
8 mm 8 mm
(1.25”) (1.25”)
1
8 mm
(1.25”)
P-27524
1 The armature plate puller (Item 1) [Figure 80-50-15] can

P-27519 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 80-50- Figure 80-50-16
13].

Assembly: Tighten the armature nut to 12 N•m (8 ft-lb).
Figure 80-50-14
1
P-27522
Attach the armature puller plate (Item 1) to the armature

plate using the three bolts (Item 2) [Figure 80-50-16].
P-27520
To remove the armature plate (Item 1) [Figure 80-50-14]

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
Clutch Disassembly And Assembly (Cont'd) following thicknesses.
Figure 80-50-17 0,1 mm (0.0039 in)

0,3 mm (0.0118 in)
0,5 mm (0.0197 in)
Figure 80-50-19
P-27521
Attach a slide hammer puller to the armature puller tool

[Figure 80-50-17].
P-27525

Figure 80-50-18
the pulley assembly.
Figure 80-50-20
2 1
P-27523
Remove the armature plate (Item 1) [Figure 80-50-18]

from the compressor clutch.
P-27526
Remove the shims (Item 2) [Figure 80-50-18] from the

armature shaft or armature plate. Remove the pulley from the compressor [Figure 80-50-
20].
Assembly: Insure that the clutch has the correct
clearance by adding the shims (Item 2) [Figure 80-50-
18].

Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-21
P-27529
Remove the harness retainer screw assembly (Item 1)

P-27527 [Figure 80-50-23].
Figure 80-50-24
The pulley assembly and bearing [Figure 80-50-21] must
be replaced as a complete unit.

Figure 80-50-22
1
2
1
P-27530

P-27528 the coil.
Remove the lock (Item 1) and connector (Item 2) [Figure

80-50-22] from the compressor harness.

COMPRESSOR (CONT'D)
Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-25
P-27531
Remove the coil from the compressor [Figure 80-50-25].

Figure 80-50-26
P-27527
The compressor [Figure 80-50-26] must be replaced as

a complete unit.

CONDENSER Figure 80-60-2

Unit on Page 80-40-1.) 1
WARNING
S38196
gas.
W-2371-0611
Remove the two bolts and nuts (Item 1) [Figure 80-60-2]

Figure 80-60-1 from each side of the condenser.
Figure 80-60-3

1
2
S38195
S38197
condenser.
Slide the condenser (Item 1) [Figure 80-60-3] forward.
Installation: Tighten the hose (Item 1) [Figure 80-60-1]
to 20 - 27 N•m (15 - 20 ft-lb) torque. Remove the hose (Item 2) [Figure 80-60-3] from the
condenser.
NOTE: Install caps and plugs on all fittings.
Installation: Tighten the hose (Item 2) [Figure 80-60-3]
to 14 - 20 N•m (15 - 20 ft-lb) torque.
Remove the condenser (Item 1) [Figure 80-60-3].


RECEIVER / DRIER Figure 80-70-2

Page 10-160-1.)
Remove the refrigerant from the A/C system. (See 1

SYSTEM CHARGING AND RECLAMATION on Page 80-
40-1.) 1

2
P125381
WARNING
Remove the two retainer screws (Item 1) and remove the
In the event of a leak, wear safety goggles. Escaping cover (Item 2) [Figure 80-70-2].
contact with a flame, R-134a refrigerant gives a toxic Figure 80-70-3
gas.
W-2371-0611
2

Figure 80-70-1
1
1
3
1
S39210
Loosen the screws (Item 1) [Figure 80-70-3] on the

P125341 clamps.
Remove the tubeline (Item 2) [Figure 80-70-3] from the

Disconnect the two connectors (Item 1) [Figure 80-70-1] receiver / drier.
from the pressure switch.
Remove the receiver / drier (Item 3) [Figure 80-70-3].
receiver / drier.
NOTE: Install caps and plugs on all fittings.


PRESSURE SWITCH

Page 10-160-1.)

40-1.)
WARNING
gas.
W-2371-0611
Figure 80-80-1

1
2 2
P125341
S38200
Disconnect the two connectors (Item 1) from the

pressure switch (Item 2) [Figure 80-80-1].
Remove the pressure switch (Item 2) [Figure 80-80-1]

from the receiver / drier assembly.


EVAPORATOR / HEATER UNIT Figure 80-90-2

5
40-1.)
4 3
WARNING
In the event of a leak, wear safety goggles. Escaping 2
refrigerant can cause severe injuries to eyes. In 1
P125341
gas.
W-2371-0611
Remove the operator seat. (See OPERATOR SEAT on hose (Item 2) [Figure 80-90-2] from the expansion valve.
Page 50-20-1.)
Figure 80-90-1
Remove the heater hoses (Items 3 and 4) [Figure 80-90-

2] from the heater.
Disconnect the blower wiring connector (Item 5)

[Figure 80-90-2] from the machine harness.
Figure 80-90-3
1
S39211
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-90-1]. 2
1
P125381

EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-90-6

2
Figure 80-90-4
1
4
1
3 1
S38203
2
P125371 [Figure 80-90-6].
Figure 80-90-7
Disconnect the connector (Item 1) and the tubes (Items 2
and 3) [Figure 80-90-4].

Remove the fluid tank (Item 4) [Figure 80-90-4] by 2
sliding it upward.
Figure 80-90-5 1
1
2
1
3
P125382

2
Remove the frame (Item 2) [Figure 80-90-7].
S38206


EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-90-10
Figure 80-90-8
2
1 1
2 1
1 S38212
1 Lift the rubber cover (Item 1) and retract the flexible hose
S38213 (Item 2) [Figure 80-90-10].
Figure 80-90-11
Remove the screws (Item 1) and remove the cover (Item
2) [Figure 80-90-8].

Figure 80-90-9
3 2
1
1
2
S38209
1 S38210
Remove the two bolts (Item 1) [Figure 80-90-11] 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 80-90-9]. blower unit (Item 2) [Figure 80-90-11] (Inset).
Loosen the clamp (Item 2) and retract the flexible hose Remove the evaporator / blower unit from the machine.
(Item 3) [Figure 80-90-9].


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 80-100-1 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-
100-1] 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 80-100-4

1
Remove the operator seat. (See OPERATOR SEAT on
2
Page 50-20-1.)
NOTE: The thermostat can be changed without 3

evacuating the A/C system, or removing the
evaporator / heater unit from the loader.
Figure 80-100-2
2
S38206
1 Remove the bolt (Item 1) [Figure 80-100-4].

2 Figure 80-100-5

1
2
P125381
1
Figure 80-100-3
S38203
3

[Figure 80-100-5].
2
P125371
Disconnect the connector (Item 1) and the tubes (Item 2)

[Figure 80-100-3].
Remove the fluid tank (Item 3) [Figure 80-100-3] by

sliding it upward.

THERMOSTAT (CONT’D) Figure 80-100-8
Figure 80-100-6
1 1 1
1
1
1
2 1
S39211
Remove the thermostat (Item 1) [Figure 80-100-8] from

S38209 the evaporator / heater unit.
Remove the nine screws (Item 1) and remove the cover

(Item 2) [Figure 80-100-6].

Figure 80-100-7
S39241
Remove the thermostat probe (Item 1) [Figure 80-100-7]

from the A/C evaporator coil.


EXPANSION VALVE Figure 80-110-2

40-1.) 1
WARNING
In the event of a leak, wear safety goggles. Escaping 2
S39212
gas.
W-2371-0611
Remove the two mount bolts (Item 1) from the expansion

Remove the operator seat. (See OPERATOR SEAT on valve (Item 2) [Figure 80-110-2].
Page 50-20-1.)
Remove the expansion valve (Item 2) [Figure 80-110-2].
Figure 80-110-1
The expansion valve (Item 2) [Figure 80-110-2] is

replaced as a complete unit.
1
1
2
1
1
P125341
S38214
Remove the A/C hoses (Item 1 and Inset) from the

expansion valve (Item 2) [Figure 80-110-1].


SPECIFICATIONS
(TL35.70(X)) 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-10-4
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Environmental* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
VISIBILITY DIAGRAMS* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Visibility Diagrams - 20” Wheels* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Visibility Diagrams - 24” Wheels* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Visibility Diagrams For Light Material Buckets* . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
LIFTING AND TIE-DOWN SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
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
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-5
791 of 836 SPEC-01 TL35.70(X) Service Manual

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
SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1

Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-3
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-3
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-3
Special Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-4
* If EC-equipped machine
Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s) are
provided for comparison purposes only and are subject to change without notice. Specification(s) for your individual
Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions, and other factors.
792 of 836 SPEC-02 TL35.70(X) Service Manual

(TL35.70(X)) 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
B
C
D M
E F
H
G I
J K L N
Q O

R
(A) Overall length (with forks) 6074 mm (239.1 in)
(B) Overall length (to forks face) 4869 mm (191.7 in)
(C) Overall length (to carrier pin) 4763 mm (187.5 in)
(D) Overall length (to front tires) 4058 mm (159.8 in)
(E) Overall height (with rotating beacon) 2477 mm (97.5 in)
(F) Overall height (with roof window wiper) 2340 mm (92.1 in)
(G) Carriage rotation angle 135°
(H) Height to back of the machine 1668 mm (65.7 in)
(I) Ground clearance 346 mm (13.6 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 and rear) 1895 mm (74.6 in)
(O) Width over standard tires 2300 mm (90.6 in)
(P) External turning radius (with forks spaced 1040 mm [40.9 in] ext.) 4925 mm (193.9 in)
(P) External turning radius (with forks spaced 1360 mm [53.4 in] ext.) 5015 mm (197.4 in)
(Q) External turning radius (at tires) 3714 mm (146.2 in)
(R) Internal turning radius (at cab) 1092 mm (43.0 in)
Operator cab inside width 900 mm (35.4 in)
793 of 836 SPEC-10-1 TL35.70(X) Service Manual

(TL35.70(X)) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)
Performance
Crowding force - Tilt (ISO 8313) 6200 daN (13938 lbf)

Crowding force - Lift (ISO 8313) 3600 daN (8093 lbf)
Drawbar pull 7900 daN (17759 lbf)
Ground pressure 11 kg/cm² (156.5 PSI)
Rated load capacity 3500 kg (7718 lb)
Capacity (at maximum height) 3500 kg (7718 lb)
Capacity (at maximum reach) 1500 kg (3308 lb)
Tipping load (at maximum reach) (ISO 14397-1) 1780 kg (3925 lb)
Lifting height (forks) 6872 mm (270.6 in)
Maximum reach (forks, COG 500 mm [19.7 in]) 4087 mm (160.9 in)
Max. reach (forks, COG 500 mm [19.7 in], at max. height) 1208 mm (47.6 in)
Travel Speed in First / Second Gear (TL35.70) 
- Low range 0 - 5 km/h (0 - 3.1 mph) / 0 - 14 km/h (0 - 8.7 mph)
- High range 0 - 10 km/h (0 - 6.2 mph) / 0 - 26 km/h (0 - 16.2 mph)
Travel Speed in First / Second Gear (TL35.70X) 
- Low range 0 - 5 km/h (0 - 3.1 mph) / 0 - 16 km/h (0 - 10 mph)
- High range 0 - 10 km/h (0 - 6.2 mph) / 0 - 35 km/h (0 - 21.8 mph)

Static and dynamic tests have been carried out and passed according to EN1459-1 and ISO 22915.*
Weights
Weight (unladen) 7050 kg (15545 lb)

Front axle weight (unladen) 2880 kg (6350 lb)
Rear axle weight (unladen) 4170 kg (9195 lb)
Weight with pallet frame and forks 7355 kg (16218 lb)
Front axle weight with pallet frame and forks 3340 kg (7365 lb)
Rear axle weight with pallet frame and forks 4015 kg (8853 lb)
Weight with pallet frame, forks and 3500 kg (7716 lb) load 10860 kg (23946 lb)
Front axle weight with pallet frame, forks and 3500 kg (7716 lb) load 9005 kg (19856 lb)
Rear axle weight with pallet frame, forks and 3500 kg (7716 lb) load 1855 kg (4090 lb)

Engine
Make / Model PERKINS / 1104D-44TA

Fuel / Cooling Diesel / Liquid
Rated power (DIN 6271) at 2200 rpm 74,5 kW (100 hp)
Rated speed 2200 rpm
Low idle speed 900 rpm
Maximum torque at 1400 rpm 410 N•m (302 ft-lb)
Number of cylinders 4
Displacement 4,4 L (1.16 U.S. gal)
Bore / Stroke 105 mm (4.13 in) / 127 mm (5 in)
Fuel consumption (average loading) 10 L/h (2.6 U.S. gal/h)
Lubrication Gear pump pressure
Crankshaft ventilation Open breathing
Air cleaner Dry replaceable cartridge with safety element
Ignition Diesel Compression
Cycle type 4 cycles

Air induction Turbocharged
Engine coolant Ethylene 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 Passive brake
Parking brake Passive 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 CAMSO 405/70-20 14PR TM R4

(450 kPa [4,5 bar] [65 psi])
Optional tires CAMSO 400/80-24 20PR TM R4
(425 kPa [4,25 bar] [62 psi])
Optional tires CAMSO 405/70-20 16PR TM R4
(450 kPa [4,5 bar] [65 psi])
Optional tires DUNLOP 405/70R20 168A2/152J MPT SPT9
(550 kPa [5,50 bar] [80 psi])
Optional tires DUNLOP 405/70R24 168A2/152J MPT SPT9
(460 kPa [4,6 bar] [67 psi])
Optional tires MICHELIN 400/80-24 162A8 IND TL POWER CL
(425 kPa [4,25 bar] [62 psi])

Optional tires MICHELIN 460/70-24 159A8/159B IND TL XMCL
(340 kPa [3,40 bar] [49 psi])
Optional tires MICHELIN 500/70-24 164A8/164B IND TL XMCL
(290 kPa [2,90 bar] [42 psi])
Optional tires* ALLIANCE 460/70R24 159A8 A 580
(360 kPa [3,60 bar] [52 psi])
Optional tires NOKIAN 460/65R24 156A8 151D TRI STEEL TL
(400 kPa [4,00 bar] [58 psi])
* Not available for models with S/N AVM114000 & Above and AVM614000 & Above
Steering
Steering Pump Priority valve on equipment

Steering Mode 2WS / 4WS / CRAB
Brakes
Engine Braking Hydrostatic

Parking and Emergency brake Passive brake
Service Brake Oil immersed discs

Fluid Capacities
Axle front / rear -

— Axle differential front 7,5 L (2.0 U.S gal)
— Axle differential rear 7,4 L (1.9 U.S gal)
— Wheel hub reduction (per wheel) 0,8 L (0.21 U.S. gal)
— Gearbox 1,8 L (0.5 U.S. gal)
Cooling system with heater 15 L (4.0 U.S. gal)
Engine oil with oil filter 8,5 L (2.2 U.S. gal)
Fuel tank 138 L (36.4 U.S. gal)
Hydraulic fluid tank 59 L (15.6 U.S. gal)
Hydraulic system plus tank 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 25,0 MPa (250 bar) (3626 psi)
Main valve type Open centre with flow sharing and flow compensators technology

Hydraulic filter specification Full flow filtration
Front auxiliary flow 100 L/min (26.4 U.S. gpm)
Hydraulic fluid PETRONAS
Electrical System
Alternator 90 A (110 A optional**)

Battery 110 Ah (140 Ah optional**)
Starter 3,2 kW (4.3 hp)
** Not allowed for EC-equipped machines
Temperature Range
Operation and storage -15 - +45°C (+5 - +113°F)
Altitude
Maximum altitude 2000 m (6500 ft)

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
Sight Level Gauge
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*
DECLARED NOISE EMISSION VALUES
Value Uncertainty
Bystander noise Level per Directive 2000/14/EC - LwA 106 dB(A) N/A**
Operator noise level per EN 12053 - LpA 77 dB(A) 4 dB(A)
DECLARED VIBRATION EMISSION VALUES
Value Uncertainty
Whole-body vibration per EN 13059 (20” tires) 1,4 m/s² 0,42 m/s²
4.6 ft/s² 1.4 ft/s²
Hand-arm vibration N/A** N/A**
RMS maximum per Directive 1978/764 N/A** N/A**
FLUORINATED GREENHOUSE GAS (F-GAS) (if equipped with HVAC)
Value
F-gas Type HFC-134a
F-gas Mass 0,90 kg (1.98 lb)

CO Equivalent 1,29 t (1.42 tn)
Global Warming Potential (GWP) 1430
* If EC-equipped machine
** N/A - Not applicable for telescopic handler.


VISIBILITY DIAGRAMS*
Visibility Diagrams - 20” Wheels*

VISIBILITY DIAGRAMS* (CONT’D)
Visibility Diagrams - 24” Wheels*

VISIBILITY DIAGRAMS* (CONT’D)
Visibility Diagrams For Light Material Buckets*


LIFTING AND TIE-DOWN SPECIFICATIONS
Lifting
X2 X1

CG location (X1) Front 1793 mm (70.6 in)
(X2) Rear 1557 mm (61.3 in)
Longitudinal Angle (q1) Front 33°
(q2) Rear 40°
Lateral Angle (d1) Front 8°
(d2) Rear 10°
Sling Length Front 3350 mm (131.9 in)
Rear 2450 mm (96.5 in)
Single Sling Force Front 49940 N (11227 lbf)
Rear 42190 N (9485 lbf)
(A) Lifting hook height minimum 3575 mm (140.7 in)
Operating mass 7470 kg (16469 lb)

LIFTING AND TIE-DOWN SPECIFICATIONS (CONT’D)
Tie Down

Wheel Stop
B
Most compact angle Angle for < 4000 DaN

(8992 lbf) sling forces
Vertical Angle (a1) Front 22° 18°
(a2) Rear 52° 29°
Horizontal Angle (bx1) Front 68° 49°
(bx2) Rear 58° 22°
Sling Length Front 2000 mm (78.7 in) 2390 mm (94.1 in)
Rear 1560 mm (61.4 in) 2500 mm (98.4 in)
Single Sling Force Front 55520 N (12481 lbf) -
Rear 48280 N (10854 lbf) -
(A) Lateral distance attachment points 2450 mm (96.5 in)
(B) Longitudinal distance attachment points 4799 mm (188.9 in) - 7105 mm (279.7 in)
Operating mass 7470 kg (16469 lb)

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 M18x1,5mm 360 266
Wheel Nuts M20x1,5mm 500 369
Boom
N•M FT-LB
Extension Cylinder Base End 640 - 700 472 - 516
Wear Pads Front 43 - 47 32 - 35
Wear Pads Rear 43 - 47 32 - 35
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 54 45
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) Property Class 8.8 Property Class 10.9
M 4 x 0.7 2,5 - 3,5 N•m 3,8 - 4,2 N•m
(2.0 - 2.5 ft-lb) (2.8 - 3.1 ft-lb)
M 5 x 0.8 5,5 - 6,5 N•m 7,6 - 8,4 N•m
(4.0 - 5.0 ft-lb) (5,6 - 6,2 ft-lb)
M 6 x 1.0 9,5 - 10,5 N•m 12,3 - 13,7 N•m
(7.0 - 7.5 ft-lb) (9.1 - 10.1 ft-lb)
M 7 x 1.0 15 - 17 N•m 20 - 22 N•m
(11.0 - 12.5 ft-lb) (14.7 - 16.2 ft-lb)
M 8 x 1.25 24 - 26 N•m 29,4 - 32,6 N•m
(18 - 19 ft-lb) (21.7 - 24.0 ft-lb)
M 10 x 1.25 43 - 47 N•m 57 - 63 N•m
(32 - 35 ft-lb) (42.0 - 46.5 ft-lb)
M 12 x 1.25 75 - 85 N•m 105 - 115 N•m
(55 - 60 ft-lb) (78 - 85 ft-lb)
M 14 x 1.5 125 - 140 N•m 160 - 180 N•m

(90 - 100 ft-lb) (118 - 133 ft-lb)
M 16 x 1.5 190 - 210 N•m 255 - 285 N•m
(140 - 155 ft-lb) (188 - 210 ft-lb)
M 18 x 1.5 260 - 290 N•m 345 - 385 N•m
(190 - 215 ft-lb) (255 - 285 ft-lb)
M 20 x 1.5 370 - 410 N•m 490 - 550 N•m
(275 - 300 ft-lb) (360 - 405 ft-lb)
M 22 x 1.5 500 - 550 N•m 660 - 740 N•m
(370 - 400 ft-lb) (490 - 545 ft-lb)
M 24 x 2.0 640 - 700 N•m 850 - 950 N•m
(470 - 520 ft-lb) (625 - 700 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
(CONT'D)
Flare Fitting
Use the following procedure to tighten the flare fitting:
Figure SPEC-40-3
TS-1619

Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-3].
Use the chart below to find the correct tightness needed

(Item 2) [Figure SPEC-40-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.
FLARE FITTING TIGHTENING TORQUE
TUBELINE NEW ROTATE RE-ASSEMBLY

TORQUE N•M
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
(FT-LB)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 23 (17) 2-1/2 1
11/16" 3/8" 9/16" - 18 30 (22) 2 1
7/8" 1/2" 3/4" - 16 54 (40) 2 1
1" 5/8" 7/8" - 14 81 (60) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 114 (84) 1 3/4
1-3/8" 1" 1-5/16" - 12 160 (118) 3/4 3/4

HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.
O-ring Flare Fitting Figure SPEC-40-5
Figure SPEC-40-4
O-ring Flare
Primary
Seal
1
TS-1619
Secondary
Seal P-13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts
The flare is the primary seal, the O-ring is the secondary of the connection (Item 1) [Figure SPEC-40-5].
seal and helps absorb vibration and pressure pulses at

the connection [Figure SPEC-40-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-40-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.
FLARE FITTING TIGHTENING TORQUE
** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE N•M
NO. OF HEX ROTATE NO. OF
DIAMETER (FT-LB)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 23 (17) 2-1/2 1
11/16" 3/8" 9/16" - 18 30 (22) 2 1
7/8" 1/2" 3/4" - 16 54 (40) 2 1
1" 5/8" 7/8" - 14 81 (60) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 114 (84) 1 3/4
1-3/8" 1" 1-5/16" - 12 160 (118) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a used hose / tubeline.

If a torque wrench is used to tighten a used fitting to a new hose / tubeline.
If a torque wrench is used to tighten a new fitting to a new hose / tubeline.
** If using the hex flat tightening method to tighten a new fitting to a new hose / tubeline.
If using the hex flat tightening method to tighten a new fitting to a used hose / tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose / tubeline.

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT'D)
O-ring Flare Fitting (Cont’d)
NOTE: O-ring flare fittings are not recommended in 2

all applications. Use the standard flare fittings
in these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Figure SPEC-40-6 1
P-13573
Copper Bonnet Orifice

When a O-ring flare fitting is used as a straight thread
port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.
Always remove the O-ring (Item 1) [Figure SPEC-40-7]

from the flare face as shown.

1 An O-ring (Item 2) [Figure SPEC-40-7] is added to the
flat boss of the fitting to seal the connection in this
application.
P-13572
Use a standard flare fitting (Item 1) [Figure SPEC-40-6]

as shown.

HYDRAULIC CONNECTION SPECIFICATIONS Do not over tighten the port seal fitting.
(CONT'D)
NOTE: If a torque wrench cannot be used, use the
Port Seal Fitting hex flat tightening method as an approximate
guideline.
Figure SPEC-40-8
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-

THREAD SIZE
WRENCH SIZE LB)
11/16" 9/16" - 18 30 (22)
15/16" 3/4" - 16 54 (40)
1-1/8" 7/8" - 14 81 (61)
Nut Seals 1-1/4" 1-1/16" - 12 114 (84)

to Fitting 1-1/2" 1-5/16" - 12 160 (118)
Figure SPEC-40-9

Nut Seals
to Port
Secondary O-ring Seal
1
P-13008
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at P-13571
the connection [Figure SPEC-40-8].
The hex portion of the nut does not contact the surface of Do not use port seal fittings when a thread in orifice
the component when the nut is tight. (Item 1) [Figure SPEC-40-9] is used in the port. The
orifice can interfere with the fitting and prevent it from
Use the following procedure to tighten the port seal sealing.
fitting:
Use an O-ring boss fitting (Item 2) [Figure SPEC-40-9]
Port seal and nut, washer and O-ring (O-ring Boss) as shown. (See Straight Thread O-ring Fitting on Page
fittings use the same tightening torque valve chart. SPEC-40-1.)
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.


HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
Use Bobcat Axle / Transmission Oil SAE 85W90 LS / API During cold weather (0°C [32°F] and below), do not
GL-5 (P/N 6987805) for the axle central housings and the operate machine until the engine has run for at least
differentials. 5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
Use Bobcat Axle / Transmission Oil ISO 100 / API GL-4 stopping. Do not operate controls during warm-up
(P/N 6987794) for the gearbox and the planetary carriers. period.
Use Bobcat Superior SH Hydraulic / Hydrostatic fluid (P/ When temperatures are below -30°C (-20°F), the
N 6987791). hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
DO NOT use automatic transmission fluids in the temperatures. Park the machine in an area where the
machine or permanent damage to the hydraulic / temperature will be above -18°C (0°F) if possible.
hydrostatic system will result. W-2027-0311
WARNING

from a physician familiar with this injury.
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


SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing the telescopic handler.
Remote Start Tools
TOOL PART
DESCRIPTION COMMENT IMAGE
NUMBER
6987761 Kit, Start Tool Complete Kit includes: 
7022042 - Remote Start Tool
6689747 - Loader Service Tool Harness
6689746 - Computer Service tool Harness
6689745 - BOSS Service Tool Harness
7023157 - USB - Serial Cable
Single parts contained in the kit are described on

next page. Some cables contained in the Kit are to
be used on other Bobcat models (Loaders, mini
excavators...etc)
7022042 Remote Start Tool Included in the Kit 6987761.


6689747 Remote Start Tool Used with 7022042 to connect remote start tool to
Harness machine. Included in the Kit 6987761.
6689746 Remote Start Tool Used with 7022042 to connect Service PC to

Harness remote start tool. Included in the Kit 6987761.
7023157 USB - Serial cable Included in the Kit 6987761.

See www.BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools
Catalogue and Doosan Shop for parts ordering information.)

821 of 836 SPEC-70-1 Service Manual
SERVICE TOOLS REQUIRED (CONT’D)
Hydraulic Tools
TOOL PART
NUMBER
7313982 Hydraulic Tester Hydraulic tester 7313982 can be used for hydraulic
(Flow Meter) testing.
6670022 O-Ring Seal Hook
4127913  Adjustable Gland Includes standard pins and offset pins. These are
Nut Wrench replaceable pins that insert into 4127913 for
disassembling various cylinders.
6670026 Cylinder Gland

Nut Wrench
6670009 Rod Seal

Installation Tool
6987774 Air Bleeding Kit
6670065 Coupler
6671361 Pressure Test Kit


Drive Tools
TOOL PART
NUMBER
7277767 Pinion Bearing Setup Tool Measurement ring T24
7277769 Pinion Setup Tool Dummy Pinion T26
Electrical Tools
TOOL PART
NUMBER
7000460 Terminal Disconnect Tool Pin Extractor No Image Available
7000461 Terminal Disconnect Tool Pin Extractor No Image Available

Engine Tools
TOOL PART
NUMBER
6671177 Engine Compression Test Kit
6671358 Compression Adapter Used in glow plug port for

testing compression -
Included with 6671177.
6689597 Camshaft Timing Pins No Image Available

6674154 Rear Crankshaft Seal Installation Tool
1801470 Cylinder Liner Removal / Installation Tool
7024835 Starting Box Interface


Special Drive Tools
Figure SPEC-70-1
T1

T2
NA15251
NA15252

Special Drive Tools (Cont’d)
Figure SPEC-70-2
T5

T6 T7
NA15253
NA15254

Figure SPEC-70-3
T8 T9

T10
NA15255
NA15256
NA15257

Figure SPEC-70-4
T11 T13

T14
T15
NA15258
NA15259
NA15260
NA25261

Figure SPEC-70-5
T16
T16A T16B
T16A

T19
T17
NA15262
NA15263
NA15264

Figure SPEC-70-6
T20 T21
T20A

T20B
NA15265
NA15266

Figure SPEC-70-7
T22

T23
T24
NA15267
NA15268
NA15269

Figure SPEC-70-8
T25
T25A
T25B
T25C T25B T25A
T25C

T26
T26A
T26B
T26C
NA15270
NA15271

Figure SPEC-70-9
T27

T28
NA15272
NA15273

ALPHABETICAL INDEX
(TL35.70(X)) TELESCOPIC HANDLER ENGINE COVER . . . . . . . . . . . . . . . . . . . 50-60-1

SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1 ENGINE LUBRICATION SYSTEM . . . . . 10-90-1
ACCUMULATORS . . . . . . . . . . . . . . . . . 20-150-1 ENGINE SPEED CONTROL . . . . . . . . . . 70-30-1
AIR CLEANER SERVICE . . . . . . . . . . . . 10-60-1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . 70-50-1 ENGINE BAY ASSEMBLY . . . . . . . . . . . . 70-20-1
AIR CONDITIONING SYSTEM FLOW . . 80-10-1 EVAPORATOR / HEATER UNIT . . . . . . . 80-90-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . 60-30-1 EXPANSION VALVE . . . . . . . . . . . . . . . 80-110-1
APPROVED BOOM STOP . . . . . . . . . . 10-150-1 EXTENSION (COMPENSATION) CYLINDER
ATTACHMENT CARRIER (QUICK-TACH) 50-80-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
ATTACHMENT CARRIER . . . . . . . . . . . 10-130-1 FAN MOTOR . . . . . . . . . . . . . . . . . . . . . 20-100-1
AUTOMATIC PARK BRAKE . . . . . . . . . 60-230-1 FENDER . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
AXLE AND DIFFERENTIAL (FRONT) . . 40-20-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . 1-11
AXLE AND DIFFERENTIAL (REAR) . . . . 40-21-1 FIXED BOOM . . . . . . . . . . . . . . . . . . . . . 50-30-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . 40-40-1 FLYWHEEL AND HOUSING . . . . . . . . . 70-130-1
AXLES (FRONT AND REAR) . . . . . . . . 10-110-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . 40-30-1
BOBCAT TELESCOPIC HANDLER FRONT WIPER MOTOR . . . . . . . . . . . . 60-100-1

IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 1-16 FUEL LEVEL SENDER . . . . . . . . . . . . . 60-170-1
BOOM ANGLE SENSOR . . . . . . . . . . . . 60-90-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10-80-1
BOOM CYLINDER . . . . . . . . . . . . . . . . . 20-20-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 70-80-1
BOOM SUSPENSION AND FLOAT SYSTEM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
GEARBOX SHIFTING CONTROL CYLINDER
CALIBRATION . . . . . . . . . . . . . . . . . . . . 60-240-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
CAMSHAFT AND TIMING GEARS . . . . 70-110-1 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
CHARGE PRESSURE . . . . . . . . . . . . . . 30-50-1 HYDRAULIC / HYDROSTATIC FLUID
COLLECTOR BLOCK . . . . . . . . . . . . . . . 20-70-1 SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-50-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . 80-50-1 HYDRAULIC / HYDROSTATIC SYSTEM
CONDENSER . . . . . . . . . . . . . . . . . . . . . 80-60-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
CONTROLLERS . . . . . . . . . . . . . . . . . . 60-210-1 HYDRAULIC CONNECTION SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . SPEC-60-1
HYDRAULIC FLUID TANK . . . . . . . . . . 20-110-1
COOLING SYSTEM . . . . . . . . . . . . . . . . 10-70-1
HYDRAULIC SYSTEM INFORMATION . 20-10-1
COOLING SYSTEM . . . . . . . . . . . . . . . . 70-60-1
HYDROSTATIC DRIVE MOTOR . . . . . . . 30-30-1
COUNTERWEIGHT . . . . . . . . . . . . . . . . 50-90-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . 30-40-1
CRANKSHAFT AND PISTONS . . . . . . . 70-100-1
HYDROSTATIC SYSTEM INFORMATION
CYLINDER HEAD . . . . . . . . . . . . . . . . . . 70-90-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
DASH COVER . . . . . . . . . . . . . . . . . . . . 50-120-1 INCHING SENSOR . . . . . . . . . . . . . . . . 60-140-1
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 1-15 INNER BOOM . . . . . . . . . . . . . . . . . . . . . 50-40-1
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 INSTRUMENT PANELS . . . . . . . . . . . . . 60-80-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . 40-90-1 JOYSTICK PANEL . . . . . . . . . . . . . . . . . 50-130-1
ELECTRICAL SYSTEM INFORMATION . 60-10-1 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
EMERGENCY BRAKE . . . . . . . . . . . . . 60-150-1 LIFTING AND BLOCKING THE TELESCOPIC
EMERGENCY EXIT . . . . . . . . . . . . . . . 10-180-1 HANDLER . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
ENGINE COVER . . . . . . . . . . . . . . . . . . 10-160-1
833 of 836 INDEX-01 TL35.70(X) Service Manual

LIFTING AND TIE-DOWN SPECIFICATIONS STEERING CYLINDER (FRONT / REAR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
LIFTING THE TELESCOPIC HANDLER 10-200-1 STEERING UNIT . . . . . . . . . . . . . . . . . . 20-120-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 STOPPING THE ENGINE AND LEAVING THE
LLMI / LLMC SYSTEM . . . . . . . . . . . . . . 60-190-1 TELESCOPIC HANDLER . . . . . . . . . . . 10-170-1
LUBRICATING THE TELESCOPIC HANDLER SYSTEM CHARGING AND RECLAMATION 
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
LUBRICATION SYSTEM . . . . . . . . . . . . . 70-70-1 TANDEM GEAR PUMP . . . . . . . . . . . . . . 20-90-1
MACHINE TORQUE SPECIFICATIONS TELESCOPIC HANDLER STORAGE AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 RETURN TO SERVICE . . . . . . . . . . . . . 10-190-1
MAIN VALVE . . . . . . . . . . . . . . . . . . . . . 20-130-1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . 80-100-1
MAINTENANCE CLOCK . . . . . . . . . . . . 60-200-1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . 20-50-1
MAINTENANCE SAFETY . . . . . . . . . . . . . . . 1-1 TIRE MAINTENANCE . . . . . . . . . . . . . . 10-140-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1 TOP WIPER MOTOR . . . . . . . . . . . . . . . 60-110-1
MULTIFUNCTION VALVES . . . . . . . . . . . 30-60-1 TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . 30-20-1
TOWING THE TELESCOPIC HANDLER 10-40-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . 10-20-1
TRAILER BRAKE VALVE . . . . . . . . . . . . 20-160-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . 50-10-1
TRANSPORTING THE TELESCOPIC HANDLER
OPERATOR SEAT . . . . . . . . . . . . . . . . . . 50-20-1 ON A TRAILER . . . . . . . . . . . . . . . . . . . . 10-30-1

PARK BRAKE . . . . . . . . . . . . . . . . . . . . . 40-60-1 TROUBLESHOOTING . . . . . . . . . . . . . . . 40-10-1
PORT RELIEF VALVES . . . . . . . . . . . . . 20-140-1 TROUBLESHOOTING . . . . . . . . . . . . . . . 80-30-1
PRESSURE SWITCH . . . . . . . . . . . . . . . 80-80-1 TURBOCHARGER . . . . . . . . . . . . . . . . 70-120-1
PUBLICATIONS AND TRAINING RESOURCES VISIBILITY DIAGRAMS* . . . . . . . . . . SPEC-11-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
WEAR PADS (FRONT) . . . . . . . . . . . . . . 50-50-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . 40-110-1
WEAR PADS (REAR) . . . . . . . . . . . . . . . 50-51-1
REAR WIPER MOTOR . . . . . . . . . . . . . 60-120-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . 80-70-1
REGULAR MAINTENANCE . . . . . . . . . . 80-20-1 * If EC-equipped machine
6987761 . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
RETRACT SENSOR . . . . . . . . . . . . . . . 60-220-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . 1-9
SELF LEVELING (COMPENSATION) CYLINDER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
SERIAL NUMBER LOCATION . . . . . . . . . . . 1-14
SERVICE BRAKE PEDAL ASSEMBLY . 60-130-1
SERVICE BRAKE VALVE . . . . . . . . . . . . 20-80-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . 40-100-1
SERVICE PC (LAPTOP COMPUTER) . 60-160-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . 10-50-1
SERVICE TOOLS REQUIRED . . . . . SPEC-70-1
SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . 60-60-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING ANGLE ADJUSTMENT . . . . 40-50-1
STEERING COLUMN COVER . . . . . . . 50-110-1
834 of 836 INDEX-02 TL35.70(X) Service Manual

835 of 836
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Dealer Copy -- Not for Resale

TL35.70(X) Telescopic Handler

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

NA5434 NA5436 B-6589

3 of 836 1-1 TL35.70(X) Service Manual

4 of 836 1-2 TL35.70(X) Service Manual

SAFETY AND 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 836 1-3 TL35.70(X) Service Manual

6 of 836 1-4 TL35.70(X) Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Dealer Copy -- Not for Resale

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7 of 836 1-5 TL35.70(X) Service Manual

8 of 836 1-6 TL35.70(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 all machine fluid

7. Check for correct function of 15. Lubricate the telescopic

8. The parking brake must 16. Check the condition of the

9 of 836 1-7 TL35.70(X) Service Manual

19. Inspect for loose or broken 22. Recommend to the owner

Dealer Copy -- Not for Resale

10 of 836 1-8 TL35.70(X) Service Manual

Dealer Copy -- Not for Resale

WARNING • The operator must know any prohibited uses or work

11 of 836 1-9 TL35.70(X) Service Manual

Dealer Copy -- Not for Resale

Cutting or drilling concrete containing sand or rock

12 of 836 1-10 TL35.70(X) Service Manual

Check hydraulic tubes, hoses and fittings for damage

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

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Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing non-metallic parts such as

Dealer Copy -- Not for Resale

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