Bobcat s570 6990681 SM 1

Service Manual
Skid-Steer Loader
S/N ALM411001 & Above
S/N B3GZ11001 & Above
6990681enUS (02-19) (K) Printed in U.S.A. ©2019 Bobcat Company. All rights reserved.
T4B S3B
1 of 1290
2 of 1290
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1694 NA1693

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
NA1674 NA1695 NA1680

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

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW39-0609
3 of 1290 1-1 S570 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECTOC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

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

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach® attachment

correctly installed, functional mounting system wedges and
and in good condition. linkages must function
correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good
correctly adjusted, clean and condition.
lubricated.
SERVICE
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
6. Machine signs (decals) must 14. Check all machine fluid

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

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

the work lights.
FW SSL-0119 SM

17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
FW SSL-0119 SM

SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or • An Operator’s Handbook fastened to the operator
service. Untrained operators and failure to follow cab. It’s brief instructions are convenient to the
instructions can cause injury or death. operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT • The AEM Safety Manual delivered with the machine

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

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

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

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

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

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

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

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1016SM

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

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

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.
Spark Arrester Exhaust System
The spark arrester exhaust system is designed to control

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

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

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

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

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1016 SM

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

requesting service information or when ordering parts.
Earlier or later models (identification made by serial
number) may use different parts, or there may be
different procedures to follow when performing a specific
service operation.
Loader Serial Number

1
Figure 1
1 P109660
The engine serial number (Item 1) [Figure 3] is located

on the side of the engine next to the oil fill cap.
P107305D
The loader serial number plate (Item 1) [Figure 1] is

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

Combination NA3095
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

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

the order in which the loader is produced.

DELIVERY REPORT
Figure 4
NA3106
The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat loader is delivered.
The delivery report must be reviewed and signed by the

owner or operator and the dealer.

LOADER IDENTIFICATION
2 20
1
11
3
19
4 12
18
5 13
10
14
6
9
7 8 15 17
16
NA5772
NA5773
ITEM DESCRIPTION ITEM DESCRIPTION

Operation & Maintenance Manual and Operator’s
1 11 Lift Cylinder (Both Sides)
Handbook
2 Front Lights 12 Rear Grille
3 Grab Handles 13 Back-up Alarm
4 Operator Seat with Seat Belt and Seat Bar 14 Rear Work Lights and Taillights
5 Tilt Cylinders 15 Rear Door
Rear Tie-down (Both Sides) Front Tie-down located
6 Bucket [A] 16
behind Bucket
7 Bucket Steps 17 Tires [C]
8 Step 18 Lift Arm Support Device
9 Alternate Front Tie-down (Both Sides) 19 Lift Arm
10 Front Auxiliary Quick Couplers 20 Operator Cab (ROPS and FOPS) [B]
[A] Bucket – Several different buckets and other attachments are available for the Bobcat loader.
[B] ROPS – Roll-Over Protective Structure per ISO 3471 and FOPS – Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
[C] Tires – Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

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

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

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

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

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

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

Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-5

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-5
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

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

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

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

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

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1


LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-90556
P-85425
Lift the rear of the loader and install jackstands in the

B-7023A notched area of the frame [Figure 10-10-2].
Figure 10-10-3
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807 P-85985
Read the Removal And Installation, Disassembly And Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the axle tubes [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tires. Make sure the tires clear the floor or any
obstacles.
NOTE: The lift arms are raised for photo clarity.

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
23 of 1290 10-10-1 S570 Service Manual

LIFT ARM SUPPORT DEVICE
Description
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407
Figure 10-20-1
P107248A
The lift arm support device (Item 1) [Figure 10-20-1] is

used to support the lift arms while working on a machine
with the lift arms up.
A decal (Item 2) [Figure 10-20-1] located on the right

side of the operator cab provides instructions for
installing and removing the lift arm support device.
The procedures are described in more detail on the

following pages. (See Installing on Page 10-20-2.) and
(See Removing on Page 10-20-3.)

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-3
Installing
DANGER
P-90567D
P-90328
AVOID DEATH Have a second person install the lift arm support device
• Disconnecting or loosening any hydraulic over the rod of one of the lift cylinders [Figure 10-20-3].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. The lift arm support device must be tight against the
• Keep out of this area when lift arms are raised cylinder rod.
unless supported by an approved lift arm
support. Replace if damaged. Figure 10-20-4
D-1009-0409
Remove attachment from the loader. (See Operation &

Maintenance Manual.)
Figure 10-20-2
P107250A
P107307
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder. The tabs
of the lift arm support device must go past the end of the
P107247A P107248
cylinder (Inset) [Figure 10-20-4].
Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-2].
Remove the lift arm support device (Item 1) [Figure 10-

20-2] from the storage position.
The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-6
Removing
DANGER
P107248
P-90328
AVOID DEATH Return the lift arm support device to the storage position
• Disconnecting or loosening any hydraulic and secure with clamping knobs [Figure 10-20-6].
can cause lift arms to drop. Remove the jackstands.
• Keep out of this area when lift arms are raised
support. Replace if damaged.
D-1009-0409
The operator must be in the operator’s seat, with the seat

belt fastened and seat bar lowered, until the lift arm
support device is removed, and the lift arms are lowered
all the way.
Start the engine and raise the lift arms all the way up.
Figure 10-20-5
P-90567D
Have a second person remove the lift arm support device

[Figure 10-20-5].
Lower the lift arms all the way and stop the engine.

OPERATOR CAB Cab Door Sensor
Description This machine may be equipped with a Cab Door Sensor.
The Bobcat loader has an operator cab (ROPS and Figure 10-30-1
FOPS) as standard equipment to protect the operator
from rollover and falling objects. The seat belt must be
worn for rollover protection.
Inspect the cab, mounting, and hardware for damage.

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

FOPS - Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
1
Level I
Protection from falling bricks, small concrete blocks,

P-68116B
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites. The cab door has a sensor (Item 1) [Figure 10-30-1]
installed that deactivates the lift and tilt valves when the
Level II door is open.
Protection from falling trees, rocks: for machines Figure 10-30-2

involved in site clearing, overhead demolition or
forestry.
2
WARNING 1
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
NA3275
rollover and falling objects, and result in injury or
death.
W-2069-0200 The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-
2] is OFF when the door is closed, the key switch is
turned to RUN, the seat bar is lowered, and the PRESS
TO OPERATE LOADER button is pressed.
The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

2] is ON when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.
[DOOR] will appear in the data display (Item 2) [Figure

10-30-2] when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.

OPERATOR CAB (CONT’D)
Raising WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See LIFT ARM • STOP ENGINE before raising or lowering cab.
SUPPORT DEVICE on Page 10-20-1.) W-2758-0908
Figure 10-30-3 NOTE: On some machines, the operator cab frame

can contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-5
P107247
Install jackstands under the rear of the loader frame

[Figure 10-30-3].
P-90564C
Figure 10-30-4
Hardware Installed Hardware Removed Lift on the grab handles and bottom of the operator cab
[Figure 10-30-5] slowly until the operator cab is all the
way up and the latching mechanism engages.
P100235A P100236A
Remove the nuts and washers [Figure 10-30-4] (both

sides) at the front corners of the operator cab.

OPERATOR CAB (CONT’D) NOTE: On some machines, the operator cab frame
can contact the steering levers while raising
Lowering or lowering the operator cab. The engine
MUST be stopped before raising or lowering
Always stop the engine before raising or lowering the the operator cab.
operator cab.
Support the operator cab and release the latching
NOTE: Always use the grab handles to lower the mechanism (Inset) [Figure 10-30-6]. Remove your hand
operator cab. from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
Figure 10-30-6 all the way down.
WARNING
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-7
Hardware Removed Hardware Installed

P100953 P-90565A
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-6].
NOTE: The weight of the operator cab increases

when equipped with options and accessories
such as: cab door, heater, air conditioning. In
these cases, the operator cab may need to be
raised slightly from the latch to be able to
release the latch.
P100236A P100235A
WARNING Install the washers and nuts (both sides) [Figure 10-30-
7].
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS Remove the jackstands.
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908

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

• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
WARNING • Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-8
NA1026
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.50 in)
thick polycarbonate front door and polycarbonate rear
window [Figure 10-30-8].
Polycarbonate top window (standard item) must be

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

OPERATOR CAB (CONT’D) Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
• Inspect for cracks or damage. Replace if required.
Figure 10-30-9 • Order part number 7171104 if door frame is damaged
and needs to be replaced.
• Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
• Prerinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
Forestry Door Emergency Exit
Figure 10-30-10
NA1819
Available for special applications to prevent flying debris

and objects from entering the cab. Kit includes 19,1 mm
(0.75 in) thick laminated polycarbonate front door,
1
polycarbonate side windows, and polycarbonate rear
window [Figure 10-30-9].
Polycarbonate top window (standard item) must be

installed as part of the Forestry Door And Window Kit to
restrict material from entering cab openings.
P100984
• Inspect both emergency exit levers (Item 1) [Figure

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

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

Rear Tie-Down Front Tie-Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can P107245A P107253A
break and cause personal injury.

W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
NOTE: Always disengage the auto idle feature when

loading or unloading the loader on a trailer.
(See Left Panel on Page 60-50-1.)
Figure 10-40-1
P-90561C
Alternate Rear Tie-Down Alternate Front Tie-Down
P107246A P-85599C
1
Use the following procedure to fasten the Bobcat loader
P-90560C to the transport vehicle to prevent the loader from moving
during sudden stops, or when going up or down slopes
A loader with an empty bucket or no attachment must be [Figure 10-40-2].
loaded backward onto the transport vehicle [Figure 10-
40-1]. 1. Lower the bucket or attachment to the floor.
The rear of the trailer must be blocked or supported (Item 2. Stop the engine.
1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up. 3. Engage the parking brake.
4. Install chains at the front and rear loader tie-down

positions [Figure 10-40-2]. (Lift arms shown raised
for visual clarity.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.

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

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

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

REMOTE START TOOL KIT - MEL1563 The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
Remote Start Tool - MEL1563 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
Tools that will be needed to complete the following steps the switch again will turn the flow OFF. The switch is used
are: when testing pressures and flow rate.
MEL1563 - Remote Start Tool Kit NOTE: With the engine running; pushing and holding
MEL1566 - Service Tool Harness Communicator the pressure release switch (Item 3) [Figure
(Computer Interface) 10-60-2] will cause the engine to stop.
Figure 10-60-1 Figure 10-60-3
2
1
P16114 P16114
The Remote Start Tool (Item 1) [Figure 10-60-1] is Remove the Service Tool Harness (Item 1) from the
required when the service technician is testing the cover (Item 2) [Figure 10-60-3].
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics. Figure 10-60-4
Figure 10-60-2
2
3
1
P-85729
P16117
Remove the cap (Item 1) [Figure 10-60-4] from the
loader harness connector.
The traction lock switch (Item 1) [Figure 10-60-2] is used
to turn traction lock ON or OFF. Push the switch to the Connect the Service Tool Harness control to the loader
override position. The switch will illuminate to indicate harness connector.
traction lock OVERRIDE, in this position the wheels are
able to turn.

REMOTE START TOOL - MEL1563 (CONT’D) Service Tool Harness Communicator - MEL1566
Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-6
Figure 10-60-5 2
1
1
2
P16119
P114629
The Service Tool Harness Communicator (Item 1) is
required to connect Remote Start Tool to the Service PC
Loaders equipped with an attachment harness (Item 1) (Item 2) [Figure 10-60-6].
must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
Connect the Service Tool Harness to the ACD connector

and the loader harness connector.
NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.

REMOTE START TOOL - MEL1563 (CONT’D) Figure 10-60-8
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit
Figure 10-60-7
1
P-85729
Figure 10-60-9
1
P16115
The Remote Start Tool (Item 1) [Figure 10-60-7] is

required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.

P114629
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Remove the cap (Item 1) [Figure 10-60-8].
Raise the operator cab (if required by the procedure).
OR
Open the rear door of the loader.
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped).

REMOTE START TOOL - MEL1563 (CONT’D)
Remote Start Procedure (Cont'd) WARNING

Figure 10-60-10
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock
1 the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area.
W-2457-1110
P114630
Figure 10-60-12
Figure 10-60-11
2
1
P16116
P114631
The Remote Start Tool (Item 1) [Figure 10-60-12] has

Connect the Remote Start Tool to the engine harness three rocker switches.
connector (Item 1) [Figure 10-60-10].
OR
Connect the Remote Start Tool to the engine harness

connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT - MEL1563 (CONT’D)
Remote Start Procedure (Cont'd) WARNING

Figure 10-60-13
• Use traction lock override switch for service work
with seat bar raised.
• Traction lock is engaged when light is OFF.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
2 • See Service Manual for more instruction.
3 1
W-2785-0209
Figure 10-60-14
P16118
The traction lock switch (Item 1) [Figure 10-60-13] is

used to turn traction lock ON or OFF. Push the switch to
the override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
The maximum flow / variable flow switch (Item 2) [Figure

10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch P166657
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when testing pressures and flow rate. Push the couplers on the front auxiliary block toward the
block and hold for 5 seconds to release the front auxiliary
NOTE: With the engine running; pushing and holding pressure [Figure 10-60-14].
the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.

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

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

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

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

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

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

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

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.
The RUN button (Item 3) [Figure 10-61-2] is used to turn

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

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

7217666 (CONT'D)
Loader Service Tool Harness - 6689747

2
Figure 10-61-3
1
1
P114629
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].
The Loader Service Tool Harness (Item 1) is used to When the remote start procedure is completed, replace
connect the Remote Start Tool (Service Tool) (Item 2) the loader connector cap (Item 1) [Figure 10-61-4] or
[Figure 10-61-3] to the electrical system on the loader. connect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4
P-85729
Loaders without an attachment control harness, remove

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

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
1 2
P-76450
P114632 The Computer Service Tool Harness (Item 1) is required

to connect Remote Start Tool (Service Tool) to the
Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

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

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

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

7217666 (CONT'D)
Remote Start Procedure
WARNING
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in P-85729
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock Loaders without an attachment control harness, remove
the keypad with a unique password (keyless) or the loader harness cap (Item 1) [Figure 10-61-9] and
otherwise disable the starter before working in connect the Loader Service Tool Harness from the
the engine area. Remote Start Tool (Service Tool).
W-2457-1110
NOTE: When using a Remote Start Tool (Service
Tool) harness on loaders not equipped with
The tool listed will be needed to do the following an attachment control device, the Remote
procedure: Start Tool (Service Tool) harness attachment
control device connector must be capped.
7217666: Remote Start Tool (Service Tool) Kit
1
1
P-76450 P114629
The Remote Start Tool (Service Tool) (Item 1) [Figure

Loaders with an attachment control harness (7 pin or 14
10-61-8] is required when the operator cab is in the
pin), the attachment harness (Item 1) must be
raised position for service and the service technician
disconnected from the loader harness (Item 2) [Figure
needs to turn on the loader or start the engine. Example:
10-61-10].
adjusting the steering linkage.
Lift and block the loader. When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-61-10] or
Raise the lift arms (if required by the procedure) and
connect the attachment control harness to the loader
install an approved lift arm support device.
harness.
Raise the operator cab (if required by the procedure).

7217666 (CONT'D)
2
Remote Start Procedure (Cont'd)
Figure 10-61-11
5 3
6 4
1
2
P-76439
1
The Remote Start Tool (Service Tool) (Item 1) [Figure
10-61-12] has five buttons.
P114632
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to
[Figure 10-61-11] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader electrical system. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the OFF position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when testing pressures and flow rate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7217666 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-61-13
1 2
P106657
Push the couplers on the front auxiliary block toward the

block and hold for 5 seconds to release the front auxiliary
P-76441 pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

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

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

SERVICE SCHEDULE
Maintenance Intervals WARNING

Maintenance work must be done at regular intervals.
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 loader. Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
Every 10 Hours (Before Starting The Loader)
• Engine Oil – Check level and add as needed.

• Engine Air Filters and Air System – Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System – Clean debris from hydraulic fluid cooler and radiator assembly, fuel cooler, air conditioning
condenser (if equipped), rear grille, and screens on the rear door and engine cover. Check coolant level COLD and
add premixed coolant as needed.
• Fuel Filter – Check the display panel. Remove the trapped water when required.
• Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges – Lubricate with multipurpose lithium based grease.
• Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks – Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
• Bobcat Interlock Control Systems (BICS™) – Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
• Front Horn / Back-up Alarm – Check for proper function.
• Tires – Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the
tire.
• Operator Cab – Check the fastening bolts, washers, and nuts. Check the condition of the cab.
• Indicators and Lights – Check for correct operation of all indicators and lights.
• Wheel Nuts – Perform every 10 hours or daily for the first 30 hours, then as scheduled. Check for loose wheel nuts
and tighten to correct torque.
• Safety Signs and Safety Treads – Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
• Hydraulic Fluid – Check fluid level and add as needed.
• Heater and Air Conditioning Filters (if equipped) – Clean or replace filters as needed.
SS SSL LF EXLF T4-B-0118

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

• Engine Oil and Filter – Perform every 100 hours when operating under severe conditions. Replace oil and filter.
Every 250 Hours or Every 12 Months
• Engine / Hydrostatic Drive Belt – Check for wear or damage. Adjust or replace as needed.
• Drive Belts (Alternator, air conditioning, water pump) – Check condition. Replace as needed.
• Bobcat Interlock Control System (BICS™) – Check the function of the lift arm bypass control.
• Fuel Filter – Replace filter element.

• Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap – Replace the charge filter and the reservoir breather
cap.
• Engine Oil and Filter – Replace oil and filter.
• Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator.
Clean the plenum drains.
• Hydraulic / Hydrostatic Filter – Replace the hydraulic / hydrostatic filter.

• Hydraulic Reservoir – Replace the fluid.
• Final Drive Transmission (Chaincase) – Replace the fluid.
• Engine Valves – Adjust the engine valve clearance.
• Coolant – Replace the coolant.
• Diesel Exhaust Fluid (DEF) / AdBlue® Filter – Replace the diesel exhaust fluid (DEF) / AdBlue® filter.
SS SSL LF EXLF T4-B-0118

ENGINE AIR CLEANER Figure 10-80-2
Replacing Filters
Figure 10-80-1
1
1
P107624
3
Open four latches (Item 1) and move the cover (Item 2)
NA3352 [Figure 10-80-2] out of the way. (One latch is not visible
in the photo.)
Replace the air filters only when necessary. The service Figure 10-80-3
indicator (Item 1) will FLASH. Press the Information
button (Item 3) until the display screen shows the service
codes. Service code [AIRF] (Replace Engine Air Filter)
or [M0117] (Air Filter Plugged) will show in the display
screen (Item 2) [Figure 10-80-1] when air filter
replacement is necessary.
NOTE: Prolonged operation with an active [AIRF] or

[M0117] code can cause severe engine
component damage.
Prolonged operation with an active [AIRF] 1

code will cause the engine to derate (torque
and rpm reduction).
P109625
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Remove the outer filter (Item 1) [Figure 10-80-3] and
Outer Filter discard.
Stop the engine, open the rear door, and remove the rear NOTE: Make sure the filter housing is free of dirt and
grille. (See REAR GRILLE on Page 50-60-1.) debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new outer filter. Push in until the filter contacts the
base of the housing.
Install the cover and secure four latches [Figure 10-80-

2].
Install the rear grille and close the rear door.

ENGINE AIR CLEANER (CONT’D) Figure 10-80-5
Replacing Filters (Cont’d)
Inner Filter
Replace the inner filter only under the following 2

conditions:
• Replace the inner filter every second time the outer

filter is replaced.
• After the outer filter has been replaced, start the 1

engine and operate at full rpm. If service code
[M0117] (Air Filter Plugged) is still displayed in the
data display, replace the inner filter.
P109624
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.) Install the cover (Item 2) and secure the latches (Item 1)
[Figure 10-80-5]. (One latch is not visible in the photo).
Remove the cover [Figure 10-80-2] and the outer filter
[Figure 10-80-3]. Install the rear grille and close the rear door.
Figure 10-80-4
P109626
Remove the inner filter (Item 1) [Figure 10-80-4].
NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.
Install new inner filter. Push in until the filter contacts the
base of the housing.
Install the outer filter [Figure 10-80-3].

ENGINE COOLING SYSTEM Cleaning
Check the cooling system every day to prevent over- See the SERVICE SCHEDULE for the correct service
heating, loss of performance, or engine damage. interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Maintenance Platform Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.)
Figure 10-90-1
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P107266 Figure 10-90-2
A maintenance platform [Figure 10-90-1] is available to

facilitate access when cleaning the engine cooling
system.
1
P109632
Use low air pressure or water pressure to clean the top of

the fuel cooler (Item 1) [Figure 10-90-2].

ENGINE COOLING SYSTEM (CONT’D) Return the support bar to storage position and lower the
air conditioning condenser.
Cleaning (Cont’d)
Figure 10-90-5
Loaders With Air Conditioning
Figure 10-90-3
1 2
1
2
P121162
Ensure the air conditioning condenser is installed into the

P109573A
two slotted brackets [Figure 10-90-5]. (Right side
shown.)
Use low air pressure or water pressure to clean the top of
the air conditioning condenser (Item 1) [Figure 10-90-3]. Ensure the clips (Item 1) are properly installed over the
two slotted brackets (Item 2) [Figure 10-90-5]. (Right
Unhook the two rubber straps (Item 2) [Figure 10-90-3]. side shown.)
NOTE: The air conditioning condenser fits into two Fasten the two rubber straps [Figure 10-90-3].
slotted brackets mounted on the hydraulic
fluid cooler and radiator assembly. Ensure the NOTE: The air conditioning condenser can be lifted
air conditioning condenser remains out of the two slotted brackets by removing
connected to the brackets when raising and the clips. This allows greater access to clean
lowering. the hydraulic fluid cooler and radiator
assembly.
Figure 10-90-4
NOTE: Be careful when removing and installing the
air conditioning condenser so that the air
conditioning condenser does not fall on the
hydraulic fluid cooler and radiator assembly
1 and damage the fins.
Skip ahead to All Loaders. (See All Loaders on Page 10-

2 90-3.)
P109572A
Pivot the air conditioning condenser (Item 1) up and

rotate the support bar (Item 2) into position. Use low air
pressure or water pressure to clean the top of the
hydraulic fluid cooler and radiator assembly (Item 3)
[Figure 10-90-4].

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Cont’d) Figure 10-90-7
Loaders Without Air Conditioning
Figure 10-90-6
1
2
1
P109633
The area between the fuel cooler and the hydraulic fluid
cooler and radiator assembly will require occasional
P107641
cleaning. Remove the bolt (Item 2) and lift the fuel cooler
up while sliding out of the bracket (Item 1) [Figure 10-90-
Use low air pressure or water pressure to clean the top of 7].
the hydraulic fluid cooler and radiator assembly (Item 1)
[Figure 10-90-6]. NOTE: Be careful when removing and installing the
fuel cooler so that the fuel cooler does not fall
on the hydraulic fluid cooler and radiator
assembly and damage the fins.
Install the fuel cooler into the bracket. Install and tighten
the bolt (Item 2) [Figure 10-90-7].
Check the cooling system for leaks.

ENGINE COOLING SYSTEM (CONT’D)
Checking And Adding Coolant

IMPORTANT
Check the engine coolant level every day before starting
the engine for the work shift. AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
grille. (See REAR GRILLE on Page 50-60-1.) Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Figure 10-90-8 damage.
1 Too little antifreeze reduces the additives which

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

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2
Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
the upper level marker on the tank [Figure 10-90-8].
P109634 Install the coolant fill cap [Figure 10-90-8].
Coolant must be between the top and bottom level NOTE: The coolant fill cap must be tightened until the
markers (Item 2) [Figure 10-90-8] when the engine is cap clicks.
cold.
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Use a refractometer to test the condition of propylene

glycol in your cooling system.
WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907
Remove the coolant fill cap (Item 1) [Figure 10-90-8] to

add coolant.
The correct mixture of coolant to provide a -37°C (-34°F)

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

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-10
Removing And Replacing Coolant
See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.) 1
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine P109814
is hot. You can be seriously burned.
W-2607-0804 Pinch off the coolant hose attached to the engine oil
cooler using a locking hose pinching plier (Item 1)
NOTE: This procedure requires the use of a spare [Figure 10-90-10] or similar tool.
0.75 in. coolant hose approximately 600 mm
(24 in) long. Install the coolant fill cap (Item 1) [Figure 10-90-9].
1 3
2
P109634 P109813
Remove the coolant fill cap (Item 1) [Figure 10-90-9]. Remove the clamp (Item 2) and disconnect the hose
(Item 3) from the engine oil cooler fitting (Item 1) [Figure
10-90-11].
Quickly install the spare 0.75 in. coolant hose onto the
engine oil cooler fitting.
Drain the coolant into a container.

ENGINE COOLING SYSTEM (CONT’D) The correct mixture of coolant to provide a -37°C (-34°F)
freeze protection is 5 L propylene glycol mixed with 4,4 L
Removing And Replacing Coolant (Cont’d) of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Figure 10-90-12
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

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

protect the internal engine components; reduces the
P109634
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

Remove the coolant fill cap (Item 1) [Figure 10-90-12] to concentrated coolant can cause serious premature
drain the coolant faster. engine damage.
I-2124-0497
Remove the spare 0.75 in. coolant hose from the engine
oil cooler fitting when the coolant has drained.
Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
Figure 10-90-13
the lower level marker on the tank (Item 2) [Figure 10-90-
12].
Install the coolant fill cap (Item 1) [Figure 10-90-12].
NOTE: The coolant fill cap must be tightened until the

cap clicks.
2 Operate the engine until coolant reaches normal

1
operating temperature. Stop the engine.
Check the coolant level when cool. Add coolant as

needed. (See Checking And Adding Coolant on Page 10-
P109635 90-4.)
Install the coolant hose (Item 2) onto the engine oil cooler
fitting and install the clamp (Item 1) [Figure 10-90-13].
Remove the tool used to pinch off the coolant hose.
Recycle or dispose of used coolant in an environmentally

safe manner.
Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-5.)

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 that can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.
Ultra low sulfur diesel fuel must be used in this machine. • Use of biodiesel blend fuel may result in premature
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur failure of fuel system components, such as: plugged
maximum. fuel filters and deteriorated fuel lines.
The following is one suggested blending guideline that • Shorter maintenance intervals may be required, such
should prevent fuel gelling during cold temperatures: as: cleaning the fuel system and replacing fuel filters
and fuel lines.
TEMPERATURE GRADE 2-D GRADE 1-D
• Using biodiesel blended fuels containing more than
Above -9°C (+15°F) 100% 0% five percent biodiesel can affect engine life and cause
Down to -21°C (-5°F) 50% 50% deterioration of hoses, tubelines, injectors, injector
Below -21°C (-5°F) 0% 100% pump, and seals.
Apply the following guidelines if biodiesel blend fuel is

NOTE: Biodiesel blend fuel may also be used in this
used:
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed
• Ensure the fuel tank is as full as possible at all times
with ultra low sulfur petroleum based diesel.
to prevent moisture from collecting in the fuel tank.
This biodiesel blend fuel is commonly
marketed as B5 blended diesel fuel. B5
• Ensure that the fuel tank cap is securely tightened.
blended diesel fuel must meet ASTM
specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
E.U. Standard (EN590)
immediately.
Use only clean, high quality diesel fuel that meets the
• Drain all water from the fuel filter daily before
EN590 specifications listed below:
operating the machine.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10
• Do not exceed engine oil change interval. Extended
ppm) sulfur maximum
oil change intervals can cause engine damage.
• Diesel fuel with cetane number of 51.0 and above.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer, and
NOTE: Biodiesel blend fuel may also be used in this
operate the engine for at least 30 minutes.
machine. Biodiesel blend fuel must contain
no more than seven percent biodiesel mixed
NOTE: Biodiesel blend fuel does not have long term
with ultra low sulfur petroleum based diesel.
stability and should not be stored for more
This biodiesel blend fuel is commonly
than 3 months.
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Stop the engine and open the rear door.

NA1684
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [Figure 10-100-2].
Install and tighten the fuel cap (Item 1) [Figure 10-100-

1 1].
NOTE: The fuel fill cap must be tightened until the

cap clicks.
Close the rear door.
P109627
WARNING
Remove the fill cap (Item 1) [Figure 10-100-1].
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D)
Fuel Filter
Removing Water

interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Figure 10-100-3
P109628
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter to remove trapped water from the filter.
NOTE: Loosen the drain until it falls free from the

threads on the filter to ensure that all trapped
water is removed.
Thread the drain onto the filter and securely tighten.
WARNING
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D)
Fuel Filter (Cont’d) WARNING

Replacing Element
See the SERVICE SCHEDULE for the correct service Always clean up spilled fuel or oil. Keep heat, flames,
interval. (See SERVICE SCHEDULE on Page 10-70-1.) sparks or lighted tobacco away from fuel and oil.
Stop the engine and open the rear door. explosion or fire.
W-2103-0508
Figure 10-100-4
3
Start the engine and allow to operate for 1 minute.
1
4 WARNING
Diesel fuel or hydraulic fluid under pressure can
2 penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
P109629
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Disconnect the electrical connector (Item 2) [Figure 10- W-2072-0807
100-4].
Stop the engine and check for leaks at the filter.
Loosen the fuel filter head (Item 3) from the fuel filter
element (Item 1) [Figure 10-100-4]. Do NOT remove the
hoses from the fuel filter head.
Loosen the clamps (Item 4) [Figure 10-100-4].
Remove the fuel filter element (Item 1) from the fuel filter
head (Item 3) [Figure 10-100-4].
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
Put clean oil on the two new fuel filter element O-rings,
install the element, and tighten to 13,5 N•m (10 ft-lb)
torque.
Install the fuel filter assembly into the clamps and tighten.
Connect the electrical connector [Figure 10-100-4].
Remove air from the fuel system. (See Removing Air

From The Fuel System on Page 10-100-5.)

FUEL SYSTEM (CONT’D) Figure 10-100-5
Removing Air From The Fuel System

1
After replacing the filter or if the fuel tank has run out of
fuel, the air must be removed from the fuel system before
starting the engine.
WARNING 2

Diesel fuel or hydraulic fluid under pressure can P109630
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible. Open the air vent plug (Item 1) [Figure 10-100-5] on the
Use a piece of cardboard or wood to find leaks. Do fuel filter assembly three full turns.
enters skin or eyes, get immediate medical attention Squeeze the hand pump (priming bulb) (Item 2) [Figure
from a physician familiar with this injury. 10-100-5] until fuel flows from the vent with no air
W-2072-0807
bubbles.
Close the vent (Item 1) [Figure 10-100-5].
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-110-1 CRANKCASE)
2 TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CJ-4 OR BETTER, OR ACEA
E9 OR BETTER)
[1] Bobcat Synthetic Oil – 5W-40
P109631
Park the loader on a level surface. Stop the engine. Open Bobcat engine oils are recommended for use in this
the rear door and remove the dipstick (Item 1) [Figure machine. If Bobcat engine oil is not available, use a good
10-110-1]. quality engine oil that meets API Service Classification of
CJ-4 or better, or ACEA E9 or better [Figure 10-110-2].
Keep the oil level between the marks on the dipstick. Do
not overfill.
Remove the oil fill cap (Item 2) [Figure 10-110-1] to add

engine oil.
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-5
Removing And Replacing Oil And Filter

1
Operate the engine until coolant reaches normal
operating temperature. Stop the engine.
Figure 10-110-3
1
P107265
Remove the oil drain cap (Item 1) [Figure 10-110-5] from

the oil drain hose and drain the oil into a container.
2 Recycle or dispose of used oil in an environmentally safe
manner.
Install and tighten the oil drain cap [Figure 10-110-5].
P107954A P107264
Return the oil drain hose to the storage location on top of
the fuel tank [Figure 10-110-4].
The oil drain hose is located behind a cover (Item 1) Install the cover and the cover mounting bolts [Figure 10-
under the rear of the loader (Inset) [Figure 10-110-3]. 110-3]. Tighten both bolts.
Loosen one cover mounting bolt and remove the other

bolt (Item 2) [Figure 10-110-3] to allow the cover to
swing open.
Open the rear door.
Figure 10-110-4
P109631
The oil drain hose (Item 1) [Figure 10-110-4] storage

location is on top of the fuel tank.

ENGINE LUBRICATION SYSTEM (CONT’D)
Removing and Replacing Oil And Filter (Cont’d)

WARNING
Figure 10-110-6
3 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
P109631
Remove the oil filter (Item 3) [Figure 10-110-6] and clean

the filter base.
Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filter only.
Remove the oil fill cap (Item 2) [Figure 10-110-6].
Put oil into the engine and replace the oil fill cap. (See
Capacities on Page SPEC-10-5.) Do not overfill.
Start the engine and allow to operate for several minutes.
WARNING
W-2072-0807
Remove the dipstick (Item 1) [Figure 10-110-6] and

check the oil level.
Add oil as needed if oil level is not at the top mark on the
dipstick. Install the dipstick and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-3

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

MACHINE USE
[1] BOBCAT All-Season Fluid
1 [2] BOBCAT Synthetic Fluid
[3] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at
operating temperatures.)
[4] VG 100; Minimum VI 130
P107282 [5] VG 46; Minimum VI 150
Bobcat hydraulic fluids are recommended for use in this

Check the fluid level in the sight gauge (Item 1) [Figure
machine. If Bobcat hydraulic fluid is not available, use a
10-120-1]. Keep the fluid level within the operating range.
good quality hydraulic fluid meeting the viscosity grade
and viscosity index shown in the chart [Figure 10-120-3].
Open the rear door and remove the rear grille. (See
(See Hydraulic System on Page SPEC-10-4.)
REAR GRILLE on Page 50-60-1.)
Figure 10-120-2
WARNING
1
explosion or fire.
W-2103-0508
P107976
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge [Figure 10-120-1].
Install the fill cap [Figure 10-120-2], install the rear grille,
and close the rear door.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Removing And Replacing Hydraulic Fluid

1
Replace the fluid if contaminated or after major repair.
Always replace the hydraulic / hydrostatic filter and the

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-120-5.)
P107955A
Remove the right side access cover bolts (Item 1)
Figure 10-120-4 [Figure 10-120-5] and remove the access cover. (Lift
arms shown raised for visual clarity.)
NOTE: The hose used to drain the hydraulic reservoir

is located under the fan motor on earlier
models and on the right side of the fan motor
on later models.
1
Figure 10-120-6
Earlier Model Later Model
P109638 1
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4]. 2

2
P109760A P115527A
Remove the clamp (Item 1). Pinch off the hose (Item 2)
[Figure 10-120-6] near the fitting and disconnect hose
from the fitting. Route the hose out the side of the loader
and drain the fluid into a container.
Connect the hose to the fitting when the fluid stops

draining. Install the clamp.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install hydraulic fill screen and add the correct fluid to the
reservoir until the fluid level is within the operating range
Removing And Replacing Hydraulic Fluid (Cont’d) of the sight gauge. (See Capacities on Page SPEC-10-
5.) and (See Checking And Adding Fluid on Page 10-
Recycle or dispose of used fluid in an environmentally 120-1.)
safe manner.
Install the hydraulic fill cap [Figure 10-120-4].

WARNING
Start the engine and operate the loader hydraulic
controls.
explosion or fire. WARNING
W-2103-0508
Install the side access cover and bolts [Figure 10-120-5]. Diesel fuel or hydraulic fluid under pressure can
Figure 10-120-7 death. Fluid leaks under pressure may not be visible.
W-2072-0807
Stop the engine and check for leaks.
1 Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)
P109639
Remove and clean the hydraulic fill screen (Item 1)

[Figure 10-120-7]. Use low air pressure to dry the
screen.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new filter ensuring that filter is fully seated in the
housing.
Removing And Replacing Hydraulic / Hydrostatic
Filter Remove the filter cap O-rings (Item 3) [Figure 10-120-9]
and discard.
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Install new filter cap O-rings and lubricate with clean oil.
Stop the engine, open the rear door, and remove the rear NOTE: The filter cap O-rings are not the same size.
grille. (See REAR GRILLE on Page 50-60-1.) Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and rotate clockwise to engage the
Figure 10-120-8 bolts [Figure 10-120-8]. Alternate tightening the bolts to
draw the cap down evenly. Tighten the bolts to 27 – 41
1 N•m (20 – 30 ft-lb) torque.
WARNING
2 explosion or fire.
W-2103-0508
P109640
Loosen the bolts (Item 1) and rotate the filter cap (Item 2) Start the engine and operate the loader hydraulic
[Figure 10-120-8] counterclockwise until the cap clears controls.
the bolts.
Slowly pry the filter cap off the housing by hand.
Figure 10-120-9
WARNING
1 Diesel fuel or hydraulic fluid under pressure can
2 Use a piece of cardboard or wood to find leaks. Do
W-2072-0807
3 Stop the engine and check for leaks at the filter.
Check the fluid level in the reservoir and add as needed.

P109072A P109073A (See Checking And Adding Fluid on Page 10-120-1.)
Remove the filter (Item 2) [Figure 10-120-9] and discard.
Lubricate the O-ring (Item 1) [Figure 10-120-9] on new

filter with clean oil.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Earlier Models
Removing And Replacing Hydraulic Charge Filter Figure 10-120-12

Stop the engine.
Figure 10-120-10
1
1
P109622
Put a suitable container below the filter housing and

remove the filter housing (Item 1) [Figure 10-120-12].
Figure 10-120-13
P109069A
Remove the left side access cover bolts (Item 1) [Figure

10-120-10] and remove the access cover. (Lift arms
shown raised for visual clarity.)
NOTE: Identification of the hydraulic charge filter

used on your machine is necessary to
perform the correct replacement procedure.
Figure 10-120-11
1
Earlier Model Later Model
P109622A
Remove the filter (Item 1) [Figure 10-120-13] and

discard.
Clean the surface of the filter housing and the filter base
where they contact the filter seal.
Put clean oil on the seal of the new filter. Install the filter
P109622B P115441A on the filter base [Figure 10-120-13].
Install and tighten the filter housing to 65 - 70 N•m (48 -

Earlier models use a separate filter housing and filter
52 ft-lb) torque [Figure 10-120-12].
element. Later models use a spin-on filter [Figure 10-
120-11].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) All Models
Removing And Replacing Hydraulic Charge Filter Recycle or dispose of used fluid in an environmentally
(Cont’d) safe manner.
Later Models
Figure 10-120-14 WARNING

explosion or fire.
W-2103-0508
1
Install the side access cover and bolts [Figure 10-120-
10].
Start the engine and operate the loader hydraulic

controls.
P115526
Put a suitable container below the filter, remove the filter

(Item 1) [Figure 10-120-14], and clean the filter base.
WARNING
Put clean oil on the new filter gasket, install the new filter, AVOID INJURY OR DEATH
and tighten the filter to 37 - 45 N•m (27 - 33 ft-lb) torque. Diesel fuel or hydraulic fluid under pressure can
W-2072-0807
Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)

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

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Figure 10-120-15
P109638
Remove the breather cap (Item 1) [Figure 10-120-15]

and discard.
Install new breather cap.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Fluid
Checking And Adding Fluid See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Park the loader on a level surface and stop the engine.
The chaincase contains the final drive sprockets and Remove the check plug (Item 1) [Figure 10-130-1] from
chains, and uses the same type fluid as the hydraulic / the front of the chaincase housing.
hydrostatic system. (See Hydraulic / Hydrostatic Fluid
Chart on Page 10-120-1.) Figure 10-130-2
Park the loader on a level surface and stop the engine.
Figure 10-130-1
P107281A
Pump the fluid out of the chaincase [Figure 10-130-2].

P107956
(Lift arms shown raised for visual clarity.)
Recycle or dispose of used fluid in an environmentally

Remove the check plug (Item 1) [Figure 10-130-1] from safe manner.
the front of the chaincase housing. (Lift arms shown
raised for visual clarity.) Add fluid through the check plug hole until fluid flows from
the hole. (See Capacities on Page SPEC-10-5.)
If fluid can be reached with the tip of your finger through
the hole, the fluid level is correct. Install and tighten the plug [Figure 10-130-1].
If the level is low, add fluid through the check plug hole
until fluid flows from the hole.
Install and tighten the plug [Figure 10-130-1]. WARNING

WARNING Always clean up spilled fuel or oil. Keep heat, flames,

AVOID INJURY OR DEATH explosion or fire.
Always clean up spilled fuel or oil. Keep heat, flames, W-2103-0508
explosion or fire.
W-2103-0508

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

1
Figure 10-140-1
Both wedges must

contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
The wedges (Item 1) [Figure 10-140-2] must extend

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

Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-140-1]. frame (Item 2) [Figure 10-140-2].
The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-140-3

The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-

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

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

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

1
Figure 10-141-1 2
1
Both wedges must
contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
2
The wedges (Item 1) [Figure 10-141-2] must extend
through the holes in the attachment mounting frame.
NA3234
The spring loaded wedges (Item 1) must contact the

Push and hold the BOB-TACH WEDGES “UP” switch lower edge of the holes in the attachment mounting
(Item 1) until wedges are fully raised. Push and hold the frame (Item 2) [Figure 10-141-2].
BOB-TACH WEDGES “DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down. If the wedges do not contact the lower edge of the holes
[Figure 10-141-2], the attachment will be loose and can
The levers and wedges must move freely. come off the Bob-Tach.
Figure 10-141-3
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-

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

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

LUBRICATING THE LOADER Lubricate the following:
Lubrication Locations Figure 10-150-2

Record the operating hours each time you lubricate the

Bobcat loader.
1
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader. (See Operation &

Maintenance Manual.)
Stop the engine.

P107286
Figure 10-150-1
1. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-2].
1
2 Figure 10-150-3
4
8
9 10 2
11
5
3
6
7
P107957
The grease fitting locations [Figure 10-150-1] are shown

P107287
in more detail in the following figures.
2. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-3].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-6
Lubrication Locations (Cont’d)
Figure 10-150-4
5
3
P107291
5. Rear Control Link (Both Sides) (2) [Figure 10-150-6].

P107285
Figure 10-150-7
3. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

150-4].
Figure 10-150-5
4
6
P107292
6. Front Control Link (Both Sides) (2) [Figure 10-150-7].
P107284
4. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

150-5].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-10
Figure 10-150-8
7
P107960
9. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-31308A
150-10].
Figure 10-150-11
7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8].
Figure 10-150-9
8 10
P107961
P107288
10. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-
11].
8. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

150-9].

LUBRICATING THE LOADER (CONT’D)
If Equipped With Power Bob-Tach
Figure 10-150-12
11
P107959
11. Power Bob-Tach Hydraulic Cylinder (2) [Figure 10-

150-12].

TIRE MAINTENANCE Rotating
Wheel Nuts Check the tires regularly for wear, damage, and pressure.
See the SERVICE SCHEDULE for the correct service Figure 10-160-2
Figure 10-160-1
NA1023A
P107283
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].
Follow the torques specified below for the wheel nuts
[Figure 10-160-1]: The same size tires must be used on each side of the
loader. If different sizes are used, each tire will turn at a
When installing wheel nuts, tighten to 217 N•m (160 different rate and cause excessive wear. The tread bars
ft-lb) torque. of all the tires must face the same direction.
When checking wheel nut torque, set the torque Recommended tire pressure must be maintained to avoid
wrench to 190 N•m (140 ft-lb) to prevent excessive tire wear, loss of stability, and loss of handling
overtightening. capability. Check for correct pressure before operating
the loader. (See Tires on Page SPEC-10-6.)

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

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

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

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

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

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

PIVOT PINS
Figure 10-170-1
P107293A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure
10-170-1].
Check that the locknuts are tightened to 48 - 54 N•m (35 -

40 ft-lb) torque.

LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat loader has been in storage, perform the
procedures below to return the loader to service:
You may decide to store your Bobcat loader for an
extended period of time. Perform the procedures below • Check the engine and hydraulic fluid levels; check
for storage: coolant level.
• Thoroughly clean the loader including the engine • Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in position.
• Park the loader in a dry protected shelter.
• Lubricate the loader.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Check tire inflation and remove blocks from under
frame.
• Put blocks under the frame to remove weight from the
tires. • Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put fuel stabilizer into the fuel tank and operate the correct operation.
engine a few minutes to circulate the stabilizer to the
pump and fuel injectors. • Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the • Stop the engine and check for leaks. Repair as
following: needed.
Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer, and operate 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 the battery in a
cool dry place above freezing temperatures and
charge it periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage

condition.

STOPPING THE ENGINE AND LEAVING THE LOADER (Standard Key Panel) Remove the key from the switch
to prevent operation of the loader by unauthorized
Procedure personnel.
Stop the loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Fully lower the lift arms and put the attachment flat on the Deluxe Instrumentation Panel allows
ground. operation of the loader without using a
password. (See Password Lockout Feature on
Figure 10-190-1 Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
Figure 10-190-3
P107184 P-85737A P-85735A
Set the engine speed control to the low idle position Exit the loader using grab handles, safety tread, and
[Figure 10-190-1]. steps (maintaining a three-point contact) [Figure 10-190-
3].
Engage the parking brake.
Figure 10-190-2
WARNING
1 1
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
P-90688A P-90214C
position to make sure the lift, tilt and traction
drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) [Figure The seat bar system must deactivate these functions
10-190-2]. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-1110
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.

EMERGENCY EXIT
The front opening on the operator cab and rear window There are two different procedures for removing the rear
provide exits. window from your machine:
Rear Window Identification 1. This window is equipped with latches [Figure 10-200-
1].
Figure 10-200-1
2. This window is equipped with a rubber cord and tag
Latches Rubber Cord [Figure 10-200-1].
NOTE: Use these procedures to remove the rear

2 window only under emergency conditions.
Damage to machine may occur.
1
P-85309B P-64994D
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 10-200-2 Figure 10-200-4
P-85309A P-64994C
Turn both latches (Item 1) [Figure 10-200-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 10-200-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 10-200-3 Figure 10-200-5
P-90676 P-90676
Exit through the rear of the operator cab [Figure 10-200- Exit through the rear of the operator cab [Figure 10-200-
3]. 5].

EMERGENCY EXIT (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 10-200-6
Figure 10-200-8
1
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 10-200-8] up and out
[Figure 10-200-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove. Front Door
OR NOTE: Use this procedure to remove the front door

only under emergency conditions. Damage to
Figure 10-200-7 machine may occur.
Figure 10-200-9
1
P-90669C
P-90725
A kit is available to allow removal of the latch equipped
rear window from outside the machine without tools.
Turn both latches (Item 1) [Figure 10-200-9] down until
Turn both knobs (Item 1) [Figure 10-200-7] they disengage from the door frame.
counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the Push the door out of the operator cab door frame and exit
cab and lift up to remove. through the opening.

EMERGENCY EXIT (CONT’D) Figure 10-200-12
Front Door (Cont’d)
Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.
Figure 10-200-10
1
1
P-90685
Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-200-12] on the door. (Bottom
hinge shown.)
2
Figure 10-200-13
P-85781A 1
NOTE: Later models route the washer fluid hose

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

hose (Item 1) (if equipped) [Figure 10-200-10].
Figure 10-200-11
P-90686A
2
3
Install cast washers (Item 2) on door hinges taking care
to match rectangular surfaces. Hold cast washer firmly
against door and rotate latch (Item 1) [Figure 10-200-13]
up to lock cast washer into position. (Bottom hinge
shown.) (Plastic cap shown removed for visual clarity.)
1
Install door on loader. Install the gas spring socket on the
ball stud fitting. Install the clip into the hole in the gas
spring socket. Rotate the clip to lock into position [Figure
P-85588A P-85589A
10-200-11].
Connect electrical connector and washer fluid hose (if

Rotate and pull the clip (Item 1) out of the gas spring equipped) [Figure 10-200-10].
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 10-200-11].
Remove the door hinges from the loader.

SEAT BELT Figure 10-210-1

1
WARNING 3
Failure to properly inspect and maintain the seat belt

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

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

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,
retractor (if equipped), hardware, or any other obvious
problem should be replaced immediately. 5
The items below are referenced in [Figure 10-210-1].

NA3113
1. Check the webbing. If the system is equipped with a

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

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

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

rays from the sun, or extreme dust or dirt. If the
original color of the webbing in these areas is
extremely faded and / or the webbing is packed with
dirt, the webbing strength may have deteriorated.
5. Check the hardware on both sides of the seat.

Hardware should be tight. Hardware must not be
missing, rusted, corroded, or damaged.

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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
CYLINDER (LIFT) (B3GZ11341 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-9
CYLINDER (TILT) (B3GZ11341 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-41-13
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-15
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-15
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-12

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-15
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-16
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

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

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
BOB-TACH (POWER) BLOCK (S/N ALM411001 - ALM413900) . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
BOB-TACH (POWER) BLOCK (S/N ALM413901 AND B3GZ11001 & ABOVE) . . . . . 20-121-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2

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

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

Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
MANUAL WITH NO OPTION
570 (S/N ALM411001 AND ABOVE)
(S/N B3GZ11001 AND ABOVE)
(PRINTED OCTOBER 2017)

V-1531legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 35 NOT USED FOR THIS MODEL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) CHARGE PUMP -
2 36
SIGHT GUAGE 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
19 PULL BUTTON ACTIVATED
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT HYDRAULIC PUMP . . . . . . . Gear Type
37
107 kPa (1,07 bar) (15 psi) ARM BY-PASS 64,7 L/min (17.1 U.S. gpm) at High Engine Idle
Normally Closed 20 LIFT CYLINDER SPOOL - MADE TO 38 VARIABLE CAPACITY DISPLACEMENT
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP
DOWN BUT NOT DURING BOOM UP
5 SPRING LOADED FILTER BY-PASS 39 RELIEF/REPLENISHING VALVE - HIGH
21 ANTICAVITATION VALVE
VALVE: 172 kPa (1,7 bar) (25 psi) PRESSURE: 34500 kPa (345 bar) (5000 psi)
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – RELIEF VALVE - CHARGE INLET:
(Fan Speed Regulator): 10797 – 12300 kPa 40
2827 kPa (28,3 bar) (410 psi) at High
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) Engine Idle With 60 ° C (140 ° F) Fluid
PORT – Factory Hydraulic Oil
23 SPRING LOADED FILTER BY-PASS VALVE:
7 RELIEF VALVE - MAIN: 41 CHECK VALVE – COLD WEATHER BY-PASS
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
23787 - 24476 kPa (238 - 245 bar) With 345 kPa (3,45 bar) (50 psi) Spring
24 FIXED CAPACITY DISPLACEMENT
(3450 - 3550 psi) at Front Quick Couplers
HYDRAULIC MOTOR
25 FILTER - HYDRAULIC (CANISTER)
8 RELIEF/ANTICAVITATION VALVE -
PORT: 27579 kPa (276 bar) (4000 psi) 26 SENSOR – CHARGE PRESSURE
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE

PORT (OPTIONAL): BLEED-OFF VALVE
27579 kPa (276 bar) (4000 psi) 28 SENSOR – HYD. TEMPERATURE
10 SOLENOID ACTIVATED DIRECTIONAL 29 FLUSHING RELIEF VALVE
CONTROL VALVE - AUXILIARY
11 LOAD CHECK VALVE
30 DRIVE MOTOR SHUTTLE VALVE
31 NOT USED FOR THIS MODEL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT
14 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC MOTOR
CONTROL VALVE - LIFT CONTROL
15 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 34 NOT USED FOR THIS MODEL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1531legend (9-27-17)
111 of 1290
INTEGRATED QUICK COUPLER BLOCK
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
B A
A Male
B B A
DRIVE MOTOR 27
29 B
P A B A
Male
30 B A
B
A
B A
1
A
A A
P B B A
A
0 2
Female
A B B A
OUT
A
B B
HYDRAULIC CONTROL VALVE
32 A
A
B A
9
A
A
A
A A B
A B
B A
9
A B A 10
A B
10
A BA CA Auxiliary Spool
6A A B
T T
B
A A
B A A B B
P A A P
A B A B B A A B A
B
T1 P T2
A B
A
R A
HYDROSTATIC PUMP 38 A
A
A T
A
A
11
A B
B A
8
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
A B
TILT CYLINDERS
B A
8
39 A P
A B
1 2 3 4
Tilt Spool
13
A B B A
M4 A
C C
M3
12 0 6
A
5
B
B
A
B
D C
11
A A
B B
B
A
B A A
A
A A
B
A B
40
B
A B
LIFT CYLINDERS
B A
B A 8 14
B A A
B A
B
A P B A A
C C A B 1 2 3
Lift Spool
M2 A
M1 A B
A B B A
A
T
B
A
B
0 5 4 P A
A A
B B A
39 A
11 20 17
B
15
B A
A B B
A
B A
IN
B
18
7 6 A
17 A
A
2
A
A
A
B
16
A B B
A
T
38 A
A
A
1 PA
41 Oil Cooler
A B
A B
19
37 HYDRAULIC RESERVOIR
4 (VENTED)
VARIABLE SPEED HYDRAULIC 2
FAN MOTOR W/ INTEGRATED FILTER
A B
5 B A
A
36
HYDRAULIC A 1
A
FILTER 3
A
A
25 B
B
26 23
A
B
A
C 2
A
B
B A
A
A WORKING CIRCUIT
24 A
1 21 CHARGE
B
PRESSURE
A A P DR
22 DRAIN / RETURN
A
A
A
DRAIN/RETURN MANIFOLD
32
28
A
A
2 0
A
1
A
B
MANUAL WITH NO OPTIONS
30 A S570 (S/N ALM411101 AND ABOVE)
29
DRIVE MOTOR
(PRINTED SEPTEMBER 2014)
112 of 1290
Printed In U.S.A. 7204247 (C)
MANUAL WITH ALL OPTIONS
S570 (S/N ALM411001 - ALM413900)
(PRINTED MARCH 2015)

V-1532legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 38 VARIABLE CAPACITY DISPLACEMENT 62 SOLENOID ACTIVATED DIRECTIONAL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE - Female
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal) 39 SOLENOID ACTIVATED DIRECTIONAL
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) RELIEF/REPLENISHING VALVE - HIGH 63
2 SIGHT GUAGE PRESSURE: 34500 kPa (345 bar) (5000 psi) CONTROL VALVE - Male
19 PULL BUTTON ACTIVATED 64 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT 40 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BUCKET POSITION
107 kPa (1,07 bar) (15 psi) ARM BY-PASS 2827 kPa (28,3 bar) (410 psi) at High
VALVE (ON/OFF)
Normally Closed Engine Idle With 60 ° C (140 ° F) Fluid
20 LIFT CYLINDER SPOOL - MADE TO 65 FLOW DIVIDER ADJUSTMENT VALVE
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM 41 CHECK VALVE – COLD WEATHER BY-PASS
PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP With 345 kPa (3,45 bar) (50 psi) Spring 66
5 SPRING LOADED FILTER BY-PASS CONTROL VALVE - FLOW CONTROL
21 ANTICAVITATION VALVE 42 NOT USED ON THIS MODEL SPOOL
VALVE: 172 kPa (1,7 bar) (25 psi)
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE –
43 67 CHECK VALVE - BUCKET POSITION
(Fan Speed Regulator): 10797 – 12300 kPa NOT USED ON THIS MODEL VALVE
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi)
44 NOT USED ON THIS MODEL 68 PILOTED ACTIVATED DIRECTIONAL
23 SPRING LOADED FILTER BY-PASS VALVE: CONTROL VALVE - UNLOADING
7 RELIEF VALVE - MAIN: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 45 NOT USED ON THIS MODEL SPOOL
23787 - 24476 kPa (238 - 245 bar) 24 FIXED CAPACITY DISPLACEMENT HIGH FLOW HYDRAULIC PUMP Gear Type
46 PILOT ACTIVATED DIRECTIONAL CONTROL 69
(3450 - 3550 psi) at Front Quick Couplers 36,4 L/min (9.6 U.S. gal) at High Engine Idle
HYDRAULIC MOTOR VALVE – HYDRAULIC POWERED BOB-TACH
25 FILTER - HYDRAULIC (CANISTER) With Build-up Valve 207 kPa (2,07 bar) (30 psi) 70 RELIEF VALVE - 24132 kPa (241 bar) (3500 psi)
26 SENSOR – CHARGE PRESSURE 47 FILTER - BOB-TACH VALVE 71 DUMP VALVE – ON / OFF
PORT: 27579 kPa (276 bar) (4000 psi)
48 RESTRICTION - 2,03 mm (0.08 in)
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE 72 CHECK VALVE - With 34,5 kPa (0,34 bar)
49 (5.0 psi) Spring
PORT (OPTIONAL): BLEED-OFF VALVE SOLENOID ACTIVATED DIRECTIONAL
27579 kPa (276 bar) (4000 psi) CONTROL VALVE (TWO COIL) 73 RIDE CONTROL VALVE
28 SENSOR – HYD. TEMPERATURE
10 SOLENOID ACTIVATED DIRECTIONAL 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
29 FLUSHING RELIEF VALVE 74 HIGH PRESSURE CHAMBER
CONTROL VALVE - AUXILIARY 51 CHECK VALVE - With 552 kPa) (5,5 bar)
11 LOAD CHECK VALVE (80 psi) Spring 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 SHUTTLE VALVE
31 HIGH PRESSURE SHUTTLE 53 RELIEF VALVE - 13790 kPa (137 bar) (2000 psi)
54 CHECK VALVE - With 2068 kPa (20,7 bar) (300
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT psi) Spring And With 0,33 mm (0.013 in) Orifice
CONTROL VALVE - LIFT CONTROL 55 RESTRICTION - 0,51 mm (0.020 in)
33 PILOT ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED 56 RESTRICTION - 0,51 mm (0.020 in)
CONTROL VALVE - BICS CONTROL 34 NOT USED FOR THIS MODEL PILOT ACTIVATED DIRECTIONAL
16 57
FILTER - BICS CONTROL VALVE CONTROL VALVE - REAR AUXILIARY
(SCREEN) 35 SOLENOID ACTIVATED DIRECTIONAL 58 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
CONTROL VALVE – Brake Valve
36 CHARGE PUMP - CONTROL VALVE - TWO COIL
49,2 L/min (13.0 U.S. gpm) at High Engine Idle NOTE: Unless otherwise specified
60 RESTRICTOR - 0,8 mm (0.031 in) springs have NO significant
HYDRAULIC PUMP . . . . . . . Gear Type pressure value.
37 61 LOAD SHUTTLE VALVE - BLEED OFF
Printed in U.S.A. 64,7 L/min (17.1 U.S. gpm) at High Engine Idle V-1532legend (3-31-15)
113 of 1290
B A
A Male
B B A
DRIVE MOTOR 27
29 B
P A B A
Male
30 B A
B
A
B A
1
A
72
A A
P B B A
A
0 2
Female
A B B A
A B
31
OUT
A
B B
A C
32 B
A
RIDE CONTROL LIFT CYLINDERS
B
(FIELD INSTALLED OPTION)
A
B A
9
A REAR AUXILIARY VALVE
(OPTIONAL) A
A A
A
2 A3 A0
A
FEMALE A A
MALE A
A B
B
75 74
1
A B A
REAR QUICK COUPLERS B A
9
1 A A
A B
A B B A
A 10 73
33
B B A B B
A A
B B B
61 A
A B
P
B
PB
10
A A
B A A A C
B
63 6A A B
62 B
B A
T
A A
T
A B B
P A A P
A B
A B A B B A A B A
B
A
A
B
A
59 T1 P T2
A
R A A B
BUCKET POSITIONING
HYDROSTATIC PUMP 38 B A VALVE (OPTIONAL)
A
A T B
A 60 A P T
A C
11 E1 E2 A1 A2
B
A B
A
8 E3
A
B
B
B
A
B A
BOBCAT INTERLOCK CONTROL 64

A B
A
A B
A SYSTEM (BICS)
A B
B P A
65
P
B A
A
58 B A
8 A
B
B
39 A P
P A T
66
A B
1 2 3 4
Tilt Spool 67
57
A A A
A
B
B 13 A B
D2
A B B A
M4
P in
B P out
A
T A B
A
2-SPEED VALVE C C
M3
12 B
B
(OPTIONAL) D B
C
0 6
A
5 A
A B
11
A A P T
B B
B
A B
B A A
A A A
A1
A
T A A
B
A B
40
B
A
A B
68
A
A
POWER BOBTACH CYLINDER A B

C2
14
A B A
(OPTIONAL)
B
B A 8
A B A A POWER BOBTACH C1 D1
P B BA A B A
A B A BB A
B
BA
B
VALVE (OPTIONAL)
P B
A A P A
B A
A
C C A B B A B 1 2 3
Lift Spool
M2 A
M1 A B
A B B A
51
C B
35 A
B
A
T
A
50 A
52 54 0
A
5
A
4
B
B B
P
A
A
39 A C
B
A A
B
A
A
11 20 17
B
B
A 1 2
49 B A
15
B A B B
A
B A
TILT CYLINDERS
IN
B
18
53 0 3
B
B A
7 6 A
17 A
B
B
56 A
2
A
A
A B
A
55
A
16
48
A
D B
A B A B
A
T
A
38 A
A
A
P A
A
1 PA
47 46 B
41 Oil Cooler
A
A B
A B
19
4 (VENTED)
A B
5 B A
A
36
HYDRAULIC A 1
70
A
71 FILTER
A
3
B A
B
C P
A B 25 B
B
69 23
A
A
26
A
B
A
C 2
A
B
B 33 A
A
A WORKING CIRCUIT
24 A
1
1 21 CHARGE
A A
B
PRESSURE
A
2 A3 A0 P DR
22 DRAIN / RETURN
A
A
A
32
B
28
C A
A
A

31
B
A
2 0
A
1
B
30
S570 (S/N ALM411001 - ALM413900)
A
29
DRIVE MOTOR
(PRINTED SEPTEMBER 2014)

114 of 1290
Printed In U.S.A. 7204247 (B)
S570 (S/N ALM413901 - ALM416717)
(S/N B3GZ11001 - B3GZ11248)
V-1532legend
LEGEND
VALVE (ON/OFF)
44 NOT USED ON THIS MODEL 68 PILOTED ACTIVATED DIRECTIONAL
26 SENSOR – CHARGE PRESSURE 47 71 DUMP VALVE – ON / OFF
PORT: 27579 kPa (276 bar) (4000 psi) FILTER - BOB-TACH VALVE
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE 48 RESTRICTION - 1,17 mm (0.46 in) 72 CHECK VALVE - With 34,5 kPa (0,34 bar)
(5.0 psi) Spring
PORT (OPTIONAL): BLEED-OFF VALVE 49 SOLENOID ACTIVATED DIRECTIONAL 73 RIDE CONTROL VALVE
CONTROL VALVE (TWO COIL)
29 FLUSHING RELIEF VALVE 50 NOT USED ON THIS MODEL 74 HIGH PRESSURE CHAMBER
11 LOAD CHECK VALVE 51 NOT USED ON THIS MODEL 75 LOW PRESSURE CHAMBER
12 ANTICAVITATION VALVE 52 NOT USED ON THIS MODEL
31 HIGH PRESSURE SHUTTLE 53
13 PILOTED ACTIVATED DIRECTIONAL RELIEF VALVE - 24131 kPa (241 bar) (3500 psi)
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT 54 CHECK VALVE
CONTROL VALVE - LIFT CONTROL 33 PILOT ACTIVATED DIRECTIONAL 55 RESTRICTION - 0,25 mm (0.10 in)
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED
56 NOT USED ON THIS MODEL
16 FILTER - BICS CONTROL VALVE 57 PILOT ACTIVATED DIRECTIONAL
(SCREEN) SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
35 58
CONTROL VALVE – Brake Valve RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
36 CHARGE PUMP - 59 SOLENOID ACTIVATED DIRECTIONAL

49,2 L/min (13.0 U.S. gpm) at High Engine Idle CONTROL VALVE - TWO COIL NOTE: Unless otherwise specified
60 springs have NO significant
HYDRAULIC PUMP . . . . . . . Gear Type RESTRICTOR - 0,8 mm (0.031 in)
37 pressure value.
Printed in U.S.A. 64,7 L/min (17.1 U.S. gpm) at High Engine Idle 61 V-1532legend (9-27-17)
LOAD SHUTTLE VALVE - BLEED OFF
115 of 1290
B A
A Male
B B A
DRIVE MOTOR 27
29 B
P A B A
Male
30 B A
B
A
B A
1
A
72
A A
P B B A
A
0 2
Female
A B B A
A B
31
OUT
A
B B
A C
32 B
A
B
A
B A
9
A REAR AUXILIARY VALVE
(OPTIONAL) A
A A
A
2 A3 A0
A
FEMALE A A
MALE A
A B
B
75 74
1
A B A
9
1 A A
A B
A B B A
A 10 73
33
B B A B B
A A
B B B
61 A
A B
P
B
PB
10
A A
B A A A C
B
63 6A A B
62 B
B A
T
A A
T
A B B
P A A P
A B
A B A B B A A B A
B
A
A
B
A
59 T1 P T2
A
R A A B
BUCKET POSITIONING
HYDROSTATIC PUMP 38 B A VALVE (OPTIONAL)
A
A T B
A 60 A P T
A C
11 E1 E2 A1 A2
B
A B
A
8 E3
A
B
B
B
A
B A

A B
A
A B
A SYSTEM (BICS)
A B
B P A
65
P
B A
A
58 B A
8 A
B
B
39 A P
P A T
66
A B
1 2 3 4
Tilt Spool 67
57
A A A
A
B
B 13 A B
D2
A B B A
M4
P in
B P out
A
T A B
A
2-SPEED VALVE C C
M3
12 B
B
(OPTIONAL) D B
C
0 6
A
5 A
A B
11
A A P T
B B
B
A B
B A A
A A A
A1
A
T A A
B
A B
40
B
A
A B
68
A
A

C2
14
A B A
(OPTIONAL)
B
B A 8
A B A A POWER BOBTACH C1 D1
P B BA A B A
A B A BB A
B
BA
B
VALVE (OPTIONAL)
P B
A A P A
B A
A
C C A B 1 2 3
Lift Spool
M2
A B B A
A
M1
54 53 A B
35 B
B
A
T
A
0 5 4 P A
A A
B B A
39 49
A
11 20 17
B
55 2 5
B
15
B A
A B B
A
B A
TILT CYLINDERS
1 4 3 IN B
B
18
D A 7 6 A
17 A
A
2
A
B
A
A
B
B A
A
16
A B B
A
T
A
38 A
A
A
P A
A
1 PA
47 46 B
41 Oil Cooler
A
A B
A B
19
4 (VENTED)
A B
5 B A
A
36
HYDRAULIC A 1
70
A
71 FILTER
A
3
B A
B
C P
A B 25 B
B
69 23
A
A
26
A
B
A
C 2
A
B
B 33 A
A
A WORKING CIRCUIT
24 A
1
1 21 CHARGE
A A
B
PRESSURE
A
2 A3 A0 P DR
22 DRAIN / RETURN
A
A
A
32
B
28
C A
A
A
31
2 0
B
A A
S570 (S/N ALM413901 - ALM416717)

1
30 A
29
DRIVE MOTOR (S/N B3GZ11001 - B3GZ11248)
116 of 1290
S570 (S/N ALM416718 AND ABOVE)
V-1652legend
LEGEND
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT RELIEF VALVE - CHARGE INLET:
40 CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) PILOTED ACTIVATED DIRECTIONAL
44 NOT USED ON THIS MODEL 68
PORT – Factory Hydraulic Oil CONTROL VALVE - UNLOADING
PORT: 27579 kPa (276 bar) (4000 psi)
49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
27579 kPa (276 bar) (4000 psi) 28 SENSOR – HYD. TEMPERATURE CONTROL VALVE (TWO COIL)
CONTROL VALVE – Ride Control (OPTIONAL)
10 SOLENOID ACTIVATED DIRECTIONAL 50 NOT USED ON THIS MODEL
29 FLUSHING RELIEF VALVE 74 ACCUMULATOR – Ride Control (OPTIONAL)
51 NOT USED ON THIS MODEL
11 LOAD CHECK VALVE 75 ORIFICE WITH CHECK VALVE:
30 DRIVE MOTOR SHUTTLE VALVE 52 NOT USED ON THIS MODEL 2,54 mm (0.10 in)
RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) 76 ORIFICE: 1,60 mm (0.063 in)
31 HIGH PRESSURE SHUTTLE 53
CONTROL VALVE - TILT CONTROL 54 CHECK VALVE 77 FAN REVERSING VALVE (OPTIONAL)
CONTROL VALVE - LIFT CONTROL 33 PILOT ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED 56 NOT USED ON THIS MODEL
57
16 FILTER - BICS CONTROL VALVE CONTROL VALVE - REAR AUXILIARY
36 CHARGE PUMP - CONTROL VALVE - TWO COIL
49,2 L/min (13.0 U.S. gpm) at High Engine Idle NOTE: Unless otherwise specified
37 LOAD SHUTTLE VALVE - BLEED OFF
117 of 1290
B A
A Male
B B A
DRIVE MOTOR 27
29 B
P A
30
B A
B A A Male
B B A
1
A
72
A A
P B B A
A
0 2
Female
A B B A
74
A B
31 RIDE CONTROL (OPTION)

OUT
A
T2 ACC
A
B B
A C
HYDRAULIC CONTROL VALVE NOTE: Cushioned Lift Cylinder
T
B
B
75 Pistons On Later Models Only.
32 B
A
B
A
LIFT CYLINDERS
76 P
A
P
A
9
A
B A
P
A REAR AUXILIARY VALVE A A
(OPTIONAL) A
A
2 A3 A0
A
FEMALE A A
MALE A
A B
B
73
A B A

9
CR2 CR CB
1
A A
A B B
A
B
B
A B
B
B
A
A
10
33 B
A
B
A
B
61 A
A B
P
B
PB
10
A A
B A A A C
B
63 6A A B
62 B
B A
T
A A
T
A B B
P A A P
A B
A B A B B A A B A
B
A
A A
B
59 T1 P T2
R A A B
BUCKET POSITIONING
HYDROSTATIC PUMP
A
38 A
A T
B
B
A VALVE (OPTIONAL)
A
A 60 A P T
A C
11 E1 E2 A1 A2
B
A B
A
8 E3
A
B
B
A
B
B A

A B
A
A B
A SYSTEM (BICS)
A B
B P A
65
P
B A
A
58 B A
8 A
B
B
39 A P
P A T
66
A
A B
1 2 3 4
Tilt Spool A A
67
A
57 B 13
B
A B
D2
A B B A
M4
P in
B P out
A
T A B
A
2-SPEED VALVE C C
M3
12 B
B
(OPTIONAL) D B
C
0 6
A
5
A
A B
11
A A P T
B B
B
A B
B A A
A A
A1
A
T A
A
A
A
B B
40
B
A
A B
68
A
A

C2
14
A B A
(OPTIONAL)
B B A 8
A
POWER BOBTACH C1 D1
P
B BA A
B B A A
A
A B A BB BA
B
BA
P VALVE (OPTIONAL)
B
A A P A
A B A
C C A B 1 2 3
Lift Spool
M2
A B B A
A
M1
54 53 A B
35 B
B
A
T
A
0 5 4 P A
A A
B B A
39 49 A
20 B
55 2 5 B
A
11 17
15
B A
A B B
A
1 4 3
B
B
A
18 TILT CYLINDERS
IN B
D A 7 6 A
17 A
A 2
48 A
A
A
B
16
A
T
B 47 B
38 A
A
A
A
1 PA
46
B
41 Oil Cooler
A B
19
A B
VARIABLE SPEED 4 (VENTED)
HYDRAULIC FAN MOTOR W/ 2
A B
INTEGRATED FILTER (Show n 5 B A

A
36 With OPTIONAL Reversing

Valve)
HYDRAULIC
A 1
70
A
71 FILTER A 3
B
A
B
A B
C P
25 23
69
B
B
A
A
26 A
B
A
C
T
1 4 B
2
B 33 A
A
P A
B
WORKING CIRCUIT
3 2 A
A
1 A
21 CHARGE
24 PRESSURE
1
A A
B
2 A3 A0
A
77 22 DRAIN / RETURN
DR P
A
A
A
32 Printable Version Click Here

B
28
C A
A
A
31
2 0
B

A A
30
A
29
DRIVE MOTOR

118 of 1290
Printed In U.S.A. 7204247 (E)
SJC WITH NO OPTIONS
V-1533legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 35 NOT USED FOR THIS MODEL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in)
36 CHARGE PUMP -
2 SIGHT GUAGE
19 PULL BUTTON ACTIVATED 49,2 L/min (13.0 U.S. gpm) at High Engine Idle
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT HYDRAULIC PUMP . . . . . . . Gear Type
37
107 kPa (1,07 bar) (15 psi) ARM BY-PASS 64,7 L/min (17.1 U.S. gpm) at High Engine Idle
Normally Closed 20 LIFT CYLINDER SPOOL - MADE TO
38 VARIABLE CAPACITY DISPLACEMENT
4 FILTER - HYDRAULIC (CANISTER) RESTRICT FLOW DURING BOOM BIDIRECTIONAL HYDROSTATIC PUMP
DOWN BUT NOT DURING BOOM UP
5 SPRING LOADED FILTER BY-PASS 39 RELIEF/REPLENISHING VALVE - HIGH
VALVE: 172 kPa (1,7 bar) (25 psi) PRESSURE: 34500 kPa (345 bar) (5000 psi)
6 DIAGNOSTIC COUPLER 22 PROPORTIONAL RELIEF VALVE – RELIEF VALVE - CHARGE INLET:
(Fan Speed Regulator): 10797 – 12300 kPa 40
2861 kPa (28,6 bar) (415 psi) at High
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) Engine Idle With 60 ° C (140 ° F) Fluid
7 RELIEF VALVE - MAIN: 41 CHECK VALVE – COLD WEATHER BY-PASS
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
23787 - 24476 kPa (238 - 245 bar) With 345 kPa (3,45 bar) (50 psi) Spring
(3450 - 3550 psi) at Front Quick Couplers
HYDRAULIC MOTOR 42 SOLENOID ACTIVATED DIRECTIONAL
25 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – FORWARD/REVERSE
8 RELIEF/ANTICAVITATION VALVE - 43
26 SENSOR – CHARGE PRESSURE FILTER
PORT: 27579 kPa (276 bar) (4000 psi)
44 SERVO PISTON – Swash Plate
9 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE
10 SOLENOID ACTIVATED DIRECTIONAL 29 FLUSHING RELIEF VALVE
11 LOAD CHECK VALVE
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - LIFT CONTROL 33 NOT USED FOR THIS MODEL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1533legend (9-27-17)
119 of 1290
Male
DRIVE MOTOR 27
29
Male
30
Female
OUT
32
9
A B 10
10
Auxiliary Spool
6A
R
HYDROSTATIC PUMP 38 T
11
42
8
X1 43 BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)
44
TILT CYLINDERS
X2 8
39
Tilt Spool
13
MA
43
MB
12
A B
MG
11
40 LIFT CYLINDERS
G 8 14
A B
MB
Lift Spool
MA 43
20
39
X2 11 17
15
44
IN 18
X1 7 6 17
43 2
42 16
T
38 R 1
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
FILTER 3
25
26 23
B A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
32
28
SJC WITH NO OPTIONS
30
29
DRIVE MOTOR
(PRINTED APRIL 2015)

120 of 1290
SJC WITH ALL OPTIONS
S570 (S/N ALM411001 - ALM413900)

V-1534legend
LEGEND
VALVE (ON/OFF)
With 345 kPa (3,45 bar) (50 psi) Spring PILOTED ACTIVATED DIRECTIONAL
DOWN BUT NOT DURING BOOM UP 66
21 ANTICAVITATION VALVE 42 SOLENOID ACTIVATED DIRECTIONAL SPOOL
CONTROL VALVE – FORWARD/REVERSE
FILTER VALVE
(Fan Speed Regulator): 10797 – 12300 kPa
44 SERVO PISTON – Swash Plate 68 PILOTED ACTIVATED DIRECTIONAL
PORT: 27579 kPa (276 bar) (4000 psi)
BLEED-OFF VALVE 49 (5.0 psi) Spring
PORT (OPTIONAL): SOLENOID ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL 50 RELIEF VALVE - 8274 kPa (83 bar) (1200 psi)
CONTROL VALVE - AUXILIARY 51 CHECK VALVE - With 552 kPa) (5,5 bar)
11 LOAD CHECK VALVE (80 psi) Spring 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 SHUTTLE VALVE
54 CHECK VALVE - With 2068 kPa (20,7 bar) (300
CONTROL VALVE - TILT CONTROL 32 FIXED CAPACITY DISPLACEMENT psi) Spring And With 0,33 mm (0.013 in) Orifice
15 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – HIGH / LOW SPEED 56 RESTRICTION - 0,51 mm (0.020 in)
16 57
36 CHARGE PUMP - CONTROL VALVE - TWO COIL NOTE: Unless otherwise specified
49,2 L/min (13.0 U.S. gpm) at High Engine Idle
121 of 1290
Male
DRIVE MOTOR 27
29
Male
30
72
Female
31
OUT
32
9
REAR AUXILIARY VALVE
(OPTIONAL)
FEMALE MALE
REAR QUICK COUPLERS 9 75 74
A B 10 73
33
61
10
Auxiliary Spool
63 6A
62
59
R BUCKET POSITIONING
HYDROSTATIC PUMP 38 VALVE (OPTIONAL)
T
60 11 E1 E2 A1 A2
42
8 E3
X1 43 BOBCAT INTERLOCK CONTROL 64
SYSTEM (BICS)
44 B 65
TILT CYLINDERS
X2 58 8
39 66
Tilt Spool 67
57 13 D2
P in P out T
2-SPEED VALVE
MA
43
MB
12
(OPTIONAL) A B
MG
11
A1 T
40
POWER BOBTACH CYLINDER
LIFT CYLINDERS 68 C2
G
(OPTIONAL)
8 14
POWER BOBTACH C1 D1
A B
A VALVE (OPTIONAL)
P
MB
Lift Spool
MA 43
51
35
50 52 54 20
39
X2 11 17
49 15
44 TILT CYLINDERS
IN 18
53
X1 7 6 17
43 56 2
42 55 16
D 48
T
38 R 1
47 46
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
70 71 FILTER 3
25
69 23
26
B 33 A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
32
28
31 Printable Version Click Here
30
29 S570 (S/N ALM411001 - ALM413900)
DRIVE MOTOR
(PRINTED APRIL 2015)

122 of 1290
S570 (S/N ALM413901 - ALM412705)
(S/N B3GZ11001 - B3GZ11248)
V-1534legend
LEGEND
VALVE (ON/OFF)
FILTER VALVE
44 SERVO PISTON – Swash Plate 68 PILOTED ACTIVATED DIRECTIONAL
PORT: 27579 kPa (276 bar) (4000 psi)
BLEED-OFF VALVE 49 SOLENOID ACTIVATED DIRECTIONAL (5.0 psi) Spring
PORT (OPTIONAL):
CONTROL VALVE - AUXILIARY 51 NOT USED ON THIS MODEL
11 LOAD CHECK VALVE 75 LOW PRESSURE CHAMBER
30 DRIVE MOTOR SHUTTLE VALVE 52 NOT USED ON THIS MODEL
CONTROL VALVE - TILT CONTROL
54 CHECK VALVE
16 57
123 of 1290
Male
DRIVE MOTOR 27
29
Male
30
72
Female
31
OUT
32
9
(OPTIONAL)
FEMALE MALE
REAR QUICK COUPLERS 9 75 74
A B 10 73
33
61
10
Auxiliary Spool
63 6A
62
59
T
60 11 E1 E2 A1 A2
42
8 E3
SYSTEM (BICS)
44 B 65
TILT CYLINDERS
X2 58 8
39 66
Tilt Spool 67
57 13 D2
P in P out T
2-SPEED VALVE
MA
43
MB
12
(OPTIONAL) A B
MG
11
A1 T
40
POWER BOBTACH CYLINDER
LIFT CYLINDERS 68 C2
G
(OPTIONAL)
8 14
POWER BOBTACH C1 D1
A B
A VALVE (OPTIONAL)
P
MB
Lift Spool
MA 43 53
54
35
20
39 49
X2 11 17
55
15
44 TILT CYLINDERS
IN 18
X1
D 7 6 17
43 2
42 16
T
38 R 1
47 46
41 Oil Cooler
19
4 (VENTED)
5
36
HYDRAULIC
1
70 71 FILTER 3
25
69 23
26
B 33 A
WORKING CIRCUIT
24
21 CHARGE
PRESSURE
P DR
22 DRAIN / RETURN
32
28
31
30 S570 (S/N ALM413901 - ALM416717)
(S/N B3GZ11001 - B3GZ11248)
29
DRIVE MOTOR

124 of 1290
V-1653legend
LEGEND
3 DIFFERENTIAL PRESSURE SWITCH: DIRECTIONAL CONTROL VALVE - LIFT RELIEF VALVE - CHARGE INLET:
40 CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
FILTER VALVE
6A DIAGNOSTIC COUPLER – FILL (108 - 123 bar) (1566 - 1784 psi) PILOTED ACTIVATED DIRECTIONAL
44 SERVO PISTON – Swash Plate 68
PORT – Factory Hydraulic Oil CONTROL VALVE - UNLOADING
PORT: 27579 kPa (276 bar) (4000 psi)
(5.0 psi) Spring
PORT (OPTIONAL): BLEED-OFF VALVE 49 SOLENOID ACTIVATED DIRECTIONAL
27579 kPa (276 bar) (4000 psi) 28 SENSOR – HYD. TEMPERATURE CONTROL VALVE (TWO COIL) 73 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE – Ride Control (OPTIONAL)
29 FLUSHING RELIEF VALVE 74 ACCUMULATOR – Ride Control (OPTIONAL)
CONTROL VALVE - AUXILIARY 51 NOT USED ON THIS MODEL
11 LOAD CHECK VALVE
30 DRIVE MOTOR SHUTTLE VALVE 52 75 ORIFICE WITH CHECK VALVE:
NOT USED ON THIS MODEL 2,54 mm (0.10 in)
31 HIGH PRESSURE SHUTTLE 53 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) 76 ORIFICE: 1,60 mm (0.063 in)
CONTROL VALVE - TILT CONTROL
54 CHECK VALVE 77 FAN REVERSING VALVE (OPTIONAL)
16 57
37 LOAD SHUTTLE VALVE - BLEED OFF
125 of 1290
Male
DRIVE MOTOR 27
29
30 Male
Female
31 74
OUT RIDE CONTROL (OPTION)
HYDRAULIC CONTROL VALVE T2 ACC NOTE: Cushioned Lift Cylinder
75 Pistons On Later Models Only.
32 T
LIFT CYLINDERS
76
9
P
(OPTIONAL)
FEMALE MALE
REAR QUICK COUPLERS 9 73
A B 10 CR2 CR CB
33
61
10
Auxiliary Spool
63 6A
62
59
T
60 11 E1 E2 A1 A2
42
8 E3
SYSTEM (BICS)
44 B 65
X2
58 8
39 66
Tilt Spool 67
57 13 D2
MA
P in P out T
2-SPEED VALVE MB 43
12
(OPTIONAL) A B
MG
11
A1 T
40 POWER BOBTACH CYLINDER

(OPTIONAL)
68 C2
G 8 14
POWER BOBTACH
C1 D1
A B VALVE (OPTIONAL)
A
P
MB
Lift Spool
MA 43 51 50
35
20
49
39
X2 52 11 17
15
44 18 TILT CYLINDERS
IN
D
X1 7 6 17
43 48 2
42 47 16
T
38 R 1
46
41 Oil Cooler
19
VARIABLE SPEED 4 (VENTED)
HYDRAULIC FAN MOTOR W/ 2
INTEGRATED FILTER (Show n 5
36 With OPTIONAL Reversing
Valve)
HYDRAULIC
1
FILTER 3
25 23
26
1 4
B 33 A
3 2 WORKING CIRCUIT
21
CHARGE
24 PRESSURE
77 22
DR P DRAIN / RETURN
32 DRAIN/RETURN MANIFOLD
28
31
30
29
DRIVE MOTOR
(S/N ALM411249 AND ABOVE)
126 of 1290
Printed In U.S.A. 7204248 (E)
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

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

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

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

noise.

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

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

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

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

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


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

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anti-cavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-
RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

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

(See Service Codes List on Page 60-90-2.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in NEUTRAL position. 4
The lift arms come down with the pedal in the NEUTRAL position. 4, 9, 10, 11
Lift bypass control valve stuck. 12
Lift arm bypass control valve stem bent or broken. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-
50-1.)
8. Using the loader for more than its rated capacity. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace lift arm bypass control valve assembly.

CYLINDER (LIFT) Figure 20-20-2
Testing
Lower the lift arms. Stop the engine. Raise the seat bar.
WARNING
AVOID INJURY OR DEATH 1
P101721
from a physician familiar with this injury. Install a cap (Item 1) [Figure 20-20-2] on the hose and
W-2072-0807
tighten.
Figure 20-20-1 Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
Operate the controls that lower the lift arms.
If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2], remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
P101720
Test only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] from the base end of the
cylinder.

CYLINDER (LIFT) (CONT’D) Figure 20-20-4
Removal And Installation
NOTE: Remove only one cylinder at a time.
2
IMPORTANT 1
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P100298
I-2003-0888
Figure 20-20-3 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
NOTE: Do not cap or plug the two hydraulic hoses

(Item 2) [Figure 20-20-4].
Place the hoses (Item 2) [Figure 20-20-4] in a suitable

container to collect the hydraulic fluid as the lift arms are
raised.
1
safe manner.
P101720 WARNING
Mark and disconnect the two hydraulic hoses (Item 1) AVOID INJURY OR DEATH
[Figure 20-20-3]. Diesel fuel or hydraulic fluid under pressure can
WARNING not use your bare hand. Wear safety goggles. If fluid
AVOID INJURY OR DEATH W-2072-0807
explosion or fire.
W-2103-0508

CYLINDER (LIFT) (CONT’D)
Removal And Installation (Cont’d)

DANGER
Figure 20-20-5
P-90328
AVOID DEATH
1 • Disconnecting or loosening any hydraulic
can cause lift arms to drop.
P101724
D-1009-0409
Remove the bolt and nut (Item 1) [Figure 20-20-5] from
the pin on the rod end of the cylinder.
Installation: Tighten the bolt and nut to 48 - 54 N•m (35 -

40 ft-lb) torque. WARNING
Figure 20-20-6
W-2059-0598
1
Figure 20-20-7
P101723
1
Remove the pin (Item 1) [Figure 20-20-6] from the rod
end of the cylinder.
NOTE: The center of the pin is threaded to allow the

use of a suitable puller for pin removal.
P-90605
Install a sling (Item 1) [Figure 20-20-7] in the middle of

the Bob-Tach.
Using a chain hoist raise the lift arms and install an

approved lift arm support device on the cylinder that is
connected to the lift arm.


2
Figure 20-20-8
1
2 1
P-90825
NOTE: The center of the pin is threaded. Remove the

P-90823 grease fitting (Item 1) [Figure 20-20-10] and
use a suitable puller to remove the pin.
Install a bolt (Item 1) through the eyelet of the cylinder Installation: Tighten the grease fitting to 20 N•m (15 ft-
and install a strap (Item 2) [Figure 20-20-8] to secure the lb) torque.
cylinder.
Remove the pin (Item 2) [Figure 20-20-10] from the base
Open the rear door. end of the cylinder.
NOTE: When removing the left side cylinder the Figure 20-20-11
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
Figure 20-20-9
P-90823
Using a chain hoist remove the cylinder (Item 1) [Figure

1 20-20-11] from the loader.
P-90834

the pin on the base end of the cylinder.

40 ft-lb) torque.

Parts Identification
1. Plug 9. Head
2. O-ring 10. Rod Seal
3. Tube 11. Wiper
4. Nut 12. Rod
5. Seal 13. Grease Fitting
6. Piston
7. Spacer
1 8. Back-up Ring
2
3
1
2
4
5
2
6
2 7
8
2
9
10
11
12
13
NA6766S

Disassembly
2
Clean the outside of the cylinder before disassembly.
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Offset Pins
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise. 3
Figure 20-20-12 P-48038
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-20-14].
NOTE: If the fiber surface (Item 3) [Figure 20-20-14]

1 on the piston becomes damaged, the piston
must be replaced.
Figure 20-20-15
1
P-81032
Insert the Adjustable Gland Nut Wrench into the holes

(Item 1) [Figure 20-20-12] to loosen the head.
2
Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
1
Figure 20-20-13
P-48039
4
3 Remove the O-ring (Item 1), back-up ring (Item 2) and
2 the O-ring (Item 3) [Figure 20-20-15].
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-13].

Disassembly (Cont’d)
Figure 20-20-16
4 2 1
P-81036
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-16].
Remove the wear ring (Item 4) [Figure 20-20-16].
Figure 20-20-17
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-

17].

Assembly
3
Clean all parts in solvent and dry with compressed air. 1
Inspect the cylinder parts for wear or damage. Replace 2

any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic fluid during

installation.
Use the following tools to assemble the cylinder:

P-48038
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor Install the O-ring (Item 1) and seal (Item 2) on the piston
MEL1075 - Adjustable Gland Nut Wrench (Item 3) [Figure 20-20-19].
Figure 20-20-20
Figure 20-20-18
N-22358
P-7424
Use a ring compressor to compress the seal to the

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-20-18]. approximately 3 minutes [Figure 20-20-20].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

Assembly (Cont’d)
Figure 20-20-21
P-7425
Install the rod seal in the head [Figure 20-20-23].

P-7427
Figure 20-20-24
Install the rod seal on the rod seal tool [Figure 20-20-21].
NOTE: During installation the spring side of the seal

must be toward the inside of the cylinder.
Figure 20-20-22
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
20-24] toward the outside of the head.
Figure 20-20-25
N20613
1
Rotate the handles to collapse the rod seal [Figure 20-
20-22].
N-22356
Install the wear ring (Item 1) [Figure 20-20-25].

Assembly (Cont’d)
Figure 20-20-26
2
2
81039
3
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-
P-48039 20-28].
Tighten the plug to 50 N•m (37 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-20-26].
Put the base end of the cylinder in a vise.
Install the back-up ring (Item 2) and O-ring (Item 3)
[Figure 20-20-26]. Figure 20-20-29
Figure 20-20-27
1
2
3 1
1
P-81032
P-48036
(Item 1) [Figure 20-20-29] to tighten the head. Tighten
Install the head (Item 1), spacer (Item 2) and the piston the head to 373 N•m (275 ft-lb) torque.
(Item 3) [Figure 20-20-27] on the rod.
Grease the piston where the nut contacts the piston. Do

not get grease on the threads.
Provide an adequate support for the cylinder before

tightening.
NOTE: Clean and dry the rod threads. Install a NEW

NUT with preapplied Loctite®.
Install the nut (Item 4) [Figure 20-20-27].
Tighten the nut to 1152 N•m (850 ft-lb) torque.

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

Stop the engine. Raise the seat bar.
1
WARNING 2
Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
P106670
physician familiar with this injury is not received
immediately.
W-2145-0290
Install a plug (Item 1) [Figure 20-21-2] in the hydraulic
hose and tighten.
Figure 20-21-1
Engage the parking brake. Lower the seat bar. Start the
Operate the controls that rolls the Bob-Tach back.

(Item 2) [Figure 20-21-2]. Remove the cylinder for repair.
1
Repeat procedure to test the other cylinder.
P106669

cylinder.

CYLINDER (TILT) (CONT’D) Figure 20-21-5
Remove the attachment from the Bob-Tach. Roll the Bob-

Tach forward.
2
Figure 20-21-3 1
1
P106669
1
Remove the two hydraulic hoses (Item 1) [Figure 20-21-

5] from the cylinder.
Remove the base end pivot bolt and washer (Item 2)

[Figure 20-21-5].
P-85554 Figure 20-21-6

the rod end pivot pin.
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb) 1

torque.
Figure 20-21-4
P-85648
Remove the nut and washer (Item 1) [Figure 20-21-6]

from the base end pivot pin.
Installation: Tighten the nut to 258 - 264 N•m (190 - 195

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

CYLINDER (TILT) (CONT’D) Base End Pivot Pin Removal And Installation
Removal And Installation (Cont'd) Remove the tilt cylinder from the cylinder base pin. (See
Removal And Installation on Page 20-21-2.)
Figure 20-21-7
Figure 20-21-8
1
P106673
P106671
Slide the cylinder from the base pin and remove the
cylinder [Figure 20-21-7]. Using a 22 mm (0.875 in) drift, drive the taper pin (Item 1)
[Figure 20-21-8] from the track side of the loader out of
the lift arm.
Figure 20-21-9
P-85567
Inspect the pivot pin and replace as needed [Figure 20-

21-9].

CYLINDER (TILT) (CONT’D)
1. Tube
2. Grease Fitting
3. O-ring
4. Plug
5. Nut
6. Seal
7. Piston
2
8. Back-up Ring
9. Head
10. Rod Seal
11. Wiper 1
12. Rod
13. Bushing
3
4
5
6
3 3
4
7
3
8
3
9
10
11
2
12
13
NA6577S

Disassembly 3
Clean the outside of the cylinder before disassembly. 2

1
Figure 20-21-10 P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].
1 Figure 20-21-13
P-53073
Remove the bushing (Item 1) [Figure 20-21-10]. 3
Figure 20-21-11
P-48073

1
P-81032



Figure 20-21-14
1
3
2
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-21-

P-48039 16].
Remove the O-ring (Item 1). Remove the O-ring (Item 2)

and back-up ring (Item 3) [Figure 20-21-14].
Figure 20-21-15
4 2 1
P-81036
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-21-15].
Remove the wear ring (Item 4) [Figure 20-21-15].

Assembly
2
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace 1

any damaged parts.

installation. 3

P-48073
Figure 20-21-19
Figure 20-21-17
N-22358
P-7424


on the piston.

Assembly (Cont’d)
Figure 20-21-20
P-7425

P-7427
Figure 20-21-23

Figure 20-21-21
N-22359
N20613

21-21].

Assembly (Cont’d) 1
Figure 20-21-24 2
P-48071
Install the head (Item 1) and the piston (Item 2) [Figure

N-22356 20-21-26] on the rod.

Install the wear ring (Item 1) [Figure 20-21-24]. not get grease on the threads.
Figure 20-21-25 Provide an adequate support for the cylinder before

tightening.
1 NOTE: Clean and dry the rod threads. Install a NEW

2
Figure 20-21-27
3
P101716
P-48039
Install the back-up ring (Item 2) and O-ring (Item 3) 1

[Figure 20-21-25].
2
81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

21-27].
Tighten the plug to 20 N•m (15 ft-lb) torque.

CYLINDER (TILT) (CONT’D)
Assembly (Cont’d)
Figure 20-21-28
1
P-81032

(Item 1) [Figure 20-21-28] to tighten the head. Tighten
the head to 373 N•m (275 ft-lb) torque.
Figure 20-21-29
P-53073
Install the bushing (Item 1) [Figure 20-21-29]. The

bushing must be aligned with the grease channel in the
cylinder.

CYLINDER (LIFT) (B3GZ11341 & ABOVE) Figure 20-22-2
Testing
Lower the lift arms. Stop the engine. Raise the seat bar.
WARNING
AVOID INJURY OR DEATH 1
P101721
from a physician familiar with this injury. Install a cap (Item 1) [Figure 20-22-2] on the hose and
W-2072-0807
tighten.
Figure 20-22-1 Engage the parking brake. Lower the seat bar. Start the
Operate the controls that lower the lift arms.

Repeat the procedure to test the other cylinder.
P101720

cylinder.

CYLINDER (LIFT) (B3GZ11341 & ABOVE) (CONT'D) Figure 20-22-4
NOTE: Remove only one cylinder at a time.
2
IMPORTANT 1
2
damage the system.
P100298
I-2003-0888
Figure 20-22-3 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-22-4].
NOTE: Do not cap or plug the two hydraulic hoses

(Item 2) [Figure 20-22-4].
Place the hoses (Item 2) [Figure 20-22-4] in a suitable

container to collect the hydraulic fluid as the lift arms are
raised.
1
safe manner.
P101720 WARNING
Mark and disconnect the two hydraulic hoses (Item 1) AVOID INJURY OR DEATH
[Figure 20-22-3]. Diesel fuel or hydraulic fluid under pressure can
WARNING not use your bare hand. Wear safety goggles. If fluid
AVOID INJURY OR DEATH W-2072-0807
explosion or fire.
W-2103-0508

CYLINDER (LIFT) (B3GZ11341 & ABOVE) (CONT'D)
Figure 20-22-5
P101724

the pin on the rod end of the cylinder.

40 ft-lb) torque.
Figure 20-22-6
P101723
Remove the pin (Item 1) [Figure 20-22-6] from the rod

NOTE: The center of the pin is threaded to allow the

use of a suitable puller for pin removal.

DANGER
1
P-90605
P-90328
AVOID DEATH Install a sling (Item 1) [Figure 20-22-7] in the middle of

• Disconnecting or loosening any hydraulic the Bob-Tach.
can cause lift arms to drop. Using a chain hoist raise the lift arms and install an
• Keep out of this area when lift arms are raised approved lift arm support device on the cylinder that is
unless supported by an approved lift arm connected to the lift arm.
D-1009-0409
Figure 20-22-8
1
WARNING 2

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

and install a strap (Item 2) [Figure 20-22-8] to secure the
cylinder.

Open the rear door. 2
NOTE: When removing the left side cylinder the

battery will need to be removed to gain access
to the lower retaining bolt and nut.
1
Page 60-20-1.)
Figure 20-22-9
P-90825
NOTE: The center of the pin is threaded. Remove the

grease fitting (Item 1) [Figure 20-22-10] and
use a suitable puller to remove the pin.
Installation: Tighten the grease fitting to 20 N•m (15 ft-

lb) torque.
1 Remove the pin (Item 2) [Figure 20-22-10] from the base

P-90834 Figure 20-22-11

the pin on the base end of the cylinder.

40 ft-lb) torque.
P-90823
Using a chain hoist remove the cylinder (Item 1) [Figure

20-22-11] from the loader.

CYLINDER (LIFT) (B3GZ11341 & ABOVE) (CONT'D)
1. Tube 6. O-ring
2. Grease Fitting 7. Spacer
3. Nut 8. Head
4. Piston 9. Wiper
2 5. Seal 10. Rod
1
3
4
5
6
7
6
5
6
6
8
5
9
10
NA14140S

Disassembly 3 1

MEL1076 - Adjustable Gland Nut Wrench

Put the base end of the cylinder in a vise. 2

P131804
Figure 20-22-12
Remove the nut (Item 1), piston (Item 2), and spacer
(Item 3) [Figure 20-22-13].
1
Figure 20-22-14
P131803
Insert the Adjustable Gland Nut Wrench (Item 1) into the 2

notch (Item 2) [Figure 20-22-12] to loosen the head.
P131807
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-
22-14] from the piston.

2 1
Figure 20-22-15
P131810
Remove the wiper (Item 1) and seal (Item 2) [Figure 20-

P131809 22-17] from the inside of the head.
Figure 20-22-18
Remove the O-ring (Item 1) [Figure 20-22-15] from the
spacer. 1
Figure 20-22-16
1
1
2
P131811
Remove the O-rings (Item 1) and back-up ring (Item 2)

P131805 [Figure 20-22-18] from the outside of the head.
Remove the head (Item 1) [Figure 20-22-16] from the

rod.

Assembly
2
Inspect the cylinder parts for wear or damage. Replace

any damaged parts.

installation.
1
P131807
MEL1396-2 - Piston Ring Compressor Install the seal (Item 1) and O-ring (Item 2) [Figure 20-
MEL1076 - Adjustable Gland Nut Wrench 22-20] on the piston.
Figure 20-22-21
Figure 20-22-19
N-22358
P-7424

fits the piston [Figure 20-22-19]. approximately three minutes [Figure 20-22-21].

on the piston.

Assembly (Cont’d)
Figure 20-22-22
1
2
N20613

P131811 22-24].
Figure 20-22-25
Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-22-22] onto the outside of the head.
Figure 20-22-23
P-7425

P-7427


Assembly (Cont’d)
1
Figure 20-22-26
P131809
Install the O-ring (Item 1) [Figure 20-22-28] in the

P131810 spacer.
Figure 20-22-29
1
Figure 20-22-27
P131808
Install the spacer (Item 1) [Figure 20-22-29] on the rod.

P131805
Install the head (Item 1) [Figure 20-22-27] onto the rod.

Assembly (Cont’d)
Figure 20-22-30
1
P131804

P131806
Install the piston (Item 1) [Figure 20-22-30] on the rod. Put the base end of the cylinder in a vise.
Figure 20-22-31 Figure 20-22-33
1
2
P131816 P131818
Provide an adequate support for the cylinder before Install the head and rod assembly (Item 1) into the
tightening. cylinder tube and thread the head into the cylinder. Install
the Adjustable Gland Nut Wrench (Item 2) [Figure 20-22-
NOTE: Clean and dry the rod threads. Apply thread 33] onto the head. Tighten to 550 N•m (405 ft-lb) torque.
locking adhesive (Item 1) [Figure 20-22-31].

CYLINDER (TILT) (B3GZ11341 & ABOVE) Figure 20-23-2
Testing
Remove the attachment. Roll the Bob-Tach fully back.

1
WARNING 2

P106670
immediately.
W-2145-0290
Install a plug (Item 1) [Figure 20-23-2] in the hydraulic
hose and tighten.
Figure 20-23-1
Operate the controls that rolls the Bob-Tach back.

1
Repeat procedure to test the other cylinder.
P106669

cylinder.

CYLINDER (TILT) (B3GZ11341 & ABOVE) (CONT'D) Figure 20-23-5
Remove the attachment from the Bob-Tach. Roll the Bob-

Tach forward.
2
Figure 20-23-3 1
1
P106669
1
Remove the two hydraulic hoses (Item 1) [Figure 20-23-

5] from the cylinder.
Remove the base end pivot bolt and washer (Item 2)

[Figure 20-23-5].
P-85554 Figure 20-23-6


torque.
Figure 20-23-4
P-85648
Remove the nut and washer (Item 1) [Figure 20-23-6]

from the base end pivot pin.

ft-lb) torque.
P-85649

CYLINDER (TILT) (B3GZ11341 & ABOVE) (CONT'D) Base End Pivot Pin Removal And Installation
Removal And Installation (Cont'd) Remove the tilt cylinder from the cylinder base pin. (See
Figure 20-23-7
Figure 20-23-8
1
P106673
P106671
Slide the cylinder from the base pin and remove the
cylinder [Figure 20-23-7]. Using a 22 mm (0.875 in) drift, drive the taper pin (Item 1)
[Figure 20-23-8] from the track side of the loader out of
the lift arm.
Figure 20-23-9
P-85567
Inspect the pivot pin and replace as needed [Figure 20-

23-9].

CYLINDER (TILT) (B3GZ11341 & ABOVE) (CONT'D)
2 1. Tube 6. O-ring
2. Grease Fitting 7. Head
1
3. Nut 8. Wiper
4. Piston 9. Rod
5. Seal 10. Bushing
3
4
5
6
6
5
6
7
5
8
9
2
6
10
NA14141S

Disassembly 1

MEL1076 - Adjustable Gland Nut Wrench
Figure 20-23-10 2
P131889
1 Remove the nut (Item 1), and piston (Item 2) [Figure 20-
23-11].
Figure 20-23-12
1
2
P131803
Insert the Adjustable Gland Nut Wrench (Item 1) into the

notch (Item 2) [Figure 20-23-10] to loosen the head. 2

cylinder. Put the rod end in a vise. P131807
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

23-12] from the piston.

Disassembly (Cont’d) 1
Figure 20-23-13
1
1
2
P131811

P131805 [Figure 20-23-15] from the outside of the head.
Remove the head (Item 1) [Figure 20-23-13] from the

rod.
Figure 20-23-14
2 1
P131810
Remove the wiper (Item 1) and seal (Item 2) [Figure 20-

23-14] from the inside of the head.

Assembly
2

any damaged parts.

installation.
1
P131807
MEL1396-2 - Piston Ring Compressor Install the seal (Item 1) and O-ring (Item 2) [Figure 20-
MEL1076 - Adjustable Gland Nut Wrench 23-17] on the piston.
Figure 20-23-18
Figure 20-23-16
N-22358
P-7424

fits the piston [Figure 20-23-16]. approximately three minutes [Figure 20-23-18].

on the piston.

Assembly (Cont’d)
Figure 20-23-19
1
2
N20613

P131811 23-21].
Figure 20-23-22
Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-23-19] onto the outside of the head.
Figure 20-23-20
P-7425

P-7427


Figure 20-23-23
P131806
Install the piston (Item 1) [Figure 20-23-25] on the rod.

P131810
Figure 20-23-26
23-23] toward the outside of the head. 1
Figure 20-23-24
P131816

tightening.
P131805
NOTE: Clean and dry the rod threads. Apply thread
locking adhesive (Item 1) [Figure 20-23-26].
Install the head (Item 1) [Figure 20-23-24] onto the rod.

CYLINDER (TILT) (B3GZ11341 & ABOVE) (CONT'D)
Assembly (Cont’d)
Figure 20-23-27
1
P131889
Figure 20-23-28
P131818
Install the head and rod assembly (Item 1) into the

cylinder tube and thread the head into the cylinder. Install
the Adjustable Gland Nut Wrench (Item 2) [Figure 20-23-
28] onto the head. Tighten to 550 N•m (405 ft-lb) torque.

CYLINDER (BOB-TACH) Figure 20-24-2
Testing
WARNING 1

P106674
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-24-2] from the

cylinder base end port.

explosion or fire. 1
W-2103-0508
Figure 20-24-1
P106675
Install a plug in the hose (Item 1) [Figure 20-24-3] and

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

P106772 (Front Accessory Panel).
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, parallel to the floor [Figure 20- (Item 2) [Figure 20-24-3], remove the cylinder for repair.
24-1].
Push and hold BOB-TACH “WEDGES UP” switch until

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

CYLINDER (BOB-TACH) (CONT’D)
Figure 20-24-4
P106672
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-24-4].
Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 -

24 ft-lb) torque.
Figure 20-24-5
1
1
P106676
Remove the bolts and washers (Item 1) [Figure 20-24-5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

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

CYLINDER (BOB-TACH) (CONT’D)
1. Tube
2. Nut
3. Seal
4. O-ring
5. Piston
6. Spacer
7. Back-up Ring
8. Head
9. Seal
10. Wiper
11. Rod 1
2
4
5
3
4
7
4
9
10
11
NA2603S

CYLINDER (BOB-TACH) (CONT’D) Figure 20-24-8
Disassembly 3
2 1
Figure 20-24-6 P-16295

Figure 20-24-9
1
2
1 1
P-81032
4
3
Remove the head and the rod assembly from the N-20611
Figure 20-24-7 Remove the wiper seal (Item 1), rod seal (Item 2), back-
up ring (Item 3), O-ring (Item 4) and O-ring (Item 5)
2 [Figure 20-24-9] from the head.
4 3
1
P-16294
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-24-7].

Assembly
3 1
Clean all parts in solvent and dry with compressed air. 2

any damaged parts.

installation.

P16295
Figure 20-24-12
Figure 20-24-10
N-22358
P-7424


on the piston.

Assembly (Cont’d)
Figure 20-24-13
P-7425

P-7427
Figure 20-24-16

Figure 20-24-14
N-22359
N20613

24-14].

Assembly (Cont’d)
Figure 20-24-17
1 1
2
1
P-81032
3
P101716 (Item 1) [Figure 20-24-19] to tighten the head. Tighten
the head to 183 N•m (135 ft-lb) torque.
Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-24-17].
Figure 20-24-18
3
1 2 4
P-81064
Install the head (Item 1), spacer (Item 2) and the piston
(Item 3) [Figure 20-24-18] on the rod.

not get grease on the threads.

tightening.
NOTE: Clean and dry the rod threads. Install a NEW


MAIN RELIEF VALVE
Description
The main relief valve limits the hydraulic system pressure

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

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

MAIN RELIEF VALVE (CONT’D) Figure 20-30-1
Testing
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine. 1
I-2024-0284
WARNING P106632
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
driving and steering controls must be in neutral and hydraulic tester to the bottom (female) quick coupler on
the parking brake engaged. Failure to do so can the loader.
cause injury or death.
W-2006-1209
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
WARNING Start the engine and run at low idle.
Figure 20-30-2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
The tools listed will be needed to do the following

procedure:
2
MEL10003 or MEL1744- Hydraulic Tester 1
MEL10006 - Hydraulic Test Kit
Lift and block the loader. (See Procedure on Page 10-10-

1.)
NA3267
NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19 mm (0.75 in) in
diameter and connected directly to the Press the AUXILIARY HYDRAULICS Button (Item 1)
hydraulic tester without using any type of once to engage the auxiliary hydraulics. The light (Item 2)
quick coupler on the connection to the tester. [Figure 20-30-2] will be on.

Testing (Cont’d)
Figure 20-30-3
1
1
P106632
1 Warm the fluid to 60°C (140°F) by turning the restrictor

P106677 control (Item 1) [Figure 20-30-4] clockwise on the tester
until it reads 6895 kPa (69 bar) (1000 psi).
After activating the auxiliary hydraulics, press the NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
continuous flow control switch (Item 1) [Figure 20-30-3] psi).
to allow constant auxiliary hydraulic fluid flow to the front
female coupler (female coupler is pressurized). Turn the restrictor control (Item 1) [Figure 20-30-4]
counterclockwise to obtain free flow.
To stop continuous auxiliary hydraulic fluid flow, press the
front auxiliary hydraulic switch (Item 1) [Figure 20-30-3] Check the free flow specification. (See Hydraulic System
a second time. on Page SPEC-10-4.)
NOTE: When the operator is seated and raises the NOTE: If free flow is below specification perform the
seat bar, the Auxiliary Hydraulic System direct pump test.
(Front and Rear) will deactivate.
Start turning the restrictor clockwise, causing more
If no flow is indicated on the tester, the hoses are restriction on the flow. The fluid flow should drop off
connected wrong. With the hoses connected correctly, slightly until the pressure reaches approximately 21374
increase the engine speed to full rpm. kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
(213,7 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23787 - 24132 kPa
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
kPa (237,9 - 241,3 bar) (3450 - 3500 psi) the flow should
be at 0 L/min (0 U.S. gpm). DO NOT exceed 25510 kPa
(255 bar) (3700 psi). Turn the restrictor (Item 1) [Figure
20-30-4] counterclockwise to free flow. Shut the auxiliary
hydraulics off.
If pressure does not match the above information, the

main relief valve needs to be adjusted.
After adjusting the main relief valve, retest the main relief
valve.

MAIN RELIEF VALVE (CONT’D)
Adjusting
Raise the operator cab. (See Raising on Page 10-30-2.)
NOTE: This procedure is for standard loaders,

loaders equipped with ACS option and
loaders equipped with SJC option. The main
relief valve is located in the same place on all
of the loaders.
Figure 20-30-5
P106708
Loosen the locknut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
Retest the main relief valve after adjusting.
NOTE: If the correct pressure can not be reached,

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

IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888
P107745A
Clean the area around the control valve. Remove the O-ring (Item 1) and the back-up rings (Item
2) [Figure 20-30-7] from the main relief valve.
NOTE: This procedure is for standard loaders,
loaders equipped with ACS option and Clean the main relief valve in clean solvent. Use air
loaders equipped with SJC option. The main pressure to dry the valve.
relief valve is located in the same place on all
of the loaders. Install new O-ring and back-up rings. Install the main
relief valve [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Test the relief valve. (See Testing on Page 20-30-2.)
P106708
Remove the main relief valve (Item 1) [Figure 20-30-6].

HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
P107871
The hydraulic control valve is located inside the

mainframe on the right hand side, below the operator’s
cab.
The hydraulic control valve is the hydraulic component

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

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

valve which is adjustable.

HYDRAULIC CONTROL VALVE (STANDARD) Remove the control panel. (See Removal And Installation
(CONT’D) on Page 50-100-2.)
Removal And Installation Remove the control linkage. (See Linkage Removal And
Installation on Page 50-90-2.)
DANGER NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation.
Clean area around control valve.
Open rear door.
Figure 20-40-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
• Keep out of this area when lift arms are raised 3
D-1009-0409 2
1
P114643
WARNING Open rear door.
Never work on a machine with the lift arms up unless Disconnect the electrical connector (Item 1), remove the
the lift arms are secured by an approved lift arm two bolts (Item 2) and reposition the fuel filter assembly
support device. Failure to use an approved lift arm (Item 3) [Figure 20-40-2].
to fall and cause injury or death. Figure 20-40-3
W-2059-0598
3
IMPORTANT 4
2
damage the system. 1
I-2003-0888 5
P114645
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.) Reposition clamp (Item 1), remove nut / bolt (Item 2),
remove the fuel tank vent hose (Item 3) and remove the
Raise the operator cab. (See Raising on Page 10-30-2.) two mounting bracket nuts / bolts (Item 4) [Figure 20-40-
3].
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) Remove the filler neck assembly and plug the fuel tank
inlet.

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-6
(CONT’D)
Figure 20-40-4
2
1
P106832
Remove the hose (Item 1) [Figure 20-40-6] that routes

from the control valve to the filter.
P106822
Remove the tubeline (Item 2) [Figure 20-40-6] that
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed Figure 20-40-7
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-40-4].
Figure 20-40-5 1
1
2
3
1
P106833
1
1 Remove the auxiliary hydraulic tubelines (Item 1) [Figure

20-40-7].
P106831
Disconnect the wire harness (Item 1) [Figure 20-40-5]

from the control valve.
Remove the hose (Item 2) [Figure 20-40-5] that routes

from the control valve to the drain manifold.
Remove the tubeline (Item 3) [Figure 20-40-5] that

routes from the control valve to the brake valve.

(CONT’D)
Figure 20-40-8
2
3
P106836
1 Remove the hose (Item 1) [Figure 20-40-10] that routes

from the control valve to the junction block at the rear of
P106834 the machine.
Remove the lift arm bypass drain hose (Item 2) [Figure

Remove the bolt (Item 1) [Figure 20-40-8] and tubeline 20-40-10] from the control valve.
clamp.
Remove the hose (Item 3) [Figure 20-40-10] that runs
Figure 20-40-9 from the control valve to the outlet fitting of the hydraulic
pump.
P-106835
Remove the three tubelines (Item 1) [Figure 20-40-9]

that route from the control valve to the junction block at
the rear of the loader.

HYDRAULIC CONTROL VALVE (STANDARD) Mount Bracket Removal And Installation
(CONT’D)
Figure 20-40-13
Figure 20-40-11
1 1
P-90280
P106837 Support the mounting bracket (Item 1) [Figure 20-40-13].
Figure 20-40-14
Remove the clips and pins (Item 1) [Figure 20-40-11]
from the linkage.
Figure 20-40-12
1
1
1
P110095
Remove the two control valve mount bolts (Item 1)

P-106838 [Figure 20-40-14].
Remove the control valve bracket from the loader.

Support the control valve and remove the two bolts (Item
1) [Figure 20-40-12].
Remove the control valve from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (CONT’D)
Identification Chart
Figure 20-40-15
C2 J2 C3
J4
B3 E3
F2 E3 G1
G2
D5 A3
D6
B2 A2 D3
E2
D4 F4 C4
D1 H2
D2
A1
H3 E1
B1
F3 MR
F1 H1 J1 J3
C1
NA5826

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Female Coupler E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Male Coupler F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(276 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – 24131 kPa (241 bar)
(276 bar) (4000 psi) (3500 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional)

(CONT’D)
Lift Load Check Valve Removal And Installation
IMPORTANT 1
damage the system.
I-2003-0888
P107873
Figure 20-40-16
Remove the lift load check valve (Item 1) [Figure 20-40-
17] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
Figure 20-40-18
1
1
P107872
2
Remove the charge tubeline (Item 1) [Figure 20-40-16]
from the BICS™ valve fitting on the top of the lift load
check valve. 3
4
P107716

[Figure 20-40-18].
Inspect the spring (Item 3) for free movement in the load

check valve (Item 4) [Figure 20-40-18].
Inspect the orifice (Item 5) [Figure 20-40-18] to make

sure it is not plugged.

(CONT’D)
Load Check Valve Removal And Installation (Tilt And

Auxiliary)
Figure 20-40-19 1
2
1
2 3
P107624
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-20].
P107874 Inspect the orifice (Item 3) [Figure 20-40-20] in the

poppet to make sure it is not plugged.
At the front side of the control valve locate and remove Installation: Install a new O-ring (Item 4) [Figure 20-40-
the tilt section load check valve (Item 1) [Figure 20-40- 20] and lubricate with oil before installing. Tighten the
19]. plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove

the auxiliary section load check valve (Item 2) [Figure
20-40-19].
NOTE: The tilt and auxiliary load check valves are

interchangeable.

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

Rod End)
Figure 20-40-21
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-40-23].
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-40-21]. Figure 20-40-24
Figure 20-40-22
1
2
2
1
4
P107952
3
P107624
port relief / anti-cavitation relief valve.
20-40-22]. Inspect the port relief / anti-cavitation seat (Item 2)
[Figure 20-40-24] for wear or damage and replace as
Inspect the orifice (Item 3) [Figure 20-40-22] in the needed.
Installation: Tighten the port relief anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-40- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
22] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

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

Installation (Tilt, Base End)
Figure 20-40-25
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-40-27]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-40-25] from the base end of the tilt section. Figure 20-40-28
Figure 20-40-26
2
1 1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Installation: Tighten the port relief anti-cavitation relief

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 N•m (35 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-40-29
P107628
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-31].
P107628
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-29] Figure 20-40-32
from the auxiliary circuit of the control valve.
Figure 20-40-30
1
1
P107629
2
P107630 Remove the O-ring (Item 1) [Figure 20-40-32] from the

optional auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2) Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
[Figure 20-40-30] from the port relief plug.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-33
P107628

P107628
Figure 20-40-34
2
P107629


(CONT’D)
Plug Removal And Installation
Figure 20-40-37
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-39].
P107631
Figure 20-40-40
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-37].
Figure 20-40-38
1
P107633

plug.
P107633
Installation: Tighten to 81,3 N•m (60 ft-lb) torque.

plug.

HYDRAULIC CONTROL VALVE (STANDARD) End Cap Block Removal And Installation
(CONT’D)
Figure 20-40-43
Rubber Boot Removal And Installation
Figure 20-40-41
1
2
1
1 P107772
P-51506 Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-43] from the
end cap block.
Remove the three screws (Item 1) [Figure 20-40-41] on
the rubber boot retainer plate. Figure 20-40-44
Installation: Lubricate the screws and tighten to 10,4 -

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-42
1
2
1 P107666
Disconnect the tubeline (Item 1) [Figure 20-40-44] from

the end cap block.
P107664
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-42].

HYDRAULIC CONTROL VALVE (STANDARD) Lift Spool And Detent Removal And Installation
(CONT’D)
End Cap Block Removal And Installation (Cont’d) procedure:
Figure 20-40-45 MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap block from the control valve. (See
End Cap Block Removal And Installation on Page 20-40-
14.)
Figure 20-40-46
2
1
P107773 1
Remove the end cap block mount screw (Item 1) [Figure

20-40-45].

11,6 N•m (95 - 105 in-lb) torque.
P107776
Remove the end cap block (Item 2) [Figure 20-40-45]

from the control valve. Remove the O-ring (Item 1) [Figure 20-40-46].
Installation: Replace the O-ring, and lubricate the O-ring

lightly with grease or oil before installation of the end cap
block.
Figure 20-40-47
P107775
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-47] from the lift spool.

(CONT’D)
Lift Spool And Detent Removal And Installation

(Cont’d)
Figure 20-40-48
P107846
NOTE: Do not remove the sleeve detent (Item 1) or

1 retaining ring (Item 2) [Figure 20-40-50] from
the spool centering block. If removed, the
P107779 sleeve detent must be inserted with the
original orientation.
Remove the four screws (Item 1) [Figure 20-40-48] from Figure 20-40-51
the spool centering block.
Figure 20-40-49
2
2
P107845A
1
P107778 NOTE: If removed, use the following for correct

installation: for a radius lift pattern machine,
align the radius side (Item 1) [Figure 20-40-51]
Remove the spool centering block (Item 1) [Figure 20- so it faces the opening of the spool centering
40-49]. block when seated. For a vertical lift pattern
machine, align the vertical side (Item 2)
Remove the O-ring (Item 2) [Figure 20-40-49]. [Figure 20-40-51] so it faces the opening when
seated. Install retaining ring over detent
sleeve.

(CONT’D)

(Cont’d)
Figure 20-40-52
P107739
2
Clamp the linkage end of the spool in a vise [Figure 20-
40-54].
1
P107790 NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly (Item 1) and O-ring (Item

2) [Figure 20-40-52] from the control valve.
IMPORTANT
Figure 20-40-53
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-55
1
P107757A
Remove the lift spool seal (Item 1) [Figure 20-40-53]

from the linkage end of the valve.
P107674A
Install the spring tool (Item 1) [Figure 20-40-55] over the

centering spring.
NOTE: Be careful when removing the detent adapter

(Item 2) [Figure 20-40-55] from the centering
spring, as it is under spring pressure.

(CONT’D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-56
4
2
1
P107676
Remove spring tool (Item 1) from the spring assembly

2 (Item 2) [Figure 20-40-58].
P107674 Figure 20-40-59
Remove the spring assembly / spring tool (Item 1) from

the spool (Item 2) [Figure 20-40-56]. 2
3 1
NOTE: The detent adapter has two detent balls (Item 4
3) held under pressure from a detent spring
(Item 4) [Figure 20-40-58]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.
Figure 20-40-57
P107677
1 Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-59].
P107675
Remove the detent adapter (Item 1) [Figure 20-40-57]

from the spring assembly.

(CONT’D)

(Cont'd)
Figure 20-40-60
1
N-18967
Clamp the collar (Item 1) [Figure 20-40-62] in a vise.
Figure 20-40-63
N-18918
Remove the stud from the end of the spool [Figure 20-
40-60]. 3
Figure 20-40-61 2
P107677
Apply grease on all the detent component surfaces

15,2 mm before assembly [Figure 20-40-63].
(0.60 in)
Install the spring (Item 1) and detent balls (Item 2) into
B-14712B the adapter (Item 3) [Figure 20-40-63] and compress
with the detent pliers (Item 1) [Figure 20-40-64].
Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-61].

(CONT’D)

(Cont'd)
Figure 20-40-64
P107674
1
Install the spring assembly to the lift spool hand tight
[Figure 20-40-66].
N-18968A Remove the spring tool.
Inspect the alignment of the detent adapter and the

Install the detent adapter to the collar [Figure 20-40-64]. washer.
NOTE: The collar and the detent adapter are held Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb).
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the NOTE: The adapter must fit in the center of the
detent adapter and collar together to prevent washer.
the detent balls and spring from falling out.
Figure 20-40-67
Figure 20-40-65
2
P107790
P107675
Lubricate and install a new O-ring (Item 1) [Figure 20-40-

Install the spring tool (Item 1) [Figure 20-40-65] over the 67].
washer, spring, collar, and detent adapter.
Lubricate and install a new O-ring (Item 2) [Figure 20-40-
67].
Install the lift spool assembly (Item 3) [Figure 20-40-67]

in the spool bore.

(CONT’D)

(Cont'd)
Figure 20-40-68
2
1
P107775
Install a spacer (Item 2) and an O-ring (Item 1) [Figure

2 20-40-70] on the lift spool.
P107779 Figure 20-40-71
Install the spool centering block (Item 1) [Figure 20-40-

68].
Install the four mounting screws (Item 2) [Figure 20-40-

68].
1
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-69
P107776
1
Install an O-ring (Item 1) [Figure 20-40-71] on the control

valve.
P107679A
Install a new spool seal (Item 1) [Figure 20-40-69] on the

linkage end of the valve.

(CONT’D)

(Cont'd)
Figure 20-40-72
2
2
1
1
3
P107772
4
Use an ohmmeter to measure the lock solenoid coils
resistance.
P107664A The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap block (Item 1) and the mount bolt (Item 2) [Figure 20-40-74] lock solenoids and tighten to
(Item 2) [Figure 20-40-72]. 52 - 61 N•m (38 - 45 ft-lb) torque.
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-72].

11,6 N•m (95 - 105 in-lb) torque.
Figure 20-40-73
P107666
Connect the tubeline (Item 1) [Figure 20-40-73].

(CONT’D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap block. (See End Cap
Block Removal And Installation on Page 20-40-14.) 2
Figure 20-40-75
1
P107778
Remove the spool centering block (Item 1) [Figure 20-

1 40-77] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

2
77] and lubricate the O-ring lightly with grease or oil
P107777 before installation of the spool centering block.
Figure 20-40-78
20-40-75] from the tilt spool.
Installation: Install the spacer (Item 1) and an O-ring

2
(Item 2) [Figure 20-40-75].
Figure 20-40-76
P107780
Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure

20-40-78].
1
P107779 78] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
Remove the four screws (Item 1) [Figure 20-40-76] from


11,6 N•m (95 - 105 in-lb) torque.

(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-79
1
P107647
Remove the bolt (Item 1) [Figure 20-40-81] holding the

centering spring to the spool.
P107781
Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105
in-lb) torque.
Remove the tilt spool seal (Item 1) [Figure 20-40-79].
Remove the spring tool from the spring assembly.
Assembly: Always use a new spool seal.
Figure 20-40-82
Figure 20-40-80
2 1
3
1 4
N-18944B
P107646
Inspect the adapter (Item 1), collar (Item 2), spring (Item
Put the linkage end of the spool in the vise [Figure 20- 3), and washer (Item 4) [Figure 20-40-82].
40-80].
NOTE: Protect spool before clamping in vise.

centering spring.

(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-40-83
1
3 2
4
1
2
4
P107783
Remove the spring (Item 1) and center spring retainer

3 (Item 2) [Figure 20-40-84] from the auxiliary spool.
P107782
20-40-84] from the auxiliary spool.
(Item 2) [Figure 20-40-83] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure
20-40-84] must be replaced, replace the
Remove the spacer (Item 3) and O-ring (Item 4) [Figure retainer on the opposite end also.
Installation: Lubricate and install an O-ring (Item 4)
NOTE: If the centering spring retainer (Item 2) [Figure [Figure 20-40-84].
retainer on the opposite end also. Figure 20-40-85
Installation: Lubricate and install an O-ring (Item 4)

[Figure 20-40-83].
P107784
Remove the auxiliary spool (Item 1) [Figure 20-40-85].

(CONT’D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-86 1
2
1
2
2
P107798
1
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-87] from the solenoid stem.
P107876
Use an ohmmeter to measure the solenoid coil
resistance.
Remove the screws (Item 1) [Figure 20-40-86] from both
solenoids. The correct resistance for the coil is 5.1 ohm.
Remove the solenoids (Item 2) [Figure 20-40-86] from Installation: Lubricate and install new O-rings (Item 1)
the control valves. and back-up rings (Item 2) [Figure 20-40-87].
Installation: Tighten the nut to 2,3 - 2,7 N•m (21.4 - 23.9

in-lb) torque.

(CONT’D)
Solenoid Removal And Installation
Figure 20-40-88
1
1
2
P107876
Remove the solenoid stem (Item 1) [Figure 20-40-90].
P107875 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-88] from the Figure 20-40-91
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-88]. 3

2
Figure 20-40-89
N-18694

[Figure 20-40-91] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-89] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-91] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve.
resistance.
The correct resistance for the coil is 9.5 - 10.08 ohm.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-40-92
2
1
1
P107937
The inside diameter of the BICS™ valve (Item 1) [Figure

20-40-94] is threaded for easier removal and installation.
P107785
Figure 20-40-95
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-40-
92]. 1 3
2
Figure 20-40-93
P107767
Remove the O-ring (Item 1) [Figure 20-40-95].
Remove and inspect the spring (Item 2) and BICS™

P107786 valve (Item 3) [Figure 20-40-95].
Remove the lift lock valve (Item 1) [Figure 20-40-93]

from the back of the control valve.
Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-96
2
1
P107937

P107788
Figure 20-40-99
Remove the lift spool lock solenoid (Item 1) [Figure 20-

40-96].
1 3
Remove the tilt spool lock solenoid (Item 2) [Figure 20-
2
40-96].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-97
P107767

valve (Item 3) [Figure 20-40-99].
1
P107789
Remove the tilt lock valve (Item 1) [Figure 20-40-97]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-40-102
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-100
P107787
1
P107693 Remove the main relief valve (Item 1) [Figure 20-40-

102].
Remove the fitting (Item 1) [Figure 20-40-100] from the Figure 20-40-103
valve.
Figure 20-40-101
1
1 2
P107745A
P-51437 Remove the O-ring (Item 1) and the back-up rings (Item
2) [Figure 20-40-103] from the main relief valve.
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
101].
NOTE: This orifice is not removable from the valve

casting.

(CONT’D)
Check Valve Removal And Installation
Figure 20-40-104
2
1
P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-40-106].
P107693
Remove the tubeline (Item 1) [Figure 20-40-104]. Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-
lb) torque.
Figure 20-40-105
P107786
Remove the check valve fitting (Item 1) [Figure 20-40-

105] from the hydraulic control valve.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P107847
The hydraulic control valve is located inside the support. Replace if damaged.
mainframe on the right hand side, below the operator’s D-1009-0409
cab.
The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
WARNING
The lift and tilt functions in the hydraulic control valve are Never work on a machine with the lift arms up unless
operated using electronic control handles / levers that the lift arms are secured by an approved lift arm
send an electronic signal to the electronic actuators to support device. Failure to use an approved lift arm
move the lift and tilt spools in the control valve. support device can allow the lift arms or attachment
The auxiliary function is operated by pilot pressure. W-2059-0598
There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
solenoid sends pilot pressure fluid to one side of the
spool and forces the spool to shift. IMPORTANT
The hydraulic control valve also contains a main relief
valve which is adjustable. When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-3
(CONT’D)
Removal And Installation (Cont’d) 3

support device. (See LIFT ARM SUPPORT DEVICE on 4
Page 10-20-1.)
2

Replacing Hydraulic Fluid on Page 10-120-2.)
1
NOTE: Mark all tubelines, hoses, and electrical 5
connections for correct installation.
P114645
Clean area around control valve.

Reposition clamp (Item 1), remove nut / bolt (Item 2),
Figure 20-41-2 remove the fuel tank vent hose (Item 3) and remove the
two mounting bracket nuts / bolts (Item 4) [Figure 20-41-
3].
Remove the filler neck assembly and plug the fuel tank
inlet.
Figure 20-41-4
1
P114643
1
Open rear door.
Disconnect the electrical connector (Item 1), remove the

two bolts (Item 2) and reposition the fuel filter assembly
(Item 3) [Figure 20-41-2]. P106822
The fixed end main valve hose assembly is connected to

a fixed end fitting on the control valve. The hose is routed
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-41-4].

(CONT’D)
Figure 20-41-5
1
3
1 2
P-90271
Disconnect the hose (Item 1) [Figure 20-41-7] that

routes from the top of the control valve to the hydraulic
P-90269 filter.
Figure 20-41-8
Disconnect the wire harness connectors (Item 1) [Figure
20-41-5] from the control valve.

routes from the control valve to the drain manifold.
2 2
routes from the control valve to the inlet fitting of the
hydraulic pump. 1
Figure 20-41-6
2
P-90272
Remove the tubeline clamp (Item 1) [Figure 20-41-8].
1 Disconnect the two tubelines (Item 2) [Figure 20-41-8]

that route from the control valve to the front auxiliary
hydraulics.
P107219

routes from the control valve to the brake valve.

routes from the control valve to the fan motor.

(CONT’D)

1
Figure 20-41-9
P-90275
1
routes from the control valve to the junction block at the
P-90273 rear of the machine.
Disconnect the lift arm bypass drain hose (Item 2)

Remove the tubeline clamp (Item 1) [Figure 20-41-9]. [Figure 20-41-11] from the control valve.
Figure 20-41-10 Figure 20-41-12
1 1
1
1
P-90274
P-90276
Disconnect the three tubelines (Item 1) [Figure 20-41- Disconnect the hose (Item 1) [Figure 20-41-12] that
10] that route from the control valve to the junction block routes from the bottom of the control valve to the outlet
at the rear of the loader. fitting of the hydraulic pump.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Figure 20-41-13
P-90278
Support the control valve and remove the two bolts (Item
1) [Figure 20-41-13].

(CONT’D)
Actuator Removal And Installation (In Loader)
WARNING
W-2059-0598
P-54587

support device. (See Installing on Page 10-20-2.) Remove the two bolts (Item 1) [Figure 20-41-15] from
the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
Mark the actuator wiring harness connectors for proper 100 in-lb) torque.
installation.
Figure 20-41-16
Figure 20-41-14
1 2
P-54566
P-90330
Pull the actuator (Item 1) [Figure 20-41-16] away from

Disconnect the actuator wire harness (Item 1) [Figure the control valve.
20-41-14].
Use a punch to remove the actuator pin (Item 2) [Figure
20-41-16] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)

(CONT’D)
Actuator Removal And Installation (In Loader)

(Cont’d)
Figure 20-41-17
1
2
P-54568
Inspect the O-ring (Item 1) [Figure 20-41-17] on the face

of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-17] and

replace as needed.

(CONT’D)
Actuator Removal And Installation (Out Of Loader)
Figure 20-41-18
1
1
P101625
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-41-20] from the actuator
and the spool.
P101623 Remove the actuator and linkage pin from the valve.
Figure 20-41-21
Remove the two mount bolts (Item 1) [Figure 20-41-18]
from the actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-41-19
P-54340

1 of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-21] and

P101624 replace as needed.
Slide the actuator retainer (Item 1) [Figure 20-41-19]

away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-19].

(CONT’D)

(Cont’d)
Figure 20-41-22
1
1
P-54343
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-41-24] from the actuator
and the spool.
P101626
Remove the actuator and linkage pin from the valve.
Remove the two mount bolts (Item 1) [Figure 20-41-22] Figure 20-41-25
from the actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-41-23
P-54340
1
of the actuator, and replace as needed.
P101627 Inspect the linkage pin (Item 2) [Figure 20-41-25] and

replace as needed.
Slide the actuator retainer (Item 1) [Figure 20-41-23]

away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-23].

(CONT’D)

(Cont’d)
Figure 20-41-26
1
3 P101629
NOTE: The two long bolts (Item 1) are used to install

the lift actuator and retainer (Item 2). The two
short bolts (Item 3) are used to install the tilt
actuator and the retainer (Item 4) [Figure 20-
41-26].
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -

100 in-lb) torque (Item 1) [Figure 20-41-26].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (CONT’D)
Identification Chart
Figure 20-41-27
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4
D1
H2
H3 D2
A1
E1
B1
F1 MR C1
H1
J3
J1
NA5825

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulics Female Coupler E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Male Coupler F1 Lift Spool
C1 Load Check F2 Tilt Spool
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579 kPa H3 BICS™ Lock Valve (Lift)
(276 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(2756 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 27579 kPa MR Main Relief Valve – 24132 kPa (241 bar)
(276 bar) (4000 psi) (3500 psi)
Tilt (Rod End)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Mount Bracket Removal And Installation
Figure 20-41-28 IMPORTANT

damage the system.
I-2003-0888
1 Figure 20-41-30
P-90280
Support the mounting bracket (Item 1) [Figure 20-41-28].
Figure 20-41-29 1
1
P107848
Remove the charge tubeline (Item 1) [Figure 20-41-30]

from the BICS™ valve fitting on the top of the lift load
check valve.
P110095
Remove the two control valve mount bolts (Item 1)

[Figure 20-41-29].
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt And
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-33

(Cont’d)
Figure 20-41-31
P107850
P107849 At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41-
33].
Remove the lift load check valve (Item 1) [Figure 20-41-
31] and fitting from the top of the control valve. At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
Installation: Lubricate the O-ring and threads and 20-41-33].
tighten to 68 - 94 N•m (50 - 70 ft-lb) torque.
NOTE: The tilt and auxiliary load check valves are
Figure 20-41-32 interchangeable.
Figure 20-41-34
1
5
1
2
2
3 4 4
P107716
3
P107624
[Figure 20-41-32].
Inspect the spring (Item 3) and the free movement in the 20-41-34].
check valve (Item 4) [Figure 20-41-32].
Inspect the orifice (Item 3) [Figure 20-41-34] in the
Inspect the orifice to make sure it is not plugged (Item 5) poppet to make sure it is not plugged.
[Figure 20-41-32].
Installation: Install a new O-ring (Item 4) [Figure 20-41-
34] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-41-37

Rod End)
Figure 20-41-35
P107628
P107628 Remove the lift circuit port relief / anti-cavitation valve

and the port relief / anti-cavitation seat (Item 1) [Figure
20-41-37].
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-41-35]. Figure 20-41-38
Figure 20-41-36
1
2
2
4 1
P107952
3
P107624
20-41-36]. Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-41-36] in the needed.
Installation: Tighten the port relief / anti-cavitation relief
Installation: Install a new O-ring (Item 4) [Figure 20-41- valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
36] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) Installation: Tighten the port relief / anti-cavitation seat
torque. to 47 N•m (35 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-41

Installation (Tilt, Base End)
Figure 20-41-39
P107628
P107628 Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-41]
from the rod end of the tilt section.
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-39] from the base end of the tilt section. Figure 20-41-42
Figure 20-41-40
1
1
P107952
P107629
port relief / anti-cavitation relief valve. Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque. needed.
Installation: Tighten the port relief / anti-cavitation relief

valve to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat

to 47 N•m (35 ft-lb) torque.

(CONT’D)
Port Relief Valve Removal And Installation
Figure 20-41-43
P107628

P107628
Figure 20-41-44
2
P107629


(CONT’D)
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-41-47
P107628

P107628
Figure 20-41-48
1
1
2
P107629


(CONT’D)
Plug Removal And Installation
Figure 20-41-51
P107632
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-53].
P107631
Figure 20-41-54
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-51].
Figure 20-41-52
1
P107633

plug.
P107633

plug.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
(CONT’D)
The tool listed will be needed to do the following
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-6.) Remove the end cap block from the control valve.
Figure 20-41-55 Figure 20-41-57
1 2 P107851
P107853
Disconnect the tubeline (Item 1) [Figure 20-41-55] from Remove the O-ring (Item 1) [Figure 20-41-57].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-41-55].
Figure 20-41-58
11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-56
1
P107753
1
P107852 20-41-58] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-56]

from the control valve.

(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-59
1
P107756
Remove the lift spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-61] from the control valve.
P107854
Figure 20-41-62
Remove the four screws (Item 1) [Figure 20-41-59] from


11,6 N•m (95 - 105 in-lb) torque.
Figure 20-41-60
P107757
2
Remove the lift spool seal (Item 1) [Figure 20-41-62]

from the actuator end of the valve.
P107855
Remove the spool centering block (Item 1) and O-ring

(Item 2) [Figure 20-41-60] from the control valve.

60] and lubricate lightly with oil before installation of the
spool centering block.

(CONT’D)
Lift Spool Disassembly And Assembly
Figure 20-41-63
1
P107647

P107740
in-lb) torque.
Clamp the actuator end of the spool in a vise [Figure 20-
41-63]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-66
Figure 20-41-64
3
4 1
1
P-51776B
P107646
3), and washer (Item 4) [Figure 20-41-66].
centering spring.

(CONT’D)
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block

Figure 20-41-67 2
P107769
Remove the tilt spool assembly (Item 1) and O-ring (Item

1 2) [Figure 20-41-69].
2 Figure 20-41-70
P107856

20-41-67] from the tilt spool.
Figure 20-41-68
P107770
Remove the spool seal (Item 1) [Figure 20-41-70].
P107769
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the spool centering block.

(CONT’D)
Tilt Spool Disassembly And Assembly

2 1
Figure 20-41-71
3
N-18944B
3), and washer (Item 4) [Figure 20-41-73].
P107646
Put the actuator end of the spool in the vise [Figure 20-
41-71].
NOTE: Protect spool before clamping in vise.

centering spring.
Figure 20-41-72
P107647


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

(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-74
2
1
2 P107760

1 (Item 2) [Figure 20-41-76] from the auxiliary spool.
P107758
NOTE: If the centering spring retainer (Item 2) [Figure
Remove the spring (Item 1) and center spring retainer retainer on the opposite end also.
(Item 2) [Figure 20-41-74] from the auxiliary spool.
Figure 20-41-77
NOTE: If the centering spring retainer (Item 2) [Figure
retainer on the opposite end also.
Figure 20-41-75
1
2
P107761
1
P107759


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
(CONT’D)
Figure 20-41-79
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-78
1
2 2
1
1
P107847
P107762 Remove the screws (Item 1) [Figure 20-41-79] from both

solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-41-78]. Remove the solenoids (Item 2) [Figure 20-41-79].
Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -

23.9 in-lb) torque.
Figure 20-41-80
P107798

[Figure 20-41-80] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 5.1 ohm.
Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-41-80].

(CONT’D)
Solenoid Removal And Installation
Figure 20-41-81 1
P107857
Remove the solenoid stem (Item 1) [Figure 20-41-83].
P107847 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-81] from the Figure 20-41-84
solenoid stem.
Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-81]. 3

2
Figure 20-41-82
N-18694

[Figure 20-41-84] from the stem.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-82] from both
ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-84] may be
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid stem needs to be replaced.
resistance.
The correct resistance for the coil is 9.5 - 10.08 ohm.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-85
1 2 P107937

P107858
Figure 20-41-88
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-
85]. 1 3
Figure 20-41-86 2
1
P107767

P107859 valve (Item 3) [Figure 20-41-88].
Remove the lift lock valve retaining cap (Item 1) [Figure

20-41-86] from the back of the control valve.


(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-89
1 P107937

P107860
Figure 20-41-91
Remove the tilt lock valve retaining cap (Item 1) [Figure

20-41-89] from the front of the control valve.
1 3
O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque. 2
P107767

valve (Item 3) [Figure 20-41-91].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-94
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-92
1
1 P107862
P107861 Remove the main relief valve (Item 1) [Figure 20-41-94].
Figure 20-41-95
Remove the fitting (Item 1) [Figure 20-41-92] from the
valve.
Figure 20-41-93 1
2
1
P107745A
Remove the O-ring (Item 1) and the back-up rings (Item

P-51437 2) [Figure 20-41-95] from the main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-41-
93].
NOTE: This orifice is not removable from the valve

casting.

(CONT’D)
Check Valve Removal And Installation
Figure 20-41-96
1 P107625
Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-98].
P107848
Remove the tubeline (Item 1) [Figure 20-41-96]. Installation: Tighten the fitting to 27 - 33 N•m (20 - 24 ft-
lb) torque.
Figure 20-41-97
P107864
Remove the check valve fitting (Item 1) [Figure 20-41-

97] from the hydraulic control valve.

LIFT ARM BYPASS CONTROL VALVE Testing
Description Figure 20-50-1
The lift arm bypass control valve is located on the right

side of the machine.
The lift arm bypass control valve is manually operated by 1

turning the lift arm bypass valve knob (Item 1) [Figure
20-50-1] 90° clockwise. Then pull up and hold the lift arm
bypass control knob until the lift arms slowly lower. The
valve releases the hydraulic fluid from the base end of the
lift cylinder(s) which allows the lift arm to slowly come
down to the transport position.
P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob must return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
DANGER 3
P-90328 P-85670
AVOID DEATH
• Disconnecting or loosening any hydraulic Hold the lift arm bypass control knob (Item 1) [Figure 20-
tubeline, hose, fitting, component or a part failure 50-2] and loosen the nut on the lift arm bypass valve
can cause lift arms to drop. shaft.
unless supported by an approved lift arm Remove the knob (Item 1). Remove the nut (Item 2)
support. Replace if damaged. [Figure 20-50-2] from the valve shaft.
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING
2
W-2059-0598
2
Lower the lift arms.
Raise the operator cab. (See Raising on Page 10-30-2.) 1
P-85671
IMPORTANT Disconnect the hydraulic tubeline (Item 1) and hose (Item

2) [Figure 20-50-3].
clean the work area before disassembly and keep all Remove the two bolts and nuts (Item 2) [Figure 20-50-3].
tubelines and ports to keep dirt out. Dirt can quickly Installation: Tighten the bolts to 21 - 23 N•m (180 - 200
damage the system. in-lb) torque.
I-2003-0888
Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] and damage and replace if necessary.
remove the bypass valve bracket.
Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
lb) torque.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on

the valve block for damage and replace if necessary.

HYDRAULIC PUMP
Description
The hydraulic pump is attached to the end of the

hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that

provide hydraulic flow to several hydraulic systems.
The hydraulic pump has a dedicated charge pump. This

supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
A seal kit is available to service the hydraulic pump. If any

of the main components of the pump are damaged, the
entire pump must be replaced.

HYDRAULIC PUMP (CONT’D) Figure 20-60-1
Pump Test At Quick Couplers

2
IMPORTANT
I-2024-0284
WARNING P106632
W-2006-1209
loader.
WARNING
W-2017-0286

procedure:
MEL10003 or MEL1744 - Hydraulic Tester


1.)

hoses must be at least 19 mm (0.75 in)
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.
This procedure will require one operator in the cab and

one operator running the tester.

Pump Test At Quick Couplers (Cont’d)
Figure 20-60-2
1
2 1
P-16903 P106632
Warm the fluid to 60°C (140°F) by turning the restrictor

NA3267 control (Item 1) [Figure 20-60-4] clockwise on the tester
so it reads 6895 kPa (69 bar) (1000 psi).
Start the engine and run at low idle. Press the Auxiliary
hydraulics button (Item 1) once to activate the auxiliary NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
hydraulics. The light (Item 2) [Figure 20-60-2] will be on. psi).
Figure 20-60-3 Turn the restrictor control (Item 1) [Figure 20-60-4]

Check the free flow specification. (See Hydraulic System

on Page SPEC-10-4.)
NOTE: If free flow is below specification perform the

direct pump test.

1 restriction on the flow. The fluid flow should drop off
slightly until the pressure reaches approximately 21374
kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
(213,7 bar) (3100 psi) the flow should start decreasing
1
P106677
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-60-3]
20-60-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
female coupler (female coupler is pressurized).
main relief valve needs to be adjusted. (See Adjusting on
front auxiliary hydraulic switch (Item 1) [Figure 20-60-3]
Page 20-30-4.)
a second time.
If flow does not match specifications go to the Direct
NOTE: When the operator is seated and raises the
Pump Testing. (See Direct Pump Test (Standard Section)
seat bar, the Auxiliary Hydraulic System
on Page 20-60-4.)
(Front and Rear) will deactivate.
If no flow is indicated on the tester, the hoses are

connected wrong. With the hoses connected correctly,
increase the engine speed to full rpm.

Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7217666 - Remote Start Tool

MEL10006 - Fitting Kit
WARNING
P106709
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-5]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-6
1.)

support device. (See Installing on Page 10-20-2.)
WARNING 2 1

P106631
W-2059-0598
Raise the operator cab. Connect the INLET hose (Item 1) [Figure 20-60-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-5]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-60-6] from the tester to the control valve fitting on the
REMOTE START TOOL (SERVICE TOOL) KIT - control valve.
7217666 on Page 10-61-1.)

HYDRAULIC PUMP (CONT’D)
Direct Pump Test (Standard Section) (Cont'd)
IMPORTANT
position before you start the engine.
I-2024-0284
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

control on the tester to about 6895 kPa (69 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.
On the Remote Start Tool engage the auxiliary

hydraulics, the light will come ON. Pull the trigger on the
right joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (U.S. gpm). The high pressure
flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (U.S. gpm) X 100

%=
FREE FLOW (U.S. gpm)
A low percentage may indicate a failed pump.
*For system relief pressure and full rpm (See Hydraulic

System on Page SPEC-10-4.)

Direct Pump Test (Charge Section) Earlier Models

procedure:

1
WARNING
P114639
Failure to use jackstands can allow the machine to Figure 20-60-8
W-2017-0286 Later Models

1.) 1

WARNING
P115656
support device can allow the lift arms or attachment Disconnect the inlet hose (Item 1) [Figure 20-60-7] or
to fall and cause injury or death. [Figure 20-60-8].
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.
Connect the Remote Start Tool. (See REMOTE START

TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)

HYDRAULIC PUMP (CONT’D) Start the engine and run at low idle rpm. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
Figure 20-60-9 rpm*.

control on the tester to about 4137 kPa (41,4 bar) (600
psi). DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.
2 1 Turn the restrictor down to system operating pressure
approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.

%=
P106631 FREE FLOW (U.S. gpm)

Connect the INLET hose (Item 1) [Figure 20-60-9] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-7] *For system relief pressure and full rpm. (See Hydraulic
or [Figure 20-60-8] of the pump. Connect the OUTLET System on Page SPEC-10-4.)
hose (Item 2) [Figure 20-60-9] from the tester to the inlet
fitting on the fan (Item 1) [Figure 20-60-7] or [Figure 20-
60-8].
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT’D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

to fall and cause injury or death. 1
W-2059-0598
1
1
1
DANGER
P-90180
Disconnect the four hoses (Item 1) [Figure 20-60-10]

from the hydraulic pump.
Remove the Power Bob-Tach block (if equipped). (See

P-90328 Removal And Installation on Page 20-120-1.)
AVOID DEATH Figure 20-60-11

unless supported by an approved lift arm 1
D-1009-0409
1
IMPORTANT
clean the work area before disassembly and keep all P-90509
Disconnect the outlet hoses (Item 1) [Figure 20-60-11]
damage the system.
I-2003-0888
from the hydraulic pump.
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)


Figure 20-60-12
1 P-43940
Remove and replace the O-ring (Item 1) [Figure 20-60-

P114386 14] from the hydraulic pump.
Reverse the removal procedure to install the hydraulic

Remove the bracket mounting bolt / nut (Item 1) [Figure pump.
20-60-12].
Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28

ft-lb) torque.
Figure 20-60-13
P106594
Remove the two mounting bolts (Item 2) [Figure 20-60-

12] and [Figure 20-60-13].

lb) torque.
Remove the hydraulic pump.

HYDRAULIC PUMP (CONT’D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-15 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
1 of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
Inspect for hydraulic leaks.
P100685
Figure 20-60-16
P114478
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-15] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-16].

Figure 20-60-17
1. Bolt 13.Auxiliary Pump Center Section

2. Charge Pump End Section 14. Auxiliary Pump End Section
3. Section Seal 15. Shaft Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
7
8
9
3
10
3 2
4
6 5
8
4
11
7
8
3 12
4
6 13
4 8
10
11
15 3
14
P-66540

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-60-11.) for proper placement of components
along with the information below.
Assembly: Tighten the eight pump housing bolts (Item 1)

[Figure 20-60-17] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plates (Item 4) [Figure 20-

60-17] as shown with the bronze side toward
the gears.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components are worn
or damaged, the complete pump must be
replaced.

HYDRAULIC PUMP (HIGH FLOW)
Description
The hydraulic pump is attached to the end of the

hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the
engine.
The hydraulic pump is a combination of gear pumps that

provide hydraulic flow to several hydraulic systems.
The hydraulic pump has a dedicated charge pump. This

supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump.
The high flow hydraulic pump has an additional pump

section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched
from a button on the panel in the cab.
A seal kit is available to service the hydraulic pump. If any

of the main components of the pump are damaged, the
entire pump must be replaced.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Figure 20-61-1
Pump Test At Quick Couplers
IMPORTANT
I-2024-0284
WARNING P106632
W-2006-1209
loader.
WARNING
W-2017-0286

procedure:


1.)

hoses must be at least 19 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the tester.
This procedure will require one operator in the cab and

one operator running the tester.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) If no flow is indicated on the tester, the hoses are
connected wrong. With the hoses connected correctly,
Pump Test At Quick Couplers (Cont’d) increase the engine speed to full rpm.
2 1
NA3267 P106632
P-16903
Start the engine and run at low idle. Press the Auxiliary Warm the fluid to 60°C (140°F) by turning the restrictor
hydraulics button (Item 1) once to activate the auxiliary control (Item 1) [Figure 20-61-4] clockwise on the tester
hydraulics. The light (Item 2) [Figure 20-61-2] will be on. so it reads 6895 kPa (69 bar) (1000 psi).
Figure 20-61-3 NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700
psi).
Turn the restrictor control (Item 1) [Figure 20-61-4]

Check the free flow specification. (See Hydraulic System

on Page SPEC-10-4.)
NOTE: If free flow is below specification perform the

1 direct pump test.

restriction on the flow. The fluid flow should drop off
slightly until the pressure reaches approximately 21374
1 kPa (213,7 bar) (3100 psi). At approximately 21374 kPa
P106677 (213,7 bar) (3100 psi) the flow should start decreasing
(237,9 - 241,3 bar) (3450 - 3500 psi). At 23787 - 24132
After activating the auxiliary hydraulics, press the
continuous flow control switch (Item 1) [Figure 20-61-3]
female coupler (female coupler is pressurized).
20-61-4] counterclockwise to free flow. Shut the front
auxiliary hydraulics off and stop the engine.
front auxiliary hydraulic switch (Item 1) [Figure 20-61-3]
a second time.
main relief valve needs to be adjusted. (See Adjusting on
Page 20-30-4.)
NOTE: When the operator is seated and raises the
seat bar, the Auxiliary Hydraulic System If flow does not match specifications go to the Direct
(Front and Rear) will deactivate. Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-61-4.)

Direct Pump Test (Standard Section)

procedure:

1
WARNING
P106709
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-5]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-6
1.)

WARNING 2 1

P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-5]
Connect the Remote Start Tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 20-61-6] from the tester to the fitting on the control valve.
7217666 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7217666 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses MEL10003 or MEL1744 - Hydraulic Tester
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

control on the tester to 6895 kPa (69 bar) (1000 psi). DO
NOT exceed system relief pressure. Open the restrictor
WARNING
control and record the free flow (U.S. gpm) at full rpm*.
On the Remote Start Tool engage the auxiliary of the frame before running the engine for service.
hydraulics, the light will come ON. Pull the trigger on the Failure to use jackstands can allow the machine to
right joystick for fluid flow to the quick coupler (fluid fall or move and cause injury or death.
pressure will go over main relief). Record the highest W-2017-0286
pressure (psi) and flow (U.S. gpm). The high pressure
flow must be at least 80% of free flow. Lift and block the loader. (See Procedure on Page 10-10-
1.)
%=
FREE FLOW (U.S. gpm) Raise the lift arms and install an approved lift arm
*For system relief pressure and full rpm. (See Hydraulic

WARNING
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.

7217666 on Page 10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)
Figure 20-61-7
Earlier Models
2 1
1
P106631

P114639 the tester to the OUTLET hose (Item 1) [Figure 20-61-7]
or [Figure 20-61-8] of the pump. Connect the OUTLET
hose (Item 2) [Figure 20-61-9] from the tester to the inlet
Figure 20-61-8 fitting on the fan (Item 1) [Figure 20-61-7] or [Figure 20-
Later Models 61-8].
1 IMPORTANT
I-2024-0284
tester, the hoses are connected wrong. With the hoses
P115656 connected correctly, increase the engine speed to full
rpm*.
Disconnect the inlet hose (Item 1) [Figure 20-61-7] or Warm the fluid to 60°C (140°F) by turning the restrictor
[Figure 20-61-8]. control on the tester to about 4137 kPa (41,4 bar) (600
psi).
NOTE: DO NOT exceed 8274 kPa (82,7 bar) (1200 psi).
gpm) at full rpm*.
Turn the restrictor down to system operating pressure

approximately 6895 kPa (69 bar) (1000 psi). DO NOT
EXCEED 8274 kPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
%=
*For pump flow and rpm. (See Hydraulic System on Page

SPEC-10-4.)

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-10] onto the

front auxiliary quick couplers.
W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)

7217666 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Lower the cab.
Direct Pump Test (High Flow Section) (Cont'd) Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
Figure 20-61-11 button (on the right control lever) for fluid flow to the quick
coupler. 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
2 engine speed to full rpm*.

control on the tester to about 6895 kPa (69 bar) (1000
psi).
NOTE: DO NOT EXCEED 25510 kPa (255 bar) (3700

psi).
1
gpm) at full rpm. Increase the restriction and the flow
P101694 should drop to 0 L/min (0 U.S. gpm) between 24132 kPa
(241 bar) (3500 psi) and 25510 kPa (255 bar) (3700 psi).
Disconnect the high flow pump OUTLET hose (Item 1) If pressure readings are not obtained go to the High Flow
from the high flow check valve INLET fitting (Item 2) Valve, relief valve adjustment procedure. (See High Flow
[Figure 20-61-11]. Relief Valve Removal And Installation on Page 20-61-11.)
Figure 20-61-12 Record the highest pressure (psi) and flow (U.S. gpm).
The high pressure flow must be at least 80% of free flow.

%=

2 1 *For system relief pressure and full rpm. (See Hydraulic
P106631

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-11]. Connect the OUTLET hose (Item 2)
[Figure 20-61-12] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-11].

High Flow Relief Valve Adjustment
If the pump is unable to reach 24132 kPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
[Figure 20-61-16] will need to be turned clockwise 1/4
turn and retested with the procedure above. (1/4 turn
equals approximately 1379 kPa (13,8 bar) (200 psi).) 1
NOTE: If the relief screw has been turned in 1/4 turn

and the pressure remains the same, go to the
high flow relief valve removal and installation
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-11.) If relief
valve has been tested and is OK, go to the P110094
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-17.) Figure 20-61-15
Remove right rear wheel. (See Wheel Nuts on Page 10-

160-1.)
Figure 20-61-13 1
2
1
P110096
1
Locate the high flow relief valve (Item 1) [Figure 20-61-
14] and [Figure 20-61-15] along the right side of the
P110093
engine.
Remove the plug (Item 2) [Figure 20-61-15] located on

Remove the bolts (Item 1) [Figure 20-61-13] from the the bottom of the high flow relief valve.
cover and remove the cover from the loader.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D)
High Flow Relief Valve Adjustment (Cont’d)
Figure 20-61-16
P101697
If the pump reaches 25511 kPa (255,1 bar) (3700 psi)

and there is flow stop the engine. The relief screw must
be turned 1/4 turn and retested with the procedure above
[Figure 20-61-16].
NOTE: The relief valve is shown removed from the

loader for photo clarity.

High Flow Relief Valve Removal And Installation

1
WARNING 4

of the frame before running the engine for service. 2
Failure to use jackstands can allow the machine to 3
W-2017-0286
Figure 20-61-17 P101698
1
Inspect the relief valve and replace the two O-rings (Item
1) and back-up ring (Item 2) [Figure 20-61-19].
1
If the relief valve is bad, it must be replaced as a
complete unit.
Remove the plug (Item 3) and O-ring (Item 4) [Figure 20-

61-19].
P110093
Remove the bolts (Item 1) [Figure 20-61-17] from the

access cover and remove the cover from the loader.
Figure 20-61-18
P110096
Remove the relief valve (Item 1) [Figure 20-61-18] from

the pump.
Installation: Tighten the relief valve to 41 - 47 N•m (30 -

35 ft-lb) torque.

Solenoid Removal And Installation 1
Figure 20-61-20
P-45461
Remove the solenoid valve (Item 1) [Figure 20-61-22].

P-43958
Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Disconnect the electrical connector (Item 1) [Figure 20-
61-20] from the high flow pump solenoid. Figure 20-61-23
Figure 20-61-21
2
2
P-45462
P-45460
[Figure 20-61-23].
Remove the solenoid nut (Item 1) [Figure 20-61-21].
Remove the solenoid (Item 2) [Figure 20-61-21].
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 -

72 in-lb) torque.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)
Remove the Power Bob-Tach block (if equipped). (See

WARNING Removal And Installation on Page 20-130-2.)

Figure 20-61-24
to fall and cause injury or death. 1
W-2059-0598
1
DANGER
1
1
P-90184
P-90328 Disconnect the INLET hoses (Item 1) [Figure 20-61-24]

from the front of the hydraulic pump.
AVOID DEATH
Figure 20-61-25
D-1009-0409
IMPORTANT 1

parts clean. Always use caps and plugs on hoses, P-90185
damage the system.
I-2003-0888 Disconnect the hoses (Item 1) [Figure 20-61-25] from
the back of the hydraulic pump.
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)


Figure 20-61-26
1
P106594

P-90509A 27] and [Figure 20-61-28].

Disconnect the OUTLET hoses (Item 1) [Figure 20-61- lb) torque.
26] from the hydraulic pump.
Remove the hydraulic pump.
Figure 20-61-27
Figure 20-61-29
2 1
P114386
P-43940
Remove the bracket mounting bolt / nut (Item 1) [Figure

20-61-27]. Remove the O-ring (Item 1) [Figure 20-61-29].
Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28 Reverse the removal procedure to install the hydraulic
ft-lb) torque. pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.
NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
Figure 20-61-30 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.

1 Check for hydraulic leaks.
P-100685
Figure 20-61-31
P114478
Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-61-30] to the starter terminal S (Item 1) and

Figure 20-61-32
1 1. High Flow Relief Valve

2. O-ring
3. Back-up Ring
2 4. Wear Plate
2 5. Section Seal
3 6. Rear Housing
6 7. Bolt
5
4 7 8. Stem
7 9. Coil
10. Nut
11. Gear Set
3 12. Gear Housing
2 13. Dowel Pin
9 2 14. Splined Shaft
15. Load Seal
8 16. Preload Seal
13
17. Center Housing
4 18. Front Housing
11
15 14 19. Shaft Seal
10 16
5
13
17 12
5
4
13
4
14 11
15
16
5
13 12
17
5
4
13
15 4
16
5 12
11
18
19
13
MS1456S

IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-16.) for proper placement of components
along with the information below.
Assembly: Tighten the eight pump housing bolts (Item 7)

[Figure 20-61-32] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plate (Item 4) [Figure 20-61-32]

inlet as shown with the bronze side toward the gears on
all wear plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components are worn
or damaged, the complete pump must be
replaced.

HYDRAULIC / HYDROSTATIC FILTERS
Description
The hydraulic / hydrostatic filters help to remove

IMPORTANT
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating. When repairing hydrostatic and hydraulic systems,
The hydraulic / hydrostatic filter system consists of one parts clean. Always use caps and plugs on hoses,
main filter and one charge flow filter. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The main filter removes contaminants before entering
gear pumps including fluid returning from the main valve.
The charge flow filter removes contaminants after the support device. (See Installing on Page 10-20-2.)
charge pump.
Housing Removal And Installation
Drain the fluid from the reservoir. (See Removing And
DANGER Figure 20-70-1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 2
tubeline, hose, fitting, component or a part failure 1
P114481
support. Replace if damaged. Disconnect the wire harness (Item 1) [Figure 20-70-1]
D-1009-0409 from the hydraulic / hydrostatic filter sender.
Disconnect the three hoses (Item 2) [Figure 20-70-1]

from the hydraulic / hydrostatic filter housing.
WARNING
W-2059-0598

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
P114480
Remove the two hoses (Item 1) [Figure 20-70-2] from

the bottom of the hydraulic / hydrostatic filter housing.
Figure 20-70-3
P106683
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the

loader.

HYDRAULIC FLUID RESERVOIR Figure 20-80-2
Description 1
The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.
The hydraulic fluid reservoir is located behind the

operator’s cab under the rear grille on the right side of the
loader.

P110098
Remove the clamps and the hoses (Item 1) [Figure 20-
Drain the fluid from the reservoir. (See Removing And 80-2].
Figure 20-80-3
Remove the Hydraulic / Hydrostatic Filter Housing. (See
Housing Removal And Installation on Page 20-70-1.)
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 20-80-1
1
2 1
P110099
Remove the two bolts (Item 1) [Figure 20-80-3].

1
Remove the hydraulic fluid reservoir from the loader.
1
P110097
Installation: Tighten the bolts and nuts to 21,7 - 24,4
N•m (16 - 18 ft-lb) torque.
Remove the bolts (Item 1) and grille (Item 2) [Figure 20-

80-1].

HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Remove the rear grille. (See Removing on Page 50-60-

1.)
Figure 20-80-4
P-90506
Remove the hydraulic fluid reservoir breather cap

[Figure 20-80-4] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-4] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER
The oil cooler and radiator are removed from the loader
as a unit. (See Radiator / Oil Cooler Removal And
Installation on Page 70-40-1.) or (See Radiator / Oil
Cooler Removal And Installation on Page 70-41-1.)

BUCKET POSITION VALVE Solenoid Removal And Installation
Description
The Bucket Position Valve is an option that allows the

operator to hold the attachment at the same angle from
DANGER
the ground to maximum lift height without using the tilt
function.
The bucket position valve is mounted to the inside lower

right rear side of the loader frame.
See the Hydraulic Schematic for more circuit information.
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888


BUCKET POSITION VALVE (CONT’D) Figure 20-100-3
Solenoid Removal And Installation (Cont’d)
Figure 20-100-1
3
1 P-90197
1

2 from the bucket position shut-off solenoid.
P114272
Disconnect the two tubelines (Item 2) [Figure 20-100-3].

Remove the two bolts (Item 1), disconnect the wire
harness (Item 2) and place the fuel filter assembly (Item Remove the solenoid nut, coil, and stem (Item 3) from the
3) [Figure 20-100-1] off to the side. bucket positioning valve [Figure 20-100-3].
Figure 20-100-2 Installation: Tighten the solenoid stem to 40,7 - 50,2

N•m (30 - 40 ft-lb) torque. Tighten the solenoid nut to 8
N•m (6 ft-lb) torque. Over tightening may cause valve
3 failure.
NOTE: The engine is shown removed for photo

clarity.
1
Figure 20-100-4
1
2 2
P114272
Remove the bolts / nuts (Item 1), move the hose clamp
(Item 2) to the middle of the hose and place the fuel inlet
assembly (Item 3) [Figure 20-100-2] off to the side.
Cover the fuel tank inlet.
N-18191
Remove the O-rings (Item 1) and the back-up ring (Item

2) [Figure 20-100-4].

BUCKET POSITION VALVE (CONT’D) Cover the fuel tank inlet.
Solenoid Testing Figure 20-100-6
Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
DANGER
1 P-90197
Disconnect the wire harness (Item 1) [Figure 20-100-6].
NOTE: The engine is shown removed for photo

P-90328 clarity.
D-1009-0409

2
Figure 20-100-5
4 3
P-90188
3
Disconnect the tilt base inlet hose (Item 1), the tilt rod
inlet hose (Item 2), the lift rod inlet hose (Item 3), and the
lift base inlet hose (Item 4) [Figure 20-100-7].
1
2 P106714
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-100-5] off to the side.

Removal And Installation (Cont'd)
Figure 20-100-8
P-90190A
2
1
Remove the bolts (Item 1) [Figure 20-100-10].
P-90189A
Remove the bucket position valve from the loader.
Disconnect the tilt cylinder hose (Item 1) and the tilt

cylinder base end hose (Item 2) [Figure 20-100-8] from
the valve block.
Figure 20-100-9
2
2
1
P-90197A
Disconnect the lift base outlet hose and tubeline (Item 1)

and the lift rod outlet hose and tubeline (Item 2) [Figure
20-100-9] that route from the lift cylinders.

Figure 20-100-11
3
1
2
1 3
2 4
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2) and plug (Item 3) [Figure 20-100-13].

Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-11]. Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
ft-lb) torque.
Assembly: Tighten the nut to of 8 N•m (6 ft-lb) torque.
Overtightening may cause valve failure. Tighten the Figure 20-100-14
solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb) torque.
Figure 20-100-12
1
2 3
2 P-90193
P-90195 Remove the plug (Item 1), spring (Item 2) and unloading
spool (Item 3) [Figure 20-100-14].
Remove the flow adjustment valve (Item 1). Remove the Remove the O-ring (Item 4) [Figure 20-100-14].
O-ring (Item 2) [Figure 20-100-12].
Assembly: Tighten the flow adjustment valve to 36,6 - Inspect all parts for wear and damage. Replace all worn
48,8 N•m (27 - 36 ft-lb) torque. and damaged parts.

REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Description
The rear auxiliary diverter valve is an optional valve that

diverts fluid from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located on each side of the rear

frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing P100765
Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
4.6 - 5.7 ohm.
Figure 20-110-3
P9137

resistance is 8.6 - 9.5 ohm.
P100763
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
resistance for the solenoid coil with a molded connector
is 8.1 - 9.9 ohm.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-4
DANGER
P-90583
P-90328
AVOID DEATH Disconnect the tubelines (Item 1) [Figure 20-110-4].

tubeline, hose, fitting, component or a part failure Figure 20-110-5
D-1009-0409
1 1
IMPORTANT
parts clean. Always use caps and plugs on hoses, P-93303
damage the system.
I-2003-0888 Disconnect the tubelines (Item 1) [Figure 20-110-5].

1.)



REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
Figure 20-110-6 assembly.
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent and dry with compressed air. Install
1 new O-rings and back-up rings.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent and dry with compressed air.
Figure 20-110-8
P100810
Disconnect the accessory wiring harness (Item 1)

[Figure 20-110-6] from the main harness.
Figure 20-110-7
1
1
2
P-48751
1 Remove the plugs (Item 1) [Figure 20-110-8].
Figure 20-110-9
P-90581
1
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-7].
P-48752

plug.

Disassembly And Assembly (Cont'd)
Figure 20-110-10
P-48755
Remove the differential sensing valve (Item 1) [Figure

P-48755 20-110-12].
Installation: Tighten the sensing valve to 68 - 75 N•m

Remove the shuttle valve (Item 1) [Figure 20-110-10]. (50 - 55 ft-lb) torque.
Installation: Tighten the shuttle valve to 14 - 16 N•m (10 Figure 20-110-13

- 12 ft-lb) torque.
Figure 20-110-11
1
2
1 1 1
1 1
2 2 P-48757
P-48756 Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-110-13].

[Figure 20-110-11].

Figure 20-110-14
P-48759
1
Remove the nut (Item 1) [Figure 20-110-16] from the

P-48753 solenoid valve stem.
Installation: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

Remove the relief valve (Item 1) [Figure 20-110-14]. torque.
Installation: Tighten the relief valve to 27 - 34 N•m (20 - NOTE: Before removing the solenoid coils mark the
25 ft-lb) torque. coils for proper alignment.
Figure 20-110-15 Figure 20-110-17
P-48754 1
P-48760
Remove the O-rings (Item 1) and back-up ring (Item 2) Remove the spacer (Item 1) and solenoid valve coils
[Figure 20-110-15] for damage. (Item 2) [Figure 20-110-17].

Figure 20-110-18
1
1
P-48763
2
Remove the O-rings (Item 1) [Figure 20-110-20] and
P-48761 back-up rings.
Figure 20-110-21
Remove the nuts (Item 1) [Figure 20-110-18] from the
solenoid valve stems.

torque.
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the coils (Item 2) [Figure 20-110-18].
Figure 20-110-19
P-48763A
Remove the solenoid valve stem (Item 1) [Figure 20-

110-21].
1
Installation: Tighten the solenoid valve stem to 41 - 47
P-48762
Remove the solenoid valve stem (Item 1) [Figure 20-

110-19].
Installation: Tighten the solenoid valve stem to 27 - 34


Figure 20-110-22
1
1
P-48766
Remove and inspect the orifice (Item 1) [Figure 20-110-

P-48764 24] for dirt and debris.
Installation: Tighten the orifice to 29,8 N•m (22 ft-lb)

Remove the O-rings (Item 1) [Figure 20-110-22] and torque.
back-up rings.
Figure 20-110-25
Figure 20-110-23
1 1
P-48765
P-48765
Remove the plug (Item 1) [Figure 20-110-25].

Installation: Tighten the plug to 13,6 N•m (10 ft-lb)
Installation: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
torque.

REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-26
P-48786
Remove the orifice (Item 1) [Figure 20-110-26].
Installation: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.
Figure 20-110-27
P-48758
Remove the plugs (Item 1) [Figure 20-110-27].
Installation: Tighten the plugs to 19 N•m (14 ft-lb)

torque.

BOB-TACH (POWER) BLOCK (S/N ALM411001 - Removal And Installation
ALM413900)
Description
The Power Bob-Tach is an option that allows the operator

WARNING
to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments. Never work on a machine with the lift arms up unless
The Power Bob-Tach is operated by a switch on the right support device. Failure to use an approved lift arm
switch panel. support device can allow the lift arms or attachment
The Power Bob-Tach block is mounted on the right side W-2059-0598
of the machine in front of the engine on the back side of
the hydraulic pump.
DANGER
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (S/N ALM411001 - Figure 20-120-2
ALM413900) (CONT’D)
1
2 4
IMPORTANT
parts clean. Always use caps and plugs on hoses, 3
3
damage the system.
I-2003-0888 3
P-90969
NOTE: After repairing a machine that required the

Power Bob-Tach valve electrical connectors Mark the hydraulic hoses for proper installation.
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function Disconnect the outlet hose (Item 1) [Figure 20-120-2]
correctly. If the wedges do not function per from block.
the information in the Operation &
Maintenance Manual, the electrical Remove the hydraulic muffler (if equipped) (Item 2)
connectors will have to be switched between [Figure 20-120-2] from block.
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function Disconnect the hoses (Item 3) [Figure 20-120-2] from
correctly. block.
Figure 20-120-1 Remove the four bolts (Item 4) [Figure 20-120-2] from
block.

lb) torque.
1
Remove the Power Bob-Tach block.
P-90968

1.)


Disconnect the two electrical solenoid connectors (Item

1) [Figure 20-120-1] from the loader electrical harness.


2
Figure 20-120-3
1
1
3
P100770
Remove the spring (Item 1) and spool (Item 2) [Figure

20-120-5].
P100820
Remove the O-ring (Item 3) [Figure 20-120-5] on the
plug and replace as needed.
Do not remove the plugs (Item 1) [Figure 20-120-3].
Figure 20-120-6
NOTE: Do not remove the two plugs located next to
the outlet port. A new Power Bob-Tach valve
will be required if tampered with. All other
plugs can be removed.
Figure 20-120-4
1
P100823

P100769 torque.
Clean the block (Item 1) [Figure 20-120-4] to remove dirt

before disassembly. Block ports are labeled for correct
assembly.

torque.

Figure 20-120-7
1
3
1 P100821
2
Remove the orifice (Item 1) [Figure 20-120-9].
P107069 Installation: Tighten the orifice to 8,1 - 10,8 N•m (6 - 8 ft-

lb) torque.
Remove the spool (Item 1), the spring (Item 2) and the Figure 20-120-10
orifice (Item 3) [Figure 20-120-7].
Installation: Clean threads on the orifice and apply

Loctite® 603 before installing the orifice.
Figure 20-120-8
P100774
Remove the solenoid coil nut (Item 1) [Figure 20-120-

10].
P100826 Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-120-8]. NOTE: Mark the solenoid coil orientation for ease of
assembly.
torque.


2 2 2
Figure 20-120-11
1 1 1 1 1
P100776
Remove the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-120-13].
P100773
Figure 20-120-14
Remove the solenoid coils (Item 1) [Figure 20-120-11].
Figure 20-120-12
P100828
Remove the fitting (Item 1) [Figure 20-120-14].

P100827
Remove the solenoid coil stem (Item 1) [Figure 20-120-

12].
Installation: Tighten the solenoid coil stem to 27,14 N•m

(20 ft-lb) torque.

Figure 20-120-15
P100841
1 Remove the filter assembly (Item 1) [Figure 20-120-17].
P100829 Figure 20-120-18
Figure 20-120-16
1
P100842
P100840 Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.

torque.

Figure 20-120-19
2
1
P100839
P100843 Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.
Remove the shuttle seat (Item 1) and check ball (Item 2) Figure 20-120-22
[Figure 20-120-19].
Figure 20-120-20
1
2
1
P100835
P100845 Remove the spring (Item 1) and the check ball (Item 2)
[Figure 20-120-22].
Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.

Figure 20-120-23
1
P100846
P100837 Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.
Figure 20-120-26

torque.
Figure 20-120-24
2
P100847
1
Remove pilot piston (Item 1) [Figure 20-120-26].
P100838
Remove the spring (Item 1) and the check ball (Item 2)

[Figure 20-120-24].

Figure 20-120-27
1 1
1
2
P100849
2
Remove the annular orifice shaft (Item 1) and the annular
orifice shaft guide (Item 2) [Figure 20-120-29].
P100834
Figure 20-120-30
Remove the back-up rings (Item 1) and the O-ring (Item

2) [Figure 20-120-27].
1
Figure 20-120-28
P100850
P100852 Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.

torque.

BOB-TACH (POWER) BLOCK (S/N ALM411001 -
Figure 20-120-31
P100851

torque.
Figure 20-120-32
P100854

Power Bob-Tach valve electrical connectors
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
Maintenance Manual, the electrical
connectors will have to be switched between
inspection to verify the wedges function
correctly.

BOB-TACH (POWER) BLOCK (S/N ALM413901 AND
B3GZ11001 & ABOVE)
Description
The Power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.
The Power Bob-Tach is operated by a switch on the right

switch panel.
The Power Bob-Tach block is mounted on the right side

of the machine in front of the engine on the back side of
the hydraulic pump.

BOB-TACH (POWER) BLOCK (S/N ALM413901 AND Figure 20-121-2
B3GZ11001 & ABOVE) (CONT'D)
Testing Relief Valve
1
WARNING
not use your bare hand. Wear safety goggles. If fluid P106674
W-2072-0807 Disconnect the hose (Item 1) [Figure 20-121-2] from the
cylinder base end port.
Figure 20-121-3
WARNING
explosion or fire. 1
W-2103-0508
The following tools are required for this procedure:

MEL1355 hydraulic test kit.
Figure 20-121-1 P122238
Install the gauge (Item 1) [Figure 20-121-3] between the

hose and cylinder base end port and tighten.
engine.
Push and hold the BOB-TACH “WEDGES DOWN” switch

(Front Accessory Panel).
Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237
Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

121-1].
Push and hold BOB-TACH “WEDGES UP” switch until

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

BOB-TACH (POWER) BLOCK (S/N ALM413901 AND Removal And Installation
Testing Relief Valve (Cont’d)
Figure 20-121-4
WARNING
W-2059-0598
1
2 DANGER
P122229
NOTE: Relief valve removed from block for photo

clarity.
If adjustment is required loosen the jam nut (Item 1) and

P-90328
turn the adjusting screw (Item 2) [Figure 20-121-4]
clockwise to increase pressure or counterclockwise to AVOID DEATH
decrease pressure. • Disconnecting or loosening any hydraulic
Test the relief valve setting after adjustment has been can cause lift arms to drop.
made. • Keep out of this area when lift arms are raised
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

Removal And Installation (Cont'd) 2
NOTE: After repairing a machine that required the 1

connectors will have to be switched between 2 2
correctly.
P122162

1.) Disconnect and cap the hose (Item 1) [Figure 20-121-6]
from block.
support device. (See Installing on Page 10-20-2.) Disconnect and cap the hoses (Item 2) [Figure 20-121-6]
from block.
Figure 20-121-7
Replacing Fluid on Page 10-130-1.)
1 1
Remove the fan duct panels. (See Removal And
Figure 20-121-5
1
1
P122157
Remove the four mounting bolts (Item 1) [Figure 20-121-

7].
Installation: Tighten the mounting bolts to 48 - 54 N•m

P122161 (35 - 40 ft-lb) torque.
Remove the Power Bob-Tach block.

Disconnect the two wire connectors (Item 1) [Figure 20-
121-5] from the solenoid coils.

IMPORTANT 3

1
damage the system. 2
I-2003-0888
4 P122197
Figure 20-121-8
Remove plug (Item 1), spring (Item 2) and spool (Item 3)
[Figure 20-121-9] and inspect. Replace damaged parts
as needed.

torque.
Replace the O-ring (Item 4) [Figure 20-121-9] on the

1
plug.
Figure 20-121-10
1
P122196
Do not remove these plugs (Item 1) [Figure 20-121-8].
NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.
1
P122198
NOTE: Mark the solenoid coil orientation for

installation.
Remove the coil nut (Item 1) [Figure 20-121-10].
Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.


2
Figure 20-121-11
P122201
3
Replace the O-rings (Item 1) and the back-up rings (Item

1 2) [Figure 20-121-13].
P122199
Figure 20-121-14
Remove the first solenoid coil (Item 1), the spacer (Item
2), and the second solenoid coil (Item 3) [Figure 20-121-
11].
Figure 20-121-12
2
1
P122202
Remove the fitting (Item 2) [Figure 20-121-12] and

1 replace the O-ring (Item 1) [Figure 20-121-14].
P122200
Remove the solenoid coil stem (Item 1) [Figure 20-121-

12].
Installation: Tighten the solenoid stem to 27,14 N•m

(20 ft-lb) torque.

Figure 20-121-15
P122206
1
Replace the O-ring (Item 1) and remove the screened
orifice (Item 2) [Figure 20-121-17]. Inspect and replace
P122203 as needed.
Figure 20-121-18
Remove the plug (Item 1) [Figure 20-121-15] and
replace the O-ring.

torque. 1
Figure 20-121-16
P122205

1
torque.
P122205
Installation: Tighten the plug (Item 1) [Figure 20-121-

16] to 17,6 N•m (13 ft-lb) torque.

Figure 20-121-19
2
3 1
P122209
2
Replace the O-ring (Item 1) and remove the orifice insert

1 (Item 2) [Figure 20-121-21]. Inspect and replace as
P122207 needed.
Figure 20-121-22
Remove the O-ring (Item 1), the spring (Item 2), and the
check ball (Item 3) [Figure 20-121-19]. Inspect and
replace as needed.
Figure 20-121-20
1
P122210
Remove the relief valve (Item 1) [Figure 20-121-22].
P122208 Installation: Tighten the relief valve to 20 N•m (15 ft-lb)

torque.

torque.

BOB-TACH (POWER) BLOCK (S/N ALM413901 AND
B3GZ11001 && ABOVE) (CONT'D)
Figure 20-121-23
P122212
Replace the O-rings (Item 1) and the back-up ring (Item

2) [Figure 20-121-23].
Figure 20-121-24
P122213
Replace the O-ring (Item 1) [Figure 20-121-24].

connectors will have to be switched between
correctly.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK For FFI/FI connector block. (See Disassembly And
Assembly (FFI/FI) on Page 20-130-2.)
Description
For FFH/FH connector block. (See Disassembly And
The front auxiliary hydraulic coupler block is the Assembly (FFH/FH) on Page 20-130-4.)
connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers Figure 20-130-3
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm.
There are two different coupler blocks that can be used

on the machine. To determine which coupler block is
used, check the supplier part number on the male
coupler.
1
Figure 20-130-1
1
P115535
If unable to identify the supplier part number on the male

coupler of an internally mounted coupler block, remove
the internally mounted coupler block from the lift arm.
(See Removal And Installation on Page 20-130-2.) The
supplier part number (Item 1) [Figure 20-130-3] is
located on the back of the block.
NOTE: FFI/FI couplers will continue to be available

P115537 but will not install in FFH/FH coupler blocks.
FFH/FH couplers will not install in FFI/FI
coupler blocks.
Figure 20-130-2
P115534A
The supplier part number (Item 1) [Figure 20-130-1] and

[Figure 20-130-2] is located on the male coupler.

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (FFI/FI)
(CONT’D)
Figure 20-130-5
All Models
1
IMPORTANT 2

3
damage the system.
I-2003-0888
P-90003
Figure 20-130-4
Remove the female coupler (Item 1), case drain coupler
(Item 2) and male coupler (Item 3) [Figure 20-130-5].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.
1
Figure 20-130-6
1
1
1
P-85281
Remove the two mounting bolts (Item 1) [Figure 20-130- 1

4].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-4].
P-90002
Remove the fittings (Item 1) [Figure 20-130-6].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-9
(CONT’D)
Disassembly And Assembly (FFI/FI) (Cont’d)

1
Figure 20-130-7
2
2 1
2
2 1
2
1 P-34665

[Figure 20-130-9] from the male coupler.
P-90001
Figure 20-130-10
Remove the springs (Item 1) [Figure 20-130-7].
1
Remove the O-rings (Item 2) [Figure 20-130-7] from the
fittings and coupler body.
Figure 20-130-8
P-34664

[Figure 20-130-10] from the female coupler.
Assembly: Install new O-rings and back-up rings and

P-34701 lightly lubricate with oil before installation.
Press center of male couplers down and inspect the seal

(Item 1) [Figure 20-130-8] for damage and replace as
needed.

(CONT’D)
Disassembly And Assembly (FFH/FH) 1

2
Figure 20-130-11
2 1
1 2
2
1
2
1
P115529B
P-90002 Remove the O-rings (Item 2) [Figure 20-130-13] from the

fittings.
Remove the coupler fittings (Item 1) and the case drain Figure 20-130-14
coupler fitting (Item 2) [Figure 20-130-11].
Installation: Tighten the coupler fittings (Item 1) [Figure

20-130-11] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-12
P115533
3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-14].
P-90003
Remove the female coupler (Item 1), case drain coupler

(Item 2), and male coupler (Item 3) [Figure 20-130-12].
Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.

(CONT’D)
Disassembly And Assembly (FFH/FH) (Cont’d)
Figure 20-130-15
2 3
2
1 1
P115532
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-17] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-15].
Inspect the pintle (Item 1), the case drain coupler (Item
2), and the seal (Item 3) [Figure 20-130-15].
Replace the case drain coupler (Item 2) [Figure 20-130-

15] as an assemble if any part is damaged.
Figure 20-130-16
2
1
P115531
Inspect the O-ring (Item 1) and seal (Item 2) [Figure 20-

130-16] and replace coupler if damaged.

AUTOMATIC RIDE CONTROL
Description
The automatic ride control is an option that provides a

smoother ride, reduced load spillage, and improved
machine control when traveling over uneven ground with
heavy loads or in heavy digging applications.

AUTOMATIC RIDE CONTROL (CONT'D)

WARNING
Open the rear door.
Remove the rear grille and engine cover. (See Removing
on Page 50-60-1.)
explosion or fire.
WARNING W-2103-0508

support device. Failure to use an approved lift arm WARNING
to fall and cause injury or death. RIDE CONTROL ACCUMULATOR INSTALLED
W-2059-0598
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
DANGER circuit before servicing.
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Drain the hydraulic fluid reservoir. (See Removing And

Figure 20-140-1
P-90328
AVOID DEATH
D-1009-0409
IMPORTANT P114272
When repairing hydrostatic and hydraulic systems, Disconnect the harness (Item 1) [Figure 20-140-1] from
clean the work area before disassembly and keep all the bottom of the filter.
tubelines and ports to keep dirt out. Dirt can quickly Remove the two bolts (Item 2) and reposition the fuel
damage the system. filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888

AUTOMATIC RIDE CONTROL (CONT'D) Figure 20-140-4
Figure 20-140-2
1
3
P128096
1
Remove the hose (Item 1) [Figure 20-140-4].
P114645
Figure 20-140-5
Reposition clamp (Item 1), remove nut / bolt (Item 2),

remove the fuel tank vent hose (Item 3) and remove the
two mounting bracket nuts (Item 4) [Figure 20-140-2].
Remove the filler neck assembly and plug the fuel tank
inlet.
Figure 20-140-3
P128339
1
the manifold.
1
P128342
Disconnect the three connectors (Item 1) [Figure 20-

140-3] from the manifold.

Figure 20-140-6
P128335
Remove the two nuts (Item 1) and the accumulator /

manifold assembly (Item 2) [Figure 20-140-6].

Checking The Pressure In The Accumulator
The nitrogen charge in the accumulator will decrease

IMPORTANT
over time. This will result in decreased effectiveness of
the automatic ride control benefits. When repairing hydrostatic and hydraulic systems,
NOTE: The signs of a low accumulator charge parts clean. Always use caps and plugs on hoses,
include: excessive lift arm movement, tubelines and ports to keep dirt out. Dirt can quickly
reduced ride control performance, or loss of damage the system.
I-2003-0888
ride control function.
Remove the automatic ride control assembly. (See

The tools listed will be needed to do the following WARNING

procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020. Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
WARNING W-2103-0508

support device can allow the lift arms or attachment WARNING
W-2059-0598 RIDE CONTROL ACCUMULATOR INSTALLED
DANGER control for 5 seconds to release pressure from lift
circuit before servicing.
W-3015-0816
Figure 20-140-7
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1
D-1009-0409
P128321

accumulator.

Checking The Pressure In The Accumulator (Cont’d)
Figure 20-140-8 1
2
1
P128489
Turn the T-handle (Item 1) [Figure 20-140-10]

P128322 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Loosen the Allen screw (Item 1) [Figure 20-140-8]
approximately 1/4 turn. Pressure in the accumulator should be 915 psi [63 bar].
Figure 20-140-9 Close the valve by turning the T-handle (Item 1) [Figure
20-140-10] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-10].
2 Remove the tool / gauge from the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-8] to 20

N•m (15 ft-lb) torque.
1
P128488
Make sure the manual bleed valve (Item 1) is closed.

Install the tool / gauge (Item 2) [Figure 20-140-9] onto
the accumulator.

Adding Nitrogen To The Accumulator

procedure:
Hydac Adapter Tool Kit Bobcat P/N 7311020.
WARNING
P128322
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present. Loosen the Allen screw (Item 1) [Figure 20-140-12]
• Engine is running. approximately 1/4 turn.
W-2505-0604
Figure 20-140-13
WARNING 1
RIDE CONTROL ACCUMULATOR INSTALLED

control for 5 seconds to release pressure from lift
circuit before servicing.
W-3015-0816
2 P128488
Figure 20-140-11 Install the tool / gauge (Item 1) [Figure 20-140-13] onto
the accumulator.
Make sure the manual bleed valve (Item 2) [Figure 20-

140-13] is closed.
P128321

accumulator.

Adding Nitrogen To The Accumulator (Cont’d)

1
Figure 20-140-14
2
1
P128491
Turn the T-handle (Item 1) [Figure 20-140-16]

P128490 counterclockwise until the gauge begins to move (DO
NOT TURN THE T-HANDLE MORE THAN THREE
TIMES).
Install the hose (Item 1) [Figure 20-140-14] to the tool on
the accumulator. Pressure in the accumulator should be 915 psi [63 bar].
Figure 20-140-15 Slowly open the valve on the nitrogen tank. Close the
valve by turning the T-handle (Item 1) [Figure 20-140-16]
until the accumulator pressure is correct. Close the valve
on the nitrogen tank.
1
Close the valve by turning the T-handle (Item 1) [Figure
20-140-16] clockwise.
Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-16].
Remove the hose from the tank and the accumulator.
Tighten the Allen screw (Item 1) [Figure 20-140-12] to 20

N•m (15 ft-lb) torque.
P128327
Install the other end of the hose / fitting (Item 1) [Figure

20-140-15] to the nitrogen tank.

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removal And Installation (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Removal And Installation (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-22
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-9
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-9
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Sender Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Sender Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-50-4
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-14

HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26
HYDROSTATIC PUMP (SJC) (S/N ALM425401 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . 30-52-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-1
Port Locations And Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-2
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-9
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-10
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52-25
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Tensioner Pulley Removal And Installation 
(Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Removal And Installation 
(Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-5
TWO-SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost do to internal leakage in the components
of the hydrostatic system.

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

(See Service Codes List on Page 60-90-2.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and / or incorrect steering drift compensation setting.

HYDROSTATIC DRIVE MOTOR Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
DANGER
There are two hydrostatic motors mounted to motor
carriers. The motor carriers are mounted to the
transmission which houses the drive chains.
The hydrostatic motors do not have an internal brake.
Inside the end cap of the hydrostatic motor, there is a

shuttle valve. The shuttle valve helps to keep the motor P-90328
cool by mixing case drain fluid with cooled low pressure
fluid from the charge circuit. The shuttle valve is shifted AVOID DEATH
by the high pressure fluid coming from the hydrostatic • Disconnecting or loosening any hydraulic
pumps. If the shuttle valve sticks, a delay or lack of drive tubeline, hose, fitting, component or a part failure
may or may not be felt in the controls and / or an can cause lift arms to drop.
overheated hydrostatic motor will result. • Keep out of this area when lift arms are raised
D-1009-0409
WARNING
W-2059-0598
WARNING
explosion or fire.
W-2103-0508


HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-2
Figure 30-20-1
P106945
Loosen the bolts (Item 1) [Figure 30-20-2] holding the

P106956 lower motor bolt access panel and swing the panel open.
The panel is located under the loader frame directly
below the motor.
Remove the four motor cover bolts (Item 1) [Figure 30-
20-1]. Figure 30-20-3
Installation: Tighten bolts to 20 - 27 N•m (15 - 20 ft-lb)

torque.
IMPORTANT
damage the system.
I-2003-0888
P106946
Remove the lower bolt (Item 1) [Figure 30-20-3] from the

motor.
Installation: Tighten the bolt to 136 N•m (100 ft-lb)

torque.

Figure 30-20-4
2 1
3 1
P129382
Remove the bolt (Item 1) [Figure 30-20-6].

P106968
Installation: Tighten the bolts to 122 - 136 N•m (90 - 100
ft-lb) torque.
the hydrostatic motor. Remove the hydrostatic motor.
Remove the case drain hose (Item 2) [Figure 30-20-4] Figure 30-20-7
from the hydrostatic motor.
NOTE: The hydraulic fittings (Item 3) [Figure 30-20-4]

must be tightened to 156 - 170 N•m (115 - 125 1
ft-lb) torque.
Figure 30-20-5 2
P129384
1
Remove the O-ring (Item 1) and shaft seal (Item 2)
[Figure 30-20-7].
P106965
Installation: Tighten the bolts to 136 N•m (100 ft-lb)

torque.
Remove the motor from the loader.

HYDROSTATIC DRIVE MOTOR (CONT’D)
Ref. Description
1. Shaft
2. Seal
3. O-ring
4. Flange
5. Seal 16
6. Back-up Ring 14
20 3
7. Spring
15
8. Outer Balance Plate 14
19 14
9. Inner Balance Plate 16
10. Ball 3 18
13
11. Geroler® 18
19
12. Valve Plate
13. End Cap 17 3 5
14. Poppet
12
15. Spring
16. Plug
17. Bolt 5
18. Sleeve
19. Spring 11
20. Shuttle Valve
10
5
9
8
7 10
6 3
3
5
4
2
1
PE2620T


1
IMPORTANT
damage the system.
I-2003-0888
P-68211
Drain the fluid from the motor.
Seal all open ports and clean the motor with solvent. Remove the bolts (Item 1) [Figure 30-20-9] from the
motor.
Figure 30-20-8
Figure 30-20-10
3
8
6
5
9
2
1
7
4
P-64267
P-68211
Put a mark across the sections of the motor for correct

assembly [Figure 30-20-8]. Assembly: Tighten the bolts to 61 - 75 N•m (45 - 55 ft-lb)
torque in the order shown. Tighten the bolts to 75 - 88
N•m (55 - 65 ft-lb) torque in the order shown [Figure 30-
20-10].

Disassembly And Assembly (Cont’d)
Figure 30-20-11
3
1
2
4
1
P-63785
Remove the plug (Item 1) spring (Item 2) and poppet

P-64267 (Item 3) that make up the relief valve assembly. Remove
the O-ring (Item 4) [Figure 30-20-13].
Once the bolts have been removed and the motor begins Installation: Tighten the plug to 41 N•m (260 in-lb)
to separate, the drive shaft (Item 1) [Figure 30-20-11] torque.
can be removed.
Figure 30-20-14
Assembly: Install drive shaft before tightening the bolts.
Figure 30-20-12
2
1
3
P-68213
P-68212 Remove the plug (Item 1) and shuttle valve assembly

(Item 2). Remove the O-ring (Item 3) [Figure 30-20-14].
Remove the end cap (Item 1) [Figure 30-20-12] from the Installation: Tighten the plug to 41 N•m (260 in-lb)
motor. torque.

Figure 30-20-15
2
P-64274

P-39897
Remove the Geroler® section as an assembly (Item 2)
[Figure 30-20-17].
Remove the remaining pieces to the shuttle valve
assembly (Item 1) [Figure 30-20-15] from the inside of NOTE: There are two check balls on the backside of
the end cap. the Geroler® section. Do not lose these check
balls (Item 1) [Figure 30-20-18].
Figure 30-20-16
Figure 30-20-18
1
2
1 1
P-39898
P-39901
Remove the O-rings (Item 1) [Figure 30-20-16].

Remove the two check balls (Item 1) [Figure 30-20-18]
Remove the valve plate (Item 2) [Figure 30-20-16]. from the Geroler®.
NOTE: Care should be taken to keep the Geroler®

assembly together. If rollers are removed,
install the rollers in the original bores.

Figure 30-20-19
2 1
3
1
P-64271

P-64268
Figure 30-20-22
Remove the inner balance plate (Item 1) [Figure 30-20-

19]. 1
Remove the outer balance plate (Item 3) [Figure 30-20-

19].
Figure 30-20-20
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-22].
Assembly: If the belleville spring is no longer cone

1 shaped, replace with new.
P-64270
Remove the back-up ring (Item 1) [Figure 30-20-20].
NOTE: One side of the back-up ring is grooved to fit

against the O-ring underneath.

HYDROSTATIC DRIVE MOTOR (CONT’D)
Figure 30-20-23
P-64273
Turn the mounting flange over and remove the seal (Item
1) [Figure 30-20-23].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing drive
loop return fluid with cooled low pressure fluid from the
charge circuit. The shuttle valve is shifted by the high
pressure fluid coming from the hydrostatic pumps. If the
shuttle valve sticks, a delay or lack of drive may or may
not be felt in the controls and / or an overheated
hydrostatic motor will result.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Remove the front and rear wheel / tire assemblies. (See
(CONT'D) Wheel Nuts on Page 10-160-1.)
Removal And Installation (Left Side) Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.) or (See CONTROL PANEL (SJC) on
Page 50-101-1.)
DANGER Remove the linkage on foot control loaders. (See Linkage
Drain the hydraulic reservoir. (See Removal And

Mark all hoses and tubelines before removing for correct

installation.
P-90328 Figure 30-21-1
AVOID DEATH
1
D-1009-0409
WARNING 2
P106956
support device. Failure to use an approved lift arm Remove the motor cover bolts (Item 1) and remove the
support device can allow the lift arms or attachment motor cover (Item 2) [Figure 30-21-1] from the loader.
W-2059-0598 Figure 30-21-2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888

1.) P106945

Loosen the bolts (Item 1) [Figure 30-21-2] and swing the
panel open. The panel is located under the loader frame
directly below the drive motor.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-5
(CONT'D)
Removal And Installation (Left Side) (Cont'd)

1
Figure 30-21-3
P-73664
1
Remove the lower bolt (Item 1) [Figure 30-21-5] from the

motor.
P106959
torque.
Remove the case drain hose (Item 1) [Figure 30-21-3].
Figure 30-21-6
Figure 30-21-4
2
1
P106958
P106957
Remove two bolts (Item 1) [Figure 30-21-6] from the

Remove the hose (Item 1) [Figure 30-21-4] from the motor.
motor.
Remove the shift pressure tubeline (Item 2) [Figure 30- torque.
21-4] from the motor.

(CONT'D)
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-7
P-82716
Figure 30-21-8
CORRECT WRONG
P-73542
Installation: Install the seal (Item 1) [Figure 30-21-8] in

the flange of the motor with the convex surface facing
outward.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Mark all hoses and tubelines before removing for correct
(CONT'D) installation.
Removal And Installation (Right Side) Figure 30-21-9
DANGER
P-90328 2
AVOID DEATH P106956
Remove the motor cover bolts (Item 1) and remove the
motor cover (Item 2) [Figure 30-21-9].
D-1009-0409 lb) torque.
Figure 30-21-10
WARNING
W-2059-0598
1
IMPORTANT P-73665
When repairing hydrostatic and hydraulic systems, Loosen the bolts (Item 1) [Figure 30-21-10] and swing
clean the work area before disassembly and keep all the panel open. The panel is located under the loader
parts clean. Always use caps and plugs on hoses, frame directly below the drive motor.
damage the system.
I-2003-0888

Drain the hydraulic reservoir. (See Removal And


(CONT'D)
Removal And Installation (Right Side) (Cont'd)
Figure 30-21-11
1 1
P106971
Disconnect the case drain tubeline (Item 1) [Figure 30-

P106970
Figure 30-21-14
Remove the shift pressure tubeline (Item 1) [Figure 30-

1
Figure 30-21-12
P-73664
Remove the lower bolt (Item 1) [Figure 30-21-14] from

the motor.
P106969
torque.
Remove the hoses (Item 1) [Figure 30-21-12] from the
motor.

(CONT'D)
Removal And Installation (Right Side) (Cont'd)

1
Figure 30-21-15
CORRECT WRONG
P-73542
Installation: Install the seal (Item 1) [Figure 30-21-17] in

the flange of the motor with the convex surface facing
P-76145 outward.
Remove two bolts (Item 1) [Figure 30-21-15] from the

motor.

torque.
Figure 30-21-16
P-82716

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Ref. Description
1. O-ring
2. Spool Housing 3
3. Plug 7
7 4
4. Bolt
5. Plug 6 5
6. Spool 2
7. Spring
8. Gasket
9. Selector Plate
10. Valve Drive 3
11. Geroler® 8 1
12. Main Drive
13. Mounting Flange
14. Shaft Seal 9
15. Bolt
16. Shuttle Valve Assembly
17. Ball Seat
18. Ball 1
19. Valve Housing
20. Poppet 11
21. Dowel
22. Back-up Ring
23. Inner Balance Ring
24. Outer Balance Ring
25. Valve 1
10
3 13
15
12 3
19
14 3
16 16
3
7
21
22 18
17
23 3
22 7
20
22 1
24 7
3
25
1
MS2315SA

(CONT'D)
Disassembly
Drain the fluid from the motor casing.
Figure 30-21-18
P106490
Figure 30-21-21
P106488
Mark the side of the motor for ease of assembly [Figure 1

30-21-18].
Figure 30-21-19
P106491
1 2
Remove the dowel pin (Item 1) [Figure 30-21-21].
P106489
Remove the bolts (Item 1) and valve housing (Item 2)

[Figure 30-21-19].

(CONT'D)
Disassembly (Cont'd) 1
Figure 30-21-22
1 P106494
Remove the outer balance ring (Item 1) [Figure 30-21-

24] from the valve housing.
P106492
Figure 30-21-25
Remove the inner balance ring (Item 1) [Figure 30-21-

22] from the valve housing.
Figure 30-21-23
1
1 1
P106496
Remove the O-ring and two back-up rings (Item 1)

[Figure 30-21-25] from the outer balance ring.
P106493
Remove four springs (Item 1) [Figure 30-21-23].

(CONT'D)
Disassembly (Cont'd)
Figure 30-21-26
1
1
1
P106498

valve housing.
1 P106497
Figure 30-21-29
Figure 30-21-27
1 P106500
Remove the plug (Item 1) [Figure 30-21-29] from the

P106495 valve housing.
Remove the back-up ring (Item 1) [Figure 30-21-27] from

the valve housing.

(CONT'D)
Figure 30-21-30
P106499
1
valve housing.
P-76394A
Figure 30-21-33
Figure 30-21-31
2
3 P-76394A
1
P106502
Remove the orifice (Item 1). Remove the O-ring (Item 2)

and the ball (Item 3) [Figure 30-21-31].
NOTE: The orifice is threaded into the valve housing.

(CONT'D)
Figure 30-21-34
1
4
3
2 P-76394A
1
P106501 Figure 30-21-37
Remove the spring seat (Item 1), spring (Item 2), spring
seat (Item 3), and shuttle valve (Item 4) [Figure 30-21-
34].
Figure 30-21-35
3
2
1
P106505
1 Remove spring seat (Item 1), spring (Item 2), and spring
seat (Item 3) [Figure 30-21-37].
P106504

(CONT'D)
Figure 30-21-38
P106506
1
P106503 Figure 30-21-41
Figure 30-21-39
P-76394A
1
P-76394A

(CONT'D)
Figure 30-21-42 1
P106509
1
2
Remove the selector plate (Item 1) [Figure 30-21-44].
P106507 Figure 30-21-45

30-21-42].
1
Figure 30-21-43
P106510
Remove the valve drive (Item 1) [Figure 30-21-45].
P106508
Remove the valve (Item 1) [Figure 30-21-43].

(CONT'D)
1
Figure 30-21-46
P106618
2 Remove the plate (Item 1) [Figure 30-21-48].
P106511 Figure 30-21-49
Remove the Geroler® (Item 2) [Figure 30-21-46].

2
Figure 30-21-47
1 1
P106620
Remove the O-ring (Item 1) and back-up ring (Item 2)

[Figure 30-21-49].
P106512
Remove the main drive (Item 1) [Figure 30-21-47].

(CONT'D)
Figure 30-21-50
1
P106622

groove in the seal.
P106621
Figure 30-21-53
Remove the spring washer (Item 1) [Figure 30-21-50].
Figure 30-21-51
P106513
Remove the shaft seal (Item 1) [Figure 30-21-53].

P106619
Remove the seal / O-ring assembly (Item 1) [Figure 30-

21-51].

(CONT'D)
1 1
Figure 30-21-54
1 1
1 P106515
Remove the screws (Item 1) [Figure 30-21-56] from the

selector spool housing.
P106514
Figure 30-21-57
Figure 30-21-55
P106516
1
Remove the gasket (Item 1) [Figure 30-21-57].

P-76394A

plug.

(CONT'D)
Figure 30-21-58
1
P106519
Remove the springs (Item 1) [Figure 30-21-60] from the

spool housing.
P106517
Figure 30-21-61
NOTE: The plug is under spring pressure.
Figure 30-21-59
P-73523
1 Remove the inner spring (Item 1) from the outer spring

(Item 2) [Figure 30-21-61].
P106518

(CONT'D)
Figure 30-21-62
P-76389
P106520 Figure 30-21-65
Remove the spool (Item 1) [Figure 30-21-62] from the

spool housing.
1
Figure 30-21-63
P106523
1
spool housing.
P106522

spool housing.

(CONT'D)
Figure 30-21-66
P-76389

(CONT'D)
Assembly
Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
1
Figure 30-21-67
P-76389
Install the O-ring (Item 1) [Figure 30-21-69] on the plug.
Figure 30-21-70
P-76389
1
Figure 30-21-68
P-73550A
1 Install the plug (Item 1) [Figure 30-21-70] in the spool

housing.
Tighten the plug to 19 - 24 N•m (14 - 18 ft-lb) torque.
P-76438
Install the plug (Item 1) [Figure 30-21-68] in the spool

housing.

(CONT'D)
Assembly (Cont’d)
Figure 30-21-71
P106518
P106520 Figure 30-21-74
Install the spool (Item 1) [Figure 30-21-71] into the spool

housing.
1
Figure 30-21-72
P106517
Install the plug (Item 1) [Figure 30-21-74] with a light

coat of oil.
P106519 Tighten the plug to 45 - 56 N•m (33 - 42 ft-lb) torque.
Install the inner and outer springs (Item 1) [Figure 30-21-

72] on the spool shaft.

(CONT'D)
Assembly (Cont'd)
Figure 30-21-75
Apply Loctite® 262 Here

1 1
1
1
P106516
1 1 1 Install the gasket (Item 1) [Figure 30-21-76] on the

selector plate.
P-73775
Figure 30-21-77
Use the correct size tap to clean any remaining thread 1 1

lock from the threaded holes (Item 1) [Figure 30-21-75].
Put a VERY SMALL amount of Loctite® 262 into each of

the threaded holes of the selector plate. DO NOT put
Loctite® on the screw threads.
NOTE: If too much Loctite® is applied and any

trapped air is not removed, it can pool in the
bottom of the threaded holes. This can 1
1
prevent the screws from reaching full thread
contact and the correct torque may not be
reached.
P106515
Wipe any excess Loctite® from the selector plate surface.
NOTE: Installing the screws can force some of the Install the screws (Item 1) [Figure 30-21-77].
Loctite® out of the holes and onto the selector
plate surface. If any Loctite® gets between the
new gasket and the selector plate it will create
a poor seal. Be sure to wipe excess Loctite®
from the surface.

(CONT'D)
Assembly (Cont'd)
Figure 30-21-78
10 4 1 6 7
1
1
P106514
9 5 2 3 8
Install the plug (Item 1) [Figure 30-21-80].
MS2316S Figure 30-21-81
Tighten the screws to 8 - 9 N•m (70 - 80 in-lb) torque

using the sequence shown [Figure 30-21-78].
Allow the Loctite® to cure for 6 hours after assembly.

1
Figure 30-21-79
P106622
Install the O-ring (Item 1) [Figure 30-21-81] in the seal

1 groove.
P-76394A

(CONT'D)
Assembly (Cont'd)
Figure 30-21-82
2
P106620
Install the O-ring (Item 1) and back-up ring (Item 2)

[Figure 30-21-84].
P106619
Figure 30-21-85
Install the seal / O-ring assembly (Item 1) [Figure 30-21-

82].
Figure 30-21-83
P106618
Install the plate (Item 1) [Figure 30-21-85].
P106621
Install the spring washer (Item 1) [Figure 30-21-83].

(CONT'D)
Assembly (Cont'd)
Figure 30-21-86 1
1 2
P106510
Install the valve drive (Item 1) and O-ring (Item 2) [Figure

30-21-88].
P106512
Install the main drive (Item 1) [Figure 30-21-86].
Figure 30-21-87
2 1
P106540
Install the Geroler® assembly (Item 1) with the groove

(Item 2) in the ring and star facing up. Align the holes
(Item 3) [Figure 30-21-87].

(CONT'D)
Assembly (Cont'd)
1
Motor Timing
Figure 30-21-89
3 2
P-73545
Install the valve (Item 1) [Figure 30-21-91] on the valve

1 2 drive. The round holes and four grooves must be facing
up.
P-73544 Align any one of the four grooves (Item 2) in the valve
with the marked tooth on the valve drive (Item 3) [Figure
Locate a tooth (Item 1) [Figure 30-21-89] that lines up 30-21-91].
with a star tip.
Rotate the valve clockwise until the spline teeth engage
Mark the spline (Item 2) in the Geroler® star that is 11.25 in the valve.
degrees counterclockwise. Mark the corresponding tooth
(Item 3) on the small end of the valve drive that aligns
with the spline mark (Item 2) [Figure 30-21-89].
Figure 30-21-90
P-73527
Install the selector plate (Item 1) with the slotted holes

facing up. Align the case drain holes (Item 2) [Figure 30-
21-90].

(CONT'D)
Assembly (Cont’d)
Figure 30-21-92
P-76394A
1
P-76389 Figure 30-21-95
Figure 30-21-93
P106507
1
Install the poppet (Item 1) and spring (Item 2) [Figure 30-
21-95].
P106503

(CONT'D)
Assembly (Cont’d)
Figure 30-21-96
P-76394A
1
P106506 Figure 30-21-99
Figure 30-21-97
P106504
1
2
3
P106505
Install the spring seat (Item 1), spring (Item 2) and spring
seat (Item 3) [Figure 30-21-97].

(CONT'D)
Assembly (Cont’d)
Figure 30-21-100
1 1
2
3 P106499
4
P106501 Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque.
Figure 30-21-103
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3) and spring seat (Item 4) [Figure 30-21-100].
Figure 30-21-101
2 1
P106502
1
Install the O-ring (Item 1) on the orifice. Install the ball

P-76394A (Item 2) and orifice (Item 3) [Figure 30-21-103].

(CONT'D)
Assembly (Cont’d)
Figure 30-21-104
1 1
P106495
Install the back-up ring (Item 1) [Figure 30-21-106] on

the valve housing.
P106500
Figure 30-21-107
Tighten the plug to 37 - 45 N•m (27 - 33 ft-lb) torque. 1
Figure 30-21-105
1
P106497
1 Install the compression springs (Item 1) [Figure 30-21-

107].
P106498
Install the O-ring (Item 1) [Figure 30-21-105] on the

valve housing.

(CONT'D)
Assembly (Cont’d)
Figure 30-21-108
1 1
P106493
1
Install the compression springs (Item 1) [Figure 30-21-

110].
P106496
Figure 30-21-111
Install the O-ring and two back-up rings (Item 1) [Figure

30-21-108] on the outer balance ring.
Figure 30-21-109
P106492
Install the inner balance ring (Item 1) [Figure 30-21-111]

in the valve housing.
P106494
Install the outer balance ring (Item 1) [Figure 30-21-109]

in the valve housing.

(CONT'D)
2
Figure 30-21-112
P106489
Install the valve housing (Item 1) [Figure 30-21-114],

taking care to maintain correct alignment.
P106491
NOTE: When installing the valve housing the balance
rings and springs must remain in position.
Install the dowel pin (Item 1) [Figure 30-21-112].
Install the bolts (Item 2) [Figure 30-21-114].
Figure 30-21-113
Figure 30-21-115
5 8
1 2 3
7 6
4 9
P106490
1 MS2317S

Initially tighten the bolts to 68 - 95 N•m (50 - 70 ft-lb)
torque in the sequence shown [Figure 30-21-115].
Finally tighten the bolts to 149 N•m (110 ft-lb) torque in

the sequence shown [Figure 30-21-115].

(CONT'D)
Assembly (Cont'd)
Figure 30-21-116
P106544
Turn the motor over and install the shaft seal (Item 1)
[Figure 30-21-116].
Figure 30-21-117
2 3
1
P106545
Lay the motor flat. Pour clean hydraulic fluid in the ports.
Rotate the shaft (Item 1) clockwise. There must be
suction at the B port (Item 2) and pressure at the A port
(Item 3) [Figure 30-21-117].

HYDROSTATIC MOTOR CARRIER
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chaincase fluid from the hydrostatic motor case drain
fluid.
A brake disc is installed on each hydrostatic motor

carrier. The brake disc is mounted to the shaft in the
motor carrier.
The hydrostatic motor carriers are made to fit on both the

right or left hand side of the loader. There are two sets of
mounting holes on each hydrostatic motor carrier to
fasten the hydrostatic motors. One set for the left hand
side and another set for the right hand side of the loader.

HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-30-2
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC

DRIVE MOTOR on Page 30-20-1.) or (See
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) on Page
30-21-1.)
WARNING P-82715
AVOID INJURY OR DEATH Use a slide hammer to remove the seal from the motor
Wear safety glasses to prevent eye injury when any carrier shaft [Figure 30-30-2].
• When fluids are under pressure. Figure 30-30-3
W-2019-0907
1
Figure 30-30-1
P-82713
Install a new seal (Item 1) [Figure 30-30-3] over the

shaft.
P-82711
Drill a 3 mm (0.125 in) hole in the motor carrier seal

[Figure 30-30-1].

HYDROSTATIC MOTOR CARRIER (CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-30-4
P-82714
Install MEL1420 Carrier Seal Tool (Item 1) [Figure 30-

30-4] over the carrier seal.
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft.
Figure 30-30-5
1 2
P-82716
NOTE: Before installing the hydrostatic motor,

inspect the plug (Item 2) [Figure 30-30-5]
located in the center of the carrier shaft. If the
plug is loose, case drain fluid from the
hydrostatic motor can leak into the chaincase.

WARNING
1
W-2059-0598
P-54227
Raise the loader lift arms and install an approved lift arm
Remove the parking brake disc (Item 1) [Figure 30-30-
Lift and block the loader. (See Procedure on Page 10-10- 6]. (See BRAKE on Page 40-10-1.)
1.)
Raise the loader operator cab. (See Raising on Page 10- inside of the chaincase.
30-2.)
Installation: Tighten the bolts to 170 - 190 N•m (125 -
Drain the fluid from the chaincase. (See Removing And 140 ft-lb) torque.
Replacing Fluid on Page 10-130-1.)
Figure 30-30-7
Remove the engine speed control. (See Removal And
1
Remove the control panel. (See Removal And Installation
on Page 50-100-2.) or (See Removal And Installation on
Page 50-101-1.)
2
Remove the lift arm bypass control valve. (See Removal
And Installation on Page 20-50-2.)
Remove the traction lock assembly. (See TRACTION

LOCK on Page 60-120-1.)
Remove the center chaincase cover. (See Center Cover

Removal And Installation on Page 40-30-2.) P-54226
Remove the front chaincase cover. (See Front Cover

Removal And Installation on Page 40-30-1.) Fasten the front drive chain to the chaincase as shown
(Item 1) [Figure 30-30-7].
Remove the front axle and sprocket. (See Axle, Sprocket
And Bearings Removal And Installation on Page 40-20- Tip the end of the sprocket toward the rear of the loader
4.) and remove the rear drive chain (Item 2) [Figure 30-30-
7] from the sprocket.
DRIVE MOTOR on Page 30-20-1.)

Figure 30-30-8
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

30-8].
Installation: Clean and dry the motor carrier sealing

surface and transmission sealing face. Apply
polyurethane sealant to both surfaces.
Figure 30-30-9
P-39813
Fasten a chain hoist to the motor carrier and remove the

carrier from the loader [Figure 30-30-9].

Ref. Description
1. Shaft
2. Plug
3. Bearing
4. Race
5. Housing
6. Snap Ring
7. Seal
2 3
4 5
6
7
NA6549S

Disassembly
Figure 30-30-10
76,2 mm O.D. Diameter

(3.00 in)
64,26 mm I.D. Diameter

(2.530 in)
177,8 mm
Length
(7.000 in) P-39816
Put the motor carrier in the hydraulic press as shown and

MC-2102 press the sprocket shaft out of the motor carrier housing
[Figure 30-30-12].
It is necessary to fabricate a press tool for this procedure. Figure 30-30-13

Refer to [Figure 30-30-10] for the correct dimensions of
the tool needed.
Remove the shaft seal. (See Shaft Seal Removal And

Figure 30-30-11 2
1
P-4365
Remove the housing from the press and install a bearing

1 puller (Item 1) [Figure 30-30-13] on the sprocket shaft.
Put the assembly in the hydraulic press and remove the

P-82709 bearing (Item 2) [Figure 30-30-13] from the shaft.
Remove the snap ring (Item 1) [Figure 30-30-11] from

the motor carrier shaft.

Disassembly
Figure 30-30-14
P-39817
Remove the inner bearing race (Item 1) from the carrier

housing (Item 2) [Figure 30-30-14].
Figure 30-30-15
P-39818
Put the motor carrier housing in the hydraulic press as

shown [Figure 30-30-15].
Press the outer bearing race from the housing.

Assembly

Inspect all part for wear or damage. Replace all worn or
damaged parts.
Figure 30-30-16
P-39819
Turn the motor carrier housing over as shown [Figure 30-

30-17].
Press the outer bearing race into the motor carrier

housing [Figure 30-30-17].
P-39820
Press the bearing race in until it is fully seated in the
carrier housing.
Put the motor carrier housing in the press as shown
[Figure 30-30-16].
Press the inner bearing race into the motor carrier


carrier housing.

Assembly (Cont’d)
Figure 30-30-18
2 2
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-30-19]
over the shaft as shown.
Use the fabricated press tool (Item 1) and a plate (Item 2)
to install the new inner bearing (Item 3) [Figure 30-30- Put the outer bearing over the end of the shaft and press
18] on the shaft as shown. the bearing on with the press tool (Item 2) [Figure 30-30-
19].

Assembly (Cont’d)
Figure 30-30-20
P-4375
1
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-30-
P-82708 22] and install the shaft seal.
Figure 30-30-23
Install the snap ring (Item 1) [Figure 30-30-20].
Press the snap ring on until it snaps into the groove on

the shaft.
Figure 30-30-21
P-39821
1 Use a rubber mallet [Figure 30-30-23] and tap down on

the shaft.
P-82707
Install the seal (Item 1) [Figure 30-30-21] on the

sprocket shaft.

Assembly (Cont’d)
Figure 30-30-24
N-15087
Install a dial indicator as shown [Figure 30-30-24].
Use a pry bar (Item 1) [Figure 30-30-24] to lift the shaft

and measure the end play on the dial indicator.
The shaft must turn freely with end play not to exceed
0,17 mm (0.007 in).

HYDROSTATIC MOTOR CARRIER (TWO-SPEED) Figure 30-31-1
Description
Single Speed Two-Speed

The hydrostatic motor carrier is the mating connection
from the hydrostatic drive motor to the transmission case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chaincase fluid from the hydrostatic motor case drain
fluid.
1 1
A brake disc is installed on each hydrostatic motor P-73920
P-68214
carrier. The brake disc is mounted to the shaft in the
motor carrier.
Figure 30-31-2
The hydrostatic motor carriers are made to fit on both the
right or left hand side of the loader. There are two sets of Single / Two-Speed
mounting holes on each hydrostatic motor carrier to
fasten the hydrostatic motors. One set for the left hand
side and another set for the right hand side of the loader.
1
P-82710
The motor carrier hydrostatic motor mounting holes (Item

1) [Figure 30-31-1] and [Figure 30-31-2] are the only
difference between the single, two-speed and single /
two-speed motor carriers with SJC controls. The
disassembly and assembly procedures are the same.
The single / two-speed motor carrier has a notch (Item 2)

[Figure 30-31-2] removed from one side of the carrier.

(CONT’D)
Shaft Seal Removal And Installation
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool

30-21-1.)
WARNING P-82711
Drill a 3 mm (0.125 in) hole in the motor carrier seal

[Figure 30-31-4].
Figure 30-31-5
• When fluids are under pressure.
W-2019-0907
Figure 30-31-3
P-82715
1 Use a slide hammer to remove the seal from the motor

carrier shaft [Figure 30-31-5].
P-82710
The motor carrier seal (Item 1) [Figure 30-31-3] is

located on the outside of the motor carrier shaft.

(CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-31-6
1 2
P-82716
P-82713 NOTE: Before installing the hydrostatic motor,

inspect the plug (Item 2) [Figure 30-31-8]
located in the center of the carrier shaft for
Installation: Install a new seal over the motor carrier correct torque. If the plug becomes loosen,
shaft [Figure 30-31-6]. case drain lubrication fluid from the
hydrostatic motor can leak into the chaincase.
Figure 30-31-7
P-82714
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-31-7].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-31-7].

(CONT’D)
WARNING 2

support device can allow the lift arms or attachment 1
W-2059-0598
P-39781
support device. (See Installing on Page 10-20-2.) Remove the parking brake disc (Item 1) [Figure 30-31-
9]. (See BRAKE on Page 40-10-1.)
1.) Remove the six motor carrier mounting bolts (Item 2)
[Figure 30-31-9] from the inside of the chaincase.
Raise the loader operator cab. (See Raising on Page 10-
30-2.) Installation: Tighten the motor carrier mounting bolts to
170 - 190 N•m (125 - 140 ft-lb) torque.
Drain the fluid from the chaincase. (See Removing And
Replacing Fluid on Page 10-130-1.) Figure 30-31-10
Remove the engine speed control. (See Removal And

Installation on Page 70-20-1.) 1

on Page 50-100-2.)
2
Remove the lift arm bypass control valve. (See Removal
Remove the traction lock assembly. (See TRACTION


Removal And Installation on Page 40-30-2.) P-54226

Removal And Installation on Page 40-30-1.) For ease of removal, fasten the front drive chain
(previously removed) to the chaincase as shown (Item 1)
Remove the front axle and sprocket. (See Axle, Sprocket [Figure 30-31-10].
And Bearings Removal And Installation on Page 40-20-
4.) Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-31-
Remove the hydrostatic motor. (See HYDROSTATIC 10] from the sprocket.
30-21-1.)

HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
(CONT’D)
Figure 30-31-11
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

31-11].
Installation: The motor carrier sealing surface and

transmission sealing surface must be clean and dry.
Apply polyurethane sealant to both surfaces.
Figure 30-31-12
P-39813
Fasten a chain hoist to the bolt (Item 1) on the motor

carrier and remove the carrier from the loader [Figure
30-31-12].

HYDROSTATIC MOTOR CARRIER (TWO-SPEED) (CONT’D)
Ref. Description
1. Shaft
2. Plug
3. Bearing
4. Race
5. Housing
6. Snap Ring
7. Seal
2 3
5
4
6
7
NA6550S

(CONT’D)
Disassembly
Figure 30-31-13
76,2 mm O.D. Diameter

(3.000 in)
64,26 mm I.D. Diameter

(2.530 in)
177,8 mm
Length
P-39816
(7.000 in)
Put the motor carrier in the hydraulic press as shown

[Figure 30-31-15].
MC-2102
Use 57,2 mm (2-1/4 in) driver tool and press the shaft out
of the housing [Figure 30-31-15].
It is necessary to locate or fabricate a press tool for this
procedure [Figure 30-31-13]. NOTE: The outer bearing will now be free from the
shaft.
Figure 30-31-14
Figure 30-31-16
2
1
P-82709
P-4365
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-31-16] on the shaft.
Remove the motor carrier shaft seal. (See Shaft Seal
Removal And Installation on Page 30-31-2.). Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-31-14] from 31-16] from the shaft.
the motor carrier shaft using the snap ring pliers.
NOTE: The sensor disc (Item 2) [Figure 30-31-16] has
been removed on late model machines and
can be eliminated on older machines that
have been upgraded to allow the removal of
the speed sensors.

(CONT’D)
Figure 30-31-17
P-39817
Fasten the housing to the work surface with the inner

bearing race (Item 1) [Figure 30-31-17] facing up.
Install the slide hammer with puller end (Item 2) [Figure

30-31-17] on the bottom side of the bearing race.
Remove the bearing race from the carrier housing

[Figure 30-31-17].
Figure 30-31-18
P-39818
Put the housing in the hydraulic press as shown [Figure

30-31-18].
Use a 98,4 mm (3-7/8 in) driver tool and press the outer
bearing race from the housing.

(CONT’D)
Assembly

Inspect all parts for wear and damage. Replace any worn
or damaged parts.
Figure 30-31-19
P-39819
Turn the motor carrier housing over as shown [Figure 30-

31-20].
Use 109,5 mm (4-5/16 in) driver tool and press the new
outer bearing race into the motor carrier housing [Figure
30-31-20].
P-39820
carrier housing.
Put the motor carrier housing in the press as shown
[Figure 30-31-19].
Use 109,5 mm (4-5/16 in) driver tool and press the new
inner bearing race into the motor carrier housing [Figure
30-31-19].

carrier housing.

(CONT’D)
Assembly (Cont’d)
Figure 30-31-21
P-4371
Put the motor carrier housing (Item 1) [Figure 30-31-22]

over the shaft as shown.
Put the outer bearing over the end of the shaft and press
the bearing on with the press tool and driver tool [Figure
30-31-22].
P-4366
Remove the press and driver tools from the sprocket

shaft.
Use the fabricated press tool (Item 1) and 76,2 mm (3.0
in) driver tool to install the inner bearing (Item 2) [Figure
30-31-21] on the shaft as shown.
Remove the press and drive tools from the shaft.

(CONT’D)
Assembly (Cont’d)
Figure 30-31-23
P-82708
Put the snap ring (Item 1) [Figure 30-31-23] over the end P-4375
of the sprocket shaft.

Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-31-
NOTE: Use the snap ring pliers to spread the snap 25] and install the shaft seal.
ring so it will fit over the sprocket shaft.
Figure 30-31-26
Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-31-23] over the shaft.
Press the snap ring on until it snaps into the groove on

the shaft.
Figure 30-31-24
P-76463
1 Use a rubber mallet [Figure 30-31-26], tap down on the

shaft.
P-82707
Put the shaft seal (Item 1) [Figure 30-31-24] on the

shaft.

(CONT’D)
Assembly (Cont’d)
Figure 30-31-27
P-76467
Install a dial indicator as shown [Figure 30-31-27].
Use a pry bar (Item 1) [Figure 30-31-27] to lift the shaft

and measure the end play on the dial indicator.
The shaft must turn freely with end play not to exceed
0,17 mm (0.007 in).

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

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
hydraulic control valve.
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre-
programmed into the main controller and are based on
loader type and options installed.

CHARGE PRESSURE (CONT’D)
Testing
WARNING
WARNING Hydraulic fluid escaping under pressure can have
Never work on a machine with the lift arms up unless and possible death if proper medical treatment by a
the lift arms are secured by an approved lift arm physician familiar with this injury is not received
support device. Failure to use an approved lift arm immediately.
support device can allow the lift arms or attachment W-2145-0290
W-2059-0598 Figure 30-40-2

procedure: 1
MEL1355-2 - Pressure gauge 6895 kPa (68,9 bar) 

(1000 psi)
MEL1723 - Female Test Coupler
7246786 - Female Test Coupler

Hydraulic hose, approximately 1,5 m (5.0 ft), purchased
locally. Must be rated for pressures above 6895 kPa (68,9 3
bar) (1000 psi). 2 3
Figure 30-40-1
P-43196D
Assemble the gauge (Item 1), hose (Item 2) and the

1 3 correct test coupler (Item 3) [Figure 30-40-2]. Tighten all
fittings.
2
4
WARNING
P121789 support device. Failure to use an approved lift arm
Test ports have changed on the Main valve. If your test W-2059-0598
port looks like (Item 2) use test coupler (Item 1). If your
test port looks like (Item 4) use test coupler (Item 3) Raise the loader lift arms and install an approved lift arm
[Figure 30-40-1]. support device. (See Installing on Page 10-20-2.)

CHARGE PRESSURE (CONT’D) Figure 30-40-5
Testing (Cont’d)
Figure 30-40-3
1 1
P106778

P109149B TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)
Figure 30-40-4
Start the loader and warm the hydraulic fluid to 60°C
(140°F).
Record the pressure on the gauge (Item 1) [Figure 30-

40-5].
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is
2620 - 3310 kPa (26,2 - 33,1 bar) (380 - 480 psi) with the
1 pump in neutral.
On SJC equipped loaders the charge pressure at high

idle, with the fluid temperature of 60°C (140°F) is 2516 -
3206 kPa (25,1 - 32,0 bar) (365 - 465 psi) with the pump
P107933 in neutral.
Connect the test coupler (Item 1) [Figure 30-40-4] to the

test port (Item 1) [Figure 30-40-3].

CHARGE PRESSURE (CONT’D) Figure 30-40-7
Adjusting
Non SJC Machines
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
N-19568
I-2003-0888
Figure 30-40-6 There are several different thickness of the shims (Item 1)
[Figure 30-40-7] used to adjust the charge pressure.
1 NOTE: 0,254 mm (0.010 in) shim is approximately
55.1 kPa (0,6 bar) (8 psi) increase in pressure.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure is 2620 - 3310 kPa (26,2 - 33,1 bar)

(380 - 480 psi).
P-43856
If the charge pressure is not correct remove the charge

relief valve plug (Item 1) [Figure 30-40-6].
NOTE: The pump is shown removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Installation: Tighten the plug to 41 - 68 N•m (30 - 50 ft-

lb) torque.
Inspect the poppet, spring and poppet seat for wear or

damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.

CHARGE PRESSURE (CONT’D) Inspect the poppet and spring for wear or damage.
Adjusting (Cont’d) Inspect the seat inside the hydrostatic pump case for
wear or damage.
SJC Machines
Figure 30-40-9
IMPORTANT
damage the system.
I-2003-0888 1
Figure 30-40-8
P-64435
There are several different thickness of shims (Item 1)

[Figure 30-40-9] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim is approximately 20,7 kPa (3,0

bar) (43.5 psi) increase in pressure. Adding
shims increases charge pressure. Removing
shims decreases charge pressure.
The charge pressure is 2516 - 3206 kPa (25,1 - 32,0 bar)

(365 - 465 psi).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-8].
NOTE: The pump is shown removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Installation: Tighten the plug to 41 - 68 N•m (30 - 50 ft-

lb) torque.

CHARGE PRESSURE (CONT’D) Sender Removal And Installation (Later Models)
Sender Removal And Installation (Earlier Models) Figure 30-40-12
Remove the fan duct. (See Fan Duct Removal And

Figure 30-40-10
2
1
P115656
1
Disconnect the wiring harness (Item 1) and remove the

hydraulic charge pressure sender (Item 2) [Figure 30-40-
P106779 12].

from the sender.
Figure 30-40-11
P106780
Remove the sender (Item 1) [Figure 30-40-11] from the

motor.
Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.

HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the fluid cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT’D) Figure 30-50-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-14.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-50-2] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-50-1 Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-3
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-50-1] on the P-90223

hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two bolts (Item 1) [Figure 30-50-3] and nuts.
ft-lb) torque.
Installation: Tighten the bolts and nuts to 88 - 95 N•m
(65 - 70 ft-lb) torque.

HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Startup on Page 20-60-10.)
Remove the hydrostatic pump from the mounting bracket
and drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-50-3.)

Replenishing / High Pressure Relief Valve Removal

And Installation 1
Figure 30-50-4
1
2
P-66670
Remove the high pressure relief valve (Item 1) [Figure

30-50-4] and [Figure 30-50-5] from the pump.
P-43857
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)
torque.
There are four replenishing / high pressure relief valves
(Item 1) [Figure 30-50-4] in the hydrostatic pump Inspect for damage and replace as needed.
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function. Inspect the O-ring (Item 2) [Figure 30-50-5] for damage
and replace as needed.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the If the high pressure relief valve must be replaced, it must
forward drive loop. be replaced as a complete unit.
The pressure setting for a new high pressure relief valve

is 35000 kPa (350 bar) (5075 psi).

HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)

Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Thrust Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block
19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
8
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

Parts Identification (Right Half)

Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Thrust Plate
16. Swash Plate
17. Housing 10
18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

Disassembly
NOTE: The disassembly procedure is shown on the

left half of the hydrostatic pump. The 3
procedure is the same for the right half of the
hydrostatic pump.
Figure 30-50-6
2 3
1
N-19571
1
Remove the pump coupler (Item 1) [Figure 30-50-8].
Remove the two O-rings (Item 3) [Figure 30-50-8].

1
P-43858 Figure 30-50-9
Remove the four bolts (Item 1) [Figure 30-50-6]. 1 1
Figure 30-50-7
N-19550
Remove the four bolts (Item 1) [Figure 30-50-9] from the

pump housing end cap.
N-19570
Separate the two hydrostatic pumps [Figure 30-50-7].

2
1
Figure 30-50-10
N-17194
2
Remove the valve plate locating pin (Item 1) [Figure 30-
N-19551 50-12].
Remove the needle bearing (Item 2) [Figure 30-50-12].

Remove the end cap (Item 1) [Figure 30-50-10].
Figure 30-50-13
Remove the gasket (Item 2) [Figure 30-50-10].
Figure 30-50-11
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-50-13]

from the pump.
Remove the valve plate (Item 1) [Figure 30-50-11].

2 2
Figure 30-50-14
1
2 1
2
2
N-17200
Remove the washer (Item 1) [Figure 30-50-16].

N-17198
Remove the four pins (Item 2) [Figure 30-50-16] from the
cylinder block.
Remove the piston retainer (Item 1) and pistons [Figure
30-50-14] from the cylinder block. Figure 30-50-17
Remove the pistons (Item 2) [Figure 30-50-14] from the

retainer.
Figure 30-50-15
1 1
N-17201
Remove the thrust plate (Item 1) [Figure 30-50-17] from

the pump housing.
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-50-

15] from the cylinder block.

Figure 30-50-18
1
1
2
N-17240
3
N-17481 the pump housing. Remove the drive shaft and bearing
from the housing.
Turn the pump over and remove the drive shaft key (Item Figure 30-50-21
1), snap ring (Item 2), and the washer (Item 3) [Figure
30-50-18].
Figure 30-50-19
N-17241

N-17239 the drive shaft. Remove the bearing.
Remove the seal (Item 1) [Figure 30-50-19] from the

pump housing.

Figure 30-50-22
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-50-24] from the pump housing.
Figure 30-50-25
Remove the snap ring (Item 1) [Figure 30-50-22].
Figure 30-50-23
1
1
1 1 N-17246
N-17243 Remove the bolts (Item 1) from the pump housing.

Remove the linkage bracket (Item 2) [Figure 30-50-25].

trunnion cover. Remove the cover.

Figure 30-50-26
1 N-17248
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17247 [Figure 30-50-28] from the pump housing.
Figure 30-50-29
Remove the trunnion cover (Item 1) [Figure 30-50-26].
Figure 30-50-27
1
N-17251
N-17250 Remove the bearing (Item 1) [Figure 30-50-29].
Remove the seal (Item 1) [Figure 30-50-27].

Figure 30-50-30
N-17252
Tilt the swash plate (Item 1) [Figure 30-50-30] and

remove the swash plate and bearing from the pump
housing.
Figure 30-50-31
N-17253
Remove the bearing (Item 1) [Figure 30-50-31] from the

swash plate.

Assembly

Inspect all parts for wear or damage. Replace any worn
or damaged parts.
Figure 30-50-32 1
N-17249
Install the bearing (Item 1) [Figure 30-50-34] on the

swash plate shaft.
Figure 30-50-35
N-17253
Install the bearing (Item 1) [Figure 30-50-32] on the

swash plate.
Figure 30-50-33
2
N-17248
Install the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-35].
N-17252
Install the swash plate and bearing into the pump


Assembly (Cont’d)
Figure 30-50-36
2 2
1 N-17246
Install the linkage bracket (Item 1) and the bolts (Item 2)

N-17250 [Figure 30-50-38]. Tighten to 24 - 30 N•m (18 - 22 ft-lb)
torque.
Install the seal (Item 1) [Figure 30-50-36] in the trunnion Figure 30-50-39
cover.
Figure 30-50-37
1
N-17244
N-17247 Install the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-39].
Install the trunnion cover (Item 1) [Figure 30-50-37].

Assembly (Cont’d)
Figure 30-50-40
N-17241
1 Install the bearing and snap ring (Item 1) [Figure 30-50-

1
N-17243 42] on the shaft.
Figure 30-50-43
Align the marks on the trunnion cover and pump housing.
Install the bolts (Item 1) [Figure 30-50-40] and tighten to
24 - 30 N•m (18 - 22 ft-lb) torque.
Figure 30-50-41
1
1
N-17240
Install the shaft into the pump housing. Install the snap
ring (Item 1) [Figure 30-50-43].
N-17242
Install the snap ring (Item 1) [Figure 30-50-41] on the

shaft.

Assembly (Cont’d)
1
1
Figure 30-50-44
1
1 3
1 2
N-17200
Install the four pins (Item 1) [Figure 30-50-46] into the

N-17239 cylinder block.
Install the washer (Item 2) into the retainer (Item 3)

Install the seal (Item 1) [Figure 30-50-44] into the pump [Figure 30-50-46].
housing.
Figure 30-50-47
Figure 30-50-45
1
3
2
1
N-17199
N-17481
Install the ball guide and washer (Item 1) [Figure 30-50-

Install the washer (Item 1), snap ring (Item 2) and the 47] onto the pins.
drive shaft key (Item 3) [Figure 30-50-45].

Assembly (Cont’d)
1
2
Figure 30-50-48
N-17194
1 Install the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-50-50].
Figure 30-50-51
Install the pistons (Item 1) into the piston retainer. Install
the piston / piston retainer (Item 2) [Figure 30-50-48] into
the cylinder bores.
Figure 30-50-49
2
1
N-17196
The bearing cage (Item 1) [Figure 30-50-51] must

protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
N-17197 surface of the end cap.
The valve plate locating spring pin (Item 2) [Figure 30-

Install the cylinder block (Item 1) [Figure 30-50-49] and 50-51] must protrude from 4,19 - 4,70 mm (0.165 - 0.185
piston assembly over the shaft and into the housing. in) from the surface of the end cap.

Assembly (Cont’d)
1 1
Figure 30-50-52
1
2
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-50-54] to 47 - 61
Coat the backside of the valve plate with assembly lube. Figure 30-50-55
Install the valve plate (Item 1) [Figure 30-50-52] onto the
end cap.
The notch (Item 2) [Figure 30-50-52] on the valve plate

must engage the locating pin.
Figure 30-50-53 1
1
1
N-19571
1
Install the O-rings (Item 1) [Figure 30-50-55].
Install the pump coupler (Item 2) [Figure 30-50-55].
N-19551
Install the gasket (Item 1) [Figure 30-50-53] on the end

cap.

Assembly (Cont’d)
Figure 30-50-56
N-19570
Align the pump coupler (Item 1) with the shaft (Item 2)

[Figure 30-50-56] and install the left pump on the right
pump.
Figure 30-50-57
1
P-43858
Install the four bolts (Item 1) [Figure 30-50-57]. Tighten

to 47 - 61 N•m (35 - 45 ft-lb) torque.

HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The end caps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1
P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-51-3] from both sides of the hydrostatic
pump.
Removal:
WARNING
of the frame before running the engine for service. IMPORTANT
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
Raise the operator cab. (See Raising on Page 10-30-2.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-51-2 I-2003-0888
Figure 30-51-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
51-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.

Hydraulic Controller Removal And Installation

(Cont'd)
1
Figure 30-51-5
1 2
3 P-90210
2
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 10,4
N•m (7.7 ft-lb) torque. Ensure bolts are tightened to
P-90210 specifications.
Remove the controller (Item 1) [Figure 30-51-5] from the NOTE: When a hydraulic controller is replaced, the
pump. hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Remove the controller gaskets (Item 2) [Figure 30-51-5] Page 30-51-26.)
from the pump.
Figure 30-51-8
Installation:
Figure 30-51-6
2 2
P-64978
1
With the engine running and the loader on jack stands:
P-90209
Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
NOTE: Do NOT remove the three screens (Item 2)
2 turns. Leave the screw loose until fluid comes dripping
[Figure 30-51-6] they will be damaged during
out of the set screw. Tighten set screw to 2 N•m (18 in-lb)
removal and must be replaced.
torque.
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in
Repeat the bleed procedure for all the solenoids.
the center of the servo piston groove (Item 1) [Figure 30-
51-6].
Use a small amount of grease on a new gasket and

install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].


Page 70-10-14.)

Remove the Drive Belt. (See Belt Replacement on Page 1

30-60-2.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-51-10] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.
I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-51-9 Remove the pump pulley from the pump drive shaft.
Figure 30-51-11
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-51-9] on the
hydrostatic pump drive shaft.
Remove the two mounting bolts and nuts (Item 1) [Figure
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 30-51-11].
ft-lb) torque.
Installation: Tighten the mounting bolts and nuts to 88 -
95 N•m (65 - 70 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-12
P114386
Remove the mounting bolt (Item 1) [Figure 30-51-12] at

the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 125 - 135 N•m (90

- 100 ft-lb) torque.

BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic fluid. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-51-6.)

Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before startup.
Figure 30-51-13
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-51-13].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic fluid until the hydraulic fluid flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

1. O-ring
2. Bolt 3 1
3. End Housing 4 1
4. Right Rotating Assembly
5. Timing Pin 6
6. Bearing 5
7. Spacer/Coupler 7
8. Pin
9. Positioning Pin
10. Position Sensor
11. Washer
12. Steel Cover
13. Hydraulic Controller 9
14. High Pressure Relief 1 8 2
15. Case Housing 1
16. Plug 10
17. Dowel Pin 11
18. Charge Pressure Relief
19. Left Servo 2
20. Right Servo 12
21. Left Rotating Assembly 16 2
22. End Housing 14
2
16 17
15 13
13
18 20
14
22 19
5
2 6
21
8 1
1
9
10 1
11
12 2
2 P-90240

High Pressure Relief And Bypass Valve
Figure 30-51-14
1
1
P-64437
Inspect the valve seat surface (Item 1) [Figure 30-51-16]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-16] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-14] in the back of the hydrostatic pump.
Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-14].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 36500 kPa (365 bar)
Figure 30-51-15 (5075 psi).
4
3
2 1
P-64436
Inspect the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-15], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-15]

from the valve cap.
Inspect the conical spring (Item 4) [Figure 30-51-15] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-51-17 1 4 5
3 6
2
1 P-64435
Inspect the O-ring (Item 1) [Figure 30-51-18].

P-64431
Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-51-18] for damage or foreign material. Ensure
The charge relief valve (Item 1) [Figure 30-51-17] is the poppet moves freely in its bore.
located on the back of the hydrostatic pump.
Inspect the sealing ring (Item 4) [Figure 30-51-18] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Assembly: Tighten charge relief valve to 70 N•m (52 ft-
lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-51-18].
NOTE: 1,0 mm shim (Item 6) [Figure 30-51-18] = 299,9

kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.

HYDROSTATIC PUMP (SJC) (CONT'D) Note the connectors facing each other.
Disassembly And Assembly Figure 30-51-21

Page 70-10-14.)
1
Remove the hydrostatic pump. (See Removal And
Figure 30-51-19
2
P-90228
1 1 Remove the mounting bolts (Item 1) for the swash plate

angle sensor (Item 2) [Figure 30-51-21].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.
P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-51-

19]. (See Hydraulic Controller Removal And Installation
on Page 30-51-2.)
Figure 30-51-20
3 3
2 2
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-20].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-20] from both sides.
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D) Right End Housing
Disassembly And Assembly (Cont'd) Figure 30-51-24
Figure 30-51-22
3
1
1
1
P-64445
P-90217
Left End Housing
Assembly: Note the slotted portion (Item 1) of the Figure 30-51-25

positioning pin tightly fits the machined section on the
swash plate angle sensor shaft (Item 2) [Figure 30-51- 3 1
22].
Figure 30-51-23
1
2
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
P-90218 [Figure 30-51-24] and [Figure 30-51-25].
Assembly: Alternately, tighten mount bolts to 130 N•m

Inspect and replace the O-ring (Item 1) [Figure 30-51- (96 ft-lb) torque.
23].

Figure 30-51-26
P-64466
Ensure servo follower (Item 2) [Figure 30-51-27] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-28].
Pull the end housings from the case housing [Figure 30- Figure 30-51-29
51-26].
Figure 30-51-27
1 1 2
2
P-64463
P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-51-29] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-27].

Figure 30-51-30
RIGHT SIDE
P-64454
Figure 30-51-31
LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-51-30] and

[Figure 30-51-31] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-51-30] and [Figure 30-51-31] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

Disassembly And Assembly (Cont'd) RIGHT SIDE

Figure 30-51-32
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-51-35
P-64455
LEFT SIDE
Figure 30-51-33 1
2
LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
P-64502 32] and [Figure 30-51-33] in the case housing with the
notch (Item 1) [Figure 30-51-34] and [Figure 30-51-35]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-51-32] and [Figure 30-51-33] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-34] and [Figure
30-51-35].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

Figure 30-51-36
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-38].

B25012
Figure 30-51-39
Right Side Rotating Group [Figure 30-51-36].
Figure 30-51-37
1
P-64475

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-37].


1
Figure 30-51-40
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64476 42].
Figure 30-51-43
Inspect the pistons for scoring and scratches. Ensure the
holes (Item 1) [Figure 30-51-40] in the slippers are not
1
plugged.
Figure 30-51-41
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-43]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-51-41].


3
Figure 30-51-44
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-51-46].
Remove the swash plate from the end cap housing (Item
Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-46].
1) [Figure 30-51-44].
Remove the slide ring (Item 3) [Figure 30-51-46], ensure
Figure 30-51-45 it pivots freely.
Figure 30-51-47
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-45] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in end cap housing (Item 2) [Figure 30-51-47].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-51-45] are not bent or damaged.

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-51-48
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-

P-64481 50].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-50] on them. The edges face towards
swash plate (Item 1) [Figure 30-51-48]. the outside of the end cap housing
Figure 30-51-49 Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-51-50].

2
Figure 30-51-51
2 1
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-49].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-51-49] on swash plate.
Inspect wear surfaces (Item 2) [Figure 30-51-51] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

Figure 30-51-52
LEFT SIDE
1
P-76742
The pump seal (Item 1) [Figure 30-51-54] is removed by

P-64486 inserting a screw into the seal and prying out.
Figure 30-51-55
Figure 30-51-53
RIGHT SIDE 1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-51-52] and a rubber mallet.
[Figure 30-51-53] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-51-55] and remove
bearing.

Figure 30-51-56
1 1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 30-

51-58].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-51-59
B25013
Servo Piston Assembly [Figure 30-51-56].

1
The Servo Piston Assembly [Figure 30-51-56] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-51-57
P-90231
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-59].
P-64490
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-57].

Figure 30-51-60
P-64466
Assembly: Align the servo piston so the guide slot

P-90237 (Item 1) [Figure 30-51-62] is parallel to the drive shaft
centerline. Measure with a straight-edge [Figure 30-51-
61].
Slide the servo piston assembly out of the bore. [Figure
30-51-60]. Figure 30-51-63
Figure 30-51-61
2
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-51-63] from the pump housing.

Figure 30-51-64 1
1
2
2
P-64496
3 Remove the servo cover (Item 1) [Figure 30-51-66] from

P-64494 the servo piston.

Each servo has a pair of bushings (Item 1), O-rings (Item cover.
2), and square-cut seals (Item 3) [Figure 30-51-64].
Figure 30-51-67
Figure 30-51-65
1
1
P-64497
P-64495
Remove snap ring (Item 1) [Figure 30-51-67] from the

Remove the locknut (Item 1) [Figure 30-51-65] from the servo piston.
servo piston.
Assembly: Tighten locknut to 30 N•m (22 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-51-68 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
1 disassembled for servicing the servo piston and the
2 setting has been disrupted.
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
WARNING
P-64498
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-51-68] from the servo piston. Raise the lift arms, and install an approved lift arm
Inspect mechanism for broken parts.
Figure 30-51-69 TOOL KIT - MEL1563 on Page 10-60-1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
2 find an accessible connector to disconnect.
1 If equipped, disconnect the speed sensors located on the

top of the drive motors. This prevents uncommanded
wheel movement error codes from occurring during
adjustments.
P-64502
WARNING
Bearings (Item 1) [Figure 30-51-69] in case housing are
replaced by using a press and bearing driver. Hydraulic fluid escaping under pressure can have
Inspect center coupler (Item 2) [Figure 30-51-69]. penetrating the skin. This can cause serious injury
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-70
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-72] from the

P-64973 MA ports on the bottom of the pump, and install 51711
kPa (517,1 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-70] Figure 30-51-73

between port X1 and port X2 on each side of the
hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-51-71
1 1
1
1
1 1
P-90243
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-73]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51711 kPa (517,1
bar) (7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the
Remove the plugs (Item 1) [Figure 30-51-71] from the pump mechanical neutral setting.
MB ports on the front side of the pump, and install 51711
kPa (517,1 bar) (7500 psi) pressure gauges.

Figure 30-51-74
1 1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-51-76]

P-90226 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment locknut (Item 1)
[Figure 30-51-74]. Figure 30-51-77
Start the loader using the Remote Start Tool and run at
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-75
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90238

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment aligns the
pump swash plate and the control spool so that a zero
Figure 30-51-78 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
2 NOTE: Procedure is shown for the left side hydraulic

controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
1 right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-90238
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the locknut (Item 2) [Figure 30-51-78] to 30 N•m
(22 ft-lb) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-2.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-51- Connect the Remote Start Tool. (See REMOTE START
26.) TOOL KIT - MEL1563 on Page 10-60-1.) or (See
7217666 on Page 10-61-1.)
WARNING
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-79
P-64975
1 Install 3447 kPa (34,5 bar) (500 psi) pressure gauges in

P-90239 the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting [Figure 30-51-81].
Disconnect the hydraulic controller connectors (Item 1) Figure 30-51-82

[Figure 30-51-79] from the loader wiring harness for the
hydraulic controller you are adjusting.
Figure 30-51-80
1
1
P-90236
Loosen the locking screw (Item 1) [Figure 30-51-82].

P-90226
an idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-51-80] pertaining to the side of the
hydrostatic pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Figure 30-51-83
P-90236

P-90236 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-51-86
in system pressure. Mark the position of the adjustment
screw.
Figure 30-51-84
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-51-86] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-84] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

HYDROSTATIC PUMP (SJC) (S/N ALM425401 &
ABOVE)
Description
The tandem closed circuit piston pumps convert input

torque to hydraulic power. The tandem design powers
two independent drive trains for dual-path propel
applications. The two-piece input shaft transmits
rotational force to the cylinder block. A splined coupling
connects the front and rear shafts. Bearings at the front,
rear, and center of the pump support the shaft. Splines
connect each shaft to a cylinder block. A lip-seal at the
front end of the pump prevents leakage where the shaft
exits the pump housing. The spinning cylinder block
contains nine reciprocating pistons. Each piston has a
brass slipper connected at one end by a ball joint. The
block spring, ball guide, and slipper retainer hold the
slippers to the swashplate. The reciprocating movement
of the pistons occurs as the slippers slide against the
inclined swashplates during rotation. Via the valve plates,
one half of each cylinder block is connected to port A or
C and the other half to port B or D (See Port Locations
And Gauge Installation on Page 30-52-2.)
Front and rear sections have independent porting in the

center section. As each piston cycles in and out of its
bore, fluid is drawn from one port and displaced to the
other thereby imparting hydraulic power into the system.
A small amount of fluid is allowed to flow from the
cylinder block/valve plate and slipper/swashplate
interfaces for lubrication and cooling. Case drain ports
return this fluid to the reservoir. An external charge pump
(not shown) provides clean, cool fluid to makeup this
lubricating flow and to maintain minimum loop pressure.
The angle of each swashplate controls the volume and

direction of fluid displaced into the system. The servo
pistons control the angle of the swashplates. Each pump
control, by varying the pressure at the servo pistons,
controls each piston’s position. An electric signal to the
control coils transmits the command from the operator to
the pump. Mechanical feedback of the swashplate
position to the control through the feedback pins allows
for very precise displacement control and increases
overall system stability. Non-feedback control options do
not use the mechanical feedback link.

HYDROSTATIC PUMP (SJC) (S/N ALM425401 & ABOVE) (CONT’D)
Port Locations And Gauge Installation
Figure 30-52-1
NA13920
PORT GAUGE SIZE,

PORT SIZE READING
IDENTIFIER BAR (PSI)
L1, L2, L3 1 1/16 - 12 Case Drain 10 BAR (100 PSI)
MA, MB, MC, MD 9/16 - 18 System 600 BAR (10,000 PSI)

Pressure
M3 9/16 - 18 Charge 50 BAR (1000 PSI)

Pressure
M4, M5 716 - 20 Servo Pressure 50 BAR (1000 PSI)
AM3 9/16 - 18 Alternate 50 BAR (1000 PSI)

Charge PSI
A, B, C, D 1 5/16 - 12 System Ports -
E 7/8 - 14 Charge Filtration -
M14 7/16 - 20 Case Gauge 10 BAR (100 PSI)

Port

HYDROSTATIC PUMP (SJC) (S/N ALM425401 & Figure 30-52-3
ABOVE) (CONT'D)

Page 70-10-14.)

1
Remove the Drive Belt. (See Belt Replacement on Page
30-60-2.)
P-90222
IMPORTANT Use a puller (Item 1) [Figure 30-52-3] to loosen the

pulley from the pump drive shaft.
clean the work area before disassembly and keep all NOTE: DO NOT strike puller or pump shaft with a
parts clean. Always use caps and plugs on hoses, hammer. Internal pump damage may result.
damage the system. Remove the nut and washer from the pump drive shaft.
I-2003-0888
Remove the pump pulley from the pump drive shaft.

Figure 30-52-2
Figure 30-52-4
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-52-2] on the

hydrostatic pump drive shaft. Remove the two mounting bolts and nuts (Item 1) [Figure
30-52-4].
ft-lb) torque Installation: Tighten the mounting bolts and nuts to 88 -
95 N•m (65 - 70 ft-lb) torque.

ABOVE) (CONT'D)
Figure 30-52-5
P114386
Remove the mounting bolt (Item 1) [Figure 30-52-5] at

the hydraulic pump mounting bracket.

Installation: BEFORE STARTUP: Fill the hydrostatic

pump with hydraulic fluid. This will remove trapped air in
the hydrostatic pumps before startup. (See Hydrostatic
Pump Startup on Page 30-52-5.)

ABOVE) (CONT'D)
Hydrostatic Pump Startup
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydraulic fluid.
1
This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
P-100685
Filling the hydrostatic pump is best done by removing a
plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the Figure 30-52-8
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before startup.
Figure 30-52-6
1
P114478
1 Attach a push button starter switch (MEL1712) (Item 1)

P133853 [Figure 30-52-7] to the starter terminal S (Item 1) and
NOTE: This procedure is necessary to prevent a dry Crank the engine for 15 seconds, then stop for at least 30
startup of the hydraulic or hydrostatic pump. seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.
BEFORE STARTUP: Fill the housing by adding hydraulic
fluid to the upper case drain port (Item 1). If the controls Start the loader from the operator’s cab and run the
are installed on top, open the plugs (Item 2) [Figure 30- engine at low idle for 1 - 2 minutes without operating the
52-6] in the top of the housing to assist in air bleed. hydraulics.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque. After operating the engine at low idle, remove the lift arm
Fill the system with hydraulic fluid. (See Removing And arms several times or until air is purged from the system.
Replacing Hydraulic Fluid on Page 10-120-2.) Avoid running over the relief valve setting at the end
of cylinder stroke.

Check for hydraulic leaks.

HYDROSTATIC PUMP (SJC) (S/N ALM425401 & ABOVE) (CONT'D)
9 3
14 15 4
5 7 6
16
10 8
12 1
17
3 11
18 13 1 2
3 5
16
19 16
20 15
11 16 14
3
13
22
21
14
24 11
28 27
16 25
23
29
16
29
26
11
16
26 12
21
24
9 16
23
22
14 15 10
7 30
16 10 16 6
17 20
13 21
3 3
13 18
5
15 18 3
14 14
12 19
3
NA14930S

ABOVE) (CONT'D)
Parts Identification (Cont’d)
Ref. Description
1. Retainer Ring
2. Seal
3. O-ring
4. Shaft Seal
5. Bearing Race
6. Bearing
7. Washer
8. Shaft
9. Controller
10. Feedback Link
11. Dowel Pin
12. Housing
13. Servo Cylinder
14. Bolt
15. Lock Plate
16. Plug
17. Slider Block
18. Piston Ring
19. Servo Piston
20. Cylinder Piston
21. Swash Plate Bearing
22. Swash Plate
23. Gasket
24. Valve Plate
25. Coupling
26. Journal Bearing
27. Lifting Bracket
28. Charge Relief Valve
29. SCR Valve Assembly
30. Shaft

HYDROSTATIC PUMP (SJC) (S/N ALM425401 & ABOVE) (CONT'D)
Parts Identification (Cont’d)
1. Screw 1
2. Cover
3. Bolt 8 2
4. Plug 10
5. Cap 11 5
6. Nut
6
7. Housing 3
8. Coil Nut
9
9. O-ring
10. Solenoid
4
11. Solenoid Valve 1 9
1 9
12. Gasket
2
7
9 8
3 12 11
8 5
1
10
10 6
1
9
11
4
12 11
1
10 8
NA14941S

ABOVE) (CONT'D)
High Pressure Relief And Bypass Valve

2
Figure 30-52-9
1 1
P133823

[Figure 30-52-11].
P133892
Inspect the valve (Item 2) [Figure 30-52-10] for damage.
There are four system check relief valves (Item 1) Inspect seats inside case housing.
[Figure 30-52-9] on the engine side of the hydrostatic
pump. Do not disassemble the relief valve assembly. If
replacement is required, replace as an assembly.
Remove the valve seat plug (Item 1) [Figure 30-52-9].
Factory setting on the relief valve is 35000 kPa (350 bar)
Assembly: Tighten plug to 80 N•m (59 ft-lb) torque. (5076 psi).
Figure 30-52-10
P133824
Inspect the valve seat plug (Item 1) [Figure 30-52-10].
Remove relief valve assembly (Item 2) [Figure 30-52-10]

and ensure valve moves freely in its bore.
Inspect the conical spring (Item 3) [Figure 30-52-10] to

ensure it is not broken or flattened.

ABOVE) (CONT'D)
Charge Pressure Relief Valve 1

2 3
Figure 30-52-12 4
1
5
P133826
P133890 Inspect the poppet (Item 2) and the mating seat (Item 3)
[Figure 30-52-13] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge pressure relief valve (Item 1) [Figure 30-52-
12] is located on the engine side of the hydrostatic pump. Inspect the spring (Item 4) [Figure 30-52-13].
Remove the charge pressure relief valve. NOTE: Replace the charge pressure relief valve as a
complete unit. Do not attempt to repair the
Assembly: Tighten charge pressure relief valve to 52 internal components of the valve.
N•m (38 ft-lb) torque and locking nut to 40 N•m (30 ft-lb)
torque. Factory setting on the charge pressure relief valve is
2400 kPa (24 bar) (348 psi) with fluid temperature at
50°C (120°F).
NOTE: Pressure change per turn of the adjusting

screw (Item 5) [Figure 30-52-13] is dependent
on charge flow entering pump. Clockwise
rotation increases charge pressure,
counterclockwise rotation decreases charge
pressure.

ABOVE) (CONT'D)
NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy” found
in the Warranty Policy and Procedure Manual. 1
Please check the list of affected part numbers
in IRW before proceeding.
IMPORTANT P133818

clean the work area before disassembly and keep all Remove the solenoid retaining nut (Item 1) [Figure 30-
parts clean. Always use caps and plugs on hoses, 52-15].
damage the system. Assembly: Tighten retaining nut to 5 N•m (3.7 ft-lb)
I-2003-0888
torque.
Drain the fluid from the pump. Figure 30-52-16
Seal all open ports and clean the pump with solvent.

Page 70-10-14.)
Remove the hydrostatic pump. (See Removal And 1

Figure 30-52-14
1
P133817
2
P133891
Remove the six bolts (Item 1) and remove the hydraulic

controller (Item 2) [Figure 30-52-14].
Assembly: Tighten bolts to 13,5 N•m (10 ft-lb) torque.

ABOVE) (CONT'D)
Figure 30-52-17
1 1
P133813
2
Remove the bolts (Item 1) and the sensor switch guard

(Item 2) [Figure 30-52-19].
P133816
Assembly: Tighten bolts to 13,5 N•m (10 ft-lb) torque.
Remove the three bolts (Item 1) and solenoid valve (Item Figure 30-52-20
2) [Figure 30-52-17].
Figure 30-52-18
2
1
1
P133801
Remove the screws (Item 1) and the sensor (Item 2)

[Figure 30-52-20].
P133815

ABOVE) (CONT'D)
Figure 30-52-21
2 1
3
P133849
Lightly tap on adjusting screw (Item 1) [Figure 30-52-23].
P133812 Figure 30-52-24
Remove the screws (Item 1), spacer (Item 2) and plug

(Item 3) [Figure 30-52-21].
Figure 30-52-22
1
3 2
1
P133848
Remove actuator assembly (Item 1) [Figure 30-52-24].
Figure 30-52-25
P133810
Remove the sensor magnet (Item 1),gasket (Item 2) and

adjusting screw locknut (Item 3) [Figure 30-52-22].
Assembly: Tighten locknut to 10 N•m (7 ft-lb) torque.
P133847
Remove the spool (Item 1) [Figure 30-52-25].

ABOVE) (CONT'D)
Figure 30-52-26
2 3
P133843
Remove the right side (Item 1) from the center block

(Item 2) [Figure 30-52-28].
P133808
NOTE: Mark the orientation and keep the valve plates
(Item 3) [Figure 30-52-28] on the same side
Inspect actuator assembly and spool [Figure 30-52-26]. that they came off. The valve plates are not
interchangeable.
Figure 30-52-27
Figure 30-52-29
1
2 1
P133844
P133842
Remove the six bolts (Item 1) [Figure 30-52-27]. (Two

bolts are not visible in the photo). Remove the housing gasket (Item 1) and swash plate
feedback pin (Item 2) [Figure 30-52-29].
Assembly: Tighten swash plate feedback pin to 25 N•m
(18 ft-lb) torque.

ABOVE) (CONT'D)
Figure 30-52-30
P-64476
1
Inspect the pistons for scoring and scratches. Ensure the
holes (Item 1) [Figure 30-52-32] in the slippers, are not
P133840 plugged.
Figure 30-52-33
Remove the piston assembly (Item 1) [Figure 30-52-30].
Figure 30-52-31
1
1
P-64477
P-64475 Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-52-33].

rotating block.

ABOVE) (CONT'D)
Figure 30-52-34
P-64474
Inspect the spherical washer for scoring and wear (Item

1) [Figure 30-52-36].
P-64471
Figure 30-52-37
Remove the spherical washer (Item 1) [Figure 30-52-

34].
1
Figure 30-52-35
2
1
3
1
P-64478
Inspect the back surface of the rotating block (Item 1)

[Figure 30-52-37] where the valve plate seals. Ensure
P-64472 there is no scratches or scoring.
Visually ensure spring (Item 2) and c-clip (Item 3)

Inspect the pins (Item 1) [Figure 30-52-35]. They should [Figure 30-52-37] are not bent or damaged.
be the same length. Do not remove.

ABOVE) (CONT'D)
Figure 30-52-38
2 2
1 1
1
P133837
Remove the seals (Item 1) and inspect the bronze slider

block (Item 2) [Figure 30-52-40].
P133839
Figure 30-52-41
Remove the locking plate bolts (Item 1) and lock plate.

Mark servo adjusters (Item 2) [Figure 30-52-38] and
remove from housing.
Assembly: Tighten the bolts to 14,5 N•m (11 ft-lb)

torque.
Figure 30-52-39
1
1
P133836
Remove the swash plate (Item 1) [Figure 30-52-41] from

the pump housing.
P133838
Remove the servo piston (Item 1) [Figure 30-52-39] from

housing.

ABOVE) (CONT'D)
Figure 30-52-42
2
1
2 P133833
1
The drive shaft (Item 1) [Figure 30-52-44] can be tapped

out of the end housing with a rubber mallet.
P133835
for excessive wear.
Inspect the swash plate (Item 1) and bearings (Item 2)
[Figure 30-52-42] for wear or damage. Inspect bearing (Item 2) [Figure 30-52-44] for wear or
damage.
Figure 30-52-43
Figure 30-52-45
P133834
P133832
Remove the drive shaft and bearing assembly (Item 1)

[Figure 30-52-43]. Inspect the bearing seats (Item 1) [Figure 30-52-45] in
the housing.

ABOVE) (CONT'D)
Figure 30-52-46
1
1
P133829
Remove the bushing (Item 1) and fitting (Item 2) [Figure

30-52-48] from the housing (Both sides).
P133831
Figure 30-52-49
Remove the valve plate (Item 1) [Figure 30-52-46] from

the center housing.
Figure 30-52-47 3 1
1 P133828
Remove the three plugs (Item 1), bolt (Item 2) and lifting
bracket (Item 3) [Figure 30-52-49].
P133830
Assembly: Tighten the plugs to 45 N•m (33 ft-lb) torque.
Remove the coupler (Item 1) [Figure 30-52-47] from the

housing.

for excessive wear.

ABOVE) (CONT'D)
Figure 30-52-50
1
1
P133822
P133827 Assembly: Tighten the plug to 48 N•m (35 ft-lb) torque.
Left side swash plate assembly is identical to right side

Remove the charge pressure relief valve (Item 1) [Figure except the input shaft and bearing procedure.
30-52-50].
NOTE: There is a earlier and later seal assembly for
Assembly: Tighten charge pressure relief valve to 52 the input shaft on the H1 hydrostatic pump.
N•m (38 ft-lb) torque and locking nut to 40 N•m (30 ft-lb) The procedure for both seals is shown.
torque.
Earlier Models
Figure 30-52-51
Figure 30-52-53
1 1
1
P133825
P133820
Remove the four HPRV valves (Item 1) [Figure 30-52-

51]. Remove snap ring (Item 1) and input shaft assembly
(Item 2) [Figure 30-52-53].
Assembly: Tighten the HPRV valves to 80 N•m (60 ft-lb)
torque.

ABOVE) (CONT'D)
Earlier Models (Cont’d)
Figure 30-52-54
P134179
Remove the seal (Item 1) [Figure 30-52-56].
Figure 30-52-57
P133819

and bearing for excessive wear [Figure 30-52-54].
Later Models
Figure 30-52-55
1
P134180
Remove the snap ring (Item 1) [Figure 30-52-54].

1
Figure 30-52-58
P134178
Remove snap ring (Item 1) [Figure 30-52-53].
P134181
Remove the input shaft and bearing assembly (Item 1)

[Figure 30-52-58].

HYDROSTATIC PUMP (SJC) (S/N ALM425401 AND Figure 30-52-61
ABOVE) (CONT'D)

3
Figure 30-52-59 2 4
P134177
2
The input shaft assembly [Figure 30-52-61] consists of
the following components:
P134182
1. Input Shaft
Remove the snap ring (Item 1) and bearing (Item 2) 2. Bearing

[Figure 30-52-59].
3. Snap Rings
Figure 30-52-60
4. Seal
1 2
P134183
Inspect surfaces for scratches and input shaft splines

(Item 1). Inspect bearing (Item 2) [Figure 30-52-60] for
wear or damage.

HYDROSTATIC PUMP (SJC) (S/N ALM425401 & Mechanical neutral is set with the pump running at 1800
ABOVE) (CONT'D) (rpm). To set neutral, you must stroke the pump in each
direction. You can do this with a small movement of the
Mechanical Neutral Adjustment eccentric screw on EDC controls. If you perform this
adjustment with the pump installed in a machine, safely
The mechanical neutral adjustment sets the position of elevate the wheels or disconnect the mechanism to allow
the servo piston and pump swash plate relative to the safe operation during adjustment.
hydraulic controller. This procedure should be followed if
the hydrostatic pump has been disassembled for This procedure details setting neutral for the entire pump,
servicing the servo piston and the setting has been one side at a time. The procedure is the same for each
disrupted. side of each pump so you will need to repeat it four times
to set mechanical neutral for both the front and rear
Place the loader on jackstands. (See Procedure on Page sections. Alternate M4/M5 and MA/MB to zero out
10-10-1.) forward and reverse directions of the front unit, then
move the gauges to M4/M5 of the rear unit and MC/MD
(system gauge ports for the rear unit). Refer to the
WARNING drawing to identify all ports (See Port Locations And

Gauge Installation on Page 30-52-2.). The front and rear
sections are basically mirror images of each other. The
Put jackstands under the front axles and rear corners control solenoids C1 and C2 are marked on each control.
of the frame before running the engine for service. While performing this adjustment, you monitor the
Failure to use jackstands can allow the machine to following pressures:
W-2017-0286 1. Servo pressure at M4 and M5.
2. System pressure at MA and MB or MC and MD.

Raise the lift arms, and install an approved lift arm
Pump setup
1. Attach a 50 bar [1000 psi] gauge to each servo
pressure port M4 and M5.
Connect the remote start tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) 2. Attach a 600 bar [10 000 psi] gauge to each system
pressure port (MA and MB for front pump, MC and MD
Disconnect the swash plate sensors in the electrical for rear pump).
harness. This prevents unwanted swash plate movement
error codes from occurring during adjustments.
3. Remove servo cylinder locking screws (E350) and
Disconnecting the sensors does not have to be done
plates (E300) from both sides of the pump.
directly at the sensor, follow the harness back to find an
accessible connector to disconnect.
4. Disconnect the control solenoids from the vehicle
wiring harness.
5. If using a PWM signal to set mechanical neutral,

WARNING connect the control solenoids C1 and C2 to the signal
source. Ensure the source supplies no current to the
solenoids until required in the following procedure.

immediately.
W-2145-0290

ABOVE) (CONT'D)
Servo Adjustment
1. Run engine at 1800 (rpm).
2. If using a PWM signal, ensure the signal is off. Check

the servo pressure gauges. Ensure the differential
between M4 and M5 is less than 2.5 bar [36 psi].
3. Using a 3/4 in deep socket, loosen both servo

cylinders 2-3 turns. This step ensures the servo
cylinders have no contact with the servo piston.
4. Stroke the pump by turning the control eccentric

screw (or supplying current to solenoid C1) until the
servo pressure at port M4 is 1 to 2 bar [14– 29 psi]
greater than at port M5 and the system pressure
gauges indicate displacement. Pressure should be
greater at port MA for clockwise rotation, or MB for
counterclockwise rotation. This also indicates the
servo piston is in contact with the servo cylinder
onside M5.
5. Maintain servo pressure differential between 1-2 bar

[14-29 psi] during this step. Slowly thread the servo
cylinder on the M5 side in until the system pressure
differential starts to decrease. Continue turning the
servo cylinder in until the system delta pressure
results in no machine movement. System delta
pressure (ports MA to MB or MC to MD) between 3-4
bar typically does not cause machine movement. If
service of a pump is not performed on the machine,
validation of machine movement must be checked
upon machine startup.
6. To complete setting neutral, repeat steps 1-5 but

stroke the pump in the opposite direction by turning
the eccentric screw in the opposite direction, or by
supplying current to solenoid C2. Reverse gauge
locations (M4 for M5, MB for MA etc.) from those
stated above since the pump is now stroking the other
direction.
7. Set neutral for the rear pump by repeating steps 1-6

on the rear pump. Remember that the rear pump is a
mirror image of the front pump and therefore the
locations of the servo gauge ports (M4/M5) and the
control solenoids (C1/C2) are opposite.
8. Remove all gauges and replace gauge port plugs.

ABOVE) (CONT'D)
Hydraulic Controller Neutral Adjustment
The hydraulic controller neutral adjustment aligns the

pump swash plate and the control spool so that a zero
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are 2 1
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.

P133892
10-10-1.)
Install a 50 bar [1000 psi] gauge in each of the two servo

gauge ports (M4 (Item 1) and M5 Item 2) [Figure 30-52-
WARNING 62]. For the port locations (See Port Locations And
Gauge Installation on Page 30-52-2.) Disconnect the
external control input (electrical connections) from the
control.
W-2017-0286
idle.
Figure 30-52-63
procedure:
MEL1355-2 - Pressure gauge 6895 kPa (68,9 bar) 

(1000 psi)
MEL1563 or 7217666 Remote Start Tool. 2
Raise the lift arms, and install an approved lift arm

1

REMOTE START TOOL (SERVICE TOOL) KIT - P133813
7217666 on Page 10-61-1.)
Hold the neutral adjusting screw (Item 1) stationary while

loosening the locknut (Item 2) [Figure 30-52-63].
WARNING Observe pressure gauges. If necessary, turn adjusting

screw to reduce any pressure differential. Adjustment of
Hydraulic fluid escaping under pressure can have the EDC is very sensitive. Be sure to hold the hex wrench
sufficient force to enter a person’s body by steady while loosening the locknut. Total adjustment is
penetrating the skin. This can cause serious injury less than 120 degrees.
immediately.
W-2145-0290

ABOVE) (CONT'D)
Rotate the neutral adjusting screw clockwise until the

pressure increases on the gauge. Note the angular
position of the wrench. Then rotate the neutral adjusting
screw counterclockwise until the pressure increases by
an equal amount on the other gauge. Again note the
angular position of the wrench.
Rotate the neutral adjusting screw clockwise half the

distance between the wrench positions noted above. The
gauges should read the same pressure, indicating that
the control is in its neutral position.
Figure 30-52-64
P133813
Hold the neutral adjusting screw (Item 1) stationary and

tighten the locknut (Item 2) [Figure 30-52-64] to 10 N•m
(7 ft-lb) torque. Do not over torque the nut.
When the neutral position is set, stop the engine, remove

the gauges, and install the gauge port plugs. Reconnect
the external control input. A small pressure differential of
2.5 bar (36 psi) or less is acceptable. Zero differential is
usually not possible.

DRIVE BELT Figure 30-60-3
Earlier Models
Belt Adjustment
The drive belt does not need adjustment. The belt has a 1
spring loaded idler that constantly maintains the correct
belt tension. The spring loaded idler stop adjustment, 2
detailed below, is critical for long belt life.
Stop Adjustment


P109784A
Figure 30-60-1
Allow the stop arm (Item 1) to contact the top of the
spring loaded idler (Item 2) [Figure 30-60-3].
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-2] to 105 – 115 N•m (78 – 85 ft-lb) torque.
Figure 30-60-4
Later Models
1
P109785
2
The spring loaded idler is located above the battery on

the left side of the engine [Figure 30-60-1].
Figure 30-60-2
P126273
1 Allow the stop arm (Item 1) to contact the top of the

spring loaded idler (Item 2) [Figure 30-60-4].
Tighten the spring loaded idler adjustment bolt and pivot

bolt (Item 1) [Figure 30-60-2] to 105 - 115 N•m (78 - 85
ft-lb) torque.
P121579
Loosen the spring loaded idler adjustment bolt and pivot

bolt (Item 1) [Figure 30-60-2].

DRIVE BELT (CONT’D) Figure 30-60-7
Belt Replacement
1

Page 60-20-1.)
Figure 30-60-5
2
1
P109783
Loosen the spring loaded idler adjustment bolt and pivot

bolt (Item 1). Insert a breaker bar (Item 2) [Figure 30-60-
7] into the slot provided in the stop arm as shown and
push the breaker bar down to release tension on the
drive belt.
P109781
Tighten the adjustment bolt (Item 1) [Figure 30-60-7] to
hold the spring loaded idler off the drive belt.
Remove the drive belt shield bolt (Item 1) [Figure 30-60- Remove the drive belt from the hydrostatic pump pulley
5]. and flywheel pulley. Inspect the pulleys for wear.
Figure 30-60-6 Install new drive belt.
Loosen the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-7] and allow the idler to contact the drive
1 belt.
Continue the procedure on the next page.

2
P109782
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
[Figure 30-60-6] toward the back of the loader to unseat
the shield from the top and bottom drive belt shield
mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-60-6].

DRIVE BELT (CONT’D) Position the drive belt shield over the drive belt shield
mounting bolts. Slide the drive belt shield toward the front
Belt Replacement (Cont’d) of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-60-9].
Figure 30-60-8
Figure 30-60-10
1 1
P115669
Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
P109781
torque wrench (Item 2) [Figure 30-60-8] into the slot
provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated. Install the drive belt shield bolt (Item 1) [Figure 30-60-
10].
Maintain torque on the stop arm and tighten the spring
loaded idler adjustment bolt and pivot bolt (Item 1) Install the battery. (See Removal And Installation on
[Figure 30-60-8] to 105 – 115 N•m (78 – 85 ft-lb) torque. Page 60-20-1.)
NOTE: This procedure is required to preload a new Close the rear door.
drive belt in order to achieve the correct stop
adjustment after the initial belt break-in NOTE: The stop arm MUST be adjusted after 50 hours
period. operation with the new drive belt. (See Stop
Adjustment on Page 30-60-1.)
Figure 30-60-9
See the SERVICE SCHEDULE for the correct
Top Mounting Bolt service interval after the initial 50 hour
adjustment. (See SERVICE SCHEDULE on
Page 10-70-1.)
1
P107207A
Bottom Mounting Bolt
P107206

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation  Figure 30-60-13

(Earlier Models)
Remove the battery. (See Removal And Installation on 2

Page 60-20-1.) 1
Remove the drive belt. (See Belt Replacement on Page

30-60-2.)
Figure 30-60-11
1 P114387
2 Remove the nut (Item 1) from the tensioner assembly

and remove the wheel (Item 2) [Figure 30-60-13].
3 Figure 30-60-14
P114385
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-60-11].
Installation: Tighten the adjustment bolt and the

mounting bolt to 105 - 115 N•m (78 - 85 ft-lb) torque.
Figure 30-60-12
1
2
P117155
Disassemble the tensioner assembly as shown [Figure

30-60-14].
Inspect the parts for wear and replace as needed.

1
NOTE: The wheel (Item 1) and the tensioner arm (Item
2) [Figure 30-60-14] are not serviceable and
must be replaced as a complete assembly.
P114384
Remove the tensioner assembly (Item 1) [Figure 30-60-

12].

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation  Figure 30-60-17

(Later Models)
3
Stop the engine and open the rear door. 1

2
Page 60-20-1.)
Remove the drive belt. (See Belt Replacement on Page

30-60-2.)
Figure 30-60-15
1
P126275
2
Remove the nut (Item 1), bolt (Item 2) and tuned weight
3 (Item 3) [Figure 30-60-17] from the tensioner assembly.
Figure 30-60-18
2 1
P126273
Remove the adjustment bolt and the spacer (Item 1), the
mounting bolt (Item 2) and remove the stop arm (Item 3)
[Figure 30-60-15].
Installation: Tighten the adjustment bolt and the

mounting bolt to 105 - 115 N•m (78 - 85 ft-lb) torque.
Figure 30-60-16
P126277
Remove the bolt (Item 1) and wheel (Item 2) [Figure 30-

60-18] from the tensioner assembly.
1
P126274
Remove the tensioner assembly (Item 1) [Figure 30-60-

16].

DRIVE BELT (CONT’D)
Tensioner Pulley Disassembly And Assembly 

(Later Models) (Cont’d)
Figure 30-60-19
1 2
P126284
Disassemble the tensioner assembly as shown [Figure

30-60-19].
NOTE: The wheel (Item 1) and the tensioner arm (Item

2) [Figure 30-60-19] are not serviceable and
must be replaced as a complete assembly.

TWO-SPEED Figure 30-70-1
Valve Block Removal And Installation
DANGER
1
P106954
P-90328
AVOID DEATH Remove the four hydraulic lines (Item 1) [Figure 30-70-1]
• Disconnecting or loosening any hydraulic from the two-speed valve block.
can cause lift arms to drop. Figure 30-70-2
D-1009-0409
WARNING
1
W-2059-0598 P106955
Disconnect the wire harness connector (Item 1) [Figure

30-70-2] from the two-speed solenoid.
WARNING Remove the two bolts (Item 2) [Figure 30-70-2] and
remove the valve block.
W-2017-0286
Mark all hydraulic hoses for proper installation.

TWO-SPEED (CONT’D)
Valve Block Disassembly And Assembly
Figure 30-70-3
P106951
Remove the two bolts (Item 1) [Figure 30-70-3] from the

valve.
Figure 30-70-4
2 1
P106952
Use a test meter and test the solenoid (Item 1) [Figure

30-70-4] for resistance.
The resistance value for the solenoid coil can be found on

the electrical schematic.
Assembly: Always install new O-rings (Item 2) [Figure

30-70-4].

DRAIN MANIFOLD Drain Manifold Removal And Installation
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic fluid to the reservoir. IMPORTANT
damage the system.
I-2003-0888

Figure 30-80-1
1
2
2
2
P106953
Disconnect the wiring harness from the fluid temperature

switch (Item 1) [Figure 30-80-1].
Remove the hoses and tubelines (Item 2) [Figure 30-80-

1].

DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3

BRAKE Disc Removal And Installation
Description Raise the loader lift arms and install an approved lift arm
Figure 40-10-1
WARNING
1 to fall and cause injury or death.
W-2059-0598

30-2.)
P-85491
Remove the control panel from the loader. (See Removal
The brake is used to hold the machine in place. The
brake is operated by a switch (Item 1) [Figure 40-10-1] Remove the center chaincase cover. (See Center Cover
located on the front accessory panel. Removal And Installation on Page 40-30-2.)
The brake is applied by a spring-loaded wedge that drops Remove the traction lock assembly.
into two notched brake discs attached to the motor carrier
shafts. An electric solenoid is sent power from a relay to Figure 40-10-2
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the
discs.
The hold signal will be interrupted and the wedge will 1

drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
For more information on the brake. (See TRACTION

N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.

BRAKE (CONT’D) Figure 40-10-4
Disc Removal And Installation (Cont’d)
Figure 40-10-3
N-19082A
1 Figure 40-10-5
N-19105
Inspect the traction lock guides (Item 1) [Figure 40-10-3]

and the brake disc for damage or wear and replace as
necessary. (See Inspecting on Page 60-120-3.)
N-19083A
Remove the snap ring (Item 1) [Figure 40-10-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

DRIVE COMPONENTS
Description
NA90845S
The drive components consist of the chaincase, drive chains, sprockets, axle shafts, hubs, drive motor carrier and a brake.
The chaincase is partially filled with hydraulic fluid to lubricate the chains and bearings.
On the bottom of the chaincase, these is a cover for access to the fuel tank drain plug.

DRIVE COMPONENTS (CONT’D) Figure 40-20-2
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool

MEL1407 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)

1.)
NOTE: If the axle and bearings are being replaced,

loosen the sprocket mounting bolt inside the 1
chaincase before lifting and blocking the P114335
loader. (See Axle, Sprocket And Bearings
Install the puller (Item 1) [Figure 40-20-2] on the hub.
Remove the tire / wheel assembly. (See Mounting on
Page 10-160-2.)

WARNING
NEVER STAND IN-LINE OF THE HUB WHEN
Remove the fluid from the chaincase. (See Removing
REMOVING A HUB FROM AN AXLE. The hub has a
And Replacing Fluid on Page 10-130-1.)
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
Figure 40-20-1
W-2186-0395
2 Remove the hub from the axle.
Figure 40-20-3
P114334
Remove the bolt (Item 1) [Figure 40-20-1] and plate.
Installation: Tighten the bolt to 1053 - 1119 N•m (775 - P114336

825 ft-lb) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1] Remove the key (Item 1) [Figure 40-20-3] from the axle.
across from each other.

DRIVE COMPONENTS (CONT’D)
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-4
P114333
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end into the axle seal.
Remove the axle seal.
Figure 40-20-5
P4814
Installation: Place the seal with the lip facing in [Figure

40-20-5].
Installation: Using a hammer, install the new axle seal

until the tool (MEL1407) is flush with the edge of the axle
tube [Figure 40-20-5].

DRIVE COMPONENTS (CONT’D) Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Axle, Sprocket And Bearings Removal And
Installation Remove the front chaincase cover. (See Front Cover
procedure: Remove the fluid from the chaincase. (See Removing
MEL1242 - Port-a-Power
MEL1202 - Axle Bearing Service Set Figure 40-20-6
NOTE: The procedure shown for removal and

installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the 2
same for the rear axle.
DANGER 1
P-68196
Remove the axle sprocket bolt (Item 1) and washer (Item

P-90328 2) [Figure 40-20-6].
AVOID DEATH Installation: Tighten the axle sprocket bolt to 410 - 450
• Disconnecting or loosening any hydraulic N•m (300 - 330 ft-lb) torque.
can cause lift arms to drop. Remove the axle hub. (See Axle Seal Removal And
• Keep out of this area when lift arms are raised Installation on Page 40-20-2.)
support. Replace if damaged. Figure 40-20-7
D-1009-0409
WARNING
W-2059-0598
Raise the lift arms and install an approved lift arm P-4158A
Lift and block the loader. (See Procedure on Page 10-10- Install a Port-a-Power ram between the two sprockets
1.) [Figure 40-20-7].

DRIVE COMPONENTS (CONT’D) NOTE: Hold the axle during removal. It will slide
freely after the bearing is removed from the
Axle, Sprocket And Bearings Removal And mounting surface.
Installation (Cont'd)
Figure 40-20-10
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Figure 40-20-8
2
P-4171
Press the splined end of the axle free from the bearing
[Figure 40-20-10].
P5406A
Remove the sprocket (Item 1) and inner bearing (Item 2)

[Figure 40-20-8].
Installation: Pack the inner and outer bearing with

grease before installation.
Figure 40-20-9
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed to

do the following procedure:
Press the bearing off the mounting surface off of the axle
[Figure 40-20-9].


Figure 40-20-11
P4812
Use the long driver handle (Item 1) [Figure 40-20-12]

and the bearing cup removal tool to remove the inner
P-4175 bearing cup.
Figure 40-20-13
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation. It will slide

freely after the bearing is pressed over the
splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-

20-11] that contacts the inner race of the bearing only.
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-11].
P5637
To remove the outer bearing, install a bearing cup

removal tool on the slide hammer.
Install the slide hammer / tool assembly behind the

bearing cup [Figure 40-20-13].


Figure 40-20-14
2
P4811
Install the installation tool (Item 1) [Figure 40-20-16] on

the threaded rod. Install the nut.
P4816
Hold the inside nut (Item 3) [Figure 40-20-15] with a
wrench and tighten the outside nut [Figure 40-20-16].
Use the slide hammer to remove the bearing cup from
the axle tube [Figure 40-20-14]. Tighten the nut until the bearing cup is seated.
Figure 40-20-15 Remove the installation tool and threaded rod.
2
1
P5468A
Use the bearing cup installation tool (Item 1) [Figure 40-

20-15] and (Item 1) [Figure 40-20-16].
Put the inner cup (Item 2) [Figure 40-20-15] in the axle

tube.
Install the long threaded rod (Item 2) [Figure 40-20-16]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-15].


To install the outer bearing cup, install the bearing cup

installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Figure 40-20-17
P4813
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-17].

DRIVE COMPONENTS (CONT’D) Remove the brake disc. (See Disc Removal And
Chain Removal And Installation
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
DANGER Figure 40-20-18
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic Front Drive
Chain
tubeline, hose, fitting, component or a part failure Rear Drive
Chain
unless supported by an approved lift arm P-68194

D-1009-0409
NOTE: It is necessary to remove the rear axle and
drive chain if the front chain has to be
removed.
WARNING
W-2059-0598


1.)

on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)

Remove the fluid from the chaincase. (See Removing


Chain Removal And Installation (Cont’d)
The tools listed are needed for the following procedure:
MEL1269 - Chain Breaker

MEL1246 - Chain Link Press Tool
MEL1364 - Chain Link Installation Tool
Figure 40-20-19
B-13504A
Use the chain breaker MEL1269 to separate the chain.
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use the chain link installation tool MEL1364 to hold both

ends of the chain.
Secure the tool MEL1246 and place the connector link in

the tool as shown [Figure 40-20-19].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-19]. Tighten the
threaded rod of the chain link tool to 339 N•m (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
support device. (See Installing on Page 10-20-2.) 2

30-2.) 3
3

on Page 50-100-2.) P-34255
Remove the front chaincase cover mounting screws

DANGER (Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.
NOTE: There are tabs (Item 3) [Figure 40-30-1] on the

side of the cover to help pry the covers off.
Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
P-90328 screw threads to stop fluid leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Disconnect the electrical connector (Item 3) [Figure 40-
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Raising on Page 10- 30-2].
30-2.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
P-90328 W-2059-0598
AVOID DEATH
Figure 40-30-3
3
D-1009-0409
2

on Page 50-100-2.)
Figure 40-30-2 1
P-90048
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
2 1
Remove the center chaincase cover (Item 2) [Figure 40-
3 30-3] from the loader.

side of the cover to help pry the covers off.
P-90047 Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
screw threads to stop fluid leakage. Tighten the mounting
If loader is equipped with SJC, skip to [Figure 40-30-3]. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
1 3
30-2.) 2
1
DANGER 3
P-90056
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-4].
Remove chain case cover (Item 2) [Figure 40-30-4].

P-90328
AVOID DEATH side of the cover to help pry the covers off.
tubeline, hose, fitting, component or a part failure Installation: Apply polyurethane sealer to mating
can cause lift arms to drop. surfaces. Polyurethane sealant should be applied to the
• Keep out of this area when lift arms are raised screw threads to stop fluid leakage. Tighten the mounting
unless supported by an approved lift arm screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Block Removal And Installation
on Page 30-70-1.)
Remove the drain manifold. (See Drain Manifold Removal

Disconnect the front steering linkage bars from the rear

linkage bars. (See Removal And Installation on Page 50-
100-2.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.

MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt And Bracket Removal And Installation (Standard) . . . . . . . . . . . . . . . . . . 50-30-2
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-6
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-6
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-7
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-12
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-16
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-20
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
FAN DUCT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1


SEAT BAR Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Description
Lower the operator cab. (See Lowering on Page 10-30-
The seat bar is the secondary restraint system that has a 3.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3
The seat bar is located in the operator cab.
Figure 50-10-1
1
P-90021
Remove the seat bar (Item 1) [Figure 50-10-3] from the

1
operator cab.
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Disconnect the seat bar sensor (Item 1) [Figure 50-10-1]

from the cab harness.
Lower the seat bar.
Figure 50-10-2
P117625
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

SEAT BAR (CONT’D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023
4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT’D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)
Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.

OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
2
1
Figure 50-20-1
P117625
Remove the retaining pin (Item 1), pin (Item 2), and the
gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D) Removal And Installation
Gas Spring Bracket Disassembly And Assembly Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
Figure 50-20-4 2.)
Figure 50-20-5
3
2
1
1
1
2
P-85661
P100756
Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50-
20-4]. Unhook the four fasteners (Item 1) and remove the cover
(Item 2) [Figure 50-20-5].
Installation: Apply threadlocker on the threads of the
gas spring rod before installing the clevis. Installation: (See Installing on Page 80-150-1.)
Figure 50-20-6
WARNING
AVOID INJURY
Cylinders for raising and lowering operator cab have 1 2
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
1
P117626
Disconnect the expansion / heater unit wiring harness

(Item 1) [Figure 50-20-6].
Remove the two heater hoses (Item 2) [Figure 50-20-6].
NOTE: Cap the heater hoses and the heater valve to

prevent coolant loss from the system.

OPERATOR CAB (CONT’D) Figure 50-20-8
Figure 50-20-7 1
P106768
1
Disconnect the cab wire harness (Item 1) [Figure 50-20-

P106767 8].
Figure 50-20-9
Disconnect the two A/C hoses (Item 1) [Figure 50-20-7].
Cap and plug the hoses and expansion valve fittings with
proper A/C caps and plugs.
Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb)

torque.
WARNING
1
Attach a chain hoist to the grab handles of the
P106769
operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and Remove the bolt and nut (Item 1) [Figure 50-20-9] from
could cause injury or death. both sides of the cab.
W-2760-0309
Installation: Tighten the bolts and nuts to 24,4 - 29,8

Remove the operator cab gas spring(s). (See Gas Spring N•m (18 - 22 ft-lb) torque.
NOTE: Use the hoist connected to the operator cab

grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

OPERATOR CAB (CONT’D)
Figure 50-20-10
P-85662
Using a strap and a hoist remove the cab from the loader
[Figure 50-20-10].

OPERATOR SEAT Seat Belt Removal And Installation (Retractable)
Removal And Installation Figure 50-30-2
Figure 50-30-1
P-90355
P-85776
Remove the mounting nut (Item 1) [Figure 50-30-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the seat belt.
Remove the four seat mounting nuts (Item 1) [Figure 50- Installation: Tighten the mounting nut to 73 N•m (54 ft-
30-1] and washers from the operator seat mounting lb) torque.
studs.

3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.

OPERATOR SEAT (CONT’D) Seat Belt Bracket Removal And Installation
Seat Belt And Bracket Removal And Installation Figure 50-30-4

(Standard)
Figure 50-30-3
3 1
P101250
P101249 Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the bracket mounting bolts (Item 1) [Figure 50-

Remove the lower mounting bolt, washer and nut (Item 30-4].
1). Remove the upper mounting bolt and nut (Item 2)
[Figure 50-30-3]. Remove the bracket (Item 3) [Figure 50-30-3].
Remove the seat belt. Installation: Tighten the mounting bolts to torque.
Installation: Tighten the mounting bolts to 73 N•m (54 ft-

lb) torque.

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Removal And Installation Figure 50-31-2
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure
Remove the four seat mounting nuts (Item 1) [Figure 50- 50-31-2].
31-1] and washers from the operator seat mounting
studs. Figure 50-31-3

3.)
Remove the seat. 2
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-31-3].
Remove the slide rail (Item 2) [Figure 50-31-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-31-6
Figure 50-31-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.
Figure 50-31-5
P-85772
Remove the nut (Item 1) [Figure 50-31-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-31-9
Figure 50-31-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50- Remove the two screws (Item 1) [Figure 50-31-9] and tilt
31-7]. the seat back to the upright position.
Figure 50-31-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-31-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-31-1.) Remove the mounting nut (Item 1) [Figure 50-31-11].
Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-31-10]. Figure 50-31-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-31-12].
Remove the seat belt retractor (Item 2) [Figure 50-31-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-31-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-31-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-31-15].
13].
Figure 50-31-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-31-14].

BOB-TACH (HAND LEVER) Figure 50-40-2
Description 1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
Figure 50-40-1
P-85649

1
Figure 50-40-3
P-85554
Tilt the Bob-Tach forward, parallel to the floor. Put blocks

(approximately 76,2 mm [3 in]) under each side of the 1
Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

P-31402
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb) both sides of the Bob-Tach pivot pin grease plug.
torque.

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-6
Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from both of
P-31404 the Bob-Tach pivot pin bolts.
Figure 50-40-7
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].
Figure 50-40-5
P-31406
1
Remove the bolt (Item 1) [Figure 50-40-7] from the Bob-
Tach pin.
P-31405
Installation: Tighten the bolt and nut to 264 N•m (195 ft-
lb) torque.

BOB-TACH (HAND LEVER) (CONT’D)
Figure 50-40-8
P-31407
With a punch (Item 1) [Figure 50-40-8] and a hammer,

drive the pivot pin out of the lift arm and Bob-Tach.
NOTE: Use tapered ream MEL1734 to clean the

tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-11
Lever And Wedge Disassembly And Assembly
Figure 50-40-9
1
2
P-85665
Remove the washer, spring (Item 1) and the lever

P-85664 assembly (Item 2) [Figure 50-40-11].
Figure 50-40-12
Figure 50-40-10
35,3 mm
(1.39 in)
P-85666
P127544 Remove the roll pin (Item 1) [Figure 50-40-12] from the
Bob-Tach wedge and spring clevis.
Installation: Tighten the lever mounting nut until the Remove the spring clevis assembly (Item 2) [Figure 50-
spring is compressed to 35,3 mm (1.39 in) [Figure 50- 40-12].
40-10].

BOB-TACH (HAND LEVER) (CONT’D) Later Design
Lever And Wedge Disassembly And Assembly Figure 50-40-15

(Cont'd)
4
Figure 50-40-13
1
3
2
P121303
P-85667 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise. Remove the bolt (Item 1) [Figure 50-40-15] and
Remove the wedge (Item 1) [Figure 50-40-13] out the replace the damaged parts as needed.
bottom of the Bob-Tach.
Assembly: Clean the threads and apply Loctite® 242 to
Always replace bent or broken wedges. the bolt (Item 1) [Figure 50-40-15], tighten to 48 - 54
Earlier Design
Figure 50-40-14
P19287
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
replace the damaged parts as needed.

the bolt (Item 1) [Figure 50-40-14], tighten to 125 - 135

BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-16
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Bob-Tach.
Remove the bushing (Item 2) [Figure 50-40-16] from the

Bob-Tach.
Figure 50-40-17
3
1
4
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach frame (Item 2) to a depth of 1,27 mm (0.050 in)
(Item 3) [Figure 50-40-17].
NOTE: To allow for the proper seal depth, it is

necessary to seat the bushing (Item 4) [Figure
50-40-17] fully into the Bob-Tach frame.

BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
Tilt the Bob-Tach forward, parallel to the floor. Put blocks

(approximately 76,2 mm [3 in]) under each side of the
IMPORTANT Bob-Tach [Figure 50-41-1].
Lower the Bob-Tach onto the blocks.

clean the work area before disassembly and keep all Mark the hoses (Item 1) [Figure 50-41-1] for correct
parts clean. Always use caps and plugs on hoses, installation.
damage the system. Remove the hoses from the cylinder.
I-2003-0888
Remove the bolts (Item 2) [Figure 50-41-1], washers and
nuts.

lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402

P-85554 both sides of the Bob-Tach pivot pin grease plug.
Figure 50-41-5
Remove the bolt (Item 1) [Figure 50-41-2] and nut from
Installation: Tighten the bolt to 48 - 54 N•m (35 - 40 ft-lb)

torque.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5].
P-85649

Figure 50-41-6
P-31406
1
Remove the bolt (Item 1) [Figure 50-41-8] from both of
P-31405 the Bob-Tach pivot pin.
Installation: Tighten the bolt and nut to 264 N•m (195 ft-
Remove the O-ring (Item 1) [Figure 50-41-6]. lb) torque.
1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 22 mm (0.875 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin bolts. and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).
Remove the Bob-Tach from the loader.
NOTE: Use tapered ream MEL1734 to clean the

tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.

Lever And Wedge Disassembly And Assembly 35,3 mm

(1.39 in)
Figure 50-41-10
1 1
P127544
Installation: Tighten the lever mounting nut until the

P-85570 spring is compressed to 35,3 mm (1.39 in) [Figure 50-
41-12].
Remove the bolts (Item 1) [Figure 50-41-10], washers Figure 50-41-13

and nuts.

lb) torque.
Remove the cylinder from the lever pivots.
Figure 50-41-11
1
2
P-85665
1
Remove the washer, spring (Item 1) and the lever
assembly (Item 2) [Figure 50-41-13].
P-85664

BOB-TACH (POWER) (CONT’D) Earlier Design
Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)
Figure 50-41-14 4
1
1 2
2
P19287
P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Remove the roll pin (Item 1) [Figure 50-41-14] from the replace the damaged parts as needed.
Bob-Tach wedge and spring clevis.
Remove the spring clevis assembly (Item 2) [Figure 50- the bolt (Item 1) [Figure 50-41-16], tighten to 125 - 135
41-14]. N•m (90 - 100 ft-lb) torque.
Figure 50-41-15 Later Design
Figure 50-41-17
1
1
P-85667
3
2
P121303
Remove the wedge (Item 1) [Figure 50-41-15] out the
bottom of the Bob-Tach.
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
Always replace bent or broken wedges. or clevis (Item 4) are damaged, put the assembly in a
replace the damaged parts as needed.

the bolt (Item 1) [Figure 50-41-17], tighten to 48 - 54

BOB-TACH (POWER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Remove the Power Bob-Tach. (See Removal And

Figure 50-41-18
2 1
P-85669

Bob-Tach.
Remove the bushing (Item 2) [Figure 50-41-18] from the

Bob-Tach.
Figure 50-41-19
3
1
4
NA5472
Installation: The seal (Item 1) needs to be seated in the

Bob-Tach frame (Item 2) to a depth of 1,27 mm (0.050 in)
(Item 3) [Figure 50-41-19].
NOTE: To allow for the proper seal depth, it is

necessary to seat the bushing (Item 4) [Figure
50-41-19] fully into the Bob-Tach frame.

LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
1
P-90591
With a slide hammer, remove the rear lift arm stabilizer

pin (Item 1) [Figure 50-50-3].
2 Remove the stabilizer bar from the loader.
Figure 50-50-4
P106928
Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Installation: Tighten the retainer bolt and nut to 48 - 54
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593
Remove the retainer bolt (Item 1) [Figure 50-50-2] from

the stabilizer bar rear pivot pin at the lift arm.


LIFT ARMS (CONT’D) Figure 50-50-7
Link Removal And Installation
Figure 50-50-5
1
P106930
Remove the retainer bolt and nut (Item 1) [Figure 50-50-

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].
Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT’D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
1
P-90610
1
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).
P106931
At the right side upright, disconnect the two tilt cylinder
Remove the lift arm link from the loader. hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
1 1
P106932
At the left side upright, disconnect the three auxiliary

hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
P-90611
With a slide hammer, remove the pin (Item 1) [Figure 50-

P114629 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)
Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.
Remove the retaining bolt and nut (Item 1) [Figure 50-

50-13] from the pin on the rod end of the lift cylinder (both
sides).


Figure 50-50-16
1
2
P-90609
2
Remove the retaining bolt and nut (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being
removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.

REAR GRILLE Installing
Removing Figure 50-60-2
Figure 50-60-1 1
P107953A P107279
Align the edge of the rear grille under the shield (Item 1),
P109623
insert the tabs into the slots (Right Side Shown) (Inset)
[Figure 50-60-2], and lower.
Lift and pull the rear grille backward to remove from the Close the rear door.
loader [Figure 50-60-1].

REAR GRILLE (CONT’D)
Shield Removal And Installation
Figure 50-60-3
1 1
2
P114171
Remove the two bolts (Item 1) and remove the shield

(Item 2) [Figure 50-60-3].

REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
2 2
1
P-85695
Remove the top and bottom door hinge bolts and nuts
P101519 (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the main frame harness. hinge as shown.
Remove both rear lights (Item 2) [Figure 50-70-1] from Installation: Tighten the bolts and nuts to 34 - 38 N•m
the door. (See Rear Removal And Installation on Page (25 - 28 ft-lb) torque.
60-60-2.)
Remove the door from the loader frame.
Figure 50-70-2
2
1 1
P-90584
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker Disassembly And Assembly
Striker Removal And Installation Figure 50-70-5
Figure 50-70-4
5
1
3 4
2 1
P106584
1
P-85698B
Remove the locknut (Item 1) [Figure 50-70-5].
Remove the two striker bolts (Item 1) [Figure 50-70-4]. Remove the bolt (Item 2), spacer (Item 3) and roller (Item
4) from the bracket (Item 5) [Figure 50-70-5].
Remove the striker assembly from the loader.

REAR DOOR (TAILGATE) (CONT’D)
Striker Adjusting
WARNING
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
P-85698B
Loosen the striker assembly bolts (Item 1) [Figure 50-70-

6].
Align the striker assembly in the center of the mounting

holes.
NOTE: Tighten the top striker assembly bolt only,

until it will hold the striker assembly in the
center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.
Tighten both bolts (Item 1) [Figure 50-70-6] to 125 - 135


REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
2
1
P109094
Remove the door handle (Item 1) [Figure 50-70-9] from

P109092 the rear door.

Remove the bolt (Item 1) and nut (Item 2) [Figure 50-70-
7] from the latch.
Installation: Tighten the bolt (Item 1) and nut (Item 2) to

34 - 38 N•m (25 - 28 ft-lb) torque.
Figure 50-70-8
P109093
Remove the spacer (Item 1) [Figure 50-70-8] from the

latch.
Remove the spring (Item 2) [Figure 50-70-8] from the

latch.

FUEL TANK Figure 50-80-3
Remove the engine / hydrostatic pump assembly from

Page 70-10-14.)
Figure 50-80-1
1 2
1
P106871
Remove the hose (Item 1) and fitting (Item 2) [Figure 50-

80-3].
Figure 50-80-4
P114311
2
Remove the fuel vent hose (Item 1) [Figure 50-80-1].
Figure 50-80-2
1
1 1
P106868
3 Remove the bolts (Item 1) and the bracket (Item 2)

[Figure 50-80-4].
P114312
Remove the bolt / nut (Item 1), two bolts (Item 2) and fuel
fill hose (Item 3) [Figure 50-80-2].
Drain the fuel into a container.

FUEL TANK (CONT’D) Figure 50-80-7
Figure 50-80-5
1
2
P106874
Remove the bolt (Item 1) [Figure 50-80-7] and tubeline

P114187 clamp.
Figure 50-80-8
At the right side of the loader, remove the two main frame
bolts and nuts (Item 1). Remove the bracket (Item 2)
[Figure 50-80-5].

ft-lb) torque.
Figure 50-80-6
P106875
Remove the tank [Figure 50-80-8].

1
P114186
At the left side of the loader, remove the two main frame
bolts and nuts (Item 1) [Figure 50-80-6].

ft-lb) torque.

FUEL TANK (CONT’D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-11
Figure 50-80-9
1
1
2
2
P114271
P106961
Remove the two bolts (Item 1) and remove the fuel fill
hose (Item 2) [Figure 50-80-11].
from the fuel level sender. Figure 50-80-12
NOTE: Loosen and reposition the hoses (Item 2)

[Figure 50-80-9] as needed to access the
sender.
Figure 50-80-10
P114273
Remove the fuel fill screen (Item 1) [Figure 50-80-12].
P106963
Remove the fuel level sender (Item 1) [Figure 50-80-10].
Inspect the fuel level sender and replace if worn or

damaged.

CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
WARNING P-85675
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Inspect the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598
Figure 50-90-2
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P-85678 5].
Remove the crossbar from the pivot (Item 2) [Figure 50-

Remove the bolt and nut (Item 1) [Figure 50-90-3] to 90-5].
disconnect the lift pedal linkage from the crossbar.
Figure 50-90-6
Figure 50-90-4
2
1
P-85681
P-85680
Installation: Inspect the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation (Cont’d) After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-7 spool must travel full stroke without the pedal hitting the
floor panel.
1 The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
2
Figure 50-90-9
P-85675

the pedal linkage.
Remove the linkage (Item 2) [Figure 50-90-7].

P-85676
Figure 50-90-8
Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.
1
Figure 50-90-10
2
2
P-85675A

the pedal linkage. P-85675
Remove the linkage (Item 2) [Figure 50-90-8]. Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
the pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-90-10] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-90-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11
1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
the lift arms are secured by an approved lift arm Inspect the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.
to fall and cause injury or death. Figure 50-91-2
W-2059-0598

DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-91-3 spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.
Figure 50-91-4 P-85676
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]

from the pedal mounting bracket.
Figure 50-91-6
1
1
P-90981 2
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot.
P-85675
Repeat for other side.
Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Inspect the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And Installation

on Page 50-91-1.)
Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7
1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].

CONTROL PANEL
Description
Figure 50-100-1
NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings [Figure 50-100-1].
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT’D) Figure 50-100-2
Removal And Installation 2
DANGER
1
P106720
P-90328

• Keep out of this area when lift arms are raised 2
D-1009-0409
1
WARNING
P106718
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598 the back-up alarm wires (Item 2) [Figure 50-100-2] and
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286

1.)


CONTROL PANEL (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Two Piece Shaft
Figure 50-100-4 Remove Control Panel. (See Removal And Installation on

Page 50-100-2.)
Figure 50-100-6
2
1 1
2 2
2
P106716
Scribe a mark across the top of the steering linkage bars 1 1

P-85864
(Item 1) [Figure 50-100-4] which are connected to the
steering shaft on the control panel.
Remove the nuts (Item 1) and the steering stabilizers
Remove the four steering linkage bolts, nuts and rubber (Item 2) [Figure 50-100-6].
isolators (Item 2) [Figure 50-100-4].
Inspect and replace any damaged parts.
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage bolts to 47,5 - 54,2
Figure 50-100-5
3
3
1
2
1
4
3 3
P106717
Remove the two bolts (Item 1) and the knob (Item 2)

[Figure 50-100-5] from the lift arm bypass valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Two Piece Shaft (Cont’d) 2
Figure 50-100-7
2
2
P-85867
1
3 1 3 3
3 Remove the four bolts (Item 1) [Figure 50-100-9] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-100-9].
Figure 50-100-8 Figure 50-100-10
4
3
1
1
P-85861 P-85868
Remove the bolt and nut (Item 1), steering link, (Item 2), Remove the tie straps (Item 1), the four nuts (Item 2), and
and washers (Item 3) [Figure 50-100-7] and [Figure 50- the plate (Item 3) [Figure 50-100-10].
100-8].
Remove the control handle (Item 4) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8].

CONTROL PANEL (CONT’D) One Piece Shaft
Disassembly And Assembly (Cont’d) Remove Control Panel. (See Removal And Installation on
Page 50-100-2.)
Two Piece Shaft (Cont’d)
Figure 50-100-13
Figure 50-100-11
1 1
2
2
1 2 1
1 1
P-85864
P-85872
Remove the nuts (Item 1) and the steering stabilizers

Remove the two bolts (Item 1) from the bellcrank (Item 2) (Item 2) [Figure 50-100-13].
[Figure 50-100-11].
Remove the bellcrank from the bracket [Figure 50-100-

11].
Figure 50-100-12
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-12] for wear and
replace as needed.
Repeat the procedure for the other control handle

assembly.


1 2
One Piece Shaft (Cont’d) 2
Figure 50-100-14
1 1
2 2
1
1
P-85867
1
3 1 3 3
3 Remove the eight bolts (Item 1) [Figure 50-100-16] from
the control panel.
P-85865 Remove the control handle assembly (Item 2) [Figure

50-100-16].
Figure 50-100-15 Figure 50-100-17
4
3
1 1
P-85861 P-85868
Remove the bolts and nuts (Item 1), steering link, (Item Remove the tie straps (Item 1), the four nuts (Item 2), and
2), and washers (Item 3) [Figure 50-100-14] and [Figure the plate (Item 3) [Figure 50-100-17] on both sides.
50-100-15].
Remove the control handles (Item 4) [Figure 50-100-17].
Installation: Verify correct orientation of components


4
One Piece Shaft (Cont’d)
Figure 50-100-18
1
P126303
1 1
2
Inspect the shaft (Item 1), bellcrank (Item 2), four
bushings (Item 3) and the two torsion bushings (Item 4)
[Figure 50-100-20] for wear and replace as needed.
P126302
Linkage Removal And Installation
Figure 50-100-19
WARNING
2
2 Never work on a machine with the lift arms up unless
W-2059-0598
1
1
P126301
WARNING
P126310

Remove the two bolts (Item 1) from the bellcrank (Item 2) of the frame before running the engine for service.
[Figure 50-100-18] and [Figure 50-100-19]. Failure to use jackstands can allow the machine to
Remove the bellcrank assembly (Item 2) [Figure 50-100- W-2017-0286
18] and [Figure 50-100-19] from the bracket.
1.)


Linkage Removal And Installation (Cont’d)

1
Figure 50-100-21
2
P-48631
2
Remove the nut (Item 1) from the end of the centering
P106716 spring shoulder bolt (Item 2) [Figure 50-100-22].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-21] which are connected to the Installation: Tighten the centering spring bolt and a
steering shaft on the control panel. NEW locknut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage bolts and nuts (Item 2) Figure 50-100-23
[Figure 50-100-21].
Installation: Align the marks on the steering linkage 1

bars. Tighten the steering linkage bolts to 47,5 - 54,2
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-12.)
P-48632
Slide the centering plate (Item 1) [Figure 50-100-23] as

shown to remove it from the hydrostatic pumps.

Figure 50-100-24
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Inspect for wear on the centering blocks (Item 1) [Figure
P-48630 50-100-25].
If the centering blocks are worn, remove the bolts (Item

The centering plate assembly consists of the following 2) [Figure 50-100-25]. Remove the centering blocks.
parts: bolt (Item 1), bushing (Item 2), washer (Item 3),
spacer (Item 4), spring (Item 5), locknut (Item 6), NOTE: If the centering blocks are worn, the blocks
centering plate (Item 7) and guide bushings (Item 8) can be removed and rotated 180 degrees and
[Figure 50-100-24]. reinstalled.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.
NOTE: The washers go between the bolts and the

centering plate.

Figure 50-100-26
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-28].

P-54617
Remove the pintle base (Item 2) [Figure 50-100-28].
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-29
26] from the pintle.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-26].
Figure 50-100-27 2
1 3
1
2 P-48659
4
3 Installation: Install the pintle base (Item 1) onto the
pump shaft (Item 2). The top of the pintle base must be
level with the top of the pump shaft. Tighten the bolts
2 (Item 3) [Figure 50-100-29] to 47,5 - 54,2 N•m (35 - 40 ft-
lb) torque.
1
P-48624 NOTE: After installing the linkage onto the
hydrostatic pumps the linkage neutral
adjusting procedure must be performed. (See
Remove the bolt and nut (Item 1) [Figure 50-100-27]. Linkage Neutral (Adjusting) on Page 50-100-
12.)
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering control lever (Item 4) [Figure 50-100-27] for
damage and replace as needed.
NOTE: The washers (Item 2) [Figure 50-100-27] are

hardened, and must be replaced with Bobcat
Parts.

CONTROL PANEL (CONT’D) NOTE: Anti-seize should be used on the adjusting
screw to prevent corrosion and allow free
Pintle Arm Disassembly And Assembly movement while adjusting.
Figure 50-100-30 Figure 50-100-32
2
4
3 1
2
3
1 P-48619
P-54624
Using a bushing driver (Item 1) remove the torsion

Remove the nut (Item 1) from the pintle roller cams (Item bushing (Item 2) by pressing the bushing through the
2) and inspect the pintle roller cams and washers (Item 3) pintle arm into an oversized socket (Item 3) to catch the
for damage [Figure 50-100-30]. torsion bushing [Figure 50-100-32].
Inspect the torsion bushing (Item 4) [Figure 50-100-30] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-32] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-100-31 arm should be the same.
4
2
P-54626
Remove the pintle base (Item 1) [Figure 50-100-31] from

the pump shaft.
Remove the retaining bolt (Item 2), adjusting screw (Item

3) and neoprene dampener (Item 4) [Figure 50-100-31]
from the pintle base.
Inspect parts for wear and damage, replace as needed.

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
Kit - 7022042 Remote Start Tool (Service Tool) or 1

MEL1563 Remote Start Tool.
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Lift and block the loader. (See Procedure on Page 10-10- P106719
1.)
Figure 50-100-33 Loosen the bolt / nut (Item 1) [Figure 50-100-34] only
until the tension is released from the torsion bushing.
3
Figure 50-100-35
2
1
P-48450A
Tool that may assist in the neutral adjustment [Figure 50- P-54613
100-33].
To make this tool use a locking grip C-clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-100-35].
[Figure 50-100-33] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-100-33] is torsion bushing (Item 2) [Figure 50-100-35] to
also needed. The centering block is placed as shown and turn freely between the torsion bushing and
welded to the C-clamp. the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT’D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-36
W-2017-0286
1
Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL KIT - MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7217666 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.
[Figure 50-100-36] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-37
Tighten the bolts (Item 3) [Figure 50-100-37] to 47,5 -
54,2 N•m (35 - 40 ft-lb).
3
NOTE: Inspect for slack between centering blocks
and pintle cams. If there is excessive slack
repeat above steps [Figure 50-100-36] and
[Figure 50-100-37].
1
P-48451
A modified locking grip C-clamp and steering block

shown may be used to help in aligning the centering
blocks [Figure 50-100-33].
Install the centering block (Item 1) on the inside of the

pintle cams and the C-clamp (Item 2) [Figure 50-100-37]
around both centering blocks.
Lock the C-clamp in place.

Linkage Neutral (Adjusting) (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-38
2 1
1
P-54610

counterclockwise until forward creep is seen.
Turn the adjustment screw (Item 1) [Figure 50-100-39] to

a point between forward and reverse where there is zero
P-48632 creep.
Stroke the left steering lever to forward and allow the

Loosen the left pump pintle adjustment lock bolts lever to return to neutral. Stroke the left steering lever to
(Item 1). (The right pump pintle adjustment lock bolts are reverse and allow the lever to return to neutral. Check
(Item 2) [Figure 50-100-38].) Loosen the bolts enough to that there is zero creep when the lever returns from either
allow free movement between the pintle arm and the direction, on the left side. Turn the adjustment screw (if
pintle base. necessary) until zero creep is obtained.
NOTE: If the bolts are too loose or too tight, the

neutral adjustment may be affected.
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
neutral adjustment.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-40
2 1
2 1
P-48632
Torque the left pump pintle adjustment bolts (Item 1)

[Figure 50-100-40] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment bolts (Item 2)

[Figure 50-100-40] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the tires do not

come to a complete stop, repeat the adjustment
procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-40] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and reinstall the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with preapplied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-16.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting procedure, inspect the torsion
bushings at the pump and at the bellcranks to 1
be sure the bushings are not binding or too
loose, which will affect the procedure.
WARNING
P106719
support device. Failure to use an approved lift arm Loosen the bolt / nut (Item 1) [Figure 50-100-41] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-42
1
WARNING
of the frame before running the engine for service. 2
W-2017-0286

1.)
P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-100-42].
Preload tension in the torsion bushings must be removed The bolts must be loose enough to allow the torsion
before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-42] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-43
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-45].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-43] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-44 Figure 50-100-46
3 2
2
4
1
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the pintle base bolt
10 mm (3/8 in) thick spacer (Item 1) between the pintle (Item 1) and both of the upper pintle bolts (Item 2) are
arm cam (Item 2) and the centering block (Item 3) tightened to 48 - 54 N•m (35 - 40 ft-lb) torque. There must
[Figure 50-100-44]. be no play between the pintle arm and the square pump
shaft [Figure 50-100-46].
Verify the cam mounting nuts (Item 4) [Figure 50-100-44]

are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-47
P-51132
1
Remove the spacer (Item 1) [Figure 50-100-49].
P106716
Figure 50-100-50
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
47] on each steering linkage bar. 2
Figure 50-100-48
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-50].
P-90615
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-100-
48]. Use a locking plier, clamp the two linkage bars
together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Inspect the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-100-51 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-52] and [Figure
50-100-53] in until it contacts the bellcrank.
1 Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,0 m (10

ft) of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P106719 adjustment bolt (Item 1) [Figure 50-100-52] and [Figure
50-100-53] in.
Tighten the two bolts and nuts (Item 1) [Figure 50-100- If the drift is excessive to the right, turn the left
51] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bellcranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation and adjusting of adjust one bolt for each test drive. Only move
the linkage, the Back-up Alarm must be inspected. (See each bolt a maximum of one turn for each test
Inspecting on Page 60-210-1.) drive. This will help prevent over-correction
and excessive reduction in travel speed.
Figure 50-100-52
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-100-54
P106721

end of the shocks connected to the steering linkages.

other end of the shocks connected to the brackets on the
control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-101-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three bolts (Item 1) [Figure 50-101-1] that

DANGER secure the controller.
Figure 50-101-2
1
1
1
2
1
P-90328
AVOID DEATH
can cause lift arms to drop. 3
1 1
P-85881
D-1009-0409
Remove the ten panel bolts (Item 1) [Figure 50-101-2].
Remove the lift arm bypass knob and rubber washer

(Item 2) [Figure 50-101-2].
WARNING Remove the control panel (Item 3) [Figure 50-101-2].
W-2059-0598

CONTROL HANDLE / LEVER Lever Removal And Installation
The control handles / levers are used to control the 2

forward and reverse travel. 3
The control handles / levers are mounted to the control

panel assembly.
P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-110-1].
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate until the

lever cannot be moved either right or left when seated in
the operator’s seat.

CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-110-2
P-85883A
Remove the rubber boot (Item 1) [Figure 50-110-2].

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Description NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
Figure 50-111-1 sensor, actuator or ACS Controller. (See Lift
And Tilt Calibration (ACS) on Page 60-160-11.)
Figure 50-111-2
1
P-21879
The control handles / levers are used to control the

P-85882
forward and reverse travel and the lift and tilt
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts until the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont’d)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector [Figure 50-111-3].
Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two screws (Item 1) [Figure 50-111-

P-21861 6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two screws (Item 1) [Figure 50-111-
7] from the handle sensor.
Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)

torque.
Figure 50-111-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, route the switch handle wire harness
4 (Item 1) [Figure 50-111-9] and [Figure 50-111-10] for
3 proper return of the control handle to neutral and
7 minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2
P-21882 [Figure 50-111-10] as shown away from stop
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-111-8]

can only be replaced as a complete assembly.
Inspect the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

Handle Removal And Installation
Figure 50-111-11
1
1 N-17384
Remove the rubber boot (Item 1) [Figure 50-111-13]

P-21879 from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page
50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the screws (Item 2) [Figure 50-111-14]
P16534 from the handle assembly.
Installation: Tighten the screws to 4 N•m (35 in-lb)

Remove the switch handle (Item 1) [Figure 50-111-12]. torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT’D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item 2) lever.
[Figure 50-111-15] from the handle.
Remove the four nuts (Item 2) and the plate (Item 3)
Inspect all parts for wear and replace as needed. [Figure 50-111-17].
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate until the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Inspect the mounting bolt (Item 1) [Figure 50-111-16]

that connects the handle to the handle sensor unit for
wear, replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A
Remove the rubber boot (Item 1) [Figure 50-111-18].

CONTROL HANDLE / LEVER (SJC) Joystick Testing
Description See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to test function.
The control panel has two electronic handles that control
the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.

CONTROL HANDLE / LEVER (SJC) (CONT’D) Figure 50-112-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-2.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890
Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the four bolts (Item 1), washer (Item 2), and
remove the right access panel (Item 3) [Figure 50-120-
Remove the four bolts, (Item 1), washer (Item 2), and 2].
remove the left access panel (Item 3) [Figure 50-120-1].

ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-121-3
Figure 50-121-1
4
2
1
1
P101581
P100731
Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-121-3].
Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-121-1]. Loosen the bolt (Item 3) and remove the engine speed
control pedal (Item 4) [Figure 50-121-3].
Figure 50-121-2
Figure 50-121-4
1
1
1 1
1
2
P100732 1
P101584
Remove the four bolts (Item 1), and remove the left
access panel (Item 2) [Figure 50-121-2]. Remove the bolts (Item 1) [Figure 50-121-4] and remove
the right access panel.

WINDOW (REAR)
Rear Window Identification There are two different procedures for removing the rear
window from your machine:
Figure 50-130-1
1. This window is equipped with latches [Figure 50-130-
Latches Rubber Cord 1].
2. This window is equipped with a rubber cord and tag

2 [Figure 50-130-1].
NOTE: Use these procedures to remove the rear

1 window only under emergency conditions.
Damage to machine may occur.
P-85309B P-64994D
—————————————————————————————————————————————————————
Rear Window Removal (Latches) Rear Window Removal (Rubber Cord)
Figure 50-130-2 Figure 50-130-4
P-85309A P-64994C
Turn both latches (Item 1) [Figure 50-130-2] in until they Pull on the tag on the top of the rear window to remove
disengage from the window frame. the rubber cord [Figure 50-130-4].
Push the rear window out of the rear of the operator cab. Push the rear window out of the rear of the operator cab.
Figure 50-130-3 Figure 50-130-5
P-90676 P-90676
Exit through the rear of the operator cab [Figure 50-130- Exit through the rear of the operator cab [Figure 50-130-
3]. 5].

WINDOW (REAR) (CONT’D) External Access (Rear Window With Rubber Cord)
External Access (Rear Window With Latches) A kit is available to allow removal of the rubber cord
equipped rear window from outside the machine.
Figure 50-130-6
Figure 50-130-8
P-90669A
P13982
The rear window can be removed from outside the loader

using a T40 TORX® Drive tool. Turn both screws (Item 1) Pull both handles (Item 1) [Figure 50-130-8] up and out
[Figure 50-130-6] counterclockwise until the latches to remove the rear window.
disengage from the window frame. Pull the top of the
window away from the cab and lift up to remove.
OR
Figure 50-130-7
P-90669C
A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools.
Turn both knobs (Item 1) [Figure 50-130-7]

counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.

WINDOW (REAR) (CONT’D) Figure 50-130-10
Disassembly And Assembly (Latches)

8
Figure 50-130-9 7
1
6
1
2
3
4
5
P-85704A
Inspect and replace any damaged parts.

P-85705
The items listed below refer to [Figure 50-130-10].
Remove the screw (Item 1) from the latch [Figure 50- 1. Latch
130-9]. 2. Spacer
Installation: Tighten the screw to 21 - 23 N•m (180 - 200 3. Bushing
in-lb) torque. 4. O-ring
5. Washer
6. Screw
7. Rear Window
8. Seal

WINDOW (TOP) Figure 50-131-3
Figure 50-131-1
1 1
P107298A
1 1
To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].
Figure 50-131-4
Figure 50-131-2
1 1
1 1
2
P-85807
P-85807
Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive (Item 2) [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.
Remove the existing adhesive from the mounting

surfaces.
Prime and paint any bare metal or scratches.
Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.
Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

WINDOW (TOP) (CONT’D)
Figure 50-131-5
1 1
1 1
P-85808
From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-5].
Tighten the nuts (Item 1) [Figure 50-131-5] to 9 - 10 N•m

(80 - 90 in-lb) torque.
NOTE: Allow 2 hours of cure time before exposing to

direct sunlight or significant temperature or
humidity changes.

WINDOW (SIDE) Figure 50-132-3

Figure 50-132-1
1 1 2 3
P-85819
Remove the spring (Item 1), knob (Item 2), and sleeve
(Item 3) [Figure 50-132-3] from the window assembly.
Figure 50-132-4
P-85314A
Remove the plastic cap (Item 1) [Figure 50-132-1].
Figure 50-132-2 1 1
1
1
1
1 1
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-4].
P-85821 Installation: Tighten the bolts to 9 - 10 N•m (80 - 90 in-

lb) torque.
Remove the nut (Item 1) [Figure 50-132-2]. Remove the window assembly.
Installation: Tighten the nut flush to the end of the bolt. NOTE: The window assembly can only be replaced
as a complete unit.

CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

1
installed kit.
Open the cab door.
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
1 2
P-85781A
NOTE: Later models route the washer fluid hose

differently and will not require this step.
Disconnect the wire harness (Item 1) and washer fluid

hose (Item 2) (If equipped) [Figure 50-140-1].
Figure 50-140-2
3
2
1 2
1 P-85837
Remove the bolts (Item 1) [Figure 50-140-4] and nuts

from the cab.
P-85588A P-85589A
Remove the hinges (Item 2) [Figure 50-140-4] from the

Rotate and pull the clip (Item 1) out of the gas spring cab.
socket. Pull the gas spring socket (Item 2) straight off the
ball stud fitting (Item 3) [Figure 50-140-2]. Installation: Tighten the bolts to 9,6 - 10,7 N•m (85 - 90
in-lb) torque.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Item 1 and 2) and the wiper arms (Item
3) [Figure 50-140-5].
2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque. Tighten the nut (Item 2) to 9 - 11 N•m 1
(80 - 97 in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), latch (Item 2), and spring (Item
3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts to 31 - 34 N•m (270 - 300

in-lb) torque.
1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4 1
P106481
3
4
P-85836
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
Remove the bolt (Item 1), latch (Item 2), and spring (Item door and the cab or the striker and the latch.
3) [Figure 50-140-9].
Adjust as needed. (See Adjusting on Page 50-140-4.)
9]. Figure 50-140-12
Installation: Tighten the nuts to 31 - 34 N•m (270 - 300 CORRECT CORRECT

in-lb) torque.
Figure 50-140-10
1 1
P106482
2 When the striker or latch is adjusted properly there will be

2 no gap (Item 1) [Figure 50-140-12] between the door
P106380 and the cab or the striker and the latch.
After verifying alignment check for proper operation. (See

Disconnect the wire harness (Item 1) [Figure 50-140- Checking Operation on Page 50-140-4.)
10].
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
2
1
P-85413F
P-85830
Sit in operator’s seat. Turn the key ON, lower the seat bar
and close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.
Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P106587
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch inspect the alignment

of the door sensor. (See Aligning on Page 50-140-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837
Adjustable armrests (Item 1) [Figure 50-150-1].

ARMREST (CONT’D) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.
P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness (Item 2) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

Remove the joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8
1
P-90838
2
Lift up on one edge and remove the armrest cover (Item
1) [Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts, bolts (Item 1) and the support tube
(Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts, washers (Item 1) and the armrest

shell (Item 2) [Figure 50-150-6].

Figure 50-150-9
3
1 1
2
2
P-90844
1
Remove the two nuts, bolts (Item 1) and the side rail
P100825 (Item 2) [Figure 50-150-11] from the armrest mount.
Repeat for the other side.

Figure 50-150-10
7 4
3
6 2
5
1 P100824
Remove the nut (Item 1), washer (Item 2) spring (Item 3)

Remove the spacer (Item 4), washer (Item 5), plastic

washer (Item 6) and the bolt (Item 7) [Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

LEFT SIDE LOWER PANEL Figure 50-160-3
Remove the seat. (See Removal And Installation on

Page 50-31-1.)
Remove the 3-Point seat belt retractor (If equipped). (See

3-Point Seat Belt Removal And Installation on Page 50-
31-4.)
Raise the operator cab.

1
Figure 50-160-1
1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)

1 [Figure 50-160-3] from the left side lower panel.
1 Figure 50-160-4
P-90897 1
1
Remove the five plastic rivets (Item 1) [Figure 50-160-1].
Lower the operator cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

[Figure 50-160-4] from the left side lower panel.
P-90867
Remove the storage compartment (Item 1) (if equipped)

[Figure 50-160-2] from the left side lower panel.

LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets, anchors (Item 1) and the
screw (Item 2) [Figure 50-160-5].
Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-9
1
1 1
P-90859
Disconnect the HVAC or radio wire harnesses (Item 1)

[Figure 50-160-9] (if equipped).

LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-12
Figure 50-160-10
1
1 1
1
1
1 1
P-90866
1
P-90860 remove the speaker from the left side lower panel.
Figure 50-160-13
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Figure 50-160-11
1
P-90864
Remove the three screws (Item 1) [Figure 50-160-13]

P-90865 and remove the washer tank from the left side lower
panel.
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Remove the seat. (See Removal And Installation on

Page 50-31-1.) 1
Raise the operator cab. 1
Figure 50-170-1
1 1
1 P-90870
1
Remove the three plastic rivets, anchors (Item 1) and the
screw (Item 2) [Figure 50-170-3].
1
Figure 50-170-4
1
P-90897
Remove the five plastic rivets (Item 1) [Figure 50-170-1].

2
1
Lower the operator cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-5
P-90872
Pull the right side lower panel (Item 1) [Figure 50-170-5]

rear out and away from the side of the cab.
NOTE: Pull the right side lower panel away from the
side of the cab far enough to access the wire
harness.
Figure 50-170-6
P-90873
Disconnect the wire harnesses (Item 1) and the antenna

(Item 2) [Figure 50-170-6] (if equipped with radio).
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D) Figure 50-170-9
Figure 50-170-7
1
1
P-90875
Remove the nut, washer and cover (Item 1) [Figure 50-

P-90879 170-9] from the headphone jack.
Remove the headphone jack from the right side lower

Remove the plastic nut and the lock washer (Item 1) panel.
[Figure 50-170-7] from power port. Remove the power
port from the right side lower panel. Figure 50-170-10
NOTE: The lock washer must be replaced with a new

lock washer when it has been removed.
Figure 50-170-8
2 1
1
1
P-90877
1
1
P-90876

remove the speaker from the right side lower panel.
P-90881
Depress the tab (Item 1) [Figure 50-170-8] and remove

the radio from the right side lower panel.
Installation: Insert a screwdriver into the slot (Item 2)

[Figure 50-170-8] to lock the tab into place.

HEADLINER Figure 50-180-3
Remove the cab light (if equipped). (See Cab Light

Removal And Installation (Earlier Models) on Page 60-
60-2.) or (See Cab Light Removal And Installation (Later
Models) on Page 60-60-3.)
Figure 50-180-1
1
1 1
P-90895
Remove the air duct (Item 1) [Figure 50-180-3] (if

equipped).
2 Figure 50-180-4
P-90893
Remove the two screws (Item 1) and the rear shelf (Item 1
1
2) [Figure 50-180-1] (if equipped).
NOTE: The rear shelf has two panel clips on the

bottom. Lift vertically to remove the shelf. 1
1
Installation: Tighten the screws to 2,3 N•m (20 in-lb)
torque.
2
Figure 50-180-2 P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
Installation: Route the cab light wire harness in the

groove on the topside of the headliner (if equipped with
HVAC).
1
P-90894
Remove the air duct (Item 1) [Figure 50-180-2] (if

equipped).

FAN DUCT PANELS Figure 50-190-3


Remove the fan duct. (See Fan Duct Removal And

1
Figure 50-190-1 P106816

1
IMPORTANT
damage the system.
I-2003-0888
P106665
Figure 50-190-4
Figure 50-190-2
1
1
3
1
2
P106666
P106664

Remove the bolts (Item 1) [Figure 50-190-1] and (Item 1)
[Figure 50-190-2] and remove the plate (Item 2) [Figure
50-190-2].

FAN DUCT PANELS (CONT’D)
Figure 50-190-5
P106668
Remove the bolts (Item 1) [Figure 50-190-5] and remove

the plate (Item 2).

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors - Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Mainframe Harness Connectors - SJC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Engine Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-11
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-11
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . . 60-50-11
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-3
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System 
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-5
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-110-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3

ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-171-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3
ENGINE SPEED CONTROL (HAND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

ENGINE SPEED CONTROL (FOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-231-1

Foot Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-231-4
CAMSHAFT AND CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . 60-240-1

TELEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-250-2

647 of 1290
648 of 1290
649 of 1290
650 of 1290
651 of 1290
652 of 1290
653 of 1290
654 of 1290
655 of 1290
656 of 1290
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CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C434-1 LEFT FRONT WORKLIGHT (37W) 2 13 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C434-2 LEFT FRONT WORKLIGHT (50W) 2 13
C105 HYD CHARGE PRESSURE SENSOR 3 9 C435-1 RIGHT FRONT WORKLIGHT (37W) 2 13 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C435-2 RIGHT FRONT WORKLIGHT (50W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C108 HYD TEMPERATURE SENDER 2 9 J2A AUX CONTROLLER 34 9,12,15

C110 ALTERNATOR 2 8 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C111 HARNESS ENGINE START CONN 3 8 C441 TWO SPEED SOLENOID 2 15
C112 HYD OIL FILTER SWITCH 2 9 C446 HYDRAULIC FAN 2 9 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C449 LEFT JOYSTICK(CAB HARN) 4 7
C114 HAND THROTTLE 6 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7
C479 LEFT PANEL(BLACK) 12 7,10 SW1 BRAKE SWITCH 6 10
C480 LEFT PANEL(GRAY) 12 10 SW2 BEACON SWITCH 6 15
C482 SEATBAR SENSOR 3 11 SW3 HAZARD SWITCH 6 15
C118 ENG-CROSSOVER 4 8 C483 TEMP CONTROL SWITCH 3 14 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C126 HORN 2 15 C486 AC COMPRESSOR 2 14
C129 CAB ACCESSORY 3 11 C489 MFR ACCESSORY 2 5,6 SW5 POWER BOBTACH SWITCH 6 15
C169 ENGINE CAN (Diagnostic) 6 7 SW6 BUCKET POSITION SWITCH 6 15
C212 POWER SOCKET 2 11 SW9 TRAVEL CONTROL SWITCH 6 10

C252 WASHER ADAPTER INTMD 2 11 SW10 BLOWER SWITCH 6 14
C253 WASHER PUMP 2 11 C499 PTOL 4 10 SW11 AC SWITCH 3 14
C277 AIR RIDE SEAT 6 15 C500 RH KEY SWITCH 6 10 SW12 DPF SWITCH 10 10
C278 RIGHT SPEAKER 2 15 C503 RH DLX PANEL 6 7,10
C279 LEFT SPEAKER 2 15 C602 LEFT REAR TAIL LIGHT 2 13 T1 BATT GROUND 1 6
C308 BRAKE SOLENOID 2 9 C603 RIGHT REAR TAIL LIGHT 2 13 T2 BUZZER GROUND 1 10
C350 AC EVAPORATOR SWITCH 2 14 C606 POWER BOBTACH OPEN 2 15 T3 FLASHER 2 15
C355 FUEL HARNESS 6 8,15 C607 POWER BOBTACH CLOSE 2 15 T6 BATT GROUND 1 6
C404 BU ALARM-MFR HARN 2 5,12 C610 HVAC DUCT FAN 2 14 T8 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C611 BLOWER MOTOR 4 14 T10 ENGINE SYSTEM GROUND 1 6
C406 FUEL SENDER 2 8 C630 THERMOSTAT 3 14 T13 BUZZER POWER 1 10
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C635 HEATER VALVE 6 14
T14 PRE HEATER 1 8
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C667 DOOR HARNESS 6 11 T15 RIGHT REAR WORK LIGHT(+) 1 13
C410 LEFT HANDLE (MAN/ACS) 10 12 C670 EXTERIOR BEACON HARNESS 6 15 T16 RIGHT REAR WORK LIGHT(-) 1 13
C411 LEFT HANDLE 5 WAY 5 15 C676 RADIO 6 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 T18 LEFT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 T19 BACKUP ALARM 1 12
C418 FRONT ROD 2 9 T20 BACKUP ALARM(GND) 1 12
C419 FRONT BASE 2 9 T32 ECU CASE GROUND 1 6
C420 HYD LOCK 2 9
C421 TILT SPOOL LOCK 3 12
C422 LIFT SPOOL LOCK 3 12
C423 BUCKET POSITION SOLENOID 2 15
C425 BRAKE SOLENOID 3 9
C426 CAN(Remote Start Tool, ACD) 7 7
C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,11,15
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 1 of 16
(PRINTED NOVEMBER 2016)
Printed In U.S.A. 7254941 (0)
663 of 1290
J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT BASE RETURN B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR RELAY - A B-4 RUN SIG ENG ECU
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY - D B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE
A-11 LH PADDLE RIGHT B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 LH PADDLE LEFT B-12
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL
A-13 RH RIGHT ROCKER UP B-13 FRONT BASE SOLENOID
A-13 TRACTION LOCK FDBK RELAY - D B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17 RH PWM LOW
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT ROD RETURN B-18 RH PWM SIGNAL
A-18 HYD FAN RETURN B-18
A-19 B-19 FRONT ROD
A-19 PTOL LED B-19 HYD FAN
A-20 LH SW-FLOAT (ACS) B-20 CAN LOW 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21 RH TRIGGER
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 LH RIGHT ROCKER DOWN B-22 SWITCHED POWER
A-22 STARTER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23 RH PWM HIGH
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 B-25
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27
A-28 LH RIGHT ROCKER UP
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30 RH LEFT ROCKER UP
A-30 HVAC FDBK RELAY - B
A-31 RH LEFT ROCKER DOWN
A-31 LIGHT FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1
HARNESS PART NUMBER

MF MFR MAN 7223849
EXMF MFR MAN 7265268
DLX CAB 7253375 Printable Version Click Here
STD CAB 7227905
STD FUEL
DLX FUEL
7149219
7266824
WIRING SCHEMATIC
BCT ENG START 7220812 (MANUAL MACHINE)
TAILGATE DOM 7217484
TAILGATE EUR 7217483 S570 (S/N ALM413083 & ALM413264 -
SUSP JSTK 7163706
BRAKE ADAPTER 7165061 ALM415479)
WHL 2 SPD ADP 7159366
TRK 2 SPD 7214626 (S/N B3GZ11001 - B3GZ11088)
Sheet 2 of 16
664 of 1290 Printed In U.S.A. 7254941 (0)
LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
3 SW POWER HYDRAULICS PAGE 9
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
4 GND CAB DISPLAY PAGE 10
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CAB PAGE 11
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
MANUAL CONTROLS PAGE 12 WIRE BREAK
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK
LIGHTS PAGE 13 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 14
ENGINE 8000 THROUGH 8999 TAN TAN
13 OPTIONS PAGE 15 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
14 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
15
19 IGN SW INPUT
21
24
25
A B C D
26
28 MAF FREQ
29 PEDAL POS 2
35 MAF TEMP
34 WATER FUEL SENSOR GND E F G H

45 ECU RELAY GND
47 CAN 1 LO
48 CAN 1 HI
J K L M
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 3 of 16
665 of 1290
UNSWITCHED BATT POWER C408 1240 RED/WHT
SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
SP7
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SHEET 10
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A SP2 J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 10
C479 LH PANEL (BLACK)
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps
FUSE 15 OPEN
T4 1
FUSE 17 OPEN
SHEET 8
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 14
FUSE 3 30 A FRC1 HVAC RELAY
1310 RED 1360 RED/WHT SHEET 9
FRC 1 TRACTION LOCK RELAY
FUSE 1 15 A 1320 RED/WHT
SHEET 13
FRC1 REAR LIGHT RELAY
1340 RED SHEET 13
SP26 FRC1 FRONT LIGHT RELAY
1330 RED/WHT
FUSE 9 50 A SHEET 13
1060 RED 1065 RED/WHT SHEET 8 FRC1 FRONT LIGHT RELAY
FRC1 PRE HEATER RELAY
1335 RED FUSE 20 5 A
1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
1325 RED FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT SHEET 5
FRC 1 ENGINE ECU RELAY
1445 RED/WHT
SHEET 8
FUSE 18 25 A FRC1 PRE HEATER RELAY
C426 REMOTE RUN, ACD
1460 RED/WHT
FUSE 22 25 A SP24 SHEET 15 C412 LH HANDLE HORN
1040 RED 1490 RED/WHT 1410 RED/WHT
SHEET 15 C408 CAB-MFR CONN
(OPTIONS)
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
1055 RED
SP60
WIRING SCHEMATIC
1050 RED
SHEET 5 (MANUAL MACHINE)
FRC1 SWITCHED PWR RELAY
1030 RED
SHEET 8 S570 (S/N ALM413083 & ALM413264 -
FRC1 STARTER RELAY
ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 4 of 16
666 of 1290
FRC1
ENGINE ECU
+12V RELAY - G
PWR
SWITCHED POWER 1506 RNG/WHT
J7A ENGINE ECU
1
SHEET 4 1035 RED/WHT 30
87 1504 RNG/WHT SP54 1507 RNG/WHT 3
1509 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45
FRC1 FUSE RELAY CENTER

1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT SHEET 8 ENG-CROSSOVER
C404
1720 RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A C489
1750 RNG/WHT 1780 RNG/WHT A MFR ACCESSORY
SP50
FUSE 6 25 A 1850 RNG/WHT
1760 RNG/WHT
SHEET 11 C438 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 10 SW12 DPF SWITCH (UNUSED)
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 15 C408 CAB-MFR CONN (BKT POSITION) SHEET 10 C479 LH PANEL (BLACK)
1940 RNG/WHT
1520 RNG/WHT SHEET 10 T13 LH PANEL BUZZER
SHEET 12 C410 LEFT HANDLE 1930 RNG/WHT
SHEET 10 C499 RH PANEL PTOL
1530 RNG/WHT SHEET 12 C409 RIGHT HANDLE 1775 RNG/WHT
SHEET 10 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 10 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 11 SW4 H/ISO SWITCH
SP11 1950 RNG/WHT
SHEET 10 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT 1590 RNG/WHT
SHEET 10 C503 RH DELUXE PANEL
1765 RNG/WHT FUSE 7 25 A SP65 SP42
SHEET 7 C426 REMOTE RUN, ACD
SP25
1725 RNG/WHT
SHEET 7 C169 ENGINE CAN
FUSE 8 25 A
1580 RNG/WHT
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS) Printable Version Click Here
FRC1 FUSE 23 15 A
SWITCHED
POWER RELAY - A
1815 RNG/WHT 1800 RNG/WHT
SHEET 8 C110 ALT EXCITATION WIRING SCHEMATIC
+12V
SHEET 4 1050 RED

PWR 30
3450 LBL 21
(MANUAL MACHINE)
87 J1A C428
SHEET 6
2055 BLK GND 85 86 3380 LBL 4
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
S570 (S/N ALM413083 & ALM413264 -
SP37
1920 RNG/WHT 9 1920 RNG/WHT 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK ALM415479)
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK (S/N B3GZ11001 - B3GZ11088)
Sheet 5 of 16
7254941 (0)
Printed In U.S.A.
667 of 1290
GROUND
2320 BRN
SHEET 9
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 11 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN 2230 BRN 17
SHEET 9
C108 HYD TEMP SENDER SP12
2190 BRN
2 SHEET 9
2001 BLK C105 HYD CHG PRESSURE SENDER
4 SP53 2810 BLK 2180 BRN
J7A 2002 BLK
SHEET 8
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 8
C405 AIR FILTER SWITCH
T32 2004 BLK
ECU CASE GND SHEET 8 2690 BRN
C408 CAB-MFR CONN (HAND THRTL)
2080 BLK
SHEET 7
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 10 2765 BLK
C479 LH PANEL SHEET 13
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
C499 PTOL 2745 BLK
SHEET 14
2960 BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 10 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B SP3 2790 BLK T8
GWY CTRLR 15 2500 BLK SHEET 11 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 10
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 15
SHEET 10 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 11
SHEET 10 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SP47 SP28
2830 BLK 2900 BLK 1 2900 BLK
SHEET 15
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 10 SHEET 15
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 15 SHEET 9
C126 HORN C425 BRAKE
2620 BLK
SHEET 13 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 12 2650 BLK
SP51 2600 BLK B 2390 BLK T1 T10
T20 BU ALARM 2600 BLK 2015 BLK
2640 BLK SP6 BATT GND SHEET 8 ENGINE
SHEET 13 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT 2455 BLK
SHEET 15
2610 BLK C423 BKT POSITION SOLENOID
C603 RH REAR LIGHT SHEET 7
C426 REMOTE RUN, ACD SP27
2630 BLK
SHEET 13 2715 BLK
T18 LH REAR LIGHT SHEET 7
C169 ENGINE CAN
2290 BLK Printable Version Click Here
2045 BLK SHEET 14
SHEET 13 D4 COMPRESSOR DIODE
SHEET 9
FRC1 TRACTION LOCK RELAY
2035 BLK
WIRING SCHEMATIC
2115 BLK SP55 2105 BLK
SHEET 13
FRC1 FRONT LIGHT RELAY (MANUAL MACHINE)
2055 BLK
SHEET 5
FRC1 SWITCHED POWER RELAY S570 (S/N ALM413083 & ALM413264 -
SHEET 14 2030 BLK
FRC1 HVAC RELAY
2005 BLK
ALM415479)
SHEET 8
FRC1 STARTER RELAY
2120 BLK
(S/N B3GZ11001 - B3GZ11088)
SHEET 13
FRC1 FRONT LIGHT RELAY Sheet 6 of 16
668 of 1290
CAN BUS
* DLX CAB HARN 7253375 ONLY
J7A
ECU CNTRLR (NOT IN STD CAB HARN 7207731) J1B
GWY CTRLR
47 9200 PUR 9215 PUR SP90 9210 PUR 9205 PUR 20

CAN LO
48 9100 PUR/WHT 9115 PUR/WHT 9110 PUR/WHT 9105 PUR/WHT 14
CAN HI
SP91 RE021
RE018
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1
8 9260 PUR 9230 PUR SP31 9220 PUR 4 9220 PUR SP18 9410 PUR
SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
RE014 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
J2B
1830 RNG/WHT 1
AUX CTRLR SHEET 5
9280 PUR 8
SHEET 6
9320 PUR/WHT
2070 BLK 2
3
*
C450
RIGHT JOYSTICK
9180 PUR/WHT 9 9420 PUR 4
1840 RNG/WHT 1
SHEET 5
9300 PUR/WHT
SHEET 6
2080 BLK 2
3
*
C449
LEFT JOYSTICK
9400 PUR 4
J2B
C426
AUX CTRLR
Remote Run Tool, ACD
14 9500 PUR/WHT A Printable Version Click Here
CAN HI
20 9600 PUR B
CAN LO
WIRING SCHEMATIC
J1B
GWY CTRLR (MANUAL MACHINE)
21 3090 LBL D
C
REMOTE RUN KEY S570 (S/N ALM413083 & ALM413264 -
1735 RNG/WHT E SWITCHED POWER
SHEET 5
SHEET 4
1165 RED/WHT F UNSWITCHED POWER ALM415479)
2710 BLK G GROUND
SHEET 6
(S/N B3GZ11001 - B3GZ11088)
Sheet 7 of 16
669 of 1290
SHEET 4
1030 RED
+12V
PWR 30
FRC1
STARTER RELAY - M
87
ENGINE 8200 TAN
C111
HARN ENG START CONN
A
B
8220 TAN
STARTER
S M
B SHEET 4
GND 85 86
3560 LBL 3560 LBL R
2005 BLK 8210 TAN 1800 RNG/WHT C 1015 RED
SHEET 6 SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 3560 LBL ALTERNATOR G
L 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND 2015 BLK
AIR FILTER SHEET 6
16 3150 LBL A SIG
SWITCH (NC) ENGINE GROUND TERMINAL
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND
SHEET 6 (30 - 270 OHM)
10 3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
CAB-MFR HARN CONN 2 HAND THROTTLE
SHEET 11 5690 YEL 7 5690 YEL C +5V PWR
3690 LBL 6 3690 LBL A
SIG
2690 BRN 8 2690 BRN B GND
J7A
ENG ECU CTRLR SHEET 6 D
E
19 8007 TAN F
C100
9 3865 LBL 1 WATER IN FUEL SENDER
SIG
34 2865 BRN 2 GND (FUEL FILTER)
C118 Printable Version Click Here

ENG-CROSSOVER
To C154 - PIN1 and
1
28 8013 TAN
SHEET 5 1511 RNG/WHT
8013 TAN 2
C155 - PIN 3 WIRING SCHEMATIC
MAF FREQ MAF Sensor - PIN 1
MAF TEMP
35 8014 TAN
+12V
8014 TAN 3
4
MAF Sensor - PIN 4 (MANUAL MACHINE)
PWR 3420 LBL
TO J7B - PIN 79
SHEET 4 1065 RED/WHT
30
87 8525 TAN 8500 TAN
PRE-HEATER Sheet 16 of 16 S570 (S/N ALM413083 & ALM413264 -
SP93
56 85 86
8510 TAN 1445 RED/WHT
SHEET 4
ALM415479)
PREHEATER
RELAY - C (S/N B3GZ11001 - B3GZ11088)
Sheet 8 of 16
Printed In U.S.A. (PRINTED NOVEMBER 2016)
7254941 (0)
670 of 1290
1360 RED/WHT PWR 30
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100 LGN
4200 LGN
C425
B
A 4200 LGN
C308
A
BRAKE
TRACK 2 SPEED
SHEET 4 87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS
7165061
8 4110 LGN
13 3430 LBL
C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A
34 3320 LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND
SHEET 6
3190 LBL C SIG HYDRAULIC CHARGE
5190 YEL A +8V PWR PRESSURE SENSOR
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE) WIRING SCHEMATIC
3.3 OHM PWM
C419 (MANUAL MACHINE)
1 2340 BRN 2 GND FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE) S570 (S/N ALM413083 & ALM413264 -
3.3 OHM PWM
ALM415479)
19 13 (S/N B3GZ11001 - B3GZ11088)
J2B
AUX CTRLR Sheet 9 of 16
671 of 1290
SHEET 5
1940 RNG/WHT
7040 WHT
T13
BUZZER (+)
LEFT PANEL
BUZZER
CAB DISPLAY C499
Press To Operate Loader
C479 (PTOL)
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408
2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
SHEET 11 DOOR SIGNAL
11 1950 RNG/WHT 5
SHEET 5 SWITCHED POWER
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWER
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DIESEL PARTICULATE 7 C503
FILTER SWITCH 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DPF INHIBIT LAMP 1240 RED/WHT 1
1 SHEET 4 UNSWITCHED POWER
2065 BLK 2 3 8060 TAN
SHEET 6 DPF OVERRIDE 2250 BLK 3
1 SHEET 6 GROUND
8070 TAN 9 6
4 DPF INHIBIT REGEN
NOT USED
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
Printed In U.S.A.
(S/N B3GZ11001 - B3GZ11088)
Sheet 10 of 16
7254941 (0)
672 of 1290
*
SW4
CAB
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3
C438
(DK GRAY)
SHEET 11 2060 BLK 5 6
4
CAB-MFR HARN CONN 3
(NOT IN STD CAB HARN 7227905)
7 4235 LGN
8 4275 LGN
1850 RNG/WHT
9
2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
SP45
* T37
DOME LIGHT (+)
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT
SHEET 4
DOME
C129 2010 BLK LIGHT
CAB ACCESSORY SP41
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 15
1885 RNG/WHT SHEET 15
SP44 2210 BLK SHEET 15
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 15
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL SP13 5370 YEL 5370 YEL C

3 +5V PWR
+5V
SHEET 8 5690 YEL
WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378
(MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 -
* C252 C253
PWR
ALM415479)
A 7310 WHT 1 WASHER
MOTOR (S/N B3GZ11001 - B3GZ11088)
2845 BLK B 2845 BLK 2 GND
Sheet 11 of 16
673 of 1290
MANUAL CONTROLS C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
K
AUX CTRLR G
C404 A
C103 1530 RNG/WHT
BU ALARM-MFR HARN SHEET 5
TAILGATE HARN 30 4940 LGN H
T19 TERMINAL (+)
(SEE ADDITIONAL 31 4930 LGN J SKI CTRL
A 7100 WHT C 7100 WHT
OPTIONS Sheet) 4920 LGN E DETENT FLOW
BACK UP
2650 BLK ALARM 13 4910 LGN F
SHEET 6 TWO SPD
4310 LGN C
T20 TERMINAL (-) 4320 LGN D
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
J2B (MANUAL/ACS ONLY)
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK 20 4640 LGN D
2 17.8 OHM 12V 28 4840 LGN C
22 4830 LGN B SKI CTRL
C422 12 4820 LGN G
2 2990 BRN 3 GND 11 4810 LGN F SIDE SHIFT
4990 LGN 1 LIFT SPOOL LOCK 1520 RNG/WHT A
SIG 17.8 OHM 12V SHEET 5
2 J
H
E
7 5
J1B Printable Version Click Here
GWY CTRLR
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 - ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 12 of 16
674 of 1290
C434-1
LIGHTS
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
FRC1 2760 BLK B GND WORK LIGHT
37.00 Watts
FRONT WORK
LIGHTS RELAY - J C438 C435-2
(DK GRAY) 6130 PNK A SIG
1350 RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
SHEET 4 87 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK SP64
2120 BLK 85 86
SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 6340 PNK SP10 6310 PNK A 6310 PNK 6320 PNK 1 SIG
87 TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
FRC1 6210 PNK SIG WORK LIGHT
REAR LIGHT T15 TERMINAL (+)
RELAY - E
+12V
PWR 30 T17 TERMINAL (+)
1320 RED/WHT SP5
SHEET 4 87 6200 PNK H 6200 PNK 6200 PNK SIG LEFT REAR
GND 85 2630 BLK GND WORK LIGHT
2045 BLK 86 SHEET 6
SHEET 6 T18 TERMINAL (-)
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 - ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 13 of 16
Printed In U.S.A.
7254941 (0)
675 of 1290
2440 BLK * C610
2 GND HVAC DUCT
HVAC
7440 WHT 1 SIG FAN
2560 BLK
* C483
C BLK
7420 WHT A DBL POTENTIOMETER
(TEMP CONTROL
* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT SWITCH)
(NOT IN STD CAB HARN 7227905) * C635

D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
3 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT
7510 WHT 3 5.00 Amps Low MOTOR
SW11
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
AC SWITCH 2580 BLK 4
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT
AC EVAPORATOR C350 2570 BLK 2

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT
C486
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH
(COMPRESSOR)
WIRING SCHEMATIC
2290 BLK 2280 BLK
SHEET 6
D4 (MANUAL MACHINE)
S570 (S/N ALM413083 & ALM413264 - ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 14 of 16
Printed In U.S.A.
7254941 (0)
676 of 1290
C428 #
OPTIONS
C355 (LT GRAY) DLX FUEL HARN 7266824 ONLY
FUEL HARN CAB-MFR HARN CONN 2
# C607 (NOT IN STD FUEL HARN 7149219 )
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
POWER BOB 2 B
GND 2470 BLK 2770 BLK 2770 BLK 4480 LGN
CLOSE SHEET 6
SW5
*POWER 2 1 * DLX CAB HARN 7253375 ONLY
# BOBTACH 3
GND
C606
2 2480 BLK SWITCH 5 4
6
POWER BOB 1 F 4480 LGN 10
OPEN
SIG 4480 LGN
6010 PNK 13 6010 PNK
1380 RED/WHT
1550 RNG/WHT 12 1550 RNG/WHT
SHEET 5
C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT
LEFT HANDLE FLASHER PWR

C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* FLASHER
T3
CONN
(FLASHER) 5 WAY C SHEET 10 3500 LBL
D1
(SEE ADDITIONAL
RIGHT A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
E
OPTIONS DWG) D2 SWITCH
LEFT D 6415 PNK 6400 PNK 3 6400 PNK 6430 PNK
3400 LBL 2725 BLK 6
C103 SHEET 10 *HAZARD
SW3
2
1
6700 PNK
4
1
5
TAILGATE HARN 3 2
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
(SEE ADDITIONAL INTERNALLY 6
D
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 * SW6
BUCKET 6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
6.13 OHM
C408
(BLACK) * C676
C412
CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
LEFT HANDLE
(HORN) 2 WAY
HORN SIGNAL
PWR
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
SHEET 4 2 AIR RIDE
(SEE ADDITIONAL
OPTIONS DWG)
RIGHT
*- C278
2 7810 WHT 6 3 SEAT
SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
SHEET 11
+ 1885 RNG/WHT 1 2210 BLK 5 GND
SHEET 11 SHEET 11
2 6
SHEET 11 2885 BLK
C415
J2A 26 2460 BRN B GND HIGH FLOW
AUX CTRLR
4460 LGN A SIG SOLENOID Printable Version Click Here
7.5 OHM 12 V
J2B
AUX CTRLR
26
WIRING SCHEMATIC
C441
TRACK 2 SPEED
(MANUAL MACHINE)
J1A 26 2350 BRN 2 GND TWO SPEED
ADAPTER
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V (SEE ADDITIONAL S570 (S/N ALM413083 & ALM413264 -
OPTIONS DWG)
J1B
GWY CTRLR
26
ALM415479)
(S/N B3GZ11001 - B3GZ11088)
Sheet 15 of 16
677 of 1290
LEGEND
ENGINE
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8-9 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 10
HARNESS
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 11
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 13 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 14 (TWO WIRE BREAKS
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT HVAC PAGE 15 JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 16
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
PRE HEATER 179

TO C118 - PIN 4 J7B
See Sheet 8 of 16 ENGINE ECU CONTROLLER
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 2 EXHAUST GAS
123 1 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151 C136
TO C113 PIN 3
1 EGR VREF3 164 4
See Sheet 5 of 14
5 POSITION SIGNAL 116 120 SENSOR GROUND 3
EGR VALVE
3 172 137 5V 2 MAF
DC MOTOR POSITION RETURN
SENSOR
6 H BRIDGE POS 192 TO C113 PIN 2 1
2 H BRIDGE NEG 193 See Sheet 5 of 14
C149
2 COOLANT TEMP SENSOR 109
COOLANT TEMP
SENSOR 1 COOLANT RETURN 145
C148 165 VREF3 OIL PRESSURE 3

OIL PRESSURE &
1 FUEL TEMP SENSOR 110 111 OIL PRESSURE SENSOR 4
FUEL TEMP TEMPERATURE
SENSOR 2 FUEL RETURN 146 148 RETURN GND 1 SENSOR
C147 104 OIL TEMPERATURE SENSOR 2

2 SENSOR SIGNAL 131
ENGINE BLOCK
ACCELEROMETER 1 1 SENSOR RETURN 130
SHIELD 128
169 RETURN 1 INTAKE
C146 194 SENSOR 2 MANIFOLD
132 TEMPERATURE
2 SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
CRANKSHAFT 1 CRANK SENSOR POS 160
POSITION
2 CRANK SENSOR NEG 136
SENSOR NOTE: ON EARLY MODELS, WIRE
C144 TO PIN 161 WAS TO PIN 141
C138
3 SENSOR RETURN 147 . 161 INTAKE PRESS SENSOR B 1
CAM SHAFT
2 POS SENSOR 159
SENSOR 112 INTAKE PRESS SENSOR A 3 INTAKE MANIFOLD
1 VREF1 CAM PRESSURE
TO C118 - PIN 1| 167 INTAKE PRESS RETURN D 2
SENSOR
C143 See Sheet 8 of 16
1 RAIL PRESSURE SENSOR 135
RAIL Printable Version Click Here
2 SENSOR RETURN 119
PRESSURE
SENSOR 3 VREF1 SENSOR 138 C139
127
126
FUEL INJECTOR HSDA
FUEL INJECTOR LSD1A
1
2 CYL 1
WIRING SCHEMATIC
151
CYL 3
FUEL INJECTOR HSDB
FUEL INJECTOR LSD1B 175 C140 (MANUAL MACHINE)
150 FUEL INJECTOR HSDB 2
FUEL INJECTOR HSDA 103

174 FUEL INJECTOR LSD2B 1 CYL 2 S570 (S/N ALM413083 & ALM413264 -
CYL 4
FUEL INJECTOR LSD2A 125
177 PWM
C154
2
ALM415479)
INLET METERING
TO C118 - PIN 1
SEE Sheet 8 of 16
1 VALVE
(S/N B3GZ11001 - B3GZ11088)
Sheet 16 of 16
7254941 (0)
678 of 1290
CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet CONN DESCRIPTION Sheet
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C434-1 LEFT FRONT WORKLIGHT (37W) 2 13 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C434-2 LEFT FRONT WORKLIGHT (50W) 2 13
C105 HYD CHARGE PRESSURE SENSOR 3 9 C435-1 RIGHT FRONT WORKLIGHT (37W) 2 13 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C108 HYD TEMPERATURE SENDER 2 9 C435-2 RIGHT FRONT WORKLIGHT (50W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C110 ALTERNATOR 2 8 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J2A AUX CONTROLLER 34 9,12,15
C111 HARNESS ENGINE START CONN 3 8 C441 TWO SPEED SOLENOID 2 15 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C112 HYD OIL FILTER SWITCH 2 9 C446 HYDRAULIC FAN 2 9
C114 HAND THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C118 ENG-CROSSOVER 4 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 10
C126 HORN 2 15 C479 LEFT PANEL(BLACK) 12 7,10 SW2 BEACON SWITCH 6 15
C129 CAB ACCESSORY 3 11 C480 LEFT PANEL(GRAY) 12 10 SW3 HAZARD SWITCH 6 15
C169 ENGINE CAN (Diagnostic) 6 7 C482 SEATBAR SENSOR 3 11 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C212 POWER SOCKET 2 11 C483 TEMP CONTROL SWITCH 3 14 SW5 POWER BOBTACH SWITCH 6 15
C252 WASHER ADAPTER INTMD 2 11 C486 AC COMPRESSOR 2 14 SW6 BUCKET POSITION SWITCH 6 15
C253 WASHER PUMP 2 11 C489 MFR ACCESSORY 2 5,6 SW9 TRAVEL CONTROL SWITCH 6 10
C277 AIR RIDE SEAT 6 15 C499 PTOL 4 10 SW10 BLOWER SWITCH 6 14
C278 RIGHT SPEAKER 2 15 C500 RH KEY SWITCH 6 10 SW11 AC SWITCH 3 14
C279 LEFT SPEAKER 2 15 C503 RH DLX PANEL 6 7,10 SW12 DPF SWITCH 10 10
C308 BRAKE SOLENOID 2 9 C602 LEFT REAR TAIL LIGHT 2 13 T1 BATT GROUND 1 6
C350 AC EVAPORATOR SWITCH 2 14 C603 RIGHT REAR TAIL LIGHT 2 13 T2 BUZZER GROUND 1 10
C355 FUEL HARNESS 6 8,15 C606 POWER BOBTACH OPEN 2 15 T3 FLASHER 2 15
C404 BU ALARM-MFR HARN 2 5,12 C607 POWER BOBTACH CLOSE 2 15 T4 MEGAFUSE LOAD SIDE 1 4
C405 AIR FILTER SWITCH 2 8 C610 HVAC DUCT FAN 2 14 T6 BATT GROUND 1 6
C406 FUEL SENDER 2 8 C611 BLOWER MOTOR 4 14 T8 BATT GROUND 1 6
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C630 THERMOSTAT 3 14
T10 ENGINE SYSTEM GROUND 1 6
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C635 HEATER VALVE 6 14 T13 BUZZER POWER 1 10
C410 LEFT HANDLE (MAN/ACS) 10 12 C667 DOOR HARNESS 6 11 T14 PRE HEATER 1 8
C411 LEFT HANDLE 5 WAY 5 15 C670 EXTERIOR BEACON HARNESS 6 15 T15 RIGHT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 C676 RADIO 6 15 T16 RIGHT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C418 FRONT ROD 2 9 T18 LEFT REAR WORK LIGHT(-) 1 13
C419 FRONT BASE 2 9 T19 BACKUP ALARM 1 12

C420 HYD LOCK 2 9 T20 BACKUP ALARM(GND) 1 12
C421 TILT SPOOL LOCK 3 12 T32 ECU CASE GROUND 1 6
C422 LIFT SPOOL LOCK 3 12 T37 DOMELIGHT (+) 1 11
C423 BUCKET POSITION SOLENOID 2 15 T38 DOMELIGHT (-) 1 11
C425 BRAKE SOLENOID 3 9
C426 CAN(Remote Start Tool, ACD) 7 7
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Sheet 1 of 16
679 of 1290 7279776 (A)
A-2 B-2 UNSW BATT
A-5 HORN RELAY B-5
A-6 B-6
A-7 B-7
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-19 B-19 FRONT ROD
A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-29
A-29
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR MAN 7276760
EXMF MFR MAN 7276758
DLX CAB 7253375
STD CAB 7227905
STD FUEL 7149219
DLX FUEL 7266824
BCT ENG START 7220812
TAILGATE EUR 7217483
SUSP JSTK 7266829 Printable Version Click Here
BRAKE ADAPTER 7165061
WHL 2 SPD ADP
TRK 2 SPD
7159366
7214626
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Sheet 2 of 16
Printed In U.S.A. 7279776 (A)
680 of 1290
LEGEND
CONNECTOR J7
PIN FUNCTION BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8 CONNECTOR
CAB PAGE 11
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK
19 IGN SW INPUT OPTIONS PAGE 15 SHEET #
28 MAF FREQ COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
34 WATER IN FUEL SENSOR

GND
35 MAF TEMP
45 ECU RELAY GND

47 CAN 1 LO A B C D
48 CAN 1 HI
56 GLOW PLUG SIGNAL
E F G H
J K L M
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Sheet 3 of 16
7279776 (A)
Printed In U.S.A.
681 of 1290
UNSWITCHED BATT POWER
C408 1240/RED/WHT
SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400/RED/WHT
SHEET 11
1450/RED/WHT 6 1450/RED/WHT C667 DOOR HARNESS
SP7
FRC1 FUSE RELAY CENTER 1420/RED/WHT
SHEET 10
1110/RED/WHT 2 C500 RH KEY SWITCH
1070/RED 1120/RED/WHT 1130/RED/WHT 3 GWY CTRLR 1440/RED/WHT
SHEET 10
+12V 1025/RED
FUSE 13 25 A
1160/RED/WHT SP36 1150/RED/WHT 3
J2B
BATTERY MEGAFUSE 1180/RED/WHT 2 AUX CTRLR
100.0 Amps
FUSE 15 OPEN
1 1
FUSE 17 OPEN
SHEET 8
STARTER
FUSE 4 25 A
1010/RED 1140/RED/WHT
SHEET 14
SHEET 9
FUSE 1 15 A 1320/RED/WHT
SHEET 13
1340/RED SHEET 13
SP26 FRC1 FRONT LIGHT RELAY
1330/RED/WHT
1060/RED 1065/RED/WHT SHEET 8 FRC1 FRONT LIGHT RELAY
1335/RED FUSE 20 5 A
1345/RED/WHT SHEET 5
1325/RED FUSE 16 25 A
SP1 1300/RED 1035/RED/WHT SHEET 5
1445/RED/WHT
SHEET 8
1190/RED 1165/RED/WHT SHEET 7
1460/RED/WHT
1040/RED 1490/RED/WHT 1410/RED/WHT
(OPTIONS)
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN Printable Version Click Here
(ACCESSORIES)
1055/RED
SP60 WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM415480 - ALM416380)
1050/RED
SHEET 5
FRC1 SWITCHED PWR RELAY (S/N B3GZ11089 - B3GZ11233)
1030/RED
SHEET 8
FRC1 STARTER RELAY Sheet 4 of 16
682 of 1290
FRC1
ENGINE ECU
+12V RELAY - G
SWITCHED POWER J7A ENGINE ECU
PWR 1506/RNG/WHT 1
SHEET 4 1035/RED/WHT 30
87 1504/RNG/WHT SP54 1507/RNG/WHT 3
1509/RNG/WHT 1508/RNG/WHT 5
85 86
8005/TAN 45

1345/RED/WHT
SHEET 4
FUSE 21 15 A
1511/RNG/WHT
SHEET 8 ENG-CROSSOVER
C404
1720/RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A C489
1750/RNG/WHT 1780/RNG/WHT A MFR ACCESSORY
SP50
FUSE 6 25 A 1850/RNG/WHT
1760/RNG/WHT SHEET 11 C438 CAB-MFR CONN (FR WIPER)
1700/RNG/WHT SHEET 10 SW12 DPF SWITCH (UNUSED)
FUSE 12 15 A
1790/RNG/WHT 1550/RNG/WHT 1620/RNG/WHT
1940/RNG/WHT
1520/RNG/WHT SHEET 10 T13 LH PANEL BUZZER
SHEET 12 C410 LEFT HANDLE 1930/RNG/WHT
1530/RNG/WHT SHEET 12 C409 RIGHT HANDLE 1775/RNG/WHT
C428 1960/RNG/WHT
1805/RNG/WHT 1570/RNG/WHT 1560/RNG/WHT 22 1785/RNG/WHT
SP11 1950/RNG/WHT
1660/RNG/WHT 2 1660/RNG/WHT 1590/RNG/WHT
1765/RNG/WHT FUSE 7 25 A SP65 SP42
SP25
1725/RNG/WHT
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
FRC1 FUSE 23 15 A
1815/RNG/WHT 1800/RNG/WHT
SWITCHED SHEET 8 C110 ALT EXCITATION
POWER RELAY - A
+12V
WIRING SCHEMATIC
(MANUAL MACHINE)
PWR 30
SHEET 4 1050/RED 21
87 3450/LBL C428
J1A
(LT GRAY)
SHEET 6 2055/BLK GND 85 86 3380/LBL 4
GWY CTRLR
CAB-MFR HARN CONN 2
SP37
S570 (S/N ALM415480 - ALM416380)
1920/RNG/WHT 9 1920/RNG/WHT 1840/RNG/WHT SHEET 7
1830/RNG/WHT
C449 LH JOYSTICK
(S/N B3GZ11089 - B3GZ11233)
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 16
Printed In U.S.A.
7279776 (A)
683 of 1290
2320/BRN
SHEET 9
GROUND
2370/BRN J1B
SHEET 11 GWY CTRLR
2220/BRN 2230/BRN 17
SHEET 9
C108 HYD TEMP SENDER SP12
2190/BRN
2 SHEET 9
2001/BLK C105 HYD CHG PRESSURE SENDER
4 SP53 2810/BLK 2180/BRN
J7A 2002/BLK
SHEET 8
ENG ECU CTRLR 6 2003/BLK C355 FUEL HARN (FUEL SENDER)
2150/BRN
SHEET 8
T32 2004/BLK
ECU CASE GND SHEET 8 2690/BRN
2080/BLK
SHEET 7
C449 LH JOYSTICK T6
2070/BLK BATT GND
SHEET 7 C408
2920/BLK CAB-MFR HARN CONN 1
SHEET 10 2765/BLK
2940/BLK SP4 2950/BLK 10 2950/BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
C499 PTOL 2745/BLK
SHEET 14
2960/BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 10 2510/BLK 2110/BLK
C500 RH PANEL KEY SWITCH J1B SP3 2790/BLK T8
GWY CTRLR 15 2500/BLK SHEET 11 BATT GND
2250/BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 10
C503 RH DELUXE PANEL 2780/BLK
2065/BLK C428 SHEET 15
(LT GRAY) 2540/BLK
SW12 DPF SWITCH 2730/BLK
2930/BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 11
SHEET 10 AUX CTRLR 2550/BLK 2090/BLK
SP47 SP28
2830/BLK 2900/BLK 1 2900/BLK
SHEET 15
2700/BLK 2770/BLK
SHEET 10 SHEET 15
2785/BLK 2200/BLK
SHEET 15 SHEET 9
2620/BLK
SHEET 13 C103 C489
T16 RH REAR LIGHT B 2720/BLK
SHEET 12 2650/BLK
SP51 2600/BLK B 2390/BLK T1 T10
T20 BU ALARM 2600/BLK 2015/BLK
2640/BLK SP6 BATT GND SHEET 8 ENGINE
C602 LH REAR LIGHT SHEET 15 2455/BLK
2610/BLK C423 BKT POSITION SOLENOID
2630/BLK Printable Version Click Here
SHEET 13 2715/BLK
C169 ENGINE CAN
SHEET 13 2045/BLK SHEET 14

2290/BLK
D4 COMPRESSOR DIODE
WIRING SCHEMATIC
SHEET 9
2035/BLK (MANUAL MACHINE)
SP55
SHEET 13
FRC1 FRONT LIGHT RELAY
2115/BLK 2105/BLK
S570 (S/N ALM415480 - ALM416380)
2055/BLK
SHEET 5
FRC1 SWITCHED POWER RELAY (S/N B3GZ11089 - B3GZ11233)
SHEET 14 2030/BLK
FRC1 HVAC RELAY
2005/BLK
Sheet 6 of 16
SHEET 8
FRC1 STARTER RELAY
2120/BLK
SHEET 13
Printed In U.S.A. FRC1 FRONT LIGHT RELAY 7279776 (A)
684 of 1290
CAN BUS
J7A (NOT IN STD CAB HARN 7227905) J1B
ECU CNTRLR GWY CTRLR
47 9200/PUR 9215/PUR SP90 9210/PUR 9205/PUR 20

CAN LO
48 9100/PUR/WHT 9115/PUR/WHT 9110/PUR/WHT 9105/PUR/WHT 14
CAN HI
SP91 RE021
RE018
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725/RNG/WHT 1
SHEET 5
2715/BLK 2
SHEET 6
9155/PUR/WHT 3
9255/PUR 4
5
6
C408
J1B (BLACK)
SP31 SP18
8 9260/PUR 9230/PUR 9220/PUR 4 9220/PUR 9410/PUR SP39 9430/PUR SP35 9450/PUR 9460/PUR 4
C479
9 9160/PUR/WHT 9130/PUR/WHT 9120/PUR/WHT 3 9120/PUR/WHT 9310/PUR/WHT 9330/PUR/WHT 9350/PUR/WHT 9360/PUR/WHT 3 LEFT PANEL (BLACK)
RE014 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440/PUR 4
C503
9340/PUR/WHT 2 RIGHT DELUXE PANEL
J2B
1830/RNG/WHT 1
*
AUX CTRLR SHEET 5 C450
2070/BLK 2
SHEET 6 RIGHT JOYSTICK
9280/PUR 8 9320/PUR/WHT 3
9180/PUR/WHT 9 9420/PUR 4
J2B
C426
AUX CTRLR 1840/RNG/WHT 1
Remote Run Tool, ACD SHEET 5
CAN HI
14 9500/PUR/WHT A
9300/PUR/WHT
SHEET 6
2080/BLK 2
3
* C449
LEFT JOYSTICK
20 9600/PUR B
CAN LO 9400/PUR 4

J1B
GWY CTRLR
21 3090/LBL D
WIRING SCHEMATIC
REMOTE RUN KEY
1735/RNG/WHT
C
E SWITCHED POWER
(MANUAL MACHINE)
SHEET 5
SHEET 4
SHEET 6
1165/RED/WHT
2710/BLK
F
G
UNSWITCHED POWER
GROUND S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Printed In U.S.A.
Sheet 7 of 16
7279776 (A)
685 of 1290
FRC1
STARTER RELAY - M
+12V
ENGINE
C111
HARN ENG START CONN
STARTER
PWR 30
1030/RED
SHEET 4 87 8200/TAN A 8220/TAN S M
B SHEET 4
3560/LBL B 3560/LBL R
GND 85 86 8210/TAN C 1015/RED
SHEET 6 2005/BLK 1800/RNG/WHT
SHEET 5
FUSE 12
C110
7 8210/TAN B S 1020/RED
22 3560/LBL ALTERNATOR G
L 1800/RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150/BRN B
SHEET 6
GND 2015/BLK
AIR FILTER SHEET 6
16 3150/LBL A SIG
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180/LBL C 3180/LBL A SIG
FUEL SENDER
2180/BRN D 2180/BRN B GND (30 - 270 OHM)
10 SHEET 6
3690/LBL
4 8007/TAN C428
(LT GRAY)
C114
SHEET 11 5690/YEL 7 5690/YEL C +5V PWR
3690/LBL 6 3690/LBL A
SIG
2690/BRN 8 2690/BRN B GND
J7A
E
19 8007/TAN F
C100
9 3865/LBL 1 WATER IN FUEL SENDER
SIG
34 2865/BRN 2 GND (FUEL FILTER)

C118
1511/RNG/WHT
ENG-CROSSOVER
1
To C154 - PIN 1, & WIRING SCHEMATIC
SHEET 5 To C114, Pin 3, Sheet 16 of 16
MAF FREQ
28 8013/TAN 8013/TAN 2
3
MAF Sensor - PIN 1, Sheet 16 of 16 (MANUAL MACHINE)
35 8014/TAN 8014/TAN MAF Sensor - PIN 4, Sheet 16 of 16
MAF TEMP
+12V
PWR
30
3420/LBL 4
TO GLOW PLUG, J7B - PIN 79,
S570 (S/N ALM415480 - ALM416380)
1065/RED/WHT 87 8525/TAN 8500/TAN
56
SHEET 4
8510/TAN 85 86
SP93
1445/RED/WHT
PRE-HEATER Sheet 16 of 16
(S/N B3GZ11089 - B3GZ11233)
PREHEATER
SHEET 4
Sheet 8 of 16
RELAY - C
7279776 (A)
686 of 1290
FRC1
TRACTION LOCK
HYDRAULICS C425
+12V RELAY - D B C308
4100/LGN BRAKE
1360/RED/WHT PWR 30
SHEET 4 4200/LGN A 4200/LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200/BLK C 2200/BLK B 9.8 OHM
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035/BLK OPTIONS DWG)
7165061
8 4110/LGN
13 3430/LBL
C108
HYDRAULIC
2220/BRN B GND
SHEET 6 TEMPERATURE
32 3220/LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320/LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320/BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYDRAULIC LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190/BRN B GND
SHEET 6
3190/LBL C SIG HYDRAULIC CHARGE
5190/YEL A +8V PWR PRESSURE SENSOR
0.5-7.5V
4200/LGN
19 13 1 23 6
J1B +8V
GWY CTRLR Printable Version Click Here
C418 WIRING SCHEMATIC

J2A 18 2330/BRN 2 GND FRONT ROD
AUX CTRLR
4330/LGN 1 SIG SOLENOID (MALE)
3.3 OHM PWM
(MANUAL MACHINE)
1 2340/BRN
C419
2 GND
S570 (S/N ALM415480 - ALM416380)
FRONT BASE
4340/LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM (S/N B3GZ11089 - B3GZ11233)
Sheet 9 of 16
19 13
J2B
Printed In U.S.A. AUX CTRLR 7279776 (A)
687 of 1290
SHEET 5
1940/RNG/WHT
7040/WHT
T13
BUZZER (+)
LEFT PANEL
BUZZER
CAB DISPLAY C499
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930/RNG/WHT 1
10 C408
2940/BLK 3
7040/WHT BUZZER SHEET 6 GROUND
(BLACK)
2920/BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960/RNG/WHT 1440/RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030/LBL 1 3030/LBL 2
PTOL OUTPUT
SW9 1620/RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380/BRN 12 2380/BRN 4
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT J1A
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500/LBL 8 C500
4
2700/BLK 2 3 3650/LBL 7 24 2 8130/TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130/TAN START
1 9
3600/LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610/LBL 4 5
SHEET 5 1775/RNG/WHT 6
2930/BLK C480 J1B 22 14
SHEET 6 LEFT PANEL (GRAY) 3040/LBL 3040/LBL 4
GWY CTRLR RUN/ENTER SWITCH
3620/LBL 12
11 1950/RNG/WHT 5
10 1420/RED/WHT 1
3 2960/BLK 3
SHEET 6 GROUND
3610/LBL 2
PARK BRAKE OUTPUT
8
SW12
1700/RNG/WHT 7 9 8050/TAN 4 1590/RNG/WHT 5
SHEET 5 DPF LAMP
1705/RNG/WHT 10 8 8055/TAN 5
SHEET 5 DPF INHIBIT LAMP Printable Version Click Here 1240/RED/WHT 1
2065/BLK 2 3 8060/TAN
SHEET 6 DPF OVERRIDE 2250/BLK 3
4
1
8070/TAN 9
DPF INHIBIT REGEN
WIRING SCHEMATIC SHEET 6
6
GROUND
NOT USED (MANUAL MACHINE)

S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Printed In U.S.A. Sheet 10 of 16
7279776 (A)
688 of 1290
*
SW4
HAND/FOOT
CAB
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 5 3
C438 2060/BLK 5 6
SHEET 11
(DK GRAY) 4
CAB-MFR HARN CONN 3 * DLX CAB HARN 7253375 ONLY
7
8
4235/LGN
4275/LGN
1850/RNG/WHT
9
2
4550/LGN
1850/RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
SP45
* T37
DOME LIGHT (+)
1370/RED/WHT 7 1370/RED/WHT 1390/RED/WHT
SHEET 4
DOME
C129 2010/BLK LIGHT
CAB ACCESSORY SP41
1210/RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580/RNG/WHT 5 1580/RNG/WHT SP8 1865/RNG/WHT B +12V SW PWR
SHEET 5
2800/BLK C GND
1510/RNG/WHT
SHEET 15
1885/RNG/WHT SHEET 15
SP44 2210/BLK SHEET 15
2730/BLK 11 2730/BLK 2885/BLK
SHEET 6 SHEET 15
2060/BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790/BLK 14 2790/BLK
SHEET 6
1850/RNG/WHT 1
3620/LBL 4
1400/RED/WHT 5
6
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B SENSOR 7310/WHT 3
2370/BRN 4 2370/BRN A GND WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370/LBL 5 3370/LBL B SIG
24 5100/YEL SP13 5370/YEL 5370/YEL C

3 +5V PWR
+5V Printable Version Click Here
SHEET 8 5690/YEL
WIRING SCHEMATIC
(MANUAL MACHINE)
HARNESS WASHER PUMP
7253378
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
* C252 C253
PWR
Sheet 11 of 16
Printed In U.S.A. A 7310/WHT 1 WASHER
MOTOR
2845/BLK B 2845/BLK 2 GND
7279776 (A)
689 of 1290
MANUAL
CONTROLS
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
K
AUX CTRLR G
C404 A
C103 SHEET 5 1530/RNG/WHT
BU ALARM-MFR HARN
TAILGATE HARN 30 4940/LGN H
T19 TERMINAL (+)
(SEE ADDITIONAL 31 4930/LGN J SKI CTRL
A 7100/WHT C 7100/WHT
OPTIONS Sheet) 4920/LGN E DETENT FLOW
BACK UP
2650/BLK ALARM 13 4910/LGN F
SHEET 6 TWO SPD
4310/LGN C
T20 TERMINAL (-) 4320/LGN D
PWM
4300/LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980/BRN 3 GND
GWY CTRLR 4980/LGN 1 TILT SPOOL LOCK 20 4640/LGN D
SIG
2 17.8 OHM 12V 28 4840/LGN C
22 4830/LGN B SKI CTRL
C422 12 4820/LGN G
2 2990/BRN 3 11 4810/LGN F SIDE SHIFT
GND
4990/LGN 1 LIFT SPOOL LOCK 1520/RNG/WHT A
SIG 17.8 OHM 12V SHEET 5
2 J
H
E
7
WIRING SCHEMATIC
5
J1B
(MANUAL MACHINE)
GWY CTRLR
S570 (S/N ALM415480 - ALM416380)

(S/N B3GZ11089 - B3GZ11233)
Sheet 12 of 16
690 of 1290
C434-1
LIGHTS
2735/BLK B GND LEFT FRONT
C408
6100/PNK A SIG WORK LIGHT
(BLACK)
C434-2
2765/BLK 9 2765/BLK SP14 2750/BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
8 6000/PNK SP15 6120/PNK A SIG RIGHT FRONT
RC1 2760/BLK B GND
WORK LIGHT
37.00 Watts
FRONT WORK
LIGHTS RELAY 1 C438 C435-2
(DK GRAY) 6130/PNK A SIG
1350/RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
SHEET 4 87 6620/PNK 6610/PNK 2705/BLK B GND WORK LIGHT
50.00 Watts
13 6610/PNK SP64
2120/BLK 85 86
SHEET 6
6630/PNK
6000/PNK
RC1
FRONT WORK
LIGHTS RELAY 2 C103
PWR 2610/BLK 2 GND
1330/RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340/PNK 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115/BLK C602
SHEET 6
6330/PNK 1 SIG
2640/BLK 2 LEFT REAR
GND
SHEET 6 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 6 RIGHT REAR
FRC1 6210/PNK SIG WORK LIGHT
RELAY - E
+12V
1320/RED/WHT SP5
SHEET 4 87 6200/PNK H 6200/PNK 6200/PNK SIG LEFT REAR
GND 85 2630/BLK GND WORK LIGHT
2045/BLK 86 SHEET 6
WIRING SCHEMATIC
(MANUAL MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Sheet 13 of 16
Printed In U.S.A.
7279776 (A)
691 of 1290
HVAC
2440/BLK * C610
2 GND HVAC DUCT
7440/WHT 1 SIG FAN
2560/BLK * C483
C BLK
POTENTIOMETER
* DLX CAB HARN 7253375 ONLY 7420/WHT
7425/WHT
A
B
DBL
WHT
(TEMP CONTROL
SWITCH)
* C635
D SIG
2130/BLK C GND HEATER
7430/WHT A +12V PWR VALVE
SP48 B
E
F
FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10
+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140/RED/WHT
SHEET 4 87 1500/RNG/WHT 10 1500/RNG/WHT 5 2
1
GND 85 86 4
2030/BLK
SHEET 6 7410/WHT 6
3 7530/WHT * C611
1 14.00 Amps High
3 7520/WHT 2 7.50 Amps Med BLOWER
7050/WHT MOTOR
7510/WHT 3 5.00 Amps Low
J1A
30 3050/LBL
SHEET 6
2745/BLK 11 2745/BLK * SW11
AC SWITCH 2580/BLK 4
GWY CTRLR SP16
2100/BLK 3
C 7400/WHT
7015/WHT 1
11 7021/WHT SP40 7020/WHT 12
*
C630
THERMOSTAT
3
AC EVAPORATOR C350 2570/BLK 2
SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT

7025/WHT 1 SIG
2290/BLK 2280/BLK
2 GND
MAGNET CLUTCH
(COMPRESSOR) WIRING SCHEMATIC
SHEET 6
D4
(MANUAL MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11089 - B3GZ11233)
Printed In U.S.A.
Sheet 14 of 16
7279776 (A)
692 of 1290
# C607
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2 #
OPTIONS
DLX FUEL HARN 7266824 ONLY
1 4470/LGN E 4470/LGN 11 4470/LGN
POWER BOB
SIG
GND 2 2470/BLK 2770/BLK B 2770/BLK 4480/LGN
(NOT IN STD FUEL HARN 7149219 )
CLOSE SHEET 6
* SW5
POWER 2 1
# C606 BOBTACH
SWITCH 5
3
4
GND 2 2480/BLK
POWER BOB
OPEN
SIG 1 4480/LGN F 4480/LGN 10
6
6010/PNK 13 6010/PNK
1380/RED/WHT
1550/RNG/WHT 12 1550/RNG/WHT
SHEET 5
C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200/RED/WHT
LEFT HANDLE FLASHER PWR

C411
B
SHEET 4
1410/RED/WHT 1 1410/RED/WHT 1430/RED/WHT X
L
* T3
FLASHER
CONN
(FLASHER) 5 WAY C SHEET 10 3500/LBL
D1
(SEE ADDITIONAL
RIGHT A 6515/PNK 6500/PNK 6 6500/PNK 6530/PNK
*BEACON
SW2
6570/PNK
E
OPTIONS DWG) D2 SWITCH
LEFT D 6415/PNK 6400/PNK 3 6400/PNK 6430/PNK
2725/BLK 6
C103 SHEET 10
3400/LBL
*HAZARD
SW3
2
1
6700/PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410/PNK (PINS 3 & 6 2850/BLK
(SEE ADDITIONAL 6
*
D 6510/PNK INTERNALLY C670
OPTIONS DWG) INSULATED) E
2780/BLK 4 2780/BLK 2780/BLK D
C423 SHEET 6 2420/BLK BEACON/FLASHER
6440/PNK F
*BUCKET
3 SW6 EXTERIOR HARNESS
SIG A 4450/LGN D3 4455/LGN 5 4455/LGN 1
BUCKET 2 6540/PNK B (SEE ADDITIONAL
POSITION 4 C OPTIONS DWG)
2830/BLK 5 POSITION
SOLENOID GND B 2450/BLK 2455/BLK SHEET 6 SWITCH A
SHEET 6 6
6.13 OHM
C408
* C676
*
(BLACK) C126 C279 RADIO CONN
C412 2785/BLK B GND LEFT + 1 7820/WHT 3
*
HORN C277
LEFT HANDLE HORN SIGNAL B 7210/WHT 13 7210/WHT A SIG SPEAKER 2 7830/WHT 4
(HORN) 2 WAY - 1
PWR A 1460/RED/WHT
SHEET 4 2
(SEE ADDITIONAL
OPTIONS DWG)
RIGHT
*-
C278
2 7810/WHT 6 3
AIR RIDE
SEAT
SPEAKER 1 7800/WHT 5 1510/RNG/WHT 4 PWR
SHEET 11
+ 1885/RNG/WHT 1 2210/BLK 5 GND
SHEET 11 SHEET 11
2885/BLK 2 6
SHEET 11
C415
J2A 26 2460/BRN B GND HIGH FLOW Printable Version Click Here
AUX CTRLR A SIG
SOLENOID
4460/LGN
J2B
26
7.5 OHM 12 V
WIRING SCHEMATIC
AUX CTRLR
(MANUAL MACHINE)
C441
J1A
GWY CTRLR
26 2350/BRN
4350/LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
TRACK 2 SPEED
ADAPTER S570 (S/N ALM415480 - ALM416380)
(SEE ADDITIONAL
J1B 26
5.1 OHM 12 V
OPTIONS DWG) (S/N B3GZ11089 - B3GZ11233)
Sheet 15 of 16
GWY CTRLR
Printed In U.S.A.
7279776 (A)
693 of 1290
ENGINE
LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8-9
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 2 EXHAUST GAS
123 1 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
TO C118 PIN 3 TEMP
1 EGR VREF3 164 See Sheet 7 of 16
4
116 120 SENSOR GROUND 3 MAF
5 POSITION SIGNAL
EGR VALVE SENSOR
DC MOTOR 3 POSITION RETURN 172 137 5V 2
6 H BRIDGE POS 192 TO C118 PIN 2 FREQ 1
2 H BRIDGE NEG 193 See Sheet 7 of 16
C149
COOLANT TEMP
SENSOR 1 COOLANT RETURN 145 C136
C148 165 VREF3 OIL PRESSURE 3

OIL PRESSURE &
1 FUEL TEMP SENSOR 110 111 OIL PRESSURE SENSOR 4
FUEL TEMP TEMPERATURE
SENSOR 2 FUEL RETURN 146 148 RETURN GND 1 SENSOR
C147 104 OIL TEMPERATURE SENSOR 2

2 SENSOR SIGNAL 131
ENGINE BLOCK
C133
SHIELD 128
169 RETURN 1 INTAKE
132 TEMPERATURE
2 SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
POSITION
SENSOR
C144
C138
3 SENSOR RETURN 147 VREF INTAKE PRESS SENSOR B
CAM SHAFT 1 INTAKE
SENSOR 2 POS SENSOR 159 PRESSURE
112 INTAKE PRESS SENSOR A 3
1 VREF1 CAM SENSOR
TO C118 - PIN 1, 187 INTAKE PRESS RETURN D 2
RAIL
2 SENSOR RETURN 119
PRESSURE
SENSOR 3 VREF1 SENSOR 138 C139 Printable Version Click Here
127 FUEL INJECTOR HSDA 1
CYL 1
FUEL INJECTOR HSDB 151
126 FUEL INJECTOR LSD1A 2
WIRING SCHEMATIC
CYL 3 175 C140
FUEL INJECTOR LSD1B
150
174
FUEL INJECTOR HSDB
FUEL INJECTOR LSD2B
2
1 CYL 2
(MANUAL MACHINE)
CYL 4
FUEL INJECTOR HSDA
FUEL INJECTOR LSD2A
103
125 C154 S570 (S/N ALM415480 - ALM416380)
177 PWM 2
TO C118 - PIN 1 1
INLET METERING
VALVE (S/N B3GZ11089 - B3GZ11233)
SEE Sheet 7 of 16
Sheet 16 of 16
7279776 (A)
694 of 1290
Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND
5 SH05 - CAN BUS
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
6 SH06 - ENGINE
7 SH07 - ENGINE CONTROL UNIT
RED LEGEND
BATT FEED, GENERAL 1000 THROUGH 1499 RED
8 SH08 - HYDRAULICS
9 SH09 - CAB DISPLAY
BATT FEED, FUSED RED/WHITE RED/WHT CONNECTOR
1000 THROUGH 1499
10 SH10 - CAB
11 SH11 - MANUAL CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
12 SH12 - LIGHTS
13 SH13 - HVAC BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
14 SH14 - OPTIONS 1
15 SH15 - OPTIONS 2 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN
1 1
MONITORING LIGHT BLUE LBL
HARNESS PART NUMBER 3000 THROUGH 3999

MF MFR MAN 7300817 1 1
EXMF MFR MAN 7300650 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7301237 * LIGHTS PINK PNK
6000 THROUGH 6999
7303755 *
WIRE BREAK
STD CAB SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT WIRE BREAK
STD FUEL 7149219 SHT1/F2 SHT1/F2

DLX FUEL 7266824
BCT ENG 7220812 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
TAILGATE DOM 7267103 COMMUNICATION PURPLE/WHITE PUR/WHT

9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALM416381-ALM419107, ALM419124-ALM419125
Wiring Schematic S630

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
PROPRIETARY NOTICE TOLERANCES: ECN 101943 Printed On August 2018
csf
THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
Standard Machine S/N B3GZ11234
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC MAN
Sheet 1 of 15
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
B2 MOVED "GND" TEXT FROM A5 TO A2
Click Here For Interactive PDF 104399 AEW 3 COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B1
REV
9205 SWAPPED SIZE AND MATERIAL VALUES
DESCRIPTION
104399 AEW
CHG NOTICE DWN
5
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 15
7300816
695 of 1290
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
C408 1400 RED/WHT
MFR HARN CONN 1 (BLACK) SHT10/D3
1450 RED/WHT 1450 RED/WHT SP7
6 6
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
1110 RED/WHT SHT9/G8
2
FUSE 11 25 A GATEWAY CTRLR
11A 11B 3
SP2
FUSE 13 25 A J1B
1025 RED 1160 RED/WHT SP36 1150 RED/WHT
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
+12V BATTERY MEGAFUSE
100.0 Amps
HW11 1 1
T5 T4
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1
FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/D3
1055 RED
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8
1445 RED/WHT
SHT6/D3
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 2 of 15
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 2 / 15
7300816
696 of 1290
FRC1 ENGINE
ECU RELAY - G
1035 RED/WHT +12V PWR 30

1506 RNG/WHT
1 SWITCHED
POWER
SHT2/D1 G1 87 1540 RNG/WHT SP54 1507 RNG/WHT
G4 3
86 85 1508 RNG/WHT
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/C7
C404
1720 RNG/WHT BU ALARM-MFR HARN
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
1750 RNG/WHT 1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT
1520 RNG/WHT SHT9/C8
SHT11/D2 1705 RNG/WHT
SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
1805 RNG/WHT 1570 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT9/D8
SP11 1960 RNG/WHT
J2B SHT9/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT10/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT9/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT SP42 1590 RNG/WHT
2 2 SHT9/E4
1555 RNG/WHT
SHT15/F4
1050 RED +12V PWR 30 FUSE 7 25 A SP65

SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
B2
86 85 GND
BUS BAR
A5 A2 1725 RNG/WHT
SHT5/C2
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
21 SWITCHED POWER RELAY FEEDBACK
3380 LBL
4 SWITCHED POWER RELAY SIGNAL
J1A
C428
MFR HARN CONN 2 (LT GRAY)
1920 RNG/WHT 1920 RNG/WHT SP37 1840 RNG/WHT
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 3 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 3 / 15
7300816
697 of 1290
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7 GATEWAY CTRLR
6 2370 BRN
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
ECU CASE GND SHT8/F7 17 SENSOR GROUND
1 2155 BLK 2190 BRN
SHT15/G5 SHT8/D7
2180 BRN
J1B
SHT6/E7
2150 BRN
SHT6/F7
2080 BLK
SHT5/E3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT9/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16
SHT15/D4
AUX CTRLR SHT14/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT15/H5 15
2065 BLK SP28 2730 BLK
SHT9/C8 J2B SHT10/E8
2930 BLK
C428
SHT9/E8 MFR HARN CONN 2 (LT GRAY)
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK
SP47
SHT9/F8
2785 BLK 2770 BLK
SHT14/B7 SHT14/H6 T10
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

SHT12/C4 MFR ACCESSORY B B
2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK BATT GND
SHT12/C4 B B 1
SP51
2610 BLK
SHT12/E4
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK AUX CTRLR

SHT5/B8
2185 BRN
2715 BLK SHT15/E7 SP58 2995 BRN
SHT5/C2 2195 BRN 17 SENSOR GND
SHT11/G2
2505 BLK 2290 BLK
SHT15/G4 SHT13/B8 J2B
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55
2115 BLK 2105 BLK
SHT12/D8
2055 BLK
SHT3/C1
2030 BLK
SHT13/F8
2005 BLK
SHT6/G7
2120 BLK
SHT12/E8

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 4 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
CHG NOTICE DWN SHEET
SHT 4 / 15
7300816
698 of 1290
CAN BUS
DLX CAB HARN 7301237 ONLY
* (NOT IN STD CAB HARN 7303755)
RE016 RE019 C479
C408
GATEWAY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
R3-1 SP18 (BLACK)
TP-09 9260 PUR TP-09 TP-10 TP-10 SP31 TP-16 TP-16 TP-01 TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 R1 TP-08 9460 PUR TP-08
9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR
CAN LO 8 4 4 4 CAN LO
SP30 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
CAN HI 9 3 3 3 CAN HI
R3-2 R2
J1B TP-11 TP-02 TP-04 TP-06
C479
C503
RH DLX PANEL
AUX CTRLR
9440 PUR TP-06
9280 PUR TP-11 4 CAN LO
8 CAN LO
9340 PUR/WHT
9180 PUR/WHT 2 CAN HI
9 CAN HI
J2B C503
* C450 C460
RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9320 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
9420 PUR 9660 PUR CAN LO
4 4 4 4
7+,66&+(0$7,& 86(',1 S/N ALM416381-ALM419107, ALM419124-ALM419125

* C449 C459
LEFT JOYSTICK
LEFT JOYSTICK CONN LEFT JOYSTICK
SHT3/B1 1 1 1 1
2080 BLK
FOR TELEMATICS SEE CAN BUS SHEET IN 7322210
2080 BLK GND
SHT4/G8 2 2 2 2
3 3 3 3
4 4 4 4
AUX CTRLR C426
SUSP SEAT JOYSTICK HARNESS
TP-12 9500 PUR/WHT TP-12
CAN HI 14 A A CAN HI R18 R21
120 OHM 0.5W RESISTOR 120 OHM 0.5W RESISTOR
ENG ECU CTRLR B1 GATEWAY CTRLR
9600 PUR R1-1 SP90 R2-1
CAN LO 20 B B CAN LO TP-17 TP-17 TP-18 TP-18 TP-20 TP-21 9205 PUR TP-21
9200 PUR 9215 PUR 9210 PUR TP-20
ENG CAN LO 47 20 ENG CAN LO
J2B
3095 LBL
REMOTE RUN 24 9100 PUR/WHT
SP91 9110 PUR/WHT
9115 PUR/WHT 9105 PUR/WHT
ENG CAN HI 48 14 ENG CAN HI
R1-2 TP-19 R2-2
J2A J7A J1B
C169
GATEWAY CTRLR ENGINE CAN
1725 RNG/WHT
3090 LBL 3085 LBL
SHT3/D1 1
REMOTE RUN 21 D D REMOTE RUN KEY
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT TP-19

3 ENG CAN HI
1735 RNG/WHT
SHT3/D1 E E SWITCHED POWER
9255 PUR
4 ENG CAN LO
1165 RED/WHT
SHT2/C1 F F UNSWITCHED POWER
C169
2710 BLK
SHT4/C6 G G GROUND

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 5 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
SHT 5 / 15
7300816
699 of 1290
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
MFR-BCT HARN CONN T21 S
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/E7
SHT3/C1 C C
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
STARTER RELAY SIGNAL 7
3560 LBL
STARTER RELAY FEEDBACK 22
2150 BRN GND
SHT4/G3 B C110 ALTERNATOR
AIR FILTER
1020 RED
3150 LBL SWITCH (NC) S
AIR FILTER SIGNAL 16 A SIG
L
J1A C405
C355 2015 BLK 1
FUEL HARN SHT4/E3
T11
3180 LBL 3180 LBL
FUEL SIGNAL 12 C C A 1
FUEL SENDER
(30 - 270 OHM) T12
2180 BRN 2180 BRN HAND THROTTLE
SHT4/G3 D D B
5690 YEL F
C406 SHT10/C7 E
D
C428
+5V PWR
MFR HARN CONN 2 (LT GRAY) C
3690 LBL 3690 LBL SIG
THROTTLE PRIMARY SIGNAL 10 6 6 A
2690 BRN GND
SHT10/D5 B
8007 TAN
C114
IGN SW ON 4 FRC1
J1B PREHEATER
RELAY - C
ENG ECU CTRLR

1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
IGN SW ON 19 C100 C4
2865 BRN GND C100 T14
WATER IN FUEL RETURN 34 2 1445 RED/WHT
WATER IN FUEL SENSOR SHT2/C1 C5 C2
(FUEL FILTER)
3865 LBL FRC1 FRC1
SIG
WIF SENSOR 9 1
8510 TAN
PRE HEATER RELAY DRIVER 56
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQ SIGNAL 28 2 2 SHT7/G3
8014 TAN
AIR INLET TEMP 35 3 3 SHT7/F3
4 4 SHT7/H7
J7A
ENG-CROSSOVER
3420 LBL

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 6 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
SHT 6 / 15
7300816
700 of 1290
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALM416381-ALM418928
ENG ECU CTRLR
GLOW PLUG FEEDBACK

SHT6/C5 79 GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR
T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT6/C5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT6/C5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2
T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T
2 46 FUEL TEMP SENSOR RETURN GND
C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1
KNOCK SENSOR 1 SHIELD-01
T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1
ENGINE BLOCK ACCELEROMETER #1 SHIELD

INTAKE MANIFOLD PRESSURE SENSOR
3 28
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
3 29 ENGINE BLOCK ACCELEROMETER #2 SHIELD
INJECTOR #1
C146 FUEL INJECTOR #1 HSDA 27 1
CRANKSHAFT POSITION SENSOR SHIELD-03

SHIELD-03
1 36 CRANKSHAFT SENSOR NEG FUEL INJECTOR #1 LSD1A 26 2
2 60 CRANKSHAFT POSITION SENSOR C139
3 87 CRANKSHAFT SENSOR SHIELD
INJECTOR #2
C145 FUEL INJECTOR #2 HSDB 50 1
CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT6/C5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
RAIL PRESSURE SENSOR

3 38 VREF 1 RAIL PRESSURE SENSOR FUEL INJECTOR #3 LSD1B 75 2
1 35 RAIL PRESSURE SENSOR C141
P
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
2 19
FUEL INJECTOR #4 HSDA 3 1
C143
FUEL INJECTOR #4 LSD2A 25 2

INLET METERING VALVE
VREF 1 INLET METERING VALVE
1 SHT6/C5 C142
2 77 INLET METERING VALVE (PWM)
C154
J7B
J7B

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 7 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 7 / 15
7300816
701 of 1290
HYDRAULICS
FRC1
TRACTION LOCK RELAY - D
C425
4100 LGN
1360 RED/WHT +12V PWR B B
SHT2/E1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
86 SHT4/D6 C C B OHM 12 V TRACK 2 SPEED ADAPTER
FRC1 FRC1 (SEE ADDITIONAL OPTIONS DWG)
C308
2035 BLK
SHT4/B8 WHEEL 2 SPD ADP HARNESS 7159366
TRACK SINGLE SPD BRAKE ADP HARNESS 7165061
GATEWAY CTRLR
4110 LGN
TRACTION LOCK SIGNAL 8
3430 LBL
TRACTION LOCK FEEDBACK 13
2220 BRN GND

SHT4/H3 B
HYDRAULIC TEMPERATURE SENDER
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
HYD TEMP SIGNAL 32 A
C108
3320 LBL SIG

HYD FILTER DIFF PRESS 34 A
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446
2410 BRN GND

HYD LOCK VALVE GROUND 1 2
J1A HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
4200 LGN C105
J1B
19
13
23
6
HYD CHARGE PRESS
SENDER POWER
HYD LOCK
SOLENOID
HYD CHARGE
PRESS SENDER
TRACTION SOLENOID
OUTPUT
HYDRAULIC
FAN
4330 LGN GND

1
AUX CTRLR
FRONT ROD SOLENOID (MALE)
2330 BRN SIG 3.3 OHM PWM
FRONT ROD SOLENOID GROUND 18 2
C418
4340 LGN GND
1
GATEWAY CTRLR
FRONT BASE SOLENOID (FEMALE)
FRONT BASE SOLENOID GROUND 1 2
J2A C419
J2B
19
13
FRONT BASE
SOLENOID
FRONT ROD
SOLENOID
AUX CTRLR

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 8 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 8 / 15
7300816
702 of 1290
1940 RNG/WHT 1
LEFT PANEL BUZZER CAB DISPLAY
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN
C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/E1 1
2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10 GATEWAY CTRLR
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
1620 RNG/WHT SWITCHED POWER
SHT3/E1 5 C499
C500
3400 LBL LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT14/F4 11
3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT14/F4 8 START ENGINE 24 2 2 2
1960 RNG/WHT
J1A
SHT3/E1
SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT

SHT4/E8 2 3 7 J1B 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5
1420 RED/WHT UNSWITCHED POWER

5 4 SHT2/G1 1
3600 LBL PARK BRAKE INPUT
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
SHT4/E8 2 1 RH DLX PANEL
C479 SHT5/G1
5 6 1590 RNG/WHT SWITCHED POWER

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1
C480 2250 BLK GROUND

1775 RNG/WHT SHT4/F8 3
SHT3/E1 LEFT PANEL CONN (GRAY)
3620 LBL DOOR SIGNAL

SHT10/D3 12
C503 SHT5/F1
3610 LBL PARK BRAKE OUTPUT

2
SW12
DESOX INHIBIT SWITCH(OPT KIT)
2065 BLK 8070 TAN DESOX INHIBIT

SHT4/E8 2 4 9
1700 RNG/WHT 8050 TAN
SHT3/E1 7 9 4 DPF LAMP
1705 RNG/WHT 8055 TAN DESOX INHIBIT LAMP
SHT3/E1 10 8 5
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 9 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 9 / 15
7300816
703 of 1290
SW4
HAND/FOOT (ACS)
*
CAB
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT
*
SHT3/E1 2 1
6
2060 BLK (NOT IN STD CAB HARN 7303755)
SHT10/D1 5
4
THESE CAB SCHEMATICS USED IN S/N ALM416381-ALM419107,
SW4 SW4
ALM419124-ALM419125
C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN
7 7
4275 LGN
8 8
4550 LGN
9 9
2795 BLK GND
*
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT
1370 RED/WHT 1370 RED/WHT SP45 1390 RED/WHT

SHT2/B1 7 7 1
C129
CAB ACCESSORY
* T37
1210 RED/WHT +12V BATT PWR 2010 BLK
A A 1
* T38
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
2800 BLK
C C GND
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B4
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
C428
2790 BLK
2790 BLK
*C667
DOOR HARNESS
SHT4/E3 14 14
(SEE ADDITIONAL
2690 BRN
SHT6/E5 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 SENSOR 3620 LBL
SHT9/D8 4 4 DOOR SIGNAL
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/G1 5 5 DOOR UNSW PWR
A
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR
2 2 WIPER MOTOR GROUND
C
5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
SEATBAR/THROTTLE +5V 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5690 YEL
SHT6/E5
HARNESS WASHER PUMP

* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 10 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 10 / 15
7300816
704 of 1290
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR 1530 RNG/WHT
SHT3/E3 A
4930 LGN
RIGHT HANDLE LEFT ROCKER DOWN 31 J
4940 LGN
RIGHT HANDLE LEFT ROCKER UP 30 H LEFT POSITION SWITCH
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
4910 LGN RIGHT POSITION SWITCH
BU ALARM-MFR HARN (SEE C103 RIGHT HANDLE RIGHT ROCKER UP 13 F
ADDITIONAL OPTION DWG) TAILGATE HARN 4920 LGN TRIGGER
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM HANDLE LOCK (ACS ONLY)
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
PWM SIGNAL
GATEWAY CTRLR
2980 BRN GND
TILT SPOOL LOCK GROUND 10 3
LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
HANDLE LOCK (ACS ONLY)

H
2990 BRN GND
LIFT SPOOL LOCK GROUND 2 3 E
J1A LIFT SPOOL LOCK 4640 LGN
FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
7.8 OHM 12V 1520 RNG/WHT
SIG
1 SHT3/E3 A
4830 LGN
C422 LEFT HANDLE RIGHT ROCKER DOWN 22 B RIGHT POSTION SWITCH
4840 LGN
LEFT HANDLE RIGHT ROCKER UP 28 C
4810 LGN
LEFT HANDLE PADDEL RIGHT 11 F PADDLE
J1B
4820 LGN
7
LEFT HANDLE PADDEL LEFT 12 G

TILT SPOOL
LOCK SOLENOID
LIFT SPOOL
LOCK SOLENOID
J2A C410
LEFT POSITION SWITCH
TRIGGER
GATEWAY CTRLR

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 11 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 11 / 15
7300816
705 of 1290
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
SP14 GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - RC1
C438
2760 BLK GND
1350 RED/WHT MFR HARN CONN 3 (DK GRAY) B RIGHT FRONT
SHT2/E1 30 6620 PNK SP23 6610 PNK 6610 PNK 6130 PNK WORK LIGHT
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK
FRONT WORK LIGHTS 2610 BLK GND

SHT4/D8 2
RELAY-RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
SHT2/E1 TAILGATE HARN
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR SIGNAL 5
C602
3460 LBL
MRKR LIGHT PWR FEEDBACK 31
REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
REAR LIGHT RELAY FEEDBACK 28
RIGHT REAR
J1A WORK LIGHT
FRC1
6210 PNK
REAR LIGHT 6210 PNK SIG 1

RELAY - E T15 TERMINAL (+)
1320 RED/WHT T17 TERMINAL (+)

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
FRC1 FRC1 T18 TERMINAL (-)
2045 BLK
SHT4/B8

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 12 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 12 / 15
7300816
706 of 1290
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

M (NOT IN STD CAB HARN 7303755)
7440 WHT SIG
1
C610
2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK
C HEATER VALVE
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
*
FRC1 C438 SW10
HVAC RELAY-B MFR HARN CONN 3
(DK GRAY)
* BLOWER SWITCH
7530 WHT
1
HIGH
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED

SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
M
7050 WHT
FRC1 FRC1 SW10

7410 WHT
4
C611
GATEWAY CTRLR
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
* THERMOSTAT
*
SP40
7021 WHT 7020 WHT 7020 WHT
AC SIGNAL MONITOR 11 12 12 1
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4
C350 MAGNET CLUTCH

2290 BLK 2280 BLK (COMPRESSOR)
SHT4/C6
GND
2
C486

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 13 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 13 / 15
7300816
707 of 1290
# C355 C428
FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE SP33
*
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
#
B B SHT4/E6
POWER BOBTACH SWITCH DLX FUEL HARN 7266824 ONLY
#
C607
(NOT IN STD FUEL HARN 7149219)
4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
3
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT SP43 1430 RED/WHT
*
SHT2/C1 1 1 X T3
FLASHER
1200 RED/WHT L
FLOAT (ACS/AHC ONLY)
3500 LBL
T3
SHT9/F8
SP21 D14
RIGHT POSTION SWITCH 6500 PNK 6500 PNK 6530 PNK
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
2
*
6415 PNK C103 SW3
D
HAZARD SWITCH
6570 PNK
6515 PNK TAILGATE HARN
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D SW2 SW2
2780 BLK 2780 BLK 4

SHT4/E3 4 4 6 2850 BLK
SP46
2725 BLK
* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED)

BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND 2450 BLK 2455 BLK
SHT4/C6 4 SHT15/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 6 5 SHT15/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT15/D4 D D
6440 PNK BEACON/FLASHER
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C676 C C
LEFT SPEAKER
* * RADIO CONN A A
HANDLE LOCK (ACS ONLY) 1

7820 WHT
3 LEFT SPEAKER (+) *
7830 WHT
2 4 LEFT SPEAKER (-)
L010
C279
FLOAT (ACS/AHC ONLY) AIR RIDE SEAT
AUX CTRLR RIGHT SPEAKER 1510 RNG/WHT
*
SHT10/E1 4 PWR
2460 BRN PWR
GND
HIGH FLOW SOLENOID GROUND 26 B 7810 WHT
RIGHT POSTION SWITCH HIGH FLOW 2 6 RIGHT SPEAKER (-)
J2A SOLENOID 2210 BLK GND
4460 LGN SIG 7.5 OHM 12 V 7800 WHT SHT10/E1 5
PADDLE HIGH FLOW SOLENOID SIGNAL 26 A 1 5 RIGHT SPEAKER (+) GND
J2B C415 C278 1885 RNG/WHT

SHT10/E1 1 RADIO SWITCHED POWER C277
2885 BLK
SHT10/D1 2 RADIO GROUND
C408 C676
MFR HARN CONN 1 C126 GATEWAY CTRLR
1460 RED/WHT
A SHT2/C1 (BLACK) HORN CONNECTOR
TRIGGER
7210 WHT 7210 WHT SIG 2350 BRN GND
B 13 13 A A _ TWO SPEED GROUND 26 2
TWO SPEED TRACK 2 SPEED
C412 J1A SOLENOID (SEE ADDITIONAL
HORN
4350 LGN OPTIONS DWG)
+ TWO SPEED SIGNAL 26
SIG
1 5.1 OHM 12 V
2785 BLK GND
SHT4/E8 B B
J1B C441

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 14 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399
CHG NOTICE DWN
AEW
SHEET
SHT 14 / 15
7300816
708 of 1290
SW7 *
OPTIONS 2
C438 RIDE CONTROL
AUX CTRLR MFR HARN CONN 3 (DK GRAY)
3410 LBL 3410 LBL 2890 BLK
RIDE CONTROL SW AUTO 23 14 14 1 2 SHT4/E8

SW7 SW7 RIDE CONTROL (NOT IN STD CAB HARN 7303755)
3480 LBL RELAY - L
RIDE CONTROL RELAY SIGNAL 7 FUSE RELAY CENTER
SP9 1575 RNG/WHT

3415 LBL 3425 LBL L1 SHT3/F1
RIDE CONTROL COIL SIGNAL 21 L4
3435 LBL 3445 LBL 2505 BLK

1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL

COIL COIL FRC1 FRC1
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK
SHT4/G8
C428 SW13
3475 LBL 3475 LBL
REVERSING FAN *
REVERSING FAN MANUAL SIGNAL 16 7 7 3
2905 BLK 2970 BLK

SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIGNAL 29 8 8 6
1555 RNG/WHT
5 SHT3/D1
4
SW13
C443 SW13
2175 BRN
REVERSING FAN RETURN SIGNAL 27 2
J2A REVERSING
FAN COIL
3485 LBL
REVERSING FAN SIGNAL 25 1
C442
2185 BRN
SHT4/C3 A
3455 LBL
C RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIGNAL 10
5105 YEL
PRESSURE SENSOR
RIDE CONTROL SENSOR +5V PWR 24 B
J2B
* SW8 * C672
SIDELIGHT SIDELIGHT CONN
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712015
B2LA11899
B2KZ13499
B3GZ12002
B3GY12002 7300816 (B)
SCHEM ELEC MAN
Sheet 15 of 15
X ± 13 MAT
B
REV
SEE SHEET 1
DESCRIPTION
104399 AEW
SHT 15 / 15
7300816
709 of 1290
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
RED LEGEND
BATT FEED, GENERAL 1000 THROUGH 1499 RED
8 SH08 - HYDRAULICS
BATT FEED, FUSED RED/WHITE RED/WHT CONNECTOR
1000 THROUGH 1499
10 SH10 - CAB
11 SH11 - MANUAL CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
12 SH12 - LIGHTS
PARTIAL CONNECTOR
14 SH14 - OPTIONS 1
1 1
MONITORING LIGHT BLUE LBL
HARNESS PART NUMBER 3000 THROUGH 3999

MF MFR MAN 7322211 1 1
EXMF MFR MAN 7322212 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7329485 * LIGHTS PINK PNK
6000 THROUGH 6999
WIRE BREAK
STD CAB 7329492 * SHT1/F2 SHT1/F2
STD FUEL 7149219 SHT1/F2 SHT1/F2

DLX FUEL 7266824

9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALM419108-ALM419123, ALM419126 & ABOVE

FOR S/N ALM419124-ALM419125, ALM419107 & BELOW SEE PREVIOUS SCHEMATIC
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
Above TOLERANCES: ECN 106368 Printed On August 2018
csf

Standard Machine S/N B2KZ13500
B2L511400 &
B2LA11900 & Above
Above 7322210
UNLESS OTHERWISE SPECIFIED SCHEM ELEC MAN
Click Here For Interactive PDF COPYRIGHT C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT DWG. NO.
Sheet 1 of 15
7322210
ORIGINALLY CREATED AND REVISED IN THE YEARS AS DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR
0 106368 MMM TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY Printable Version Click Here
REV DESCRIPTION CHG NOTICE DWN SHEET
RESERVES ALL RIGHTS. NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT, SHT 1 / 15
710 of 1290
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
C408 1400 RED/WHT
6 6 SHT5/F7
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
100.0 Amps
HW11 1 1
T5 T4
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1
FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/D3
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/D3
1055 RED
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8
1200 RED
SHT3/C8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

Standard Machine S/N B2LA11900
B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 2 of 15
7322210
0 SEE SHEET 1 106368 MMM TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
711 of 1290
FRC1 ENGINE
ECU RELAY - G

1506 RNG/WHT
1 SWITCHED
G1 SP54
POWER
SHT2/D1 87 1540 RNG/WHT 1507 RNG/WHT
G4 3
86 85 1508 RNG/WHT
G2 G5 5 ENG ECU CTRLR
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/C7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
SP50
BUS BAR
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT
SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
C428 1785 RNG/WHT
SHT10/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT9/F4
FRC1 SWITCHED 2 2 SHT9/E4
POWER RELAY - A 1555 RNG/WHT
SHT15/F4
1050 RED 30 FUSE 7 25 A SP65

SHT2/B1 A1 87 A4 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
+12V PWR 7A 7B SHT5/B8
1920 RNG/WHT 86 85 2055 BLK

A5 A2 1725 RNG/WHT
GND SHT5/C2
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
3390 LBL
FRC1 SWITCHED
POWER RELAY - F
FRC1 FRC1
1200 RED 30 2055 BLK
SHT2/B1
+12V PWR
F1 87 F4 1585 RNG/WHT SHT4/B8
GATEWAY CTRLR
3385 LBL 86 85 2065 BLK
F5 F2 SHT4/C8 3450 LBL
SP100 GND
FRC1
FRC1
3380 LBL
J1A
C428
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 3 of 15
7322210
0 SEE SHEET 1 106368 MMM IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE Printable Version Click Here
712 of 1290
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
6 2370 BRN
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/G4 SHT8/D7
2180 BRN
J1B
SHT6/E7
2605 BLK 2150 BRN
SHT5/E7 SHT6/F7
2080 BLK
SHT5/E3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16
SHT15/D4
AUX CTRLR SHT14/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT15/H4 15
2065 BLK SP28 2730 BLK
2930 BLK
C428
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK
SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND
SHT12/C4 B B
SP51
2610 BLK
SHT12/E4
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6

SHT5/B8
2185 BRN
2715 BLK SHT15/E7 SP58 2995 BRN
2065 BLK SHT5/C2 2195 BRN 17 SENSOR GND
SHT3/C6 SHT11/G2
2505 BLK 2290 BLK
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55
2115 BLK 2105 BLK
SHT12/D8
2055 BLK
SHT3/C1
2030 BLK
SHT13/F8
2005 BLK
SHT6/G8
2120 BLK
SHT12/E8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 4 of 15
7322210
713 of 1290
CAN BUS
C479
C408 LEFT PANEL
Z3 Z4
GATEWAY CTRLR MFR HARN CONN 1 (BLACK) (BLACK)
120 OHM 0.5 W RESISTOR SP18 120 OHM 0.5 W RESISTOR
SP31 SP39 SP35
9260 PUR 9230 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR CAN LO
CAN LO 8 4 4 4
SP30 SP17 SP38 SP34

J1B
C479
C503
RH DLX PANEL
AUX CTRLR
TELEMATICS USED IN S/N ALM419108-ALM419123, 9440 PUR
9280 PUR 4 CAN LO
ALM419126 & ABOVE 8 CAN LO
9340 PUR/WHT
9 CAN HI
S/N ALM419124-ALM419125, ALM419107 & BELOW J2B C503
SEE PREVIOUS SCHEMATIC
TELEMATICS * C450 C460
RIGHT JOYSTICK
1305 RED/WHT SHT3/B1 1 1 1 1
PWR 10 SHT2/G1 2070 BLK 2070 BLK GND
2605 BLK SHT4/G8 2 2 2 2
GND 11 SHT4/G8 9320 PUR/WHT 9560 PUR/WHT CAN HI
C448 3 3 3 3
MFR HARN CONN 4 (BLACK) 9420 PUR 9660 PUR CAN LO
Z5 SP104 4 4 4 4
120 OHM 0.5 W RESISTOR 9500 PUR/WHT
9515 PUR/WHT 9505 PUR/WHT 7 7
CAN HI 3 9510 PUR/WHT
9 9 * C449 C459
LEFT JOYSTICK
9610 PUR LEFT JOYSTICK CONN LEFT JOYSTICK
9615 PUR 9605 PUR 10 10 1840 RNG/WHT 1840 RNG/WHT +12V PWR
CAN LO 4 9600 PUR SHT3/B1 1 1 1 1
8 8 2080 BLK 2080 BLK GND
SP103 SHT4/G8 2 2 2 2
C481 9300 PUR/WHT 9540 PUR/WHT CAN HI
3 3 3 3
4 4 4 4
AUX CTRLR C426
CAN HI 14 A A CAN HI
9600 PUR 9610 PUR ENG ECU CTRLR Z1 Z2 GATEWAY CTRLR

CAN LO 20 B B CAN LO
120 OHM 0.5W RESISTOR SP90 120 OHM 0.5W RESISTOR
J2B 9200 PUR 9215 PUR 9210 PUR 9205 PUR
3615 LBL C CAN SELECT
CAN SELECT 25 C
SP91 9110 PUR/WHT 9105 PUR/WHT
3095LBL ENG CAN HI 48 14 ENG CAN HI
REMOTE RUN 24
J7A J1B
J2A
C169
1725 RNG/WHT
3090 LBL 3085 LBL
SHT3/D1 1
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT
3 ENG CAN HI
1735 RNG/WHT
9255 PUR
4 ENG CAN LO
1165 RED/WHT
C169
2710 BLK
SHT4/C6 G G GROUND
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
Sheet 5 of 15
7322210
714 of 1290
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1
2005 BLK
SHT4/B8 SHT2/E7
SHT3/C1 C C
1015 RED
GATEWAY CTRLR
3560 LBL
2150 BRN GND
AIR FILTER
1020 RED
L
J1A C405
C355 2015 BLK 1
FUEL HARN SHT4/E3
T11
3180 LBL 3180 LBL
FUEL SENDER HAND
(30 - 270 OHM) T12
2180 BRN 2180 BRN
THROTTLE
SHT4/G3 D D B
C406
C428
5690 YEL +5V PWR
MFR HARN CONN 2 (LT GRAY) SHT10/C8 C
2690 BRN GND
SHT10/D5 B
8007 TAN
C114
IGN SW ON 4
J1B FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR

1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL SIG FRC1 FRC1
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
8014 TAN
4 4 SHT7/H7
J7A
ENG-CROSSOVER
3420 LBL
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 6 of 15
7322210
0 SEE SHEET 1 106368 MMM IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
RESERVES ALL RIGHTS. NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT, Printable Version Click Here
SHT 6 / 15
REV DESCRIPTION CHG NOTICE DWN SHEET ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
715 of 1290
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALM418929 & ABOVE
FOR S/N ALM418928 & BELOW SEE PREVIOUS SCHEMATIC
ENG ECU CTRLR
GLOW PLUG FEEDBACK

EGR VALVE DC MOTOR
1 64 VREF 3 EGR
MAF SENSOR
4 OPEN MAF FREQ
SHT6/C5 1
MAF TEMP
C151 SHT6/C5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148
KNOCK SENSOR 1 BOOST PRESSURE AND TEMPERATURE SENSOR

SHIELD-01 SHIELD-01
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN BOOST TEMP SIGNAL 94 2
2 31 ENGINE BLOCK ACCELEROMETER #1 BOOST PRESSURE PWR 61 3
T
3 28 ENGINE BLOCK ACCELEROMETER #1 SHIELD BOOST PRESSURE SIGNAL 12 4 P
C147 BOOST TEMP/PRESSURE GND 67 1
KNOCK SENSOR 2 C150

SHIELD-02 SHIELD-02

INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
INJECTOR #3

P
INJECTOR #4
2 19
C143
INLET METERING VALVE FUEL INJECTOR #4 LSD2A 25 2

1 SHT6/C5 C142
C154
J7B J7B
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
Sheet 7 of 15
7322210
716 of 1290
HYDRAULICS
FRC1
C425
4100 LGN
SHT2/E1 D1 87 4200 LGN 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
3430 LBL
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
2410 BRN GND

1
C420
2190 BRN
SHT4/G3 A
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-4.5V
5190 YEL +5 PWR
SHT10/C8 B
4200 LGN C105
J1B
19
13
6
HYD LOCK
SOLENOID
PRESS SENDER
HYD CHARGE
TRACTION SOLENOID
OUTPUT
HYDRAULIC
FAN
4330 LGN GND

1
AUX CTRLR
C418
4340 LGN GND
1
GATEWAY CTRLR
J2A C419
J2B
19
13
FRONT BASE
SOLENOID
SOLENOID
FRONT ROD
AUX CTRLR
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 8 of 15
7322210
717 of 1290
1940 RNG/WHT T13
SHT3/E1 1
7040 WHT
1 C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10 GATEWAY CTRLR
SHT2/G1 1 PTOL LED 19 12 12 4
SHT3/E1 5 C499
C500
SHT14/F4
3400 LBL
11 LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
1960 RNG/WHT
J1A
SHT3/E1
SW9

SHT3/D1 5

5 4 SHT2/G1 1
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT10/D3 12
C503 SHT5/F1

2
SW12

SHT4/E8 2 4 9
SHT3/E1 10 8 5
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
Sheet 9 of 15
7322210
718 of 1290
SW4
HAND/FOOT (ACS)
*
CAB
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT
*
SHT3/E1 2 1
6 (NOT IN STD CAB HARN 7329492)
2060 BLK
SHT10/D1 5
4 THESE CAB HARNESSES USED IN S/N ALM419108-ALM419123,
SW4 SW4 ALM419126 & ABOVE
C438
FOR S/N ALM419124-ALM419125, ALM419107 & BELOW SEE
7 7
4235 LGN PREVIOUS SCHEMATIC
4275 LGN
8 8
4550 LGN
9 9
2795 BLK GND
1
*
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408

SHT2/B1 7 7 1
C129
CAB ACCESSORY
* T37
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
SP8 SP41
SHT3/D1
1580 RNG/WHT
5 5
B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B4
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
C428
2790 BLK
2790 BLK
*C667
DOOR HARNESS
SHT4/E3 14 14
(SEE ADDITIONAL
2690 BRN
2370 BRN 2370 BRN 2375 BRN
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
A
+5V PWR
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
C482
J1B
SHT8/D7
5190 YEL HARNESS WASHER PUMP
5690 YEL
* C252
7253378
SHT6/E5 2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 10 of 15
DWG. NO.
7322210
719 of 1290
MANUAL
CONTROLS
RIGHT HANDLE
SHT3/E3 A
4930 LGN
4940 LGN
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
7100 WHT 7100 WHT T19 E
A A C C
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
PWM SIGNAL
GATEWAY CTRLR
2980 BRN GND
LEFT HANDLE
TILT SPOOL LOCK
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421

H
2990 BRN GND
4990 LGN
SIG
1 SHT3/E3 A
4830 LGN
4840 LGN
4810 LGN
J1B
4820 LGN
7

C410
LOCK SOLENOID
TILT SPOOL
J2A
LOCK SOLENOID
LIFT SPOOL
TRIGGER
GATEWAY CTRLR
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 11 of 15
DWG. NO.
7322210
0 SEE SHEET 1 106368 MMM IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
RESERVES ALL RIGHTS. NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT, Printable Version Click Here
SHT 11 / 15
REV DESCRIPTION CHG NOTICE DWN SHEET ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
720 of 1290
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/F3 9 9 B
SP14 GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK
2610 BLK GND

FRONT WORK LIGHTS
SHT4/D8 2
RELAY-RC2 RIGHT REAR
C103
TAIL LIGHT
TAILGATE HARN
SHT2/E1
1330 RED/WHT
30 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
87 A A 1
C603
86 85
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
SHT4/D8 2
C602
3460 LBL
REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
RIGHT REAR
J1A WORK LIGHT
FRC1
6210 PNK


SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 12 of 15
DWG. NO.
7322210
0 SEE SHEET 1 106368 MMM TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
721 of 1290
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK
C HEATER VALVE
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
*
FRC1 C438 SW10
(DK GRAY)
* BLOWER SWITCH
7530 WHT
1
HIGH

SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
M
7050 WHT
FRC1 FRC1 SW10

7410 WHT
4
C611
GATEWAY CTRLR
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
7015 WHT
1
3
C
* THERMOSTAT
*
SP40
7021 WHT 7020 WHT 7020 WHT
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
C350
D4
MAGNET CLUTCH
SHT4/C6 GND
2
C486
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 13 of 15
DWG. NO.
7322210
722 of 1290
# C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE SP33
*
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
B B
DLX FUEL HARN 7266824 ONLY
#
SHT4/E6
POWER BOBTACH SWITCH
#
C607

1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
3
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
*
SHT2/C1 1 1 X T3
FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT9/F8
SP21 D1
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D2
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
SW3 2
*
6415 PNK C103
D
TAILGATE HARN HAZARD SWITCH
6515 PNK
A
E E 1
TRIGGER
(SEE ADDITIONAL
2780 BLK 2780 BLK 4
SHT4/E3 4 4 6 2850 BLK
SP46
2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT15/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 2830 BLK
6 5 SHT15/F4 E E
2810 BLK 2420 BLK C670
LEFT HANDLE F F
SHT4/E8
EXTERIOR HARNESS
6540 PNK
LIFT (ACS/AHC ONLY)
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY
GATEWAY CTRLR OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG)
2350 BRN GND

TWO SPEED GROUND 26 2
HANDLE LOCK (ACS ONLY) J1A SOLENOID (SEE ADDITIONAL
4350 LGN OPTIONS DWG) C676
SIG 5.1 OHM 12 V
TWO SPEED SIGNAL 26
J1B C441
1 LEFT SPEAKER
* * RADIO CONN
FLOAT (ACS/AHC ONLY) 7820 WHT L010

*
1 3 LEFT SPEAKER (+)
AUX CTRLR HEATED SEAT
7830 WHT 1510 RNG/WHT
RIGHT POSTION SWITCH 2460 BRN GND
2 4 LEFT SPEAKER (-) SHT10/E1 4 PWR
HIGH FLOW SOLENOID GROUND 26 B PWR
HIGH FLOW C279
J2A SOLENOID RIGHT SPEAKER
*
PADDLE 4460 LGN 2210 BLK GND
SIG
A 7.5 OHM 12 V 5
HIGH FLOW SOLENOID SIGNAL 26 SHT10/E1
7810 WHT GND
J2B C415 2 6 RIGHT SPEAKER (-)
C277
7800 WHT SEE OPTION PAGES FOR HARNESSES
1 5 RIGHT SPEAKER (+)
C408 C278
MFR HARN CONN 1 C126 1885 RNG/WHT
1460 RED/WHT SHT10/E1 1 RADIO SWITCHED POWER
TRIGGER
7210 WHT 7210 WHT SIG 2885 BLK
B 13 13 A A SHT10/D1 2 RADIO GROUND
+
C412 C676
HORN
_
2785 BLK GND
SHT4/E8 B B
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800&
AHGM13900
AJDT15600
AJZV18500
ALJ821600
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400 &
B2LA11900 & Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 14 of 15
DWG. NO.
7322210
723 of 1290
SW7 *
OPTIONS 2
C438 RIDE CONTROL
AUX CTRLR MFR HARN CONN 3 (DK GRAY)
3410 LBL 3410 LBL 2890 BLK
RIDE CONTROL SW AUTO 23 14 14 1 2 SHT4/E8

SW7 SW7
3480 LBL
FRC1 SWITCHED
RIDE CONTROL RELAY SIGNAL 7 POWER RELAY - L
SP9 1575 RNG/WHT

3415 LBL 3425 LBL L1 SHT3/F1
3435 LBL 3445 LBL 3480 LBL 2505 BLK

1 1 L5 L2 SHT4/C8

COIL COIL FRC1 FRC1
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK 2155 BLK
SHT4/G8
C428 SW13
3475 LBL
3475 LBL
REVERSING FAN *
2905 BLK 2970 BLK

SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
1555 RNG/WHT
5 SHT3/D1
4
SW13
C443 SW13
2175 BRN
J2A REVERSING
FAN COIL
3485 LBL
C442
2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIGNAL 10 C
5105 YEL PRESSURE SENSOR
J2B
* SW8 * C672
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM418800
AHGL13800
AHGM13900
ALJ821600
AJDT15600 &
AJZV18500
ALJG23700
ALJU24500
WARNING &&
&&Above
Above
Above
Above
csf

B2L511400
B2KZ13500 &
& Above
Above 7322210
COPYRIGHT C
X ± 13 MAT
Sheet 15 of 15
DWG. NO.
7322210
724 of 1290
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
7 SH07 - ENGINE CONTROL UNIT LEGEND
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
8 SH08 - HYDRAULICS
9 SH09 - CAB DISPLAY RED/WHITE CONNECTOR
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHT
10 SH10 - CAB
11 SH11 - MANUAL CONTROLS BATT FEED, SWITCHED ORANGE/WHITE RNG/WHT 1 1
1500 THROUGH 1999
12 SH12 - LIGHTS
PARTIAL CONNECTOR
14 SH14 - OPTIONS 1
1 1
HARNESS PART NUMBER
MF MFR MAN 7331093 1 1
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL

WIRE BREAK
DLX CAB 7301237 LIGHTS PINK PNK
6000 THROUGH 6999
WIRE BREAK
STD CAB 7303755 SHT1/F2 SHT1/F2
SHT1/F2 SHT1/F2
STD FUEL 7149219
DLX FUEL 7266824

9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
WARNING Above PROPRIETARY NOTICE TOLERANCES: ECN 110295 Printed On August 2018
csf

Standard Machine 7331097
SCHEM ELEC MAN
Sheet 1 of 15
Click Here For Interactive PDF COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
0
REV DESCRIPTION
110295 PML
SHT 1 / 15
7331097
725 of 1290
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
C408 1400 RED/WHT
6 6
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
100.0 Amps
HW11 1 1
T5 T4
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1
FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/D3
1055 RED
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/D3
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 2 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 2 / 15
7331097
726 of 1290
FRC1 ENGINE
ECU RELAY - G

1506 RNG/WHT
1 SWITCHED
86 85
G4
1508 RNG/WHT
3
ENG ECU CTRLR

POWER
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/C7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT
SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
SWITCHED SHT10/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT9/F4
2 2 SHT9/E4
1555 RNG/WHT
SHT15/F4
1050 RED +12V PWR 30 FUSE 7 25 A SP65

A4 7A 7B SHT5/B8
B2
86 85 GND
BUS BAR
A5 A2 1725 RNG/WHT
SHT5/C2
1580 RNG/WHT
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
J1A
C428
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 3 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 3 / 15
7331097
727 of 1290
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
6 2370 BRN
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/G5 SHT8/D7
2180 BRN
J1B
SHT6/E7
2150 BRN
SHT6/F7
2080 BLK
SHT5/E3
2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16
SHT15/D4
AUX CTRLR SHT14/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT15/H5 15
2065 BLK SP28 2730 BLK
2930 BLK
C428
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK
SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK BATT GND
SHT12/C4 B B 1
SP51
2610 BLK
SHT12/E4
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6

SHT5/B8
2185 BRN
2715 BLK SHT15/E7 SP58 2995 BRN
SHT5/C2 2195 BRN 17 SENSOR GND
SHT11/G2
2505 BLK 2290 BLK
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55
2115 BLK 2105 BLK
SHT12/D8
2055 BLK
SHT3/C1
2030 BLK
SHT13/F8
2005 BLK
SHT6/G7
2120 BLK
SHT12/E8

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 4 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295 PML
SHT 4 / 15
7331097
728 of 1290
CAN BUS
RE016 RE019 C479
C408
GATEWAY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
R3-1 SP18 (BLACK)
TP-09 9260 PUR TP-09 TP-10 TP-10 SP31 TP-16 TP-16 TP-01 TP-01 TP-03 TP-03
SP30 SP17 SP38 SP34

R3-2 R2
J1B TP-11 TP-02 TP-04 TP-06
C479
C503
RH DLX PANEL
AUX CTRLR
9440 PUR TP-06
9280 PUR TP-11 4 CAN LO
8 CAN LO
9340 PUR/WHT
9 CAN HI
J2B C503
* C450 C460
RIGHT JOYSTICK
SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
3 3 3 3
4 4 4 4
* C449 C459
LEFT JOYSTICK
LEFT JOYSTICK CONN LEFT JOYSTICK
SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
3 3 3 3
4 4 4 4
AUX CTRLR C426
TP-12 9500 PUR/WHT TP-12
CAN HI 14 A A CAN HI R18 R21
120 OHM 0.5W RESISTOR 120 OHM 0.5W RESISTOR
ENG ECU CTRLR B1 GATEWAY CTRLR
9600 PUR R1-1 SP90 R2-1
CAN LO 20 B B CAN LO TP-17 TP-17 TP-18 TP-18 TP-20 TP-21 9205 PUR TP-21
9200 PUR 9215 PUR 9210 PUR TP-20
J2B
3095 LBL
REMOTE RUN 24 9100 PUR/WHT
SP91 9110 PUR/WHT
ENG CAN HI 48 14 ENG CAN HI
R1-2 TP-19 R2-2
J2A J7A J1B
C169
1725 RNG/WHT
3090 LBL 3085 LBL
SHT3/D1 1
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT TP-19

3 ENG CAN HI
1735 RNG/WHT
9255 PUR
4 ENG CAN LO
1165 RED/WHT
C169
2710 BLK
SHT4/C6 G G GROUND

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 5 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295 PML
SHT 5 / 15
7331097
729 of 1290
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/E7
SHT3/C1 C C
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
3560 LBL
2150 BRN GND
AIR FILTER
1020 RED
L
J1A C405
C355 2015 BLK 1
FUEL HARN SHT4/E3
T11
3180 LBL 3180 LBL
FUEL SENDER
(30 - 270 OHM) T12
2180 BRN 2180 BRN HAND THROTTLE
SHT4/G3 D D B
5690 YEL F
C406 SHT10/C7 E
D
C428
+5V PWR
2690 BRN GND
SHT10/D5 B
8007 TAN
C114
IGN SW ON 4 FRC1
J1B PREHEATER
RELAY - C
ENG ECU CTRLR

1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL FRC1 FRC1
SIG
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
8014 TAN
4 4 SHT7/H7
J7A
ENG-CROSSOVER
3420 LBL

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 6 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 6 / 15
7331097
730 of 1290
ENGINE CONTROL UNIT
ENG ECU CTRLR
GLOW PLUG FEEDBACK

EGR VALVE DC MOTOR
T
EXHAUST GAS TEMP SENSOR 2 6 2
OPEN
MAF SENSOR
4 MAF FREQ
SHT6/C5 1
MAF TEMP
C151 SHT6/C5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T

T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
C150
ENGINE BLOCK ACCELEROMETER #1 SHIELD

3 28
C147
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
INJECTOR #3

P
INJECTOR #4
2 19
C143

1 SHT6/C5 C142
C154
J7B
J7B

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 7 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 7 / 15
7331097
731 of 1290
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/E1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
3430 LBL
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
2410 BRN GND

1
C420
2190 BRN GND

SHT4/G3 A
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-4.5V
5190 YEL +5 PWR
SHT10/C8 B
4200 LGN C105
J1B
19
13
6
HYD LOCK
SOLENOID
HYD CHARGE
PRESS SENDER
TRACTION SOLENOID
OUTPUT
HYDRAULIC
FAN
4330 LGN GND

1
AUX CTRLR
C418
4340 LGN GND
1
GATEWAY CTRLR
J2A C419
J2B
19
13
FRONT BASE
SOLENOID
FRONT ROD
SOLENOID
AUX CTRLR

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 8 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 8 / 15
7331097
732 of 1290
1940 RNG/WHT 1
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10 GATEWAY CTRLR
SHT2/G1 1 PTOL LED 19 12 12 4
SHT3/E1 5 C499
C500
SHT14/F4 11
1960 RNG/WHT
J1A
SHT3/E1
SW9

SHT3/D1 5

5 4 SHT2/G1 1
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT10/D3 12
C503 SHT5/F1

2
SW12

SHT4/E8 2 4 9
SHT3/E1 10 8 5
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 9 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 9 / 15
7331097
733 of 1290
SW4
HAND/FOOT (ACS)
* H/ISO (SJC, AWS)
1785 RNG/WHT
SWITCH
CAB
SHT3/E1 2 1
6
SHT10/D1 5
4
SW4 SW4
C438
4235 LGN
7 7
4275 LGN
8 8
4550 LGN
9 9
2795 BLK GND
1850 RNG/WHT 1
SHT3/F1
1850 RNG/WHT
2 2
1375 RED/WHT +12V PWR
* C212
POWER SOCKET
2
C212
C408

SHT2/B1 7 7 1
C129
CAB ACCESSORY
* T37
1210 RED/WHT +12V BATT PWR 2010 BLK
A A 1
SP8 SP41
SHT3/D1
1580 RNG/WHT
5 5
B B +12V SW PWR
* T38
2800 BLK
C C GND
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B4
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/C2
2885 BLK
SHT14/B4
2060 BLK
SHT10/H8
C428
2790 BLK
2790 BLK
*C667
DOOR HARNESS
SHT4/E3 14 14
(SEE ADDITIONAL
2690 BRN
2370 BRN 2370 BRN 2375 BRN
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
A
+5V PWR
C
5100 YEL SP13 5370 YEL 5370 YEL SP52 5375 YEL 7310 WHT
C482
J1B
5190 YEL 5690 YEL
SHT8/D7 SHT6/E5
HARNESS WASHER PUMP

* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 10 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 10 / 15
7331097
734 of 1290
MANUAL
CONTROLS
RIGHT HANDLE
SHT3/E3 A
4930 LGN
4940 LGN
2195 BRN
SHT4/C3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
7100 WHT 7100 WHT T19 E
A A C C
2650 BLK 1 K
SHT4/D8
T20 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
TRIGGER RETURN
RIGHT HANDLE
PWM HIGH
RIGHT HANDLE
PWM SIGNAL
GATEWAY CTRLR
2980 BRN GND
LEFT HANDLE
TILT SPOOL LOCK
LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421

H
2990 BRN GND
4990 LGN
SIG
1 SHT3/E3 A
4830 LGN
4840 LGN
4810 LGN
J1B
4820 LGN
7

TILT SPOOL
LOCK SOLENOID
LIFT SPOOL
LOCK SOLENOID
J2A C410
TRIGGER
GATEWAY CTRLR

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 11 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 11 / 15
7331097
735 of 1290
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
SHT4/F3 9 9 B
SP14 GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK

SHT4/D8 2
RELAY-RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
SHT4/D8 2
C602
3460 LBL
REAR LIGHT RELAY SIGNAL 17 C604

2620 BLK
3440 LBL SHT4/D8 1
RIGHT REAR
J1A WORK LIGHT
FRC1
6210 PNK
REAR LIGHT 6210 PNK

2
RELAY - E
1320 RED/WHT C605

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H 2
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK
SHT4/C8 1
FRC1 FRC1
2045 BLK
SHT4/B8

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 12 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 12 / 15
7331097
736 of 1290
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
7425 WHT
B
C483
*
D
2130 BLK
C HEATER VALVE
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
M
7050 WHT
FRC1 FRC1 SW10

7410 WHT
4
C611
GATEWAY CTRLR
HVAC RELAY SIGNAL 3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
SP40 * THERMOSTAT
AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12 7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
D4
C350 MAGNET CLUTCH

SHT4/C6
GND
2
C486

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 13 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 13 / 15
7331097
737 of 1290
C355 C428
# FUEL HARN MFR HARN CONN 2 (LT GRAY)
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE SP33
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
B B SHT4/E6
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
# 4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
SHT2/C1 1 1 X T3
* FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT9/F8
SP21 D14
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
6415 PNK SW3 2
C103
D
* HAZARD SWITCH
6570 PNK
A
E E 1
TRIGGER
(SEE ADDITIONAL
2780 BLK 2780 BLK 4

SHT4/E3 4 4 6 2850 BLK
SP46
2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED)

BUCKET A SIG 5 5 1
POSITION 2
D3
SOLENOID 3
9.8 OHM B GND 2450 BLK 2455 BLK
SHT4/C6 4 SHT15/F6
2905 BLK
2970 BLK 6700 PNK

*
C423 6 5 SHT15/F4 E E
2810 BLK 2420 BLK C670
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C676 C C
LEFT SPEAKER
* * RADIO CONN A A
HANDLE LOCK (ACS ONLY) 1

7820 WHT
3 LEFT SPEAKER (+) *
7830 WHT
2 4 LEFT SPEAKER (-)
L010
C279
FLOAT (ACS/AHC ONLY) AIR RIDE SEAT
AUX CTRLR RIGHT SPEAKER 1510 RNG/WHT
SHT10/E1 4
HIGH FLOW SOLENOID GROUND 26
2460 BRN GND
B * 7810 WHT
PWR
PWR
RIGHT POSTION SWITCH HIGH FLOW 2 6 RIGHT SPEAKER (-)

J2A SOLENOID 2210 BLK GND
4460 LGN SIG 7.5 OHM 12 V 7800 WHT SHT10/E1 5
PADDLE HIGH FLOW SOLENOID SIGNAL 26 A 1 5 RIGHT SPEAKER (+) GND
J2B C415 C278 1885 RNG/WHT

SHT10/E1 1 RADIO SWITCHED POWER C277
2885 BLK
SHT10/D1 2 RADIO GROUND
C408 C676
MFR HARN CONN 1 C126 GATEWAY CTRLR
1460 RED/WHT
TRIGGER
7210 WHT 7210 WHT SIG 2350 BRN GND
B 13 13 A A _ TWO SPEED GROUND 26 2
C412 J1A SOLENOID (SEE ADDITIONAL
HORN
4350 LGN OPTIONS DWG)
+ TWO SPEED SIGNAL 26
SIG
1 5.1 OHM 12 V
2785 BLK GND
SHT4/E8 B B
J1B C441

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 14 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295
CHG NOTICE DWN
PML
SHEET
SHT 14 / 15
7331097
738 of 1290
C438
SW7 *
AUX CTRLR
3410 LBL
14 14
3410 LBL
1
RIDE CONTROL
2
2890 BLK
OPTIONS 2
RIDE CONTROL SW AUTO 23 SHT4/E8

SW7 SW7 RIDE CONTROL (NOT IN STD CAB HARN 7303755)
3480 LBL RELAY - L
SP9 1575 RNG/WHT

3415 LBL 3425 LBL L1 SHT3/F1
3435 LBL 3445 LBL 2505 BLK

1 1 L5 L2 SHT4/C8

COIL COIL FRC1 FRC1
2040 BLK 2020 BLK
2 2
SP32
C439 C440
2155 BLK
SHT4/G8
C428 SW13
3475 LBL 3475 LBL
REVERSING FAN *
2905 BLK 2970 BLK

SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
1555 RNG/WHT
5 SHT3/D1
4
SW13 SW13
C443
2175 BRN
J2A REVERSING
FAN COIL
3485 LBL
C442
2185 BRN
SHT4/C3 A
3455 LBL
C RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIGNAL 10
5105 YEL
PRESSURE SENSOR
J2B
* SW8 * C672
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
SW8 SW8

S570
T590 S/N B3GZ12003
B3GY12003
B3Z712016 && Above
csf

SCHEM ELEC MAN
Sheet 15 of 15
X ± 13 MAT
0
REV
SEE SHEET 1
DESCRIPTION
110295 PML
SHT 15 / 15
7331097
739 of 1290
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C100 FUEL FILTER 2 8 C434-1 LEFT WORKLIGHT 1 2 14 FRC1 FUSE RELAY CENTER 112 4,5,8,10,14,15
C103 TAILGATE 8 6,13,14,16 C434-2 LEFT WORKLIGHT 2 2 14
C105 HYD CHARGE PRESSURE 3 10 C435-1 RIGHT WORKLIGHT 1 2 14 J1A GATEWAY CONTROLLER 34 5,8,10,11,13,14,15,16
C107 MASS AIR FLOW SENSOR 6 8 C435-2 RIGHT WORKLIGHT 2 2 14 J1B GATEWAY CONTROLLER 26 4,6,7,8,10,11,12,13,16
C108 HYD TEMPERATURE SENDER 2 10 C428 TILT ACTUATOR 8 17,18 J2A AUX CONTROLLER 34 10,13,16
C110 ALTERNATOR 2 8 C429 LIFT ACTUATOR 8 17,18 J2B AUX CONTROLLER 26 4,5,6,7,10,13,16
C111 MFR-BCT ENG HARN CONN 3 8 C438 CAB-MFR HARN CONN(DK GRY) 14 12,15,16
C112 HYD OIL FILTER SWITCH 2 10 C441 TWO SPEED 2 16 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C446 HYDRAULIC FAN 2 10 J7B ENG ECU CONTROLLER(DSN) 96 9
C114 HAND THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7
C115 FOOT THROTTLE 6 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 11
C116 FOOT THROTTLE INTDM 3 8 C467 LIFT PEDAL LOCK 3 17 SW2 BEACON SWITCH 6 16
C117 CAN BUS 2 2 7 C468 TILT PEDAL LOCK 3 17 SW3 HAZARD SWITCH 6 16
C117-1 CAN BUS 2 2 7 C469 TILT HANDLE 3 17 SW4 HAND/FOOT, H/ISO SWITCH 6 12,14
C118 ENG-CROSSOVER 4 5 C470 TILT PEDAL 3 17
C126 HORN 2 16 C471 LIFT PEDAL 3 17 SW5 POWER BOBTACH SWITCH 6 16
C129 CAB ACCESSORY 3 12 C472 LIFT HANDLE 3 17 SW6 BUCKET POSITION SWITCH 6 16
C169 ENGINE CAN (Diagnostic) 8 7 C474 BRAKE LIGHT 1 18
C209 DOME LIGHT 3 12 C479 LEFT PANEL(BLACK) 12 11 SW9 TRAVEL CONTROL SWITCH 6 11
C212 POWER SOCKET 2 12 C480 LEFT PANEL(GRAY) 12 12 SW10 BLOWER SWITCH 5 15
C252 WASHER 2 12 C482 SEATBAR SENSOR 3 15 SW11 AC SWITCH 3 15
C277 AIR RIDE SEAT 6 16 C483 TEMP CONTROL SWITCH 3 15 SW12 DPF SWITCH 10 11
C278 RIGHT SPEAKER 2 16 C486 AC COMPRESSOR 2 5,6
C279 LEFT SPEAKER 2 16 C489 MFR ACCESSORY 2 5,6,7,12 T1 BATT GROUND 1 6
C308 BRAKE SOLENOID 2 10 C492 ACS/SJC/AWS-MFR HARN 8 4,6 T2 BUZZER GROUND 1 11
C350 AC EVAPORATOR SWITCH 2 15 C493 ACS/SJC/AWS-MFR HARN 4 T3 FLASHER 1 16
C355 DLX or STD FUEL HARNESS 6 8,16 C497 SJC HORN/BLINKER 3 16 T6 BATT GROUND 1 6
C404 BU ALARM-MFR HARN 2 5,13 C499 PTOL 4 11 T8 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C500 RH KEY SWITCH 6 11 T10 ENGINE SYSTEM GROUND 1 6
C406 FUEL SENDER 2 8 C501 PUMP HARNESS 8 18 T13 BUZZER POWER 1 11
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,11, C503 RH DLX PANEL 6 7,11
T14 PRE HEATER 1 9
12,14,16
C409 RIGHT HANDLE 10 13 C536 RIGHT SWASH PLATE 4 18 T15 RIGHT REAR WORK LIGHT(+) 1 14
C410 LEFT HANDLE 10 13 C537 LEFT SWASH PLATE 4 18 T16 RIGHT REAR WORK LIGHT(-) 1 14
C411 LEFT HANDLE 5 WAY 5 16 C602 LEFT REAR TAIL LIGHT 2 14 T17 LEFT REAR WORK LIGHT(+) 1 14
C412 LEFT HANDLE 2 WAY 2 16 C603 RIGHT REAR TAIL LIGHT 2 14 T18 LEFT REAR WORK LIGHT(-) 1 14
C415 HIGH FLOW SOLENOID 2 16 C606 POWER BOBTACH OPEN 2 16 T19 BACKUP ALARM 1 13
C418 FRONT ROD 2 10 C607 POWER BOBTACH CLOSE 2 16 T20 BACKUP ALARM(GND) 1 13
C419 FRONT BASE 2 10 C610 HVAC DUCT FAN 2 15 T32 ECU CASE GROUND 1 6
C420 HYD LOCK 2 10 C611 BLOWER MOTOR 4 15
C421 TILT SPOOL LOCK 3 9 C630 THERMOSTAT 3 15
C422 LIFT SPOOL LOCK 3 13 C635 HEATER VALVE 6 15
C423 BUCKET POSITION 2 16 C667 DOOR 6 12
C425 BRAKE SOLENOID 3 10 C670 EXTERIOR BEACON 6 16
C426 CAN(Remote Start Tool, ACD) 7 7 C676 RADIO 6 16
C404 Back-up Alarm 2 18
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 1 of 18
(PRINTED FEBRUARY 2015)
7228618 (A)
Printed In U.S.A.
740 of 1290
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN B-1
A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD
A-5 HORN RELAY B-5 REAR AUX (F)
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK
A-6 B-6 RELIEF SOLENOID
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD
A-7 B-7 REAR AUX (M)
A-7 STARTER RELAY B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 TRACTION PULL RELAY B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 REAR AUX (M) RETURN B-10
A-10 TILT SPOOL LOCK RETURN B-10
A-11 B-11
A-12 B-12
A-13 B-13 FRONT AUX (F)
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD
A-14 B-14
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2
A-15 B-15 GROUND
A-15 ENGINE SPEED B-15 GROUND P1
A-16 B-16 GROUND
A-17 B-17
A-17 REAR LIGHT 2 RELAY B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN B-18
A-18 FAN 2 RETURN B-18
A-19 B-19 FRONT AUX (M)
A-19 PTOL LED B-19 FAN 2 OUTPUT
A-20 B-20
A-21 B-21
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE RUN KEY
A-22 B-22 SWITCHED POWER
A-22 STATER RELAY FDBK B-22 RUN/ENTER
A-23 B-23
A-24 B-24
A-25 B-25 HYDRAULIC BOOST
A-25 WATER IN FUEL B-25 TWO SPEED MAKEUP
A-27 HYDRAULIC BOOST RETURN
A-27 TWO SPEED MAKE-UP RETURN
A-28
A-28 REAR LIGHT 2 RELAY FDBK
A-29
A-29
A-30
A-30 FUEL PULL RELAY FDBK
A-31
A-31 FRONT WORK LIGHT 1 RELAY FDBK
A-32
A-33
A-33
A-34
HARNESS PART NUMBER

FOR 400 MODEL FOR 500 MODELS FOR 600 MODELS
MFR CTRL 7220815 7228632 7228718
DLX CAB 7235319 7234736 7234736
STD CAB 7227905 7227905 7227905
STD FUEL 7200449 7149219 7149219
DLX FUEL 7200460 7184255 7184255
BCT ENG START 7220812 7220812 7220812
ENGINE 7030824 7030824 7030824
TAILGATE DOM 7217484 7217484 7217484
TAILGATE EUR 7217483 7217483 7217483
SUSP JSTK 7163706 7163706 7163706
BRAKE ADAPTER 7124853 7165061 7165061 Printable Version Click Here
WHL 2 SPD ADP 7159366 7159366 7159366
TRACK 2 SPD
ACS 7222766 7190593
7214626
7164144
WIRING SCHEMATIC
SJC 7200463 Wheel
7236542 Track
7210505 Wheel
7210505 Track
7210503 Wheel
7210504 Track
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 2 of 18
7228618 (A)
Printed In U.S.A. -
741 of 1290
ENGINE CONTROLLER
CONNECTOR J7
PIN FUNCTION
1 SW POWER
2 GND
3 SW POWER
4 GND
5 SW POWER
6 GND
9 WATER FUEL SENSOR
13 PEDAL POS 2
14 PEDAL POS 2
15 AIR MASS FLOW SENSOR
19 IGN SW INPUT
24 PEDAL POS 1
25 PEDAL POS 1
26 PEDAL POS 1
29 PEDAL POS 2
34 WATER FUEL SENSOR

45 SW POWER SIGNAL
47 CAN 1 HI
48 CAN 1 LOW
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 3 of 18
7228618 (A)
742 of 1290
M SCHEMATIC INDEX LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3 PARTIAL CONNECTOR
UNSWITCHED
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 10 CONNECTOR
BATT POWER
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL MANUAL CONTROLS PAGE 13
LIGHTS 6000 THROUGH 6999 PINK PNK LIGHTS PAGE 14 WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 15
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
OPTIONS PAGE 16
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
C408 1240 RED/WHT SHEET 11

(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 12
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SHEET 11
FUSE 11 25 A J1B
SHEET 11
C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT 1150 RED/WHT 3
J2B
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
C493
ACS/SJC/AWS-MFR HARN
FUSE 17 25 A (4 PIN)
1280 RED 1235 RED/WHT 2
SHEET 8
STARTER
FUSE 4 25 A
SHEET 15
SHEET 14
1350 RED/WHT FRC1 REAR LIGHT RELAY
1340 RED
1330 RED/WHT
1335 RED FUSE 20 5 A
1345 RED/WHT SHEET 5
1325 RED FUSE 16 25 A
1445 RED/WHT
SHEET 8
1460 RED/WHT
FUSE 22 25 A SHEET 16 C412 LH HANDLE HORN
(OPTIONS)
FUSE 24 15 A
SHEET 12
C408 CAB-MFR CONN
SP60 (ACCESSORIES)
1055 RED
WIRING SCHEMATIC
1050 RED
SHEET 5
(ACS / SJC MACHINE)
FRC1 SWITCHED PWR RELAY
1030 RED
SHEET 8
S570 (S/N ALM411001 - ALM413082 &
FRC1 STARTER RELAY
ALM413084 - ALM413263)
Sheet 4 of 18
7228618 (A)
743 of 1290 Printed In U.S.A.
M SCHEMATIC INDEX LEGEND
SWITCHED
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 10 CONNECTOR
POWER
CAB PAGE 12
MANUAL CONTROLS PAGE 13
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
LIGHTS PAGE 14
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
HVAC PAGE 15 JOIN ONE WIRE)
OPTIONS PAGE 16
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
FRC1 1505 RNG/WHT

ENGINE ECU SHEET ?
8 J7A ENGINE ECU
+12V RELAY MASS AIR FLOW SENSOR
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP54
87 1504 RNG/WHT 1507 RNG/WHT 3

85 86
8005 TAN 45
C118
FRC1 FUSE RELAY CENTER ENG-CROSSOVER
1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT B
C404
(SEE ADDITIONAL
OPTIONS SHEET)
FUSE 5 25 A SP50 C489

FUSE 6 25 A 1850 RNG/WHT
1760 RNG/WHT
1700 RNG/WHT SHEET 11 SW12 DPF SWITCH
1705 RNG/WHT SHEET 11 SW12 DPF SWITCH
FUSE 12 15 A
SHEET 16 C408 CAB-MFR CONN (BKT POSITION) SHEET 11 C479 LH PANEL
1940 RNG/WHT
C428 1960 RNG/WHT
FUSE 14 5 A SP11 J2B (LT GRAY) SHEET 11 SW9 TRAVEL CONTROL SWITCH
1950 RNG/WHT
1765 RNG/WHT FUSE 7 25 A
1725 RNG/WHT
FUSE 8 25 A
1580 RNG/WHT
FRC1 FUSE 23 15 A
SWITCHED
POWER RELAY
SHEET 8 C110 ALT EXCITATION
WIRING SCHEMATIC
+12V
SHEET 4 1050 RED

PWR 30
87 3450 LBL 21
C428
(ACS / SJC MACHINE)
J1A
SHEET 6
2055 BLK GND 85 86 3380 LBL 4
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2 S570 (S/N ALM411001 - ALM413082 &
SHEET 7
1920 RNG/WHT
C492
9 1920 RNG/WHT 1840 RNG/WHT
C449 LH JOYSTICK ALM413084 - ALM413263)
1830 RNG/WHT
1740 RNG/WHT 6 SHEET 7
(8 PIN) C450 RH JOYSTICK Sheet 5 of 18
7228618 (A)
Printed
744 of 1290 In U.S.A.
LEGEND
GROUND
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
ENGINE PAGE 8-9 CONNECTOR
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
MANUAL CONTROLS PAGE 13 2320 BRN
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS SHEET 10
LIGHTS PAGE 14 C112 HYD OIL FILTER SWITCH
HVAC PAGE 15 2370 BRN J1B
SHEET # SHEET 12 GWY CTRLR
OPTIONS PAGE 16 C408 CAB-MFR CONN (SEATBAR SENSOR)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 2220 BRN 2230 BRN 17
SHEET 10
C108 HYD TEMP SENDER
2190 BRN
2 SHEET 10
2001 BLK C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2810 BLK 2180 BRN
J7A SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
ECU CASE GND 2690 BRN
SHEET 8
2832 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 8 2695 BRN
C107 MAF SENSOR SHEET 8
C115 FOOT THROTTLE
2080 BLK C493 3 2235 BLK

SHEET 7 ACS/SJC/AWS-MFR HARN
C449 LH JOYSTICK 4 2240 BLK T6
2070 BLK (4 PIN)
SHEET 7 C408 BATT GND
SHEET 11 2765 BLK
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 11
2745 BLK
C499 PTOL SHEET 15
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
SHEET 11
(LT GRAY) 2540 BLK
SW12 DPF SWITCH 2730 BLK
2830 BLK 2900 BLK 1 2900 BLK
SHEET 16
2700 BLK 2770 BLK
SHEET 11 SHEET 16
2785 BLK 2200 BLK
SHEET 16 SHEET 10
2620 BLK
SHEET 14 C103 C489
T16 RH REAR LIGHT B 2720 BLK
SHEET 13 2650 BLK
T20 BU ALARM 2600 BLK B 2600 BLK 2390 BLK T1 2015 BLK T10
2640 BLK BATT GND SHEET 8 ENGINE
C602 LH REAR LIGHT 2455 BLK
SHEET 16
2610 BLK C423 BKT POSITION SOLENOID
2630 BLK
SHEET 14 2715 BLK
C169 ENGINE CAN
2045 BLK SHEET 15
SHEET 14 D4 COMPRESSOR DIODE
SHEET 10 2035 BLK WIRING SCHEMATIC
SHEET 14
2115 BLK SP55 2105 BLK
2520 BLK
SP5 2000 BLK
(ACS / SJC MACHINE)
SHEET 13
2055 BLK
SHEET 5
FRC1 SWITCHED POWER RELAY
C410 LEFT HANDLE
SHEET 13
2530 BLK
S570 (S/N ALM411001 - ALM413082 &
SHEET 15 2030 BLK
FRC1 HVAC RELAY
C409 RIGHT HANDLE
ALM413084 - ALM413263)
SHEET 8 2005 BLK
FRC1 STARTER RELAY
2120 BLK
Sheet 6 of 18
SHEET 14
FRC1 FRONT LIGHT RELAY (PRINTED FEBRUARY 2015)
7228618 (A)
Printed In U.S.A.
745 of 1290
LEGEND
PARTIAL CONNECTOR
CAN BUS
OPTIONS PAGE 16
J7A J1B
ECU CNTRLR GWY CTRLR
47 9200 PUR 9215 PUR SP90 9210 PUR 9205 PUR 20

CAN LO
48 9100 PUR/WHT 9115 PUR/WHT SP91 9110 PUR/WHT 9105 PUR/WHT 14
CAN HI
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C117
CAN BUS 2 C169
ENGINE CAN
CAN HI
53 9700 PUR/WHT SP83 9705 PUR/WHT 1 1725 RNG/WHT 1
(FOR DEVELOPMENT SHEET 5
54 9800 PUR SP84 9805 PUR 2 DIAGNOSTICS ONLY) 2715 BLK 2
CAN LO SHEET 6
9155 PUR/WHT 3
9255 PUR 4
9710 PUR/WHT 5
9810 PUR 6
7
8
C408
J1B (BLACK)
8 9260 PUR 9230 PUR SP31 9250 PUR SP79 9270 PUR SP19 9220 PUR 4 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
SP30 SP80
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
C492
(8 PIN)
1830 RNG/WHT 1
SHEET 5 C450
9290 PUR 7 2070 BLK 2
9190 PUR/WHT 8 9320 PUR/WHT 3 SHEET 10
9420 PUR 4
9240 PUR 1
9140 PUR/WHT 4
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
9300 PUR/WHT 3
SHEET 10
9400 PUR 4
J2B J2B
C426 AUX CTRLR
AUX CTRLR
14 9500 PUR/WHT A 9280 PUR 8 Printable Version Click Here
CAN HI 9
20 9180 PUR/WHT
CAN LO 9600 PUR B
WIRING SCHEMATIC
J1B
GWY CTRLR (ACS / SJC MACHINE)
21 3090 LBL D
C
REMOTE RUN KEY S570 (S/N ALM411001 - ALM413082 &
SHEET 5
1735 RNG/WHT
1165 RED/WHT
E
F
SWITCHED POWER
UNSWITCHED POWER
ALM413084 - ALM413263)
SHEET 4
2710 BLK G
SHEET 6
GROUND
Sheet 7 of 18
7228618 (A)
LEGEND
ENGINE
PARTIAL CONNECTOR
LOADER SIDE
OPTIONS PAGE 16
FRC1 C111
+12V STARTER RELAY MFR-BCT HARN CONN
PWR 30 STARTER
1030 RED
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 ALTERNATOR G
3560 LBL L 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B GND 2015 BLK
SHEET 6 AIR FILTER SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
C116 C115
FOOT THROTTLE INTDM FOOT THROTTLE
5695 YEL C 5695 YEL C +5V PWR

SHEET 12
33 3695 LBL A 3695 LBL A
SIG
2695 BRN B 2695 BRN B GND
SHEET 6
E
FOOT THROTTLE D
ADAPTER HARNESS F
7217683
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
10 3690 LBL SHEET 6
4 8007 TAN C428
(LT GRAY)
C114
SHEET 12 5690 YEL 7 5690 YEL C +5V PWR
3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
9 3865 LBL 1 WATER IN FUEL SENSOR
SIG
34 2865 BRN 2 (FUEL FILTER)
GND
56
PREHEATER Printable Version Click Here
+12V RELAY
28 8013 TAN
35 8014 TAN SHEET 4 1065 RED/WHT

PWR 30
87 8500 TAN WIRING SCHEMATIC
85 86
8510 TAN 1445 RED/WHT
SHEET 4
(ACS / SJC MACHINE)
C107
S570 (S/N ALM411001 - ALM413082 &
MASS AIR FLOW SENSOR
SHEET 5 1505 RNG/WHT 3 +12V SW PWR ALM413084 - ALM413263)

2832 BLK 4 GND
SHEET 6
8013 TAN 5
Sheet 8 of 18
8014 TAN 2
1
6 7228618 (A)
LEGEND
ENGINE
PARTIAL CONNECTOR
HARNESS
OPTIONS PAGE 16
T14 PRE HEATER 179

PRE HEATER J7B
105
ENGINE ECU CONTROLLER
(ENGINE HARNESS) 122
186
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
1 5V 161 123 TEMP SENSOR
SENSOR RETURN 2
MAP BEFORE TURBO
2 GND 167
3 SIG 112 107
C151 124
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 INTAKE
EGR VALVE
3 172 169 MANIFOLD
DC MOTOR POSITION RETURN SENSOR RETURN 4
TEMP SENSOR
6 H BRIDGE POS 192
2 H BRIDGE NEG 193 166
108
114 144
171
C149 184
COOLANT TEMP 183
163
C148 170
1 FUEL TEMP SENSOR 110 115
FUEL TEMP
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136 SHEET ?
C147 165 VREF3 OIL PRESSURE
131 OIL PRESSURE &
ENGINE BLOCK
1 SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
1 SENSOR SIGNAL 132
ENGINE BLOCK 156
129 157
SHIELD
154
C145 155
CRANKSHAFT CRANK SENSOR POS 160
POSITION 182
CRANK SENSOR NEG 136
SENSOR
C144
C138
1 SENSOR RETURN 147
141
CAM SHAFT 2 159
POS SENSOR 112
SENSOR INTAKE PRESS SENSOR A
3 140 INLET TEMP
VREF1 CAM 167 INTAKE PRESS RETURN D PRESSURE
C143 134 SENSOR
1 RAIL PRESSURE SENSOR 135 168

RAIL PRESSURE 119
2 SENSOR RETURN
SENSOR
3 138 C139
VREF 1 SENSOR
C141
127
126
FUEL INJECTOR HSDA
FUEL INJECTOR LSD1A CYL 1
WIRING SCHEMATIC
151
CYL 3
FUEL INJECTOR HSDB
FUEL INJECTOR LSD1B 175 C140 (ACS / SJC MACHINE)
150 FUEL INJECTOR HSDB
C142
FUEL INJECTOR HSDA 103
174 FUEL INJECTOR LSD2B CYL 2 S570 (S/N ALM411001 - ALM413082 &
CYL 4
FUEL INJECTOR LSD2A 125
177 PWM
C154
2
ALM413084 - ALM413263)
INLET METERING
1 VALVE
Sheet 9 of 18
748 of 1290 7228618 (A)
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
CONTROLLER GROUND/RETURN
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
CONNECTOR
WIRE BREAK
HYDRAULICS
ENGINE 8000 THROUGH 8999 TAN TAN OPTIONS PAGE 16 SHEET #
FRC1
TRACTION LOCK C425
+12V RELAY
4100 LGN B C308
PWR 30 BRAKE
SHEET 4 1360 RED/WHT 4200 LGN A 4200 LGN A TRACK 2 SPEED
87 SOLENOID
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035 BLK OPTIONS SHEET)
8 4110 LGN
13 3430 LBL
C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
3.3 OHM PWM
C419 (ACS / SJC MACHINE)
1 2340 BRN 2 GND FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE) S570 (S/N ALM411001 - ALM413082 &
3.3 OHM PWM
ALM413084 - ALM413263)
19 13 Sheet 10 of 18
J2B
AUX CTRLR (PRINTED FEBRUARY 2015)
7228618 (A)
Printed
749 of 1290 In U.S.A.
LEGEND
BATT FEED, FUSED
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
1000 THROUGH 1499
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
RED/WHITE
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
RED/WHT
RNG/WHT
BLK
BRN
LBL
LGN
GROUND
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
PAGE 6
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
CONNECTOR CAB DISPLAY
LIGHTS 6000 THROUGH 6999 PINK PNK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
HVAC PAGE 15 JOIN ONE WIRE)
OPTIONS PAGE 16 SHEET #
T13
BUZZER (+)
1940 RNG/WHT
SHEET 5
LEFT PANEL C499
BUZZER Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
10 C408 2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 16
GWY CTRLR
5 6 SHEET 16
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
3620 LBL 12
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWE
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
3 1 SHEET 4 UNSWITCHED POW
2065 BLK 2 8060 TAN
SHEET 6 DPF FORCE REGEN 2250 BLK 3
1 SHEET 6 GROUND
5 6 9 6
8070 TAN
4 DPF INHIBIT REGEN
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 11 of 18
Printed In U.S.A.
7228618 (A)
750 of 1290
LEGEND
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
CAB
GROUND PAGE 6
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
LIGHTS
OTHER FUNCTIONS
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
JOIN ONE WIRE)
* DLX CAB HARN 7207730 AND
HVAC PAGE 15
ENGINE
COMMUNICATION
8000 THROUGH 8999
9000 THROUGH 9999
TAN
PURPLE
TAN
PUR
OPTIONS PAGE 16 SHEET # 7208877(SF) ONLY
*SW4
HAND/FOOT (NOT IN STD CAB HARN)
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
SHEET 5 3
C438 2060 BLK 5 6
C492 SHEET 12
ACS/SJC/AWS-MFR HARN 4230 LGN (DK GRAY) 4
(8 PIN) SHEET 13 CAB-MFR HARN CONN 3
SHEET 13 4240 LGN
5 4220 LGN 4235 LGN 7 4235 LGN
3 4275 LGN 8 4275 LGN
9
2 4550 LGN
1850 RNG/WHT 2
4550 LGN
1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
2010 BLK
* C209
B GND
1370 RED/WHT 7 1370 RED/WHT 1390 RED/WHT A +12V PWR DOME
SHEET 4
C LBL
3640 DOOR SIG LIGHT
C129
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 16
2210 BLK SHEET 16
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 16
2060 BLK SHEET 12
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS SHEET)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 3630 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

+5V
5690 YEL
* C252
L SIG
SHEET 8
SHEET 8 5695 YEL
2845 BLK X GND
WASHER
MOTOR WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 12 of 18
7228618 (A)
751 of 1290 Printed In U S A
LEGEND
MANUAL
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLS
HVAC PAGE 15
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
J2A
2530 BLK K
SHEET 6
AUX CTRLR SHEET 12 4230 LGN G
C404 A
C103 SHEET 5 1530 RNG/WHT
BU ALARM-MFR HARN
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
OPTIONS SHEET) 4920 LGN E DETENT FLOW
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK 20 4640 LGN D
2 7.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 2990 BRN 3 GND 11 4810 LGN F SIDE SHIFT
4990 LGN 1 LIFT SPOOL LOCK 1520 RNG/WHT A
SIG SHEET 5
7.8 OHM 12V J
2
4240 LGN H
SHEET 12
2520 BLK E
SHEET 6
7 5
J1B
GWY CTRLR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 13 of 18
7228618 (A)
Printed In U.S.A.
752 of 1290
LEGEND
PARTIAL CONNECTOR
LIGHTS
LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 14
HVAC PAGE 15
OPTIONS PAGE 16
C434-1
C408
(BLACK)
C434-2
2765 BLK 9 2765 BLK 2750 BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
6000 PNK 8 6000 PNK 6120 PNK A SIG RIGHT FRONT
FRC1 WORK LIGHT
2760 BLK B GND
FRONT WORK 37.00 Watts
LIGHT RELAY
C438 C435-2
50.00 Watts
13 6610 PNK SP64
2120 BLK 85 86
SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY C103
PWR 2610 BLK 2 GND
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
6210 PNK SIG WORK LIGHT
FRC1
+12V RELAY
1320 RED/WHT
SHEET 4 87 6200 PNK H 6200 PNK SIG LEFT REAR
GND 85 2630 BLK GND WORK LIGHT
86 SHEET 6
SHEET 6 2045 BLK
T18 TERMINAL (-)
WIRING SCHEMATIC Printable Version Click Here

(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 14 of 18
7228618 (A)
LEGEND
PARTIAL CONNECTOR
BATT FEED, SWITCHED
BATTERY GROUND
MONITORING
HYDRAULIC
CONTROLLER SUPPLY
1500 THROUGH 1999
2000 THROUGH 2999
2000 THROUGH 2999
3000 THROUGH 3999
4000 THROUGH 4999
5000 THROUGH 5999
ORANGE/WHITE
BLACK
BROWN
LIGHT BLUE
LIGHT GREEN
YELLOW
RNG/WHT
BLK
BRN
LBL
LGN
YEL
CAN BUS
ENGINE
HYDRAULICS
CAB DISPLAY
CAB
MANUAL CONTROLS
PAGE 7
PAGE 8-9
PAGE 10
PAGE 11
PAGE 12
PAGE 13
CONNECTOR
HVAC
WIRE BREAK
ENGINE 8000 THROUGH 8999 TAN
PURPLE
TAN
PUR
HVAC
OPTIONS
PAGE 15
PAGE 16
JOIN ONE WIRE)
SHEET # * DLX CAB HARN 7207730 AND
COMMUNICATION 9000 THROUGH 9999
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT 7208877(SF) ONLY
2440 BLK * C610
2 GND
(NOT IN STD CAB HARN)
HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK * C483

C BLK
7425 WHT B (TEMP CONTROL
WHT SWITCH)
C635
* D SIG
2130 BLK C GND HEATER
B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
1
2030 BLK GND 85 86 4
SHEET 6 6
7410 WHT
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
30 SW11 7510 WHT 3 5.00 Amps Low
J1A
3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT 7020 WHT 12
C630
* 3
THERMOSTAT
A 7024 WHT WIRING SCHEMATIC
7025 WHT
C486
1 SIG
(ACS / SJC MACHINE)
2 MAGNET CLUTCH
SHEET 6
2290 BLK 2280 BLK
GND
(COMPRESSOR) S570 (S/N ALM411001 - ALM413082 &
D4
ALM413084 - ALM413263)
Sheet 15 of 18
7228618 (A)
Printed In U.S.A.
754 of 1290
LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
OVERVIEW PAGE 1-3
OPTIONS
HYDRAULICS PAGE 10
CAB DISPLAY PAGE 11
CAB PAGE 12
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL #
MANUAL CONTROLS PAGE 13 WIRE BREAK DLX FUEL HARN 7184255, 7200460(SF) ONLY
HVAC PAGE 15 JOIN ONE WIRE) (NOT IN STD FUEL HARN 7149219, 7200449(SF) )
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT C428
#
C355
FUEL HARN
(LT GRAY)
CAB-MFR HARN CONN 2 * DLX CAB HARN 7207730, 7208877(SF) ONLY
C607
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN (NOT IN STD CAB HARN)
POWER BOB 2
GND 2470 BLK 2770 BLK B 2770 BLK 4480 LGN
CLOSE SHEET 6
SW5
*POWER 2 1
# C606 BOBTACH 3
SWITCH 5 4
GND 2 2480 BLK 6
POWER BOB 1
SIG 4480 LGN F 4480 LGN 10
OPEN
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
C411
B
SHEET 4
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 11 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS SHEET) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS SHEET)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
4
2 * SW6
OPTIONS SHEET)
POSITION 2830 BLK 5 POSITION C
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676
LEFT HANDLE C412

2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS SHEET) SHEET 4 2
C497
SJC
RIGHT
*-
C278
2 7810 WHT 6 3
AIR RID
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 12
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 12 1885 RNG/WHT SHEET 12
3 6520 PNK B OPTIONS SHEET) 2 6
J2A
SHEET 12 2885 BLK
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW
SOLENOID Printable Version Click Here
4460 LGN A SIG
7.5 OHM 12 V
J2B
AUX CTRLR
26 WIRING SCHEMATIC
C441
TRACK 2 SPEED
(ACS / SJC MACHINE)
J1A 26 2350 BRN 2 GND TWO SPEED
GWY CTRLR 4350 GRN 1 SIG SOLENOID
5.1 OHM 12 V
ADAPTER
(SEE ADDITIONAL S570 (S/N ALM411001 - ALM413082 &
OPTIONS SHEET)
J1B
GWY CTRLR
26
ALM413084 - ALM413263)
Sheet 16 of 18
7228618 (A)
755 of 1290Printed In U S A
ACS CONTROLLER
ACS
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS
PIN FUNCTION PIN FUNCTION PIN FUNCTION
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
TILT ACTUATOR FEEDBACK
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS
K TILT PEDAL K TILT MOTOR 2
(500 Models - Track & Wheel) 7169053
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
PAGE FOR HARNESS CONN
MAINFRAME HARNESS 1170 RED/WHT C409 C466
C492 C493 J3-ACS K A
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4260 LGN 4280 LGN 1 LIFT C TWO SPD
B 1740 RNG/WHT 6 2 SOLENOID D
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTR
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GRD LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
5750 YEL A A HALL SENSOR 2980 BRN 1 GND
+5V PWR
3980 LBL 2 SIG
A C471
B 2660 BRN 2 GND C428 TILT ACTUATOR
C
J 3 K 4645 LGN 8
4660 LGN SIG LIFT PEDAL
D 1 +5V PWR HALL SENSOR 7
5660 YEL
2990 BRN
2980 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 4
GND
K 4760 LGN 3 SIG 5990 YEL 3 +5V PWR
TILT PEDAL
5760 YEL 1 +5V PWR HALL SENSOR 2990 BRN 1 GND
5750 YEL 3990 LBL 2 SIG
5650 YEL 5980 YEL
5970 YEL 5990 YEL
H 3980 LBL WIRING SCHEMATIC

E 3990 LBL
(ACS / SJC MACHINE)
S570 (S/N ALM411001 - ALM413082 &
ALM413084 - ALM413263)
Sheet 17 of 18
7228618 (A)
Printed In U.S.A.
756 of 1290
ACS CONTROLLER J5 DRIVE CONTROLLER
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS PIN FUNCTION
PIN FUNCTION PIN FUNCTION PIN FUNCTION 1 SAFETY IN
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 6 ISO LITE
F F LIFT HANDLE F LIFT MOTOR 1 7 L SWASH PLATE ANGLE
G GROUND G TILT HANDLE G PEDAL ENABLE 8 R SWASH PLATE ANGLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 9 SPARE ANALOG 4
J LIFT PEDAL J GROUND 10 SPARE ANALOG 5
K TILT PEDAL K TILT MOTOR 2 11 L FWD RETURN
12 CAN HIGH
HARNESS PART NUMBER 13 LF ANGLE
SJC SEE SHEET 1 LIFT 14 RF ANGLE
C429 ACTUATOR
A22 PUMP 7188448 15 LR ANGLE
4600 LGN 5 61 LGN
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 4690 LGN 17 RR ANGLE
2980 BRN 1 62 BRN
GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
3980 LBL 2 SIG
63 LBL 20 R JOYSTICK X
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR YEL
22 CAN LOW
33
C428 23 R QUAD A DRIVE
34 TILT ACTUATOR
5990 YEL 3 +5V PWR YEL 24 R QUAD B DRIVE
40 5890 YEL 4 25 TWO SPEED 1
5970 YEL
3990 LBL 2 4770SIGLBL 26 BRAKE LIGHT OUTPUT
6 27 GROUND
23 1 GND
2990 BRN 64 BRN
24 28 GROUND
4290 LGN 5 4780 LGN
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8 4790 LGN
2810/BRN BRN 4 2810 BRN 1 GND
31 L REV DRIVE
8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860 YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
C 38 SPARE ANALOG 1
LEFT
C501 C546 SWASHPLATE D 39 SPARE PWM COIL 7
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660 BRN 2 2 A
ACS CONTROLLER
2660 BRN 41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 80 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN OR BLK BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H 49 SPARE PWN COIL 6
C544 C
21 4280 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A 1 1
C474 1830 RNG/WHT
D 2 2
26 4210 LGN A 2070 BLK
J3-ACS
F 4 9660 PUR 4 RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1480 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1
JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI
27 2470 BLK C493

28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2 Printable Version Click Here
48 1260 RED/WHT 1170 RED/WHT 1
2240 BLK 4
WIRING SCHEMATIC
(ACS / SJC MACHINE)
1760 RNG/WHT
2280 BLK S570 (S/N ALM411001 - ALM413082 &
2270 BLK
2260 BLK
1180 RED/WHT
ALM413084 - ALM413263)
1190 RED/WHT
Sheet 18 of 18
36 7100 WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR (PRINTED FEBRUARY 2015)
HARNESS)
757 of 1290
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C425 BRAKE SOLENOID 3 9 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C426 CAN(Remote Start Tool, ACD) 7 7
C105 HYD CHARGE PRESSURE SENSOR 3 9 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,11,15 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C434-1 LEFT FRONT WORKLIGHT 1 (37W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C108 HYD TEMPERATURE SENDER 2 9 C434-2 LEFT FRONT WORKLIGHT 2 (50W) 2 13 J2A AUX CONTROLLER 34 9,12,15
C110 ALTERNATOR 2 8 C435-1 RIGHT FRONT WORKLIGHT 1 (37W) 2 13 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C111 HARNESS ENGINE START CONN 3 8 C435-2 RIGHT FRONT WORKLIGHT 2 (50W) 2 13
C112 HYD OIL FILTER SWITCH 2 9 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C441 TWO SPEED SOLENOID 2 15
C114 HAND THROTTLE 6 8 C446 HYDRAULIC FAN 2 9
C115 FOOT THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 10
C116 FOOT THROTTLE INTDM 3 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW2 BEACON SWITCH 6 15
C479 LEFT PANEL(BLACK) 12 7,10 SW3 HAZARD SWITCH 6 15
C480 LEFT PANEL(GRAY) 12 10 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C118 ENG-CROSSOVER 4 8 C482 SEATBAR SENSOR 3 11
C126 HORN 2 15 C483 TEMP CONTROL SWITCH 3 14 SW5 POWER BOBTACH SWITCH 6 15
C129 CAB ACCESSORY 3 11 C486 AC COMPRESSOR 2 14 SW6 BUCKET POSITION SWITCH 6 15
C169 ENGINE CAN (Diagnostic) 6 7 C489 MFR ACCESSORY 2 5,6
C212 POWER SOCKET 2 11 C492 ACS/SJC/AWS-MFR HARN 8 5,7,11 SW9 TRAVEL CONTROL SWITCH 6 10
C252 WASHER PUMP INTDM 2 11 C493 ACS/SJC/AWS-MFR HARN 4 4,6 SW10 BLOWER SWITCH 6 14
C253 WASHER PUMP 2 11 C497 SJC HORN/BLINKER 3 15 SW11 AC SWITCH 3 14
C277 AIR RIDE SEAT 6 15 C499 PTOL 4 10 SW12 DPF SWITCH 10 10
C278 RIGHT SPEAKER 2 15 C500 RH KEY SWITCH 6 10
C279 LEFT SPEAKER 2 15 C503 RH DLX PANEL 6 7,10 T1 BATT GROUND 1 6
C308 BRAKE SOLENOID 2 9 C602 LEFT REAR TAIL LIGHT 2 13 T2 BUZZER GROUND 1 10
C350 AC EVAPORATOR SWITCH 2 14 C603 RIGHT REAR TAIL LIGHT 2 13 T3 FLASHER 2 15
C355 FUEL HARNESS 6 8,15 C606 POWER BOBTACH OPEN 2 15 T6 BATT GROUND 1 6
C404 BU ALARM-MFR HARN 2 5,12 C607 POWER BOBTACH CLOSE 2 15 T8 BATT GROUND 1 6
C405 AIR FILTER SWITCH 2 8 C610 HVAC DUCT FAN 2 14 T10 ENGINE SYSTEM GROUND 1 6
C406 FUEL SENDER 2 8 C611 BLOWER MOTOR 4 14 T13 BUZZER POWER 1 10
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C630 THERMOSTAT 3 14
T14 PRE HEATER 1 8
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C635 HEATER VALVE 6 14 T15 RIGHT REAR WORK LIGHT(+) 1 13
C410 LEFT HANDLE (MAN/ACS) 10 12 C667 DOOR HARNESS 6 11 T16 RIGHT REAR WORK LIGHT(-) 1 13
C411 LEFT HANDLE 5 WAY 5 15 C670 EXTERIOR BEACON HARNESS 6 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 C676 RADIO 6 15 T18 LEFT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 T19 BACKUP ALARM 1 12
C418 FRONT ROD 2 9 T20 BACKUP ALARM(GND) 1 12
C419 FRONT BASE 2 9 T32 ECU CASE GROUND 1 6
C420 HYD LOCK 2 9 T37 DOME LIGHT(+) 1 11
C421 TILT SPOOL LOCK 3 12 T38 DOME LIGHT(-) 1 11
C422 LIFT SPOOL LOCK 3 12
C423 BUCKET POSITION SOLENOID 2 15

(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 1 of 18
7253420 (0)
758 of 1290
A-2 B-2 UNSW BATT
A-5 HORN RELAY B-5
A-6 B-6
A-7 B-7
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-19 B-19 FRONT ROD
A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-29
A-29
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR CTRL 7228632
EXMF MFR CTRL 7265268
DLX CAB 7253375
STD CAB 7227905
STD FUEL 7149219
DLX FUEL 7266824
BCT ENG START 7220812 Printable Version Click Here
SUSP JSTK 7163706
WIRING SCHEMATIC
BRAKE ADAPTER
WHL 2 SPD ADP
7165061
7159366
(ACS / SJC MACHINE)
TRK 2 SPD 7214626
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 2 of 18
7253420 (0)
Printed In U.S.A.
759 of 1290
LEGEND
CONNECTOR J7
PIN FUNCTION
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8 CONNECTOR
CAB PAGE 11
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 13
13 OPTIONS PAGE 15
15
19 ECU RUN SIGNAL

21
24
25
26 A B C D
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29 PEDAL POS 2
SENSOR TEMP
34 WATER FUEL SENSOR GND
E F G H
45 ECU RELAY GND
47 ECU CAN 1 LO
48 ECU CAN 1 HI
J K L M
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 3 of 18
Printed In U.S.A.
7253420 (0)
760 of 1290
UNSWITCHED BATT POWER C408 1240 RED/WHT
SHEET 10
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 11
FRC1 FUSE RELAY CENTER SP7 1420 RED/WHT
SHEET 10
SHEET 10
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT 1
T4 1 C493
1280 RED 1235 RED/WHT 2
SHEET 8
STARTER
FUSE 4 25 A
SHEET 14
FRC1 HVAC RELAY
FUSE 3 30 A
FUSE 1 15 A
1320 RED/WHT
SHEET 13
1340 RED SHEET 13
SP26 1330 RED/WHT
FUSE 20 5 A
1325 RED FUSE 16 25 A
1445 RED/WHT
SHEET 8
1460 RED/WHT
(OPTIONS)
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
1055 RED
SP60
WIRING SCHEMATIC
1050 RED
(ACS / SJC MACHINE)
SHEET 5
1030 RED
FRC1 SWITCHED PWR RELAY S570 (S/N ALM413083 & ALM413264 -
SHEET 8
FRC1 STARTER RELAY ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 4 of 18
7253420 (0)
Printed
761 of 1290
In U.S.A.
+12V
FRC1
ENGINE ECU
SWITCHED POWER J7A ENGINE ECU
PWR RELAY -G 1506 RNG/WHT 1

SHEET 4 1035 RED/WHT 30 SP54
87 1504 RNG/WHT 1507 RNG/WHT 3

85 86
8005 TAN 45

1345 RED/WHT
SHEET 4
FUSE 21 15 A
1511 RNG/WHT SHEET 8 ENG-CROSSOVER
C404
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A C489
SP50
FUSE 6 25 A
FUSE 12 15 A
1940 RNG/WHT
C428 1960 RNG/WHT
SP11 1950 RNG/WHT
FUSE 7 25 A SP65 SP42
1725 RNG/WHT
FUSE 8 25 A
1580 RNG/WHT
FRC1 FUSE 23 15 A
SWITCHED
POWER RELAY -A
+12V
SHEET 4 1050 RED

PWR 30
3450 LBL 21
(ACS / SJC MACHINE)
87 J1A C428
SHEET 6
2055 BLK GND 85 86 3380 LBL 4
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
S570 (S/N ALM413083 & ALM413264 -
SP37
1920 RNG/WHT 9 1920 RNG/WHT 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK ALM415479)
C492 1830 RNG/WHT
1740 RNG/WHT 6 ACS/SJC/AWS-MFR HARN
(8 PIN)
SHEET 7
C450 RH JOYSTICK (S/N B3GZ11001 - B3GZ11096)
Sheet 5 of 18
7253420 (0)
Printed In U.S.A.
762 of 1290
2320 BRN
SHEET 9
GROUND
2370 BRN J1B
SHEET 11 GWY CTRLR
2220 BRN SP12 2230 BRN 17
SHEET 9
2190 BRN
2 2001 BLK SHEET 9
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2810 BLK 2180 BRN
J7A SHEET 8
2150 BRN
SHEET 8
T32 2004 BLK
ECU CASE GND SHEET 8 2690 BRN
SHEET 8 2695 BRN
C115 FOOT THROTTLE
2080 BLK C493 3 2235 BLK

C449 LH JOYSTICK 4 2240 BLK T6
2070 BLK (4 PIN)
SHEET 10 2765 BLK
C479 LH PANEL (BLACK) SP4 SHEET 13
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
C499 PTOL 2745 BLK
SP3 SHEET 14
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
SHEET 10
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 15
2700 BLK 2770 BLK
SHEET 10 SHEET 15
2785 BLK 2200 BLK
SHEET 15 SHEET 9
2620 BLK
SHEET 13 C103 C489
T16 RH REAR WORK LIGHT B 2720 BLK
SHEET 12 2650 BLK SP6
SP51 2600 BLK 2390 BLK
T20 BU ALARM B 2600 BLK T1
2015 BLK T10
2640 BLK BATT GND SHEET 8 ENGINE
C602 LH REAR TAIL LIGHT 2455 BLK
SHEET 15
2610 BLK C423 BKT POSITION SOLENOID SP27
C603 RH REAR TAIL LIGHT SHEET 7
2630 BLK C426 REMOTE RUN, ACD
SHEET 13 2715 BLK
T18 LH REAR WORK LIGHT SHEET 7
C169 ENGINE CAN
SHEET 13 2045 BLK SHEET 14
D4 COMPRESSOR DIODE
SHEET 9
2035 BLK
SP55 SP5
WIRING SCHEMATIC
SHEET 13 2115 BLK 2105 BLK 2000 BLK
2055 BLK SHEET 12
2520 BLK (ACS / SJC MACHINE)
SHEET 5 C410 LEFT HANDLE
2030 BLK
SHEET 12 2530 BLK S570 (S/N ALM413083 & ALM413264 -
SHEET 14 C409 RIGHT HANDLE
FRC1 HVAC RELAY
SHEET 8 2005 BLK ALM415479)
FRC1 STARTER RELAY
SHEET 13
2120 BLK (S/N B3GZ11001 - B3GZ11096)
Sheet 6 of 18
7253420 (0)
Printed In U.S.A.
763 of 1290
J7A
ECU CNTRLR
CAN BUS J1B
GWY CTRLR
47 9200 PUR 9215 PUR 9210 PUR 9205 PUR 20

CAN LO
48 9100 PUR/WHT 9115 PUR/WHT 9110 PUR/WHT 9105 PUR/WHT 14
CAN HI
R18 R21
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725 RNG/WHT 1
SHEET 5
2715 BLK 2
SHEET 6
9155 PUR/WHT 3
9255 PUR 4
5
6
C408
J1B (BLACK)
8 9260 PUR 9230 PUR 9250 PUR 9270 PUR 9220 PUR 4 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR 4
C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
R14 R19
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440 PUR 4
C503
C492
(8 PIN)
1830 RNG/WHT 1
SHEET 5 C450
9290 PUR 7 2070 BLK 2
9190 PUR/WHT 8 9320 PUR/WHT 3
9420 PUR 4
9240 PUR 1
9140 PUR/WHT 4
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
9300 PUR/WHT 3
9400 PUR 4
J2B J2B
C426 AUX CTRLR
AUX CTRLR
14 9500 PUR/WHT A 9280 PUR 8 Printable Version Click Here
CAN HI 9180 PUR/WHT 9
20 9600 PUR B
CAN LO
WIRING SCHEMATIC
J1B
GWY CTRLR
(ACS / SJC MACHINE)
21 3090 LBL D
REMOTE RUN KEY
S570 (S/N ALM413083 & ALM413264 -
C
SHEET 5
1735 RNG/WHT
1165 RED/WHT
E
F
SWITCHED POWER ALM415479)
UNSWITCHED POWER
SHEET 4
SHEET 6
2710 BLK G GROUND
(S/N B3GZ11001 - B3GZ11096)
Sheet 7 of 18
7253420 (0)
764 of 1290
FRC1
NOTE: SEE ENGINE HARNESS ON Sheet 16 of 18
ENGINE
STARTER RELAY - M C111
+12V HARN ENG START CONN
PWR 30 STARTER
1030 RED
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
SHEET 5
FUSE 12
C110
7 8210 TAN B S 1020 RED
22 ALTERNATOR G
3560 LBL L 1800 RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150 BRN B
SHEET 6
GND 2015 BLK
AIR FILTER SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
C116 C115
5695 YEL C 5695 YEL C +5V PWR

SHEET 11
33 3695 LBL A 3695 LBL A
SIG
2695 BRN B 2695 BRN B GND
SHEET 6
E
FOOT THROTTLE D
ADAPTER HARNESS F
7217683
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
SHEET 6
10 3690 LBL
4 8007 TAN C428
(LT GRAY)
C114
5690 YEL 7 5690 YEL C +5V PWR
SHEET 11 3690 LBL 6 3690 LBL A
SIG
J7A
E
19 8007 TAN F
C100
9 3865 LBL 1 WATER IN FUEL SENDER
SIG
34 2865 BRN 2 GND (FUEL FILTER) Printable Version Click Here
C118
WIRING SCHEMATIC
ENG-CROSSOVER
1511 RNG/WHT 1
To C154 - PIN1 and (ACS / SJC MACHINE)
SHEET 5 C155 - PIN 3
MAF FREQ
35
28 8013 TAN
8014 TAN
8013 TAN
8014 TAN
2
3
MAF Sensor - PIN 1 S570 (S/N ALM413083 & ALM413264 -
MAF TEMP MAF Sensor - PIN 4
+12V
PWR 30
3420 LBL 4
TO J4B - PIN 179 ALM415479)
SHEET 4 1065 RED/WHT 87 8525 TAN 8500 TAN Sheet 16 of 18
56 8510 TAN 85 86 1445 RED/WHT PRE-HEATER (S/N B3GZ11001 - B3GZ11096)
SHEET 4
PREHEATER Sheet 8 of 18
RELAY - C
7253420 (0)
Printed In U.S.A.
765 of 1290
FRC1
TRACTION LOCK
HYDRAULICS C425
+12V RELAY - D B C308
4100 LGN BRAKE
1360 RED/WHT PWR 30
SHEET 4 4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200 BLK C 2200 BLK B 9.8 OHM
SHEET 6 ADDITIONAL
2035 BLK GND 85 86 12 V
SHEET 6 OPTIONS DWG)
7165061
8 4110 LGN
13 3430 LBL
C108
HYDRAULIC
2220 BRN B GND
SHEET 6 TEMPERATURE
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
SHEET 6
C446
7.2 OHM 12 V
C420
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE SENSOR
0.5-7.5V
4200 LGN
19 13 1 23 6
J1B +8V
GWY CTRLR
C418
J2A
AUX CTRLR
18 2330 BRN 2 GND FRONT ROD
SOLENOID (MALE)
WIRING SCHEMATIC
4330 LGN 1 SIG
C419
3.3 OHM PWM
(ACS / SJC MACHINE)
1 2340 BRN
4340 LGN
2
1
GND
SIG
FRONT BASE
SOLENOID (FEMALE)
S570 (S/N ALM413083 & ALM413264 -
3.3 OHM PWM
ALM415479)
19 13 (S/N B3GZ11001 - B3GZ11096)
J2B
AUX CTRLR Sheet 9 of 18
7253420 (0)
Printed In U.S.A.
766 of 1290
SHEET 5
1940 RNG/WHT
T13
BUZZER (+)
LEFT PANEL
CAB DISPLAY C499
BUZZER Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
10 C408 2940 BLK 3
(BLACK)
SHEET 6 GROUND
PTOL OUTPUT
SHEET 5 19 2380 BRN 12 2380 BRN 4
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500 LBL 8 C500
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
2930 BLK C480 J1B 22 3040 LBL 14 4
GWY CTRLR
SHEET 11 3620 LBL 12
DOOR SIGNAL
11 1950 RNG/WHT 5
10 1420 RED/WHT 1
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
SW12 8
DERATE OVERRIDE SWITCH 6 RIGHT PANEL DELUXE DISPLAY
SHEET 5 DPF LAMP
1705 RNG/WHT 10 8 8055 TAN 5
2065 BLK 2 3 8060 TAN
SHEET 6 DPF OVERRIDE 2250 BLK 3
1 SHEET 6 GROUND
8070 TAN 9 6
4 DPF INHIBIT REGEN
NOT USED
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 -
Printed In U.S.A.
ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 10 of 18
7253420 (0)
767 of 1290
SW4
HAND/FOOT *
SHEET 5
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785 RNG/WHT 2 1
3
6
CAB
2060 BLK 5
C492
SHEET 12 4230 LGN
C438
(DK GRAY)
SHEET 11
4 * DLX CAB HARN 7253375 ONLY
(8 PIN) CAB-MFR HARN CONN 3
5
SHEET 12 4240 LGN SP29
7 4235 LGN
4220 LGN 4235 LGN
3 4275 LGN 8 4275 LGN
9
2 4550 LGN
1850 RNG/WHT 2
4550 LGN
1850 RNG/WHT
*C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
* T37
DOME LIGHT (+)
SHEET 4 1390 RED/WHT
SP41 DOME
C129 2010 BLK LIGHT
CAB ACCESSORY
SP8
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 15
SP44
2210 BLK SHEET 15
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 15
2060 BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
3620 LBL 4
1400 RED/WHT 5
6
WIPER MOTOR GROUND
J1B 7310 WHT
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 3
WASHER SIGNAL
11 3370 LBL 5 3370 LBL B SIG
24 5100 YEL 5370 YEL 3 5370 YEL C +5V PWR

SP13
SHEET 8
SHEET 8
5690 YEL
5695 YEL
WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 -
* C252
A
C253
1
PWR ALM415479)
7310 WHT WASHER
MOTOR
2845 BLK B 2845 BLK 2 GND
(S/N B3GZ11001 - B3GZ11096)
Sheet 11 of 18
768 of 1290
MANUAL CONTROLS C409
RIGHT HANDLE
(MANUAL/ACS ONLY) C466
J2A 2530 BLK K A

SHEET 6
AUX CTRLR 4230 LGN G B HANDLE LOCK (ACS)
C404 SHEET 11
C103 1530 RNG/WHT A
T19 TERMINAL (+)
A 7100 WHT C 7100 WHT
OPTIONS SHEET) 4920 LGN E DETENT FLOW
BACK UP
SHEET 6 TWO SPD
4310 LGN C
PWM
4300 LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980 BRN 3 GND
GWY CTRLR 1 SIG TILT SPOOL LOCK 20 4640 LGN D FLOAT (ACS)
4980 LGN
2 17.8 OHM 12V 28 4840 LGN C
C422 12 4820 LGN G
2 3 11 4810 LGN F SIDE SHIFT
2990 BRN GND
1 LIFT SPOOL LOCK 1520 RNG/WHT A
4990 LGN SIG SHEET 5
17.8 OHM 12V J C465
2
4240 LGN H A
SHEET 11
2520 BLK E B HANDLE LOCK (ACS)
SHEET 6
7 5
J1B SEE OPTIONS SHEET FOR HORN AND TURN SIGNALS
GWY CTRLR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 - ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 12 of 18
7253420 (0)
Printed In U.S.A.
769 of 1290
LIGHTS
C434-1
C408
(BLACK)
C434-2
2765 BLK 9 2765 BLK 2750 BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
6000 PNK 8 6000 PNK 6120 PNK A SIG RIGHT FRONT
FRC1 WORK LIGHT
2760 BLK B GND
LIGHTS RELAY - J
C438 C435-2
50.00 Watts
13 6610 PNK
2120 BLK 85 86
SHEET 6
FRC1
6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
PWR 2610 BLK 2 GND
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
T16 TERMINAL (-)

2620 BLK GND
SHEET 6 RIGHT REAR
6210 PNK SIG WORK LIGHT
FRC1
RELAY - E
+12V
1320 RED/WHT
SHEET 4 87 6200 PNK H 6200 PNK SP96 6200 PNK SIG LEFT REAR
2630 BLK GND WORK LIGHT
GND 85 86 SHEET 6
2045 BLK
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 - ALM415479
(S/N B3GZ11001 - B3GZ11096)
Sheet 13 of 18
Printed In U.S.A.
770 of 1290 7253420 (0)
HVAC * C610
2440 BLK 2 GND HVAC DUCT
7440 WHT 1 SIG FAN
2560 BLK
* C483
C BLK
B (TEMP CONTROL
7425 WHT WHT SWITCH)
* DLX CAB HARN 7253375 ONLY C635
* D
(NOT IN STD CAB HARN) 2130 BLK C
SIG
GND HEATER
SP48 B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY - B CAB-MFR HARN CONN 3 SWITCH

1140 RED/WHT PWR 30 OFF
1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6 2745 BLK 11 2745 BLK SP16 *
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

A 7024 WHT

7025 WHT 1 SIG
MAGNET CLUTCH
2290 BLK 2280 BLK
2 GND
(COMPRESSOR) WIRING SCHEMATIC
SHEET 6
D4
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 - ALM415479
(S/N B3GZ11001 - B3GZ11096)
Sheet 14 of 18
7253420 (0)
Printed In U.S.A.
771 of 1290
# C607
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
OPTIONS
POWER BOB
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
# DLX FUEL HARN 7266824 ONLY
GND 2 2470 BLK 2770 BLK B 2770 BLK
CLOSE SHEET 6
SW5
*POWER 2 1
#
GND
C606
2 2480 BLK
BOBTACH
SWITCH 5
3
4
6
POWER BOB
OPEN
SIG 1 4480 LGN F 4480 LGN 10 4480 LGN (NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK
1380 RED/WHT
SHEET 5
C438
(DK GRAY)
PWR
C411
B
SHEET 4
L
* T3
FLASHER
LEFT HANDLE CONN
(FLASHER) 5 WAY C SHEET 10 3500 LBL D1
RIGHT A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2
6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK D2 6430 PNK SWITCH
LEFT 3 6400 PNK
3400 LBL 2725 BLK 6
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK D
SHEET 6 2420 BLK BEACON/FLASHER
C423
4
2 *SW6
OPTIONS DWG)
POSITION 5 POSITION C
2830 BLK
6.13 OHM SHEET 6 6
C408
(BLACK) * C676
LEFT HANDLE C412

CAB-MFR HARN CONN 1
SHEET 6
2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
SIG
PWR
B
A
7210 WHT
1460 RED/WHT
13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2 AIR RIDE
C497
SJC RIGHT
*-
C278
2 7810 WHT 6 3 SEAT
5 7200 WHT C SPEAKER 1 5 1510 RNG/WHT 4 PWR
HORN/BLINKER 7800 WHT SHEET 11
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL 1885 RNG/WHT SHEET 11
3 6520 PNK B SHEET 11 6
J2A OPTIONS DWG) 2885 BLK 2
SHEET 11
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW Printable Version Click Here
A SIG
SOLENOID
4460 LGN
7.5 OHM 12 V
J2B
26
WIRING SCHEMATIC
AUX CTRLR
(ACS / SJC MACHINE)
C441
J1A
GWY CTRLR
26 2350 BRN
4350 LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
TRACK 2 SPEED
ADAPTER S570 (S/N ALM413083 & ALM413264 -
5.1 OHM 12 V (SEE ADDITIONAL
J1B 26
OPTIONS DWG) ALM415479)
GWY CTRLR
(S/N B3GZ11001 - B3GZ11096)
Sheet 15 of 18
7253420 (0)
Printed In U.S.A.
772 of 1290
LEGEND
ENGINE
PARTIAL CONNECTOR
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 EXHAUST GAS
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
1 EGR VREF3 164 C136
TO C113 PIN 3
5 POSITION SIGNAL 116 See Sheet 5 of 14 4
EGR VALVE
DC MOTOR 3 POSITION RETURN 172 120 SENSOR GROUND 3
6 192 137 5V 2 MAF
H BRIDGE POS
SENSOR
2 H BRIDGE NEG 193 TO C113 PIN 2 1
See Sheet 5 of 14
C149
COOLANT TEMP
165 VREF3 OIL PRESSURE 3
OIL PRESSURE &
C148 111 OIL PRESSURE SENSOR 4 TEMPERATURE
1 FUEL TEMP SENSOR 110 148 1 SENSOR
FUEL TEMP RETURN GND
SENSOR 2 FUEL RETURN 146
104 OIL TEMPERATURE SENSOR 2
C147
2 SENSOR SIGNAL 131
ENGINE BLOCK
SHIELD 128 .
169 RETURN 1 INTAKE
2 132 TEMPERATURE
SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
POSITION
SENSOR NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141
C144
C138
1 SENSOR RETURN 147 . 161 INTAKE MANIFOLD PRESSURE 1
CAM SHAFT 2 159
POS SENSOR 112 3
SENSOR INTAKE PRESS SENSOR INTAKE MANIFOLD
167 INTAKE PRESS RETURN 2
TO C118 - PIN 1 SENSOR
RAIL
PRESSURE 2 SENSOR RETURN 119 Printable Version Click Here
SENSOR C139
3 VREF1 SENSOR 138
C141 126 FUEL INJECTOR LSD1A 2 CYL 1 WIRING SCHEMATIC
CYL 3 2 FUEL INJECTOR LSD1B 175
C140
2 (ACS / SJC MACHINE)
174 CYL 2
C142
FUEL INJECTOR LSD2B 1
S570 (S/N ALM413083 & ALM413264 -
CYL 4 C154
177 PWM 2
INLET METERING ALM415479)
TO C118 - PIN 1 1 VALVE
SEE Sheet 8 of 18 (S/N B3GZ11001 - B3GZ11096)
Sheet 16 of 18
7253420 (0)
Printed In U.S.A.
773 of 1290
ACS CONTROLLER
ACS
E
F
G
H
CAN LOW
GROUND
GROUND
E
F
G
H
J
LIFT HANDLE
TILT HANDLE
LIFT ACTUATOR FEEDBACK
LIFT PEDAL
E
F
G
H
J
HANDLE ENABLE
LIFT MOTOR 1
PEDAL ENABLE
GROUND
GROUND
CONTROLS
ACS AND AHC HARNESS
J1-ACS
CONTROLLER
H 2280 BLK
2280 BLK
SEE MANUAL CONTROL
2240 BLK
MAINFRAME HARNESS 1170 RED/WHT C409 C466
4275 LGN
4220 LGN 5 4 2240 BLK CONTROLLER
G B HANDLE
4275 LGN 3 3 B 1190 RED/WHT LOCK
A
C 4550 LGN 2 2 C 1180 RED/WHT H
7 1 1170 RED/WHT E J SKI CTRL
4220 LGN
8 J 2260 BLK C467 E DETENT
E 9240 PUR 1 H 3 F FLOW
2270 BLK 2510 BLK
D 9140 PUR/WHT 4 G 4280 LGN 1 LIFT C TWO SPD
4260 LGN
B 1740 RNG/WHT 6 2 SOLENOID D
A 5970 YEL PWM
+5V 13 OHM B
G 2250 BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500 BLK
1 TILT D
4270 LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650 BRN B B GRD LIFT ACTUATOR SIDE
D 4610 LGN 8 F
F 4650 LGN C C SIG LIFT HANDLE SHIFT
7 A
5650 YEL A A +5V PWR HALL SENSOR
6 J
F 4600 LGN 5 H A
C469 HANDLE
4 E B
2750 BRN B B GND LOCK
G 4750 LGN C C SIG 5980 YEL 3 +5V PWR
TILT HANDLE
5750 YEL A A +5V PWR HALL SENSOR 2980 BRN 1 GND
3980 LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660 BRN GND
C
J 4660 LGN 3 SIG K 4645 LGN 8
LIFT PEDAL
5660 YEL
2980 BRN
2990 BRN
6
C470 A 4640 LGN 5
2760 BRN 2 GND 4
K 4760 LGN 3 SIG 5990 YEL 3 +5V PWR
TILT PEDAL
5760 YEL 1 +5V PWR HALL SENSOR 2990 BRN 1 GND
3990 LBL 2 SIG
5750 YEL Printable Version Click Here
5650 YEL 5980 YEL
5970 YEL 5990 YEL
WIRING SCHEMATIC
H 3980 LBL (ACS / SJC MACHINE)
E 3990 LBL
S570 (S/N ALM413083 & ALM413264 -
ALM415479)
(S/N B3GZ11001 - B3GZ11096)
Sheet 17 of 18
7253420 (0)
Printed In U.S.A.
774 of 1290
SJC A
B
C
D
E
+5V TO SENSORS
SWITCHED POWER
HAND/FOOT INPUT
CAN HIGH
CAN LOW
A
B
C
D
E
LIFT CYLINDER SENSOR-SPARE
FLOAT-SPARE
RESPONSE SELECTOR-SPARE
TILT CYLINDER SENSOR-SPARE
A
B
C
D
E
TILT MOTOR 1
UNSWITCHED POWER
UNSWITCHED POWER
LIFT MOTOR 2
HANDLE ENABLE
2
3
4
5
6
TWO SPEED SWITCH
SPARE DIGITAL INPUT 2
H PAT SWITCH
ISO PAT SWITCH
ISO LITE
CONTROLS
12 CAN HIGH
C429 ACTUATOR
4600 LGN 5
6
16 H PAT LITE
SUSP JSTK 7163706
4610 LGN 8 17 RR ANGLE
2980 BRN 1 GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
3980 LBL 2 SIG 20 R JOYSTICK X
29 2890 BRN 7
21 L FWD DRIVE
5980 YEL 3 +5V PWR
22 CAN LOW
33
34 TILT ACTUATOR
5990 YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890 YEL 4 25 TWO SPEED 1
5970 YEL
3990 LBL 2 SIG 26 BRAKE LIGHT OUTPUT
6 27 GROUND
23 2990 BRN 1 GND
24 28 GROUND
4640 LGN 5
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7169309 or 7188448) 30 SENSOR SUPPLY 2 +5V
2970 BRN
5810 YEL 2 C543 4650 LGN 8
2810/BRN BRN 4 2810 BRN 1 GND
31 L REV DRIVE
8 3810 LBL 3 3810 LBL 3 SIG 32 CAN SHIELD
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
SWASHPLATE E 35 SAFETY OUT
5860 YEL 2 C542
H
2860 BRN 4 2860 BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL LBL 3 3860 LBL 3 SIG 37 R JOYSTICK Y
G
1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
43 4260 LGN 1 4260 LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250 LGN 3 4250 LGN 1 A 43 R FWD DRIVE
45 2650 BRN 4 2650 BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
J1-ACS
F 45 R REV RETURN
C545 9240 PUR E 46 TWO SPEED 2
31 4280 LGN 5 4280 LGN 1
9140 PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1760 RNG/WHT B 48 UNSWITCHED BATTERY
2280 BLK H 49 SPARE PWN COIL 6
C544 C
21 4270 LGN 7 4270 LGN 1 50 SWITCHED BATTERY
11 2670 BRN 8 2670 BRN 2 LEFT FORWARD DRIVE
K
A 1 1
C474 1830 RNG/WHT +12V PWR
D 2 2
26 4210 LGN A 2070 BLK GND
J3-ACS
F 4 9660 PUR 4 CAN LO RIGHT
2270 BLK H JOYSTICK
2260 BLK J 3 3
C492 9560 PUR/WHT CAAN HI
1180 RED/WHT C
12 9190 PUR/WHT 8
1190 RED/WHT B
22 9290 PUR 7
E
4 4550 LGN 2 1 1840 RNG/WHT 1 +12V PWR
G
6 4220 LGN 5
16 4275 LGN 3 2 2080 BLK 2 GND
9140 PUR/WHT 4
LEFT
4 9640 PUR 4 CAN LO
9240 PUR 1
JOYSTICK
50 1750 RNG/WHT 1740 RNG/WHT 6 3 9540 PUR/WHT 3 CAN HI
27 2470 BLK C493

28 2490 BLK 2235 BLK 3
47 1250 RED/WHT 1235 RED/WHT 2
48 1260 RED/WHT 1170 RED/WHT 1 WIRING SCHEMATIC Printable Version Click Here
2240 BLK 4
(ACS / SJC MACHINE)
S570 (S/N ALM413083 & ALM413264 -
1760 RNG/WHT
2280 BLK
2270 BLK
ALM415479)
2260 BLK
1180 RED/WHT
(S/N B3GZ11001 - B3GZ11096)
1190 RED/WHT
Sheet 18 of 18
36 7100 WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR (PRINTED NOVEMBER 2016)
HARNESS)
775 of 1290
PINS PINS PINS
C100 WATER IN FUEL SENDER 2 8 C425 BRAKE SOLENOID 3 9 FRC1 FUSE RELAY CENTER 112 4,5,8,9,13,14
C103 TAILGATE HARNESS 8 6,12,13,15 C426 CAN(Remote Start Tool, ACD) 7 7
C105 HYD CHARGE PRESSURE SENSOR 3 9 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,8,11,15 J1A GATEWAY CONTROLLER 34 5,8,9,10,12,13,14,15
C434-1 LEFT FRONT WORKLIGHT 1 (37W) 2 13 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,10,11,12,15
C108 HYD TEMPERATURE SENDER 2 9 C434-2 LEFT FRONT WORKLIGHT 2 (50W) 2 13 J2A AUX CONTROLLER 34 9,12,15
C110 ALTERNATOR 2 8 C435-1 RIGHT FRONT WORKLIGHT 1 (37W) 2 13 J2B AUX CONTROLLER 26 4,5,6,7,9,12,15
C111 HARNESS ENGINE START CONN 3 8 C435-2 RIGHT FRONT WORKLIGHT 2 (50W) 2 13
C112 HYD OIL FILTER SWITCH 2 9 C438 CAB-MFR HARN CONN(DK GRY) 14 11,13,14,15 J7A ENG ECU CONTROLLER(BCT) 58 5,6,7,8
C441 TWO SPEED SOLENOID 2 15
C114 HAND THROTTLE 6 8 C446 HYDRAULIC FAN 2 9
C115 FOOT THROTTLE 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7 SW1 BRAKE SWITCH 6 10
C116 FOOT THROTTLE INTDM 3 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7 SW2 BEACON SWITCH 6 15
C118 ENG-CROSSOVER 4 8 C479 LEFT PANEL(BLACK) 12 7,10 SW3 HAZARD SWITCH 6 15
C126 HORN 2 15 C480 LEFT PANEL(GRAY) 12 10 SW4 HAND/FOOT, H/ISO SWITCH 6 11
C129 CAB ACCESSORY 3 11 C482 SEATBAR SENSOR 3 11
C169 ENGINE CAN (Diagnostic) 6 7 C483 TEMP CONTROL SWITCH 3 14 SW5 POWER BOBTACH SWITCH 6 15
C212 POWER SOCKET 2 11 C486 AC COMPRESSOR 2 14 SW6 BUCKET POSITION SWITCH 6 15
C252 WASHER PUMP INTDM 2 11 C489 MFR ACCESSORY 2 5,6
C253 WASHER PUMP 2 11 C492 ACS/SJC/AWS-MFR HARN 8 5,7,11 SW9 TRAVEL CONTROL SWITCH 6 10
C277 AIR RIDE SEAT 6 15 C493 ACS/SJC/AWS-MFR HARN 4 4,6 SW10 BLOWER SWITCH 6 14
C278 RIGHT SPEAKER 2 15 C497 SJC HORN/BLINKER 3 15 SW11 AC SWITCH 3 14
C279 LEFT SPEAKER 2 15 C499 PTOL 4 10 SW12 DPF SWITCH 10 10
C308 BRAKE SOLENOID 2 9 C500 RH KEY SWITCH 6 10 T1 BATT GROUND 1 6
C350 AC EVAPORATOR SWITCH 2 14 C503 RH DLX PANEL 6 7,10 T2 BUZZER GROUND 1 10
C355 FUEL HARNESS 6 8,15 C602 LEFT REAR TAIL LIGHT 2 13 T3 FLASHER 2 15
C404 BU ALARM-MFR HARN 2 5,12 C603 RIGHT REAR TAIL LIGHT 2 13 T4 MEGAFUSE LOAD SIDE 1 4
C405 AIR FILTER SWITCH 2 8 C606 POWER BOBTACH OPEN 2 15 T6 BATT GROUND 1 6
C406 FUEL SENDER 2 8 C607 POWER BOBTACH CLOSE 2 15 T8 BATT GROUND 1 6
C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,10, C610 HVAC DUCT FAN 2 14
T10 ENGINE SYSTEM GROUND 1 6
11,13,15
C409 RIGHT HANDLE (MAN/ACS) 10 12 C611 BLOWER MOTOR 4 14 T13 BUZZER POWER 1 10
C410 LEFT HANDLE (MAN/ACS) 10 12 C630 THERMOSTAT 3 14
T14 PRE HEATER 1 8
C411 LEFT HANDLE 5 WAY 5 15 C635 HEATER VALVE 6 14 T15 RIGHT REAR WORK LIGHT(+) 1 13
C412 LEFT HANDLE 2 WAY 2 15 C667 DOOR HARNESS 6 11 T16 RIGHT REAR WORK LIGHT(-) 1 13
C415 HIGH FLOW SOLENOID 2 15 C670 EXTERIOR BEACON HARNESS 6 15 T17 LEFT REAR WORK LIGHT(+) 1 13
C418 FRONT ROD 2 9 C676 RADIO 6 15 T18 LEFT REAR WORK LIGHT(-) 1 13
C419 FRONT BASE 2 9 T19 BACKUP ALARM 1 12
C420 HYD LOCK 2 9 T20 BACKUP ALARM(GND) 1 12
C421 TILT SPOOL LOCK 3 12 T32 ECU CASE GROUND 1 6
C422 LIFT SPOOL LOCK 3 12 T37 DOME LIGHT(+) 1 11
C423 BUCKET POSITION SOLENOID 2 15 T38 DOME LIGHT(-) 1 11
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 1 of 18
776 of 1290 7279775 (A)
A-2 B-2 UNSW BATT
A-5 HORN RELAY B-5
A-6 B-6
A-7 B-7
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 B-9 CAN HI 1
A-10 B-10
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-19 B-19 FRONT ROD
A-24 B-24
A-25 B-25
A-25 B-25
A-27
A-27
A-29
A-29
A-32
A-33
A-33 FOOT THROTTLE
A-34
HARNESS PART NUMBER

MF MFR CTRL 7276760
EXMF MFR CTRL 7276758
DLX CAB 7253375
STD CAB 7227905
STD FUEL 7149219
DLX FUEL 7266824 Printable Version Click Here
BCT ENG START 7220812
TAILGATE DOM
TAILGATE EUR
7217484
7217483
WIRING SCHEMATIC
SUSP JSTK
BRAKE ADAPTER
7266829
7165061
(ACS / SJC MACHINE)
WHL 2 SPD ADP
TRK 2 SPD
7159366
7214626
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 2 of 18
7279775 (A)
777 of 1290
Printed In U.S.A.
LEGEND
CONNECTOR J7
PIN FUNCTION
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 8 CONNECTOR
CAB PAGE 11
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 13
13 OPTIONS PAGE 15
15
19 ECU RUN SIGNAL

21
A B C D
24
25
26
SENSOR FREQUENCY
29
E F G H
SENSOR TEMP
34 WATER FUEL SENSOR GND
45 ECU RELAY GND J L
K M
47 ECU CAN 1 LO
48 ECU CAN 1 HI
56 GLOW PLUG SIGNAL
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 3 of 18
7279775 (A)
778 of 1290
UNSWITCHED BATT POWER C408
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400/RED/WHT
SHEET 11
1450/RED/WHT 6 1450/RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER SP7 1420/RED/WHT
SHEET 10
1110/RED/WHT 2 C500 RH KEY SWITCH
1070/RED 1120/RED/WHT 1130/RED/WHT 3 GWY CTRLR 1440/RED/WHT
SHEET 10
+12V 1025/RED
FUSE 13 25 A
1160/RED/WHT SP36 1150/RED/WHT 3
J2B
BATTERY MEGAFUSE 1180/RED/WHT 2 AUX CTRLR
100.0 Amps
FUSE 15 25A
1270/RED 1170/RED/WHT 1
T4 1 C493
1280/RED 1235/RED/WHT 2
SHEET 8
STARTER
1010/RED SHEET 14
FUSE 1 15 A
1320/RED/WHT
SHEET 13
FUSE 2 20 A 1350/RED/WHT SHEET 13
1340/RED
SP26 1330/RED/WHT
1060/RED 1065/RED/WHT SHEET 8 FRC1 FRONT LIGHT RELAY
1335/RED FUSE 20 5 A
1325/RED FUSE 16 25 A
SP1 1300/RED 1035/RED/WHT SHEET 5
1445/RED/WHT
SHEET 8
1460/RED/WHT
1040/RED 1490/RED/WHT 1410/RED/WHT
(OPTIONS) Printable Version Click Here
FUSE 24 25 A
SHEET 11
C408 CAB-MFR CONN
(ACCESSORIES)
WIRING SCHEMATIC
1055/RED
SP60
(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
1050/RED
SHEET 5
FRC1 SWITCHED PWR RELAY Sheet 4 of 18
1030/RED
SHEET 8
Printed In U.S.A.
FRC1 STARTER RELAY (PRINTED NOVEMBER 2016)
7279775 (A)
779 of 1290
FRC1
+12V ENGINE ECU
PWR RELAY -G
SWITCHED POWER 1506/RNG/WHT
J7A ENGINE ECU
1
SHEET 4 1035/RED/WHT 30 SP54
87 1504/RNG/WHT 1507/RNG/WHT 3
1509/RNG/WHT 1508/RNG/WHT 5
85 86
8005/TAN 45

1345/RED/WHT
SHEET 4
FUSE 21 15 A
1511/RNG/WHT
SHEET 8 ENG-CROSSOVER
C404
1720/RNG/WHT B BU ALARM-MFR HARN
(SEE ADDITIONAL
OPTIONS DWG)
FUSE 5 25 A C489
1750/RNG/WHT 1780/RNG/WHT A MFR ACCESSORY
SP50
1760/RNG/WHT
FUSE 12 15 A
1940/RNG/WHT
1520/RNG/WHT SHEET 10 T13 LH PANEL BUZZER
SHEET 12 C410 LEFT HANDLE 1930/RNG/WHT
1530/RNG/WHT SHEET 12 C409 RIGHT HANDLE 1775/RNG/WHT
C428 1960/RNG/WHT
1805/RNG/WHT 1570/RNG/WHT 1560/RNG/WHT 22 1785/RNG/WHT
1950/RNG/WHT
SP11 SHEET 10 C500 RH PANEL KEY SWITCH
1660/RNG/WHT 2 1660/RNG/WHT 1590/RNG/WHT
FUSE 7 25 A SP65 SP42
1765/RNG/WHT 1795/RNG/WHT 1730/RNG/WHT 1735/RNG/WHT
1725/RNG/WHT
FUSE 8 25 A
1580/RNG/WHT Printable Version Click Here
SHEET 11 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
FRC1
SWITCHED
1815/RNG/WHT
FUSE 23 15 A
1800/RNG/WHT
POWER RELAY -A
1050/RED
+12V
PWR 30 (ACS / SJC MACHINE)
SHEET 4 3450/LBL 21
2055/BLK GND 85
87
86 3380/LBL 4
J1A
GWY CTRLR
C428
(LT GRAY)
CAB-MFR HARN CONN 2
S570 (S/N ALM415480 - ALM416380)
SHEET 6
SP37
C449 LH JOYSTICK
(S/N B3GZ11097 - B3GZ11233)
1740/RNG/WHT 6
C492
1830/RNG/WHT
SHEET 7
C450 RH JOYSTICK
Sheet 5 of 18
(8 PIN)

780 of 1290
2320/BRN
SHEET 9
GROUND
2370/BRN J1B
SHEET 11 GWY CTRLR
2220/BRN SP12 2230/BRN 17
SHEET 9
2190/BRN
2 2001/BLK SHEET 9
C105 HYD CHG PRESSURE SENDER
4 2002/BLK SP53 2810/BLK 2180/BRN
J7A SHEET 8
ENG ECU CTRLR 6 2003/BLK C355 FUEL HARN (FUEL SENDER)
2150/BRN
SHEET 8
T32 2004/BLK
ECU CASE GND SHEET 8 2690/BRN
SHEET 8 2695/BRN
C115 FOOT THROTTLE
2080/BLK C493 3 2235/BLK

C449 LH JOYSTICK 4 2240/BLK T6
2070/BLK (4 PIN)
2920/BLK CAB-MFR HARN CONN 1
SHEET 10 2765/BLK
C479 LH PANEL (BLACK) SP4 SHEET 13
2940/BLK 2950/BLK 10 2950/BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 10
C499 PTOL 2745/BLK
SP3 SHEET 14
2960/BLK 16 C408 CAB-MFR CONN (HVAC)
C500 RH PANEL KEY SWITCH J1B 2790/BLK T8
GWY CTRLR 15 2500/BLK SHEET 11 BATT GND
2250/BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 10
C503 RH DELUXE PANEL 2780/BLK
2065/BLK C428 SHEET 15
(LT GRAY) 2540/BLK
SW12 DPF SWITCH SP28 2730/BLK
2930/BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 11
SHEET 10 AUX CTRLR 2550/BLK 2090/BLK
2830/BLK SP47 2900/BLK 1 2900/BLK
SHEET 15
2700/BLK 2770/BLK
SHEET 10 SHEET 15
2785/BLK 2200/BLK
SHEET 15 SHEET 9
2620/BLK
SHEET 13 C103 C489
T16 RH REAR WORK LIGHT B 2720/BLK
SHEET 12 2650/BLK SP6
SP51 2600/BLK B 2390/BLK T1 T10
T20 BU ALARM 2600/BLK 2015/BLK
2640/BLK BATT GND SHEET 8 ENGINE
C602 LH REAR TAIL LIGHT 2455/BLK
SHEET 15
2610/BLK C423 BKT POSITION SOLENOID SP27
C603 RH REAR TAIL LIGHT SHEET 7
2630/BLK C426 REMOTE RUN, ACD Printable Version Click Here
SHEET 13 2715/BLK
T18 LH REAR WORK LIGHT SHEET 7
SHEET 13 2045/BLK
C169 ENGINE CAN
SHEET 14
2290/BLK WIRING SCHEMATIC
D4 COMPRESSOR DIODE
SHEET 9 2035/BLK (ACS / SJC MACHINE)
FRC1 TRACTION LOCK RELAY SP55 SP5
SHEET 13
2115/BLK 2105/BLK
2520/BLK
2000/BLK
S570 (S/N ALM415480 - ALM416380)
SHEET 12
SHEET 5
2055/BLK C410 LEFT HANDLE
2530/BLK
(S/N B3GZ11097 - B3GZ11233)
SHEET 12
2030/BLK
SHEET 14
FRC1 HVAC RELAY
C409 RIGHT HANDLE
Sheet 6 of 18
SHEET 8 2005/BLK
FRC1 STARTER RELAY
2120/BLK
SHEET 13
FRC1 FRONT LIGHT RELAY 7279775 (A)
Printed In U.S.A.
781 of 1290
J7A
ECU CNTRLR
CAN BUS J1B
GWY CTRLR
47 9200/PUR 9215/PUR 9210/PUR 9205/PUR 20

CAN LO
48 9100/PUR/WHT 9115/PUR/WHT 9110/PUR/WHT 9105/PUR/WHT 14
CAN HI
R18 R21
120 OHM 120 OHM
0.5 W 0.5W
RESISTOR RESISTOR
C169
ENGINE CAN
1725/RNG/WHT 1
SHEET 5
2715/BLK 2
SHEET 6
9155/PUR/WHT 3
9255/PUR 4
5
6
C408
J1B (BLACK)
8 9260/PUR 9230/PUR 9250/PUR 9270/PUR 9220/PUR 4 9220/PUR 9410/PUR 9430/PUR 9450/PUR 9460/PUR 4
C479
9 9160/PUR/WHT 9130/PUR/WHT 9150/PUR/WHT 9170/PUR/WHT 9120/PUR/WHT 3 9120/PUR/WHT 9310/PUR/WHT 9330/PUR/WHT 9350/PUR/WHT 9360/PUR/WHT 3 LEFT PANEL (BLACK)
R14 R19
120 OHM 120 OHM
O.5W 0.5 W
RESISTOR RESISTOR
9440/PUR 4
C503
9340/PUR/WHT 2 RIGHT DELUXE PANEL
C492
(8 PIN)
1830/RNG/WHT 1
SHEET 5 C450
9290/PUR 7 2070/BLK 2
9190/PUR/WHT 8 9320/PUR/WHT 3
9420/PUR 4
9240/PUR 1
9140/PUR/WHT 4
1840/RNG/WHT 1
SHEET 5 C449
2080/BLK 2
9300/PUR/WHT 3
9400/PUR 4
J2B J2B
C426 AUX CTRLR
AUX CTRLR
9280/PUR 8 Printable Version Click Here
14 9500/PUR/WHT A
CAN HI 9
9180/PUR/WHT
WIRING SCHEMATIC
20 9600/PUR B
CAN LO
J1B
GWY CTRLR
(ACS / SJC MACHINE)
21 3090/LBL D
REMOTE RUN KEY
S570 (S/N ALM415480 - ALM416380)
C
SHEET 5
1735/RNG/WHT E SWITCHED POWER (S/N B3GZ11097 - B3GZ11233)
1165/RED/WHT F UNSWITCHED POWER
SHEET 4
SHEET 6
2710/BLK G GROUND Sheet 7 of 18
Printed In U.S.A.
7279775 (A)
782 of 1290
SHEET 4
1030/RED
+12V
PWR 30
FRC1
STARTER RELAY - M
87
ENGINE 8200/TAN
C111
HARN ENG START CONN
A 8220/TAN
STARTER
S B SHEET 4
M
GND 85 86
3560/LBL B 3560/LBL R
2005/BLK 8210/TAN 1800/RNG/WHT C 1015/RED
SHEET 6 SHEET 5
FUSE 12
C110
7 8210/TAN B S 1020/RED
22 ALTERNATOR G
3560/LBL L 1800/RNG/WHT
J1A C405 EXCITATION
GWY CTRLR 2150/BRN B GND 2015/BLK
SHEET 6 AIR FILTER SHEET 6
16 3150/LBL A SIG
C116 C115
5695/YEL C 5695/YEL C +5V PWR

SHEET 11
33 3695/LBL A 3695/LBL A
SIG
2695/BRN B 2695/BRN B GND
SHEET 6
E
FOOT THROTTLE D
ADAPTER HARNESS F
7217683
J1B C355
GWY CTRLR FUEL HARN
C406
12 3180/LBL C 3180/LBL A SIG
FUEL SENDER
2180/BRN D 2180/BRN B GND (30 - 270 OHM)
10 SHEET 6
3690/LBL
4 8007/TAN C428
(LT GRAY)
C114
5690/YEL 7 5690/YEL C +5V PWR
SHEET 11 3690/LBL 6 3690/LBL A
SIG
2690/BRN 8 2690/BRN B GND
J7A
E
19 8007/TAN F
C100
9 3865/LBL 1 WATER IN FUEL SENDER
SIG
34 2865/BRN 2 (FUEL FILTER)
GND
C118
ENG-CROSSOVER
To C154 - PIN 1, &
1511/RNG/WHT 1
SHEET 5 To C114, Pin 3, Sheet 16 of 18
28 8013/TAN 8013/TAN 2
MAF FREQ MAF Sensor - PIN 1, Sheet 16 of 18 Printable Version Click Here
35 8014/TAN 8014/TAN 3
MAF TEMP MAF Sensor - PIN 4, Sheet 16 of 18
+12V
PWR 30
3420/LBL 4
TO GLOW PLUG, J7B - PIN 79, WIRING SCHEMATIC
SHEET 4 1065/RED/WHT 87 8525/TAN 8500/TAN Sheet 16 of 18
56 8510/TAN 85 86 1445/RED/WHT
SHEET 4 PRE-HEATER
(ACS / SJC MACHINE)
PREHEATER
RELAY - C
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 8 of 18
Printed In U.S.A.
783 of 1290
7279775 (A)
FRC1
TRACTION LOCK
+12V RELAY - D
HYDRAULICS 4100/LGN
C425
B C308
BRAKE
1360/RED/WHT PWR 30
SHEET 4 4200/LGN A 4200/LGN A SOLENOID TRACK 2 SPEED
87 ADAPTER (SEE
2200/BLK C 2200/BLK B 9.8 OHM
SHEET 6 ADDITIONAL
GND 85 86 12 V
SHEET 6 2035/BLK OPTIONS DWG)
7165061
8 4110/LGN
13 3430/LBL
C108
2220/BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
32 3220/LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320/LBL A SIG
HYDRAULIC OIL
GWY CTRLR 2320/BRN B GND FILTER SWITCH (NC)
SHEET 6
C446
18 2910/BRN 2 GND HYDRAULIC
4010/LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410/BRN B GND HYDRAULIC LOCK
4410/LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190/BRN B GND HYDRAULIC
SHEET 6
3190/LBL C SIG CHARGE
5190/YEL A +8V PWR PRESSURE SENSOR
0.5-7.5V
4200/LGN
19 13 1 23 6
J1B +8V
GWY CTRLR

C418
J2A
AUX CTRLR
18 2330/BRN
4330/LGN
2
1
GND
SIG
FRONT ROD
3.3 OHM PWM
C419 (ACS / SJC MACHINE)
1 2340/BRN 2 GND
4340/LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) S570 (S/N ALM415480 - ALM416380)
3.3 OHM PWM
(S/N B3GZ11097 - B3GZ11233)
19 13 Sheet 9 of 18
J2B
AUX CTRLR (PRINTED NOVEMBER 2016)
7279775 (A)
Printed In U.S.A.
784 of 1290
SHEET 5
1940/RNG/WHT
7040/WHT
T13
BUZZER (+)
T2
LEFT PANEL
BUZZER
C479
LEFT PANEL (BLACK)
CAB DISPLAY C499
(PTOL)
BUZZER (-) 1930/RNG/WHT 1

10 2940/BLK 3
7040/WHT BUZZER C408 SHEET 6 GROUND
(BLACK)
2920/BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960/RNG/WHT 1440/RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030/LBL 1 3030/LBL 2
PTOL OUTPUT
SW9 1620/RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380/BRN 12 2380/BRN 4
SWITCH (OPTIONAL) 3400/LBL 11 LEFT BLINKER INPUT J1A
SHEET 15
GWY CTRLR
5 6 SHEET 15
3500/LBL 8 C500
4
2700/BLK 2 3 3650/LBL 7 24 8130/TAN 2 8130/TAN 2
1 9
3600/LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610/LBL 4 5
SHEET 5 1775/RNG/WHT 6
2930/BLK C480 J1B 22 3040/LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040/LBL RUN/ENTER SWITCH
GWY CTRLR
SHEET 11 3620/LBL 12
DOOR SIGNAL
11 1950/RNG/WHT 5
10 1420/RED/WHT 1
3 2960/BLK 3
SHEET 6 GROUND
3610/LBL 2
PARK BRAKE OUTPUT
SW12 8
DERATE OVERRIDE SWITCH 6 RIGHT PANEL DELUXE DISPLAY
1700/RNG/WHT 7 9 8050/TAN 4 1590/RNG/WHT 5
SHEET 5 DPF LAMP
1705/RNG/WHT 10 8 8055/TAN 5
SHEET 5 DPF INHIBIT LAMP
SHEET 4 1240/RED/WHT 1
3 8060/TAN 1 UNSWITCHED POWER
2065/BLK 2 DPF OVERRIDE
SHEET 6 2250/BLK 3
1 SHEET 6 GROUND
8070/TAN 9 6
4 DPF INHIBIT REGEN
WIRING SCHEMATIC
NOT USED
(ACS / SJC MACHINE) Printable Version Click Here

S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 10 of 18
7279775 (A)
785 of 1290
SW4
*
CAB
HAND/FOOT
(ACS)
H/ISO
(SJC, AWS)
SWITCH
1785/RNG/WHT 2 1
SHEET 5 3
2060/BLK 5 6
C492
SHEET 12 4230/LGN
C438
(DK GRAY)
SHEET 11
CAB-MFR HARN CONN 3

(8 PIN)
5
SHEET 12 4240/LGN
4220/LGN
SP29
4235/LGN 7 4235/LGN
3 4275/LGN 8 4275/LGN
2 4550/LGN
1850/RNG/WHT
9
2
4550/LGN
1850/RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795/BLK 1 GND
1375/RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370/RED/WHT 7 1370/RED/WHT SP45
* T37
DOME LIGHT (+)
SHEET 4 1390/RED/WHT
SP41 DOME
C129 2010/BLK LIGHT
CAB ACCESSORY
SP8
1210/RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580/RNG/WHT 5 1580/RNG/WHT 1865/RNG/WHT B +12V SW PWR
SHEET 5
2800/BLK C GND
1510/RNG/WHT
SHEET 15
SP44 2210/BLK SHEET 15
2730/BLK 11 2730/BLK
SHEET 6 2885/BLK SHEET 15
2060/BLK SHEET 11
C428
(LT GRAY) * C667
DOOR HARNESS
OPTIONS DWG)
2790/BLK 14 2790/BLK
SHEET 6
1850/RNG/WHT 1
3620/LBL 4
1400/RED/WHT 5
6
C482 SEATBAR 2840/BLK 2
WIPER MOTOR GROUND
J1B
2370/BRN 2370/BRN A SENSOR 7310/WHT 3
4 GND WASHER SIGNAL
GWY CTRLR SHEET 6
11 3370/LBL 5 3370/LBL B SIG
24 5100/YEL 5370/YEL 3 5370/YEL C +5V PWR

SP13
SHEET 8
SHEET 8
5690/YEL
5695/YEL
WIRING SCHEMATIC
HARNESS WASHER PUMP
7253378
(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
* C252
A
C253
1
PWR
WASHER
(S/N B3GZ11097 - B3GZ11233)
7310/WHT
2845/BLK B 2845/BLK 2 GND

MOTOR
Sheet 11 of 18
7279775 (A)
Printed In U.S.A.
786 of 1290
MANUAL CONTROLS 2530/BLK
C409
RIGHT HANDLE
(MANUAL/ACS ONLY)
K
C466
A
J2A SHEET 6
AUX CTRLR 4230/LGN G B HANDLE LOCK (ACS)
C404 SHEET 11
C103 1530/RNG/WHT A
TAILGATE HARN 30 4940/LGN H
T19 TERMINAL (+)
(SEE ADDITIONAL 31 4930/LGN J SKI CTRL
A 7100/WHT C 7100/WHT
OPTIONS SHEET) 4920/LGN E DETENT FLOW
BACK UP
2650/BLK ALARM 13 4910/LGN F
SHEET 6 TWO SPD
4310/LGN C
T20 TERMINAL (-) 4320/LGN D
PWM
4300/LGN B
C410
21 17 18 23
LEFT HANDLE
C421
AUX CTRLR K
J1A 10 2980/BRN 3 GND
GWY CTRLR 1 SIG TILT SPOOL LOCK 20 4640/LGN D FLOAT (ACS)
4980/LGN
2 17.8 OHM 12V 28 4840/LGN C
22 4830/LGN B SKI CTRL
C422 12 4820/LGN G
2 3 11 4810/LGN F SIDE SHIFT
2990/BRN GND
1 LIFT SPOOL LOCK 1520/RNG/WHT A
4990/LGN SIG 17.8 OHM 12V SHEET 5
J C465
2
4240/LGN H A
SHEET 11
2520/BLK E B HANDLE LOCK (ACS)
SHEET 6
7 5 SEE OPTIONS SHEET FOR HORN AND TURN SIGNALS

J1B Printable Version Click Here
GWY CTRLR
WIRING SCHEMATIC
(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 12 of 18

7279775 (A)
Printed In U.S.A.
787 of 1290
C434-1
LEFT FRONT
LIGHTS
C408 2735/BLK B GND
(BLACK)
C434-2
2765/BLK 9 2765/BLK 2750/BLK B GND LEFT FRONT
SHEET 6
50.00 Watts
C435-1
8 6000/PNK 6120/PNK A SIG RIGHT FRONT
RC1 WORK LIGHT
2760/BLK B GND
LIGHTS RELAY 1
C438 C435-2
(DK GRAY) 6130/PNK A SIG
1350/RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
SHEET 4 87 6620/PNK 6610/PNK 2705/BLK B GND WORK LIGHT
50.00 Watts
13 6610/PNK
2120/BLK 85 86
SHEET 6
6630/PNK
6000/PNK
RC2
FRONT WORK
LIGHTS RELAY 2 C103
PWR 2610/BLK 2 GND
1330/RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340/PNK 6310/PNK A 6310/PNK 6320/PNK 1 SIG
TAIL LIGHT
GND 85 86
2115/BLK C602
SHEET 6
6330/PNK 1 SIG
2640/BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320/PNK
31 3460/LBL
J1A
17 6210/PNK
GWY CTRLR
28 3440/LBL
T16 TERMINAL (-)

2620/BLK GND
SHEET 6 RIGHT REAR
6210/PNK SIG WORK LIGHT
FRC1
RELAY - E
+12V
1320/RED/WHT
SHEET 4 87 6200/PNK H 6200/PNK SP96 6200/PNK SIG LEFT REAR
GND 85 2630/BLK GND WORK LIGHT
2045/BLK 86 SHEET 6

(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 13 of 18

7279775 (A)
788 of 1290
HVAC 2440/BLK * C610
2 GND HVAC DUCT
7440/WHT 1 SIG FAN
2560/BLK
* C483
C BLK
7420/WHT A DBL POTENTIOMETER
B (TEMP CONTROL
7425/WHT WHT SWITCH)
* DLX CAB HARN 7253375 ONLY * C635

D SIG
(NOT IN STD CAB HARN) 2130/BLK C GND
A +12V PWR
HEATER
VALVE
7430/WHT
SP48 B
E
F
FRC1
C438
(DK GRAY)
*BLOWER
SW10
+12V HVAC RELAY - B CAB-MFR HARN CONN 3 SWITCH

1140/RED/WHT PWR 30 OFF
SHEET 4 87 1500/RNG/WHT 10 1500/RNG/WHT 5 2
1
2030/BLK GND 85 86 4
SHEET 6 7410/WHT 6
3 7530/WHT * C611
1 14.00 Amps High
3 7520/WHT 2 7.50 Amps Med BLOWER
7050/WHT MOTOR
7510/WHT 3 5.00 Amps Low
J1A
30 3050/LBL
SHEET 6 2745/BLK 11 2745/BLK SP16 * SW11
AC SWITCH 2580/BLK 4
GWY CTRLR
2100/BLK 3
C 7400/WHT
7015/WHT 1
11 7021/WHT SP40 7020/WHT 12
*
C630
THERMOSTAT
3
AC EVAPORATOR C350 2570/BLK 2
SWITCH B 7023/WHT 7020/WHT 1
A 7024/WHT
C486
7025/WHT 1 SIG
MAGNET CLUTCH
WIRING SCHEMATIC
2 GND
SHEET 6
2290/BLK 2280/BLK
(COMPRESSOR)
(ACS / SJC MACHINE)
D4
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 14 of 18
7279775 (A)
789 of 1290
# C607
1
C355
FUEL HARN
E
C428
(LT GRAY)
CAB-MFR HARN CONN 2
11
OPTIONS
POWER BOB
SIG
GND 2
4470/LGN
2470/BLK 2770/BLK B
4470/LGN
2770/BLK
4470/LGN # DLX FUEL HARN 7266824 ONLY
CLOSE SHEET 6
*POWER
SW5
2 1
# C606 BOBTACH 3
POWER BOB
GND 2 2480/BLK SWITCH 5 4
SIG 1 4480/LGN F 4480/LGN 10 4480/LGN
OPEN
6010/PNK 13 6010/PNK
1380/RED/WHT
SHEET 5
C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200/RED/WHT
PWR
C411
B
SHEET 4
1410/RED/WHT 1 1410/RED/WHT 1430/RED/WHT X
L
* FLASHER
T3
LEFT HANDLE CONN

(FLASHER) 5 WAY C SHEET 10 3500/LBL
D1
(SEE ADDITIONAL
RIGHT A 6515/PNK 6500/PNK 6 6500/PNK 6530/PNK
*BEACON
SW2
6570/PNK
E
OPTIONS DWG) D 6415/PNK 6400/PNK D2 6430/PNK SWITCH
LEFT 3 6400/PNK
3400/LBL 2725/BLK 6
SW3
2
1
6700/PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410/PNK (PINS 3 & 6 2850/BLK
6
* C670E
(SEE ADDITIONAL D 6510/PNK INTERNALLY
OPTIONS DWG) INSULATED)
2780/BLK 4 2780/BLK 2780/BLK D
C423 SHEET 6 2420/BLK BEACON/FLASHER
6440/PNK F
*
3 SW6 EXTERIOR HARNESS
BUCKET SIG A 4450/LGN D3 4455/LGN 5 4455/LGN 1 B (SEE ADDITIONAL
2 BUCKET 6540/PNK
POSITION 4 C OPTIONS DWG)
2830/BLK 5 POSITION
SOLENOID GND B 2450/BLK 2455/BLK SHEET 6 SWITCH A
6.13 OHM SHEET 6 6
C408
(BLACK) * C676
LEFT HANDLE C412

CAB-MFR HARN CONN 1
SHEET 6
2785/BLK
C126
B GND LEFT
*+ C279
1 7820/WHT
RADIO CONN
3
*
HORN C277
(HORN) 2 WAY SIG B 7210/WHT 13 7210/WHT A SIG SPEAKER 2 7830/WHT 4
(SEE ADDITIONAL - 1
PWR A 1460/RED/WHT SHEET 4 2 AIR RIDE
OPTIONS DWG)
C497
SJC RIGHT
*- C278
2 7810/WHT 6 3 SEAT
5 7200/WHT C SPEAKER 1 5 1510/RNG/WHT 4 PWR
HORN/BLINKER 7800/WHT SHEET 11
4 6420/PNK A + 1 2210/BLK 5 GND
(SEE ADDITIONAL 1885/RNG/WHT SHEET 11
3 6520/PNK B SHEET 11 6
J2A OPTIONS DWG) 2885/BLK 2
AUX CTRLR
SHEET 11
C415
26 2460/BRN B GND HIGH FLOW Printable Version Click Here
A SIG SOLENOID
4460/LGN
7.5 OHM 12 V
J2B
AUX CTRLR
26 WIRING SCHEMATIC
C441
(ACS / SJC MACHINE)
J1A
GWY CTRLR
26 2350/BRN
4350/LGN
2
1
GND
SIG
TWO SPEED
SOLENOID
TRACK 2 SPEED
ADAPTER S570 (S/N ALM415480 - ALM416380)
5.1 OHM 12 V (SEE ADDITIONAL
J1B 26
OPTIONS DWG)
(S/N B3GZ11097 - B3GZ11233)
GWY CTRLR
Sheet 15 of 18
Printed In U.S.A.
7279775 (A)
790 of 1290
ENGINE
LEGEND
HARNESS
OPTIONS PAGE 16
PRE HEATER 179

TO C118 - PIN 4 J7B
(ENGINE HARNESS)
C131
106 TEMP SENSOR 2 EXHAUST GAS
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO
C151
1 EGR VREF3 164
TO C118 PIN 3
5 POSITION SIGNAL 116 See Sheet 8 of 18 4
EGR VALVE
3 172 120 SENSOR GROUND 3 MAF
DC MOTOR POSITION RETURN
SENSOR
6 192 137 5V 2
H BRIDGE POS
2 H BRIDGE NEG 193 TO C118 PIN 2 1
See Sheet 8 of 18
C149
COOLANT TEMP C136
165 VREF3 OIL PRESSURE 3
OIL PRESSURE &
C148 111 OIL PRESSURE SENSOR 4 TEMPERATURE
1 FUEL TEMP SENSOR 110 148 1 SENSOR
FUEL TEMP RETURN GND
SENSOR 2 FUEL RETURN 146
104 OIL TEMPERATURE SENSOR 2
C147
2 SENSOR SIGNAL 131
ENGINE BLOCK
SHIELD 128 .
169 RETURN 1 INTAKE
2 132 TEMPERATURE
SENSOR SIGNAL
ENGINE BLOCK
SHIELD 129
C145
POSITION
SENSOR NOTE: ON EARLY MODELS, WIRE TO PIN
161 WAS TO PIN 141
C144
C138
1 SENSOR RETURN 147 INTAKE MANIFOLD PRESSURE 1
CAM SHAFT 2 159
POS SENSOR
SENSOR 112 INTAKE PRESS SENSOR 3 INTAKE
167 INTAKE PRESS RETURN 2
TO C118 - PIN 1 SENSOR
RAIL
PRESSURE 2 SENSOR RETURN 119
SENSOR C139
3 VREF1 SENSOR 138
127 FUEL INJECTOR HSDA 1 Printable Version Click Here
C141 126 2 CYL 1
FUEL INJECTOR LSD1A
CYL 3 2
FUEL INJECTOR LSD1B
151
175 C140 WIRING SCHEMATIC
150 FUEL INJECTOR HSDB 2
C142
174 FUEL INJECTOR LSD2B 1 CYL 2 (ACS / SJC MACHINE)
CYL 4
177 PWM
C154
2
S570 (S/N ALM415480 - ALM416380)
INLET METERING
TO C118 - PIN 1
SEE Sheet 8 of 18
1 VALVE
(S/N B3GZ11097 - B3GZ11233)
Sheet 16 of 18
7279775 (A)
ACS CONTROLLER
ACS
CONTROLS
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND ACS AND AHC HARNESS
J1-ACS
CONTROLLER
H 2280/BLK
SEE MANUAL CONTROL
2280/BLK
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER HANDLE
G B
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4280/LGN 1 LIFT C TWO SPD
4260/LGN
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GRD LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
A C471
B 2 C428 TILT ACTUATOR
2660/BRN GND
C
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
5660/YEL
6
2990/BRN
2980/BRN
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
3990/LBL 2 SIG
5750/YEL
5650/YEL 5980/YEL Printable Version Click Here
5970/YEL 5990/YEL
H
WIRING SCHEMATIC
3980/LBL
E 3990/LBL
(ACS / SJC MACHINE)
S570 (S/N ALM415480 - ALM416380)
(S/N B3GZ11097 - B3GZ11233)
Sheet 17 of 18
7279775 (A)
Printed In U.S.A.
792 of 1290
SJC
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 2 TWO SPEED SWITCH
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER 3 SPARE DIGITAL INPUT 2
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER 4 H PAT SWITCH
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 5 ISO PAT SWITCH
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE 6 ISO LITE
CONTROLS
12 CAN HIGH
C429 ACTUATOR
4600/LGN 5 4680
6
16 H PAT LITE
SUSP JSTK 7284703
4610/LGN 8 4690 17 RR ANGLE
2980/BRN 1 GND 18 L JOYSTICK X
4 19 L JOYSTICK Y
3980/LBL 2 SIG 20 R JOYSTICK X
29 2890/BRN 7
21 L FWD DRIVE
5980/YEL 3 +5V PWR
22 CAN LOW
33
34 TILT ACTUATOR
5990/YEL 3 +5V PWR 24 R QUAD B DRIVE
40 5890/YEL 4 25 TWO SPEED 1
5970/YEL
3990/LBL 2 SIG 26 BRAKE LIGHT OUTPUT
6
23
27 GROUND
2990/BRN 1 GND
24 28 GROUND
4640/LGN 5 4780
7 29 SENSOR GROUND
C536 A22 PUMP HARNESS (7198705) 30 SENSOR SUPPLY 2 +5V
2970/BRN
5810/YEL 2 C543 4650/LGN 8 4790
2810/BRN/BRN 4 2810/BRN 1 GND
31 L REV DRIVE
8 3810/LBL 3 3810/LBL 3 SIG 32 CAN SHIELD
1710/RNG/WHT 1 1710/RNG/WHT 2 +12V PWR K 33 L QUAD A DRIVE
J 34 L QUAD B DRIVE
J2-ACS
C537 RIGHT
E
5860/YEL 2 C542 SWASHPLATE 35 SAFETY OUT
H
2860/BRN 4 2860/BRN 1 GND 36 BACKUP ALARM
F
7 3860/LBL/LBL 3 3860/LBL 3 SIG 37 R JOYSTICK Y
G
1770/RNG/WHT 1 1770/RNG/WHT 2 +12V PWR 38
C SPARE ANALOG 1
LEFT
43 4260/LGN 1 4260/LGN 1 B 40 SENSOR SUPPLY 1 +5V
RIGHT FORWARD DRIVE
42 2660/BRN 2 2660/BRN 2 A
ACS CONTROLLER
41 L REV RETURN
42 R FWD RETURN
C547
44 4250/LGN 3 4250/LGN 1 A 43 R FWD DRIVE
45 2650/BRN 4 2650/BRN 2 RIGHT REVERSE DRIVE G 44 R REV DRIVE
45 R REV RETURN
J1-ACS
F
C545 9240/PUR E 46 TWO SPEED 2
31 4280/LGN 5 4280/LGN 1
9140/PUR/WHT D 47 UNSWITCHED BATTERY
41 2680/BRN/BRN 6 2680/BRN 2 LEFT REVERSE DRIVE
1760/RNG/WHT B 48 UNSWITCHED BATTERY
2280/BLK H 49 SPARE PWN COIL 6
C544 C
21 4270/LGN 7 4270/LGN 1 50 SWITCHED BATTERY
11 2670/BRN 8 2670/BRN 2 LEFT FORWARD DRIVE
K
A 1 1
C474 1830/RNG/WHT +12V PWR
D 2 2
26 4210/LGN A 2070/BLK GND
J3-ACS
F 4 9660/PUR 4 CAN LO RIGHT
2270/BLK H JOYSTICK
2260/BLK J 3 3
C492 9560/PUR/WHT CAAN HI
1180/RED/WHT C
12 9190/PUR/WHT 8
1190/RED/WHT B
22 9290/PUR 7
E
4 4550/LGN 2 1 1480/RNG/WHT 1 +12V PWR
G
6 4220/LGN 5
16 4275/LGN 3 2 2080/BLK 2 GND
9140/PUR/WHT 4
LEFT
4 9640/PUR 4 CAN LO
9240/PUR 1 JOYSTICK
3 9540/PUR/WHT 3 CAN HI
50 1750/RNG/WHT 1740/RNG/WHT 6
27 2470/BLK C493
28 2490/BLK 2235/BLK 3
47 1250/RED/WHT 1235/RED/WHT 2
48 1260/RED/WHT 1170/RED/WHT 1
2240/BLK 4 WIRING SCHEMATIC Printable Version Click Here
(ACS / SJC MACHINE)
1760/RNG/WHT S570 (S/N ALM415480 - ALM416380)
2280/BLK
2270/BLK
2260/BLK
(S/N B3GZ11097 - B3GZ11233)
1180/RED/WHT
1190/RED/WHT
Sheet 18 of 18
36 7100/WHT A (CONNECTS TO BACKUP
B ALARM C404 ON MFR (PRINTED NOVEMBER 2016)
HARNESS)
793 of 1290
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
8 SH08 - HYDRAULICS
BATT FEED, GENERAL RED RED LEGEND
1000 THROUGH 1499
10 SH10 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT CONNECTOR
11 SH11 - MANUAL CONTROLS
12 SH12 - LIGHTS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
13 SH13 - HVAC
14 SH14 - OPTIONS 1 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
15 SH15 - OPTIONS 2
1 1
HARNESS PART NUMBER LIGHT GREEN
HYDRAULIC 4000 THROUGH 4999 LGN
MF MFR CTRL 7300790 1 1
EXMF MFR CTRL 7300339 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7301237 * LIGHTS 6000 THROUGH 6999 PINK PNK SHT1/F2
WIRE #
SHT1/F2
WIRE #
STD CAB 7303755 * WHITE
SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHT
STD FUEL 7149219
DLX FUEL 7266824

9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALM416381-ALM419107, ALM419124-ALM419125
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899 TOLERANCES: ECN 101943 Printed On August 2018
csf

ACS / SJC Machine S/N B3GZ11234
B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
B3 MOVED "GND" TEXT FROM A5 TO A2 104399 AEW 3 OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
UNLESS OTHERWISE SPECIFIED SCHEM ELEC CTRL
B2 2195 Here
Click ASSIGNED
ForSIZE OF 18
Interactive PDF 104399 AEW 11 COPYRIGHT C
Sheet 1 of 17
7300789
B1 9205 SWAPPED SIZE AND MATERIAL VALUES 104399 AEW 5 TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
794 of 1290
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
1400 RED/WHT
C408 SHT10/D3
6 6
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
1160 RED/WHT
SP36
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
FUSE 15 25A C493
100.0 Amps
HW11 1 1 1270 RED 1170 RED/WHT
15A 15B 1 1
T5 T4
FUSE 17 25 A
17A 17B 2 2
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1
FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/C3
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/C3
RED
FUSE 18 25 A
1055

18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT6/G8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 2 of 17
7300789
B SEE SHEET 1 104399 AEW TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
795 of 1290
FRC1 ENGINE
ECU RELAY - G
SWITCHED
ENG ECU CTRLR
1506 RNG/WHT
1
G1
POWER
SHT2/D1 87 1540 RNG/WHT SP54 1507 RNG/WHT
G4 3
86 85 1508 RNG/WHT
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT
SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
SWITCHED SHT10/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT9/F4
2 2 SHT9/E4
1555 RNG/WHT
SHT15/F4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
B3 A4 7A 7B SHT5/B8
86 85 GND
A5 A2
BUS BAR
1725 RNG/WHT
SHT5/C2
1580 RNG/WHT
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
FRC1 FRC1
2055 BLK
SHT4/B8
GATEWAY CTRLR
3450 LBL
3380 LBL
J1A
C428
9 9 SHT5/E3
1830 RNG/WHT
SHT5/F3
C492
1740 RNG/WHT
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 3 of 17
7300789
B SEE SHEET 1 104399 AEW IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE Printable Version Click Here
796 of 1290
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7
6 2370 BRN GATEWAY CTRLR
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/F4 SHT8/D7 J1B
2180 BRN
SHT6/D7
C493
2150 BRN
ACS/SJC/AWS CONN 2 SHT6/F7
2235 BLK 2695 BRN
2080 BLK 3 3 SHT6/E7
SHT5/E3
2240 BLK
2070 BLK 4 4
SHT5/F3
C493 T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16
SHT15/D4
AUX CTRLR 2780 BLK
2890 BLK 2550 BLK 2090 BLK SHT14/E7
SHT15/H4 15
2065 BLK SP28 2730 BLK
C428
2930 BLK
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK 1 BATT GND AUX CTRLR
SHT12/C4 B B 2195 BRN
SP51 SHT11/G2 SP58 2995 BRN
2610 BLK 2185 BRN 17 SENSOR GROUND
SHT12/E4 SHT15/E7
J2B
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
SHT5/C2
2505 BLK 2290 BLK

SHT15/G4 SHT13/B8
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55 SP5 2000 BLK

2115 BLK 2105 BLK
SHT12/D8
2055 BLK 2520 BLK

SHT3/C1 SHT11/D2
2030 BLK 2530 BLK

SHT13/F8 SHT11/F2
2005 BLK
SHT6/G7
2120 BLK
SHT12/E8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 4 of 17
7300789
797 of 1290
CAN BUS
RE016 RE019
C408
GATEWAY CTRLR 120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR C479
R3-1 SP19 SP18 LEFT PANEL (BLACK)
TP-09 9260 PUR TP-09 TP-10 TP-10 SP31 TP-12 TP-12 SP79 TP-14 9270 PUR TP-14 TP-16 9220 PUR TP-16 TP-01 TP-01 TP-03 TP-03
SP30 SP80 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
R3-2 SP20 R2
J1B TP-11 TP-13 TP-15 TP-02 TP-04 TP-06
C479
C503
RH DLX PANEL
9440 PUR TP-06
C492 4 CAN LO
ACS/SJC/AWS-MFR HARN (8 PIN)
9340 PUR/WHT
9290 PUR TP-15 2 CAN HI
7 7
9190 PUR/WHT C503

8 8
*
9240 PUR TP-13
1 1 C450 C460
RIGHT JOYSTICK CONN RIGHT JOYSTICK RIGHT JOYSTICK
9140 PUR/WHT 1830 RNG/WHT 1830 RNG/WHT +12V PWR
4 4 SHT3/B1 1 1 1 1
SHT4/G8 2 2 2 2
3 3 3 3
AUX CTRLR 4 4 4 4
9280 PUR TP-11
8
*
CAN LO
C449 C459
9180 PUR/WHT LEFT JOYSTICK CONN LEFT JOYSTICK LEFT JOYSTICK
9 CAN HI 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
J2B 2080 BLK 2080 BLK GND
THIS SCEMATIC USED IN 61$/0$/0, ALM419124-ALM419125 SHT4/G8 2 2 2 2
3 3 3 3
FOR TELEMATICS SEE CAN BUS SHEET IN 4 4 4 4
R18 R21
C426 ENG ECU CTRLR 120 OHM 0.5W RESISTOR 120 OHM 0.5W RESISTOR
AUX CTRLR B1 GATEWAY CTRLR
Remote Run Tool, ACD R1-1 SP90 R2-1
TP-22 TP-22 TP-17 TP-17 TP-18 TP-18 TP-20 TP-21 9205 PUR TP-21
9500 PUR/WHT 9200 PUR 9215 PUR 9210 PUR TP-20
CAN HI 14 A A CAN HI ENG CAN LO 47 20 ENG CAN LO
9600 PUR
9100 PUR/WHT
SP91 9110 PUR/WHT 9105 PUR/WHT
9115 PUR/WHT
J2B ENG CAN HI 48 14 ENG CAN HI
R1-2 TP-19 R2-2
3095 LBL J7A J1B
REMOTE RUN KEY 24
J2A C169
ENGINE CAN
GATEWAY CTRLR
1725 RNG/WHT
3090 LBL 3085 LBL SHT3/D1 1
REMOTE RUN KEY 21 D D REMOTE RUN KEY
SP93
2715 BLK
J1B SHT4/C6 2
9155 PUR/WHT TP-19

3 ENG CAN HI
1735 RNG/WHT
9255 PUR
4 ENG CAN LO
1165 RED/WHT
C169
2710 BLK
SHT4/C6 G G GROUND
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 5 of 17
7300789
798 of 1290
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

SHT2/E7
SHT3/C1 C C
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR

3560 LBL FOOT THROTTLE
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN
B
GND FOOT THROTTLE HARNESS
SHT4/G3
AIR FILTER C110 ALTERNATOR
7217683 1020 RED
3150 LBL SWITCH (NC) C116 D S
AIR FILTER SENDER SIGNAL 16 A SIG
E
FOOT THROTTLE INTDM F L
C405 5695 YEL
5695 YEL +5V PWR
SHT10/C8 C C C 2015 BLK 1
3695 LBL SHT4/E3
3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A T11
2695 BRN 2695 BRN GND
SHT4/G3 B B B 1
T12
C115
J1A
C355
FUEL HARN
3180 LBL 3180 LBL HAND THROTTLE
FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT10/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
3690 LBL
C406
3690 LBL SIG
2690 BRN GND
SHT10/D5 B
C114
8007 TAN
IGN SW ON 4
J1B FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR
1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL FRC1 FRC1
SIG
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT7/G3
8014 TAN
J7A 4 4 SHT7/H7
ENG-CROSSOVER
3420 LBL
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 6 of 17
7300789
B SEE SHEET 1 104399 AEW IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
799 of 1290
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALM416381-ALM418928
ENG ECU CTRLR
GLOW PLUG FEEDBACK

SHT6/B5 79 GLOW PLUG FEEDBACK
EGR VALVE DC MOTOR EXHAUST GAS TEMP SENSOR 2 6 2
T
MAF SENSOR
4 OPEN MAF FREQ
SHT6/B5 1
MAF TEMP
C151 SHT6/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T

KNOCK SENSOR 1 SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
T
SHIELD-01
C150
C147
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
1 SHT6/B5 FUEL INJECTOR #2 LSD2B 74 2
INJECTOR #3

P
INJECTOR #4
2 19
C143
INLET METERING VALVE FUEL INJECTOR #4 LSD2A 25 2

1 SHT6/C5 C142
C154
J7B
J7B
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 7 of 17
7300789
800 of 1290
HYDRAULICS
FRC1
C425
4100 LGN
SHT2/E1 D1 87 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
TRACTION LOCK RELAY SIGNAL 8
3430 LBL
TRACTION LOCK RELAY FEEDBACK 13
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
HYDRAULIC LOCK SOLENOID
J1A
1
C420
2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19
13
23
4330 LGN GND

PRESS SENDER
TRACTION SOLENOID
HYD CHARGE PRESS
1
HYDRAULIC
HYD LOCK
HYD CHARGE
SOLENOID
AUX CTRLR
SENDER POWER
3.3 OHM PWM

FAN
2330 BRN SIG

OUTPUT
C418
4340 LGN GND
1
GATEWAY CTRLR 3.3 OHM PWM
2340 BRN SIG
J2A C419
J2B
19
13
FRONT BASE
FRONT ROD
SOLENOID
SOLENOID
AUX CTRLR
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 8 of 17
7300789
801 of 1290
1940 RNG/WHT 1
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10
SHT4/G8 2 20 1 1 2
SHT2/G1 1 19 12 12 4
SHT3/E1 5 C499
GATEWAY CTRLR C500
SHT14/F4
3400 LBL
11 LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT14/F4 8 24 2 2 2
1960 RNG/WHT J1A

SHT3/E1
SW9 3040 LBL

3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) 22 14 14 4
2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5

5 4 SHT2/G1 1
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK C503
C479 SHT5/G1

SHT3/D1 5
4
SW1 SW1 SHT2/H1 1


SHT10/D3 12
C503 SHT5/F1

2
SW12
2065 BLK 8070 TAN

SHT4/E8 2 4 9 DESOX INHIBIT
SHT3/E1 10 8 5 DESOX INHIBIT LAMP
8060 TAN
3 1 DPF FORCE REGEN
SW12 SW12
C480
NOT USED
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
Sheet 9 of 17
7300789
802 of 1290
SW4
HAND/FOOT (ACS)
*
CAB
H/ISO (SJC, AWS)
SWITCH
1785 RNG/WHT
*
SHT3/E1 2 1
6
SHT10/D1 5
4
SHT11/F2
4230 LGN
THESE CAB SCHEMATICS USED IN S/N ALM416381-ALM419107,
SW4 3
SHT11/D2
4240 LGN
ALM419124-ALM419125
SW4
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C438
4220 LGN SP29 4235 LGN 4235 LGN
5 5 7 7
4275 LGN 4275 LGN
*
3 3 8 8
C212
4550 LGN 4550 LGN
2 2 9 9 POWER SOCKET
2795 BLK GND
SHT3/F1 2 2
1375 RED/WHT +12V PWR
2
C212
C408
SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
SP8 SP41
*
SHT3/D1 5 5 B B +12V SW PWR T38
2800 BLK
C C GND
1510 RNG/WHT
SHT14/C2
1885 RNG/WHT
SHT14/B3
2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT14/B2
2885 BLK
SHT14/B3
2060 BLK
SHT10/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
(SEE ADDITIONAL
2690 BRN
SHT6/D4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
A
+5V PWR
C
SP13 SP52
5100 YEL 5370 YEL 5370 YEL 5375 YEL 7310 WHT
5V PWR 24 3 3 3 3 WASHER SIGNAL
C482
J1B
5690 YEL
5695 YEL SHT6/E4
SHT6/F7
HARNESS WASHER PUMP
* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984through
AHGM12591
AJDT13779
AJZV16256
ALJ818499
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148 through
B3GY11170
B2LA11412
B2KZ12106
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 10 of 17
DWG. NO.
7300789
803 of 1290
MANUAL
CONTROLS
RIGHT HANDLE
AUX CTRLR
1530 RNG/WHT
SHT3/E3 A
4930 LGN
4940 LGN
2195 BRN
B2 SHT4/D3 C
4320 LGN PADDLE
D
4300 LGN
B
C404
BU ALARM-MFR HARN (SEE 4910 LGN RIGHT POSITION SWITCH
C103 RIGHT HANDLE RIGHT ROCKER UP 13 F
7100 WHT 7100 WHT T19 E
A A C C
1 BACK UP ALARM 2530 BLK HANDLE LOCK (ACS ONLY)
2650 BLK 1 SHT4/B6 K
SHT4/D8 4230 LGN
T20 SHT10/H8 G
C409
TILT (ACS/AHC ONLY)
J2B
21
18
23
RIGHT HANDLE
RIGHT HANDLE
TRIGGER RETURN
PWM SIGNAL
RIGHT HANDLE
PWM HIGH
GATEWAY CTRLR
TILT SPOOL LOCK 2980 BRN GND

10 3
SOLENOID GROUND LEFT HANDLE
TILT SPOOL LOCK
7.8 OHM 12V AUX CTRLR LIFT (ACS/AHC ONLY)
4980 LGN SIG
1
C421
4240 LGN HANDLE LOCK (ACS ONLY)

SHT10/G8 H
LIFT SPOOL LOCK 2990 BRN GND 2520 BLK
SOLENOID GROUND 2 3 SHT4/B6 E
LIFT SPOOL LOCK 4640 LGN
J1A FLOAT SIGNAL 20 D FLOAT (ACS/AHC ONLY)
4990 LGN
SIG
1 SHT3/E3 A
C422 LEFT HANDLE RIGHT ROCKER DOWN 4830 LGN
22 B RIGHT POSTION SWITCH
4840 LGN
4810 LGN
J1B
4820 LGN
7

C410
LOCK SOLENOID
LOCK SOLENOID
J2A
TILT SPOOL
LIFT SPOOL
TRIGGER
GATEWAY CTRLR
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 11 of 17
DWG. NO.
7300789
804 of 1290
6100 PNK
C434-1
A
LIGHTS
SIG
37 WATT
C408
2735 BLK GND
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND
50 WATT
6110 PNK SIG

A
C434-2
C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
RELAY - RC1
C438
2760 BLK GND
87 13 13 A
SIG
SP64
86 85 50 WATT
2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/A8
6630 PNK
6320 PNK

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603
RC2 RC2
SHT4/B8 1
LEFT REAR
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR RELAY 5
C602
3460 LBL
MRKR LIGHT PWR RELAY FEEDBACK 31
REAR LIGHT RELAY 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
RIGHT REAR
WORK LIGHT
6210 PNK
J1A FRC1

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
2045 BLK
SHT4/B8
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 12 of 17
DWG. NO.
7300789
805 of 1290
2440 BLK GND
* HVAC
2
HVAC DUCT FAN

7440 WHT SIG
1
C610
2560 BLK
*
C
A
CONTROL SWITCH)
B
C483
7425 WHT
*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635
2030 BLK
SHT4/B8
BLOWER MOTOR
*
FRC1 C438 SW10
(DK GRAY)
* BLOWER SWITCH
7530 WHT
1
HIGH

SHT2/F1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT
FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611
HVAC RELAY SIGNAL

3
7400 WHT
3050 LBL
2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK
SW11
1
3
C
* THERMOSTAT
*
SP40
7021 WHT 7020 WHT 7020 WHT
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH
7023 WHT
B
AC EVAPORATOR
A 1
C350
D4
MAGNET CLUTCH
SHT4/C6
GND
2
C486
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 13 of 17
DWG. NO.
7300789
B SEE SHEET 1 104399 AEW TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
806 of 1290
# C355 C428
POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
*
2470 BLK 2770 BLK 2770 BLK
2 GND B B SW5
#
SHT4/E6
SP33 POWER BOBTACH SWITCH DLX FUEL HARN 7266824 ONLY
#
C607
1 SIG F F 10 10 2
POWER BOB
OPEN 2480 BLK SW5
3
GND
2 SW5
C606
13 13
SHT3/F1 12 12
C438 1405 RED/WHT

SHT15/D6
*
SHT2/C1 1 1 X T3
FLASHER
1200 RED/WHT L
3500 LBL
T3
SHT9/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
RIGHT POSTION SWITCH
6 6
PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL
6510 PNK
6410 PNK
B SHT9/G8 1
SW3 2
*
6415 PNK C103
D
HAZARD SWITCH
6570 PNK
A
E E 1
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2
2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK
SP46 2725 BLK
* SW6
SW3
(PINS 3 & 6
SW3
4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6700 PNK
BUCKET A SIG 5 5 1
POSITION 2
*
D3
SOLENOID 3
2450 BLK 2455 BLK 2905 BLK
9.8 OHM B GND SHT4/C6 4 SHT15/F6
2970 BLK
C423 6 5 SHT15/F4 E E
2810 BLK 2420 BLK
D D C670
SW6 SW6 SHT15/D5
LEFT HANDLE F F
2830 BLK EXTERIOR HARNESS
AUX CTRLR SHT4/E8 6540 PNK
LIFT (ACS/AHC ONLY)
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY
C676 OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG)
HORN SIGNAL 5
7200 WHT
C497
C C
LEFT SPEAKER
* * RADIO CONN C
A
C
A
SJC HORN/BLINKER 7820 WHT LEFT
6420 PNK 1 3
HANDLE LOCK (ACS ONLY) RIGHT BLINKER SIGNAL 4 A A (SEE ADDITIONAL SPEAKER (+)
OPTIONS DWG) 7830 WHT LEFT
2 4
*
6520 PNK SPEAKER (-)
LEFT BLINKER SIGNAL 3 B B
C279
FLOAT (ACS/AHC ONLY) 2460 BRN RIGHT SPEAKER 1
*
HIGH FLOW SOLENOID GROUND 26
2
J2A GND 7810 WHT RIGHT L010
B 2 6 3 AIR RIDE SEAT
RIGHT POSTION SWITCH HIGH FLOW SPEAKER (-)
1510 RNG/WHT
SOLENOID 7800 WHT RIGHT SHT10/E1 4 PWR
SIG 7.5 OHM 12 V 1 5 SPEAKER (+) PWR
PADDLE A
C278 1885 RNG/WHT
C415 SHT10/E1 1 2210 BLK GND
4460 LGN
HIGH FLOW SOLENOID 26 SHT10/E1 5
2885 BLK GND
J2B SHT10/D1 2 6
C408 GATEWAY CTRLR C676 C277
MFR HARN CONN 1 C126
1460 RED/WHT
A SHT2/C1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
_
C412 SOLENOID (SEE ADDITIONAL
HORN 4350 LGN OPTIONS DWG)
SIG
1 5.1 OHM 12 V
2785 BLK GND +
SHT4/E8 B B TWO SPEED SIGNAL 26 C441
J1B
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 14 of 17
DWG. NO.
7300789
807 of 1290
AUX CTRLR
C438
*SW7
RIDE CONTROL
OPTIONS 2
23
3410 LBL
14 14
3410 LBL
1 2
2890 BLK
SHT4/E8
RIDE CONTROL SW AUTO
SW7 SW7
RIDE CONTROL
RELAY - L
3480 LBL
1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
3435 LBL 3445 LBL 2505 BLK

1 1 L5 L2 SHT4/C8
RIDE CONTROL
RIDE CONTROL
COIL FRC1 FRC1
SP32 COIL
2040 BLK 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8
*
C428 SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
2905 BLK 2970 BLK
SHT14/D3 1 2 SHT14/D3
3470 LBL 3470 LBL
1555 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW8 SW8
J2A REVERSING
FAN COIL
3485 LBL
C442
2185 BRN
SHT4/D3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIGNAL 10 C
5105 YEL
PRESSURE SENSOR
J2B
* SW8 * C672
6710 PNK
1405 RED/WHT 1 1 1
SHT14/G3 2
2810 BLK
SHT14/D3 2 2
2860 BLK
6 SHT4/E8
P697 P697
PROPRIETARY NOTICE
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861
WARNING through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
csf

B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
COPYRIGHT C
X ± 13 MAT
Sheet 15 of 17
DWG. NO.
7300789
808 of 1290
ACS CONTROLLER
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE
F F LIFT HANDLE F LIFT MOTOR 1
G GROUND G TILT HANDLE G PEDAL ENABLE
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND
J LIFT PEDAL J GROUND
HARNESS PART NUMBER

J1-ACS
CONTROLLER
ACS 7164144 EXMF, LF
H 2280/BLK
ACS 7190593 MF
2280/BLK
SEE MANUAL CONTROL
2240/BLK
MAINFRAME HARNESS 1170/RED/WHT C409 C466
4275/LGN
4220/LGN 5 4 2240/BLK CONTROLLER HANDLE
G B
4275/LGN 3 3 B 1190/RED/WHT LOCK
A
C 4550/LGN 2 2 C 1180/RED/WHT H
7 1 1170/RED/WHT E J SKI CTRL
4220/LGN
8 J 2260/BLK C467 E DETENT
E 9240/PUR 1 H 3 F FLOW
2270/BLK 2510/BLK
D 9140/PUR/WHT 4 G 4260/LGN 4280/LGN 1 LIFT C TWO SPD
B 1740/RNG/WHT 6 2 SOLENOID D
A 5970/YEL PWM
+5V 13 OHM B
G 2250/BRN 12V
C468
FOOT PEDAL LOCK
2 C410
3 K
2500/BLK
1 TILT D
4270/LGN FLOAT
SOLENOID C
B SKI CTRL
J2-ACS C472
CONTROLLER C429 G
2650/BRN B B GND LIFT ACTUATOR SIDE
D 4610/LGN 8 F
F 4650/LGN C C SIG LIFT HANDLE SHIFT
7 A
5650/YEL A A +5V PWR HALL SENSOR
6 J
F 4600/LGN 5 H A
C469 HANDLE
4 E B
2750/BRN B B GND LOCK
G 4750/LGN C C SIG 5980/YEL 3 +5V PWR
TILT HANDLE
5750/YEL A A +5V PWR HALL SENSOR 2980/BRN 1 GND
3980/LBL 2 SIG
C471
2660/BRN 2 GND C428 TILT ACTUATOR
J 4660/LGN 3 SIG K 4645/LGN 8
LIFT PEDAL
1 +5V PWR HALL SENSOR 7
5660/YEL
2980/BRN
2990/BRN
6
C470 A 4640/LGN 5
2760/BRN 2 GND 4
K 4760/LGN 3 SIG 5990/YEL 3 +5V PWR
TILT PEDAL
5760/YEL 1 +5V PWR HALL SENSOR 2990/BRN 1 GND
A 2
5750/YEL 3990/LBL SIG
B
C 5650/YEL 5980/YEL
D 5970/YEL 5990/YEL
H 3980/LBL
E 3990/LBL

S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861 through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899 Printed On August 2018
B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
Sheet 16 of 17
809 of 1290
S550
S650
S570
T630
T550
T650
T590 S/N ALM416381
AHGL12984
AHGM12591
ALJ818499
AJDT13779 through
AJZV16256
ALJG19317
ALJU21861 through
through
through
throughALJ821599
AJZV18499
ALJU24499
AJDT15599
ALJG23699
ALM418799
AHGL13799
AHGM13899 Printed On August 2018
B2L511148
B3GY11170
B2LA11412
B2KZ12106 through
B3Z711155 through
throughB2L511399
B3Z712000
B2LA11899
B2KZ13499
B3GZ12000
B3GY12000 7300789 (B)
Sheet 17 of 17
810 of 1290
Index Diagram
1 SH01 - INDEX
4 SH04 - GROUND
5 SH05 - CAN BUS
6 SH06 - ENGINE
8 SH08 - HYDRAULICS
BATT FEED, GENERAL RED RED LEGEND
1000 THROUGH 1499
10 SH10 - CAB BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT CONNECTOR
11 SH11 - MANUAL CONTROLS
12 SH12 - LIGHTS BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
13 SH13 - HVAC
14 SH14 - OPTIONS 1 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
PARTIAL CONNECTOR
15 SH15 - OPTIONS 2
1 1
HARNESS PART NUMBER LIGHT GREEN
HYDRAULIC 4000 THROUGH 4999 LGN
MF MFR CTRL 7322232 1 1
EXMF MFR CTRL 7322233 CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
WIRE BREAK
DLX CAB 7329485 * LIGHTS 6000 THROUGH 6999 PINK PNK SHT1/F2
WIRE #
SHT1/F2
7329492 *
WIRE #
STD CAB WHITE
SHT1/F2 SHT1/F2
OTHER FUNCTIONS 7000 THROUGH 7999 WHT
STD FUEL 7149219
DLX FUEL 7266824

9000 THROUGH 9999
SUSP JSTK 7163706
TRK 2 SPD 7243409
* THESE CAB HARNESSES USED IN S/N ALM419108-ALM419123, ALM419126 & ABOVE

FOR S/N ALM419124-ALM419125, ALM419107 & BELOW SEE PREVIOUS SCHEMATIC

S570
T550
T590 S/N ALM418800
AHGM13900&&&Above
AJZV18500
ALJU24500
WARNING Above
Above PROPRIETARY NOTICE TOLERANCES: ECN 106368
Printed On August 2018
csf

ACS / SJC Machine 7322231 (A)

SCHEM ELEC CTRL
Sheet 1 of 19
A Click
PARTSHere For Interactive
LIST STRUCTURE REVISED PDF 112541 RWE COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR X ± 13 MAT DWG. NO.
REV
PER THIS DRAWING
DESCRIPTION CHG NOTICE DWN SHEET
SHT 1 / 15
7322231
811 of 1290
UNSWITCHED
BATT POWER
1240 RED/WHT
SHT9/E4
1400 RED/WHT
C408 SHT10/D3
6 6 SHT5/E7
1420 RED/WHT
SHT9/E4
FUSE RELAY CENTER
1440 RED/WHT
2
11A 11B 3
SP2
FUSE 13 25 A J1B
1160 RED/WHT
SP36
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
FUSE 15 25A C493
100.0 Amps
HW11 1 1 1270 RED 1170 RED/WHT
15A 15B 1 1
T5 T4
FUSE 17 25 A
17A 17B 2 2
FUSE 4 25 A
1140 RED/WHT
4A 4B SHT13/E8
BUS BAR
1010 RED
SHT6/G1
FUSE 3 30 A
3A 3B SHT8/H8
FUSE 1 15 A
1320 RED/WHT
1A 1B SHT12/B8
BUS BAR
FUSE 2 20 A
2A 2B SHT12/D8
1350 RED/WHT
SP26 SHT12/F8
FUSE 9 50 A
9A 9B SHT6/C3
1325 RED
FUSE 20 5 A
20A 20B SHT3/G8
FUSE 16 25 A
16A 16B SHT3/H8
1445 RED/WHT
SHT6/C3
1055 RED
FUSE 18 25 A
18A 18B SHT5/B8
1460 RED/WHT
SHT14/B7
FUSE 22 25 A
22A 22B SHT14/F7
SP24
FUSE 24 25 A
24A 24B SHT10/F8
FRC1 FRC1
1200 RED
SHT3/C8
1050 RED
SHT3/D8
1030 RED
SHT6/G8

S570
T550
T590 S/N ALM418800
AHGM13900
AJZV18500 &&&Above
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 2 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
Printable
SHT 2 / 15
7322231
Version Click Here
812 of 1290
FRC1 ENGINE
ECU RELAY - G
ENG ECU CTRLR

1506 RNG/WHT
1 SWITCHED
86 85
G4
1508 RNG/WHT
3
POWER
G2 G5 5
FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER
FUSE 21 15 A
21A 21B SHT6/B7
C404
B B
(SEE ADDITIONAL
OPTION DWG)
FUSE 5 25 A
BUS BAR
SP50
FUSE 6 25 A
6A 6B SHT10/G8
1575 RNG/WHT
SHT15/G4
FUSE 12 25 A
12A 12B SHT14/G7
1700 RNG/WHT
SHT9/B8
SHT11/G2 SHT9/G8
1940 RNG/WHT
SHT9/H8
1930 RNG/WHT
FUSE 14 5 A SHT9/H4
SP11 1960 RNG/WHT
J2B SHT9/F8
C428 1785 RNG/WHT
SHT10/H8
MFR HARN CONN 2
1950 RNG/WHT
(LT GRAY) SHT9/F4
FRC1 SWITCHED 2 2 SHT9/E4
POWER RELAY - A 1555 RNG/WHT
SHT15/F4
1050 RED 30 FUSE 7 25 A SP65

+12V PWR
A4 7A 7B SHT5/B8
86 85 2055 BLK
A5 A2 GND 1725 RNG/WHT
SHT5/C2
8A 8B SHT10/F8
FUSE 23 15 A
23A 23B SHT6/G8
3390 LBL
FRC1 SWITCHED
FRC1 FRC1
POWER RELAY - F
2055 BLK
SHT4/B8
1200 RED 30
SHT2/B1
+12V PWR
F1 87 1585 RNG/WHT
F4
3385 LBL 86 85 2065 BLK GATEWAY CTRLR
F5 F2 GND
SHT4/C8
SP100 3450 LBL
FRC1 21 SWITCHED POWER RELAY FEEDBACK
FRC1
3380 LBL
J1A
C428
9 9 SHT5/E3
C492 1830 RNG/WHT

1740 RNG/WHT SHT5/F3
6 6 ACS/SJC/AWS-MFR HARN
(8 PIN)

S570
T550
T590 S/N ALM418800
AHGM13900
AJZV18500 &&&Above
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 3 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 3 / 15
7322231
813 of 1290
ENG ECU CTRLR
2
2001 BLK GROUND
2002 BLK SP53 2810 BLK
4
2320 BRN
2003 BLK SHT8/F7
6 2370 BRN GATEWAY CTRLR
SHT10/D8
T32 J7A 2004 BLK 2220 BRN SP12 2230 BRN
1 2155 BLK 2190 BRN
SHT15/F4 SHT8/D7 J1B
2180 BRN
SHT6/D7
C493
2150 BRN
2605 BLK ACS/SJC/AWS CONN 2 SHT6/F7
SHT5/E7 2235 BLK 2695 BRN
2080 BLK 3 3 SHT6/E7
SHT5/E3
2240 BLK
2070 BLK 4 4
SHT5/F3
C493 T6
2920 BLK 1 BATT GND
SHT9/G8 C408
2940 BLK SP4 2950 BLK 2950 BLK
SHT9/G4 10 10
2960 BLK
SHT9/E4
2250 BLK 2510 BLK SP3 2110 BLK

SHT9/D4 16
GATEWAY CTRLR
2500 BLK
15
2765 BLK
J1B SHT12/H8
2745 BLK
SHT13/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT10/D8
2860 BLK 16
SHT15/D4
AUX CTRLR 2780 BLK
2890 BLK 2550 BLK 2090 BLK SHT14/E7
SHT15/H4 15
2065 BLK SP28 2730 BLK
C428
2930 BLK
2830 BLK 2900 BLK 2900 BLK
SHT14/D5 1 1
2700 BLK SP47
SHT9/F8
2785 BLK 2770 BLK
SHT6/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT8/H4
2620 BLK C489 2720 BLK

2650 BLK
SHT11/F8 C103
TAILGATE HARN
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK T1 AUX CTRLR
SHT12/C4 B B 1 BATT GND 2195 BRN
SP51 SHT11/G2 SP58 2995 BRN
2610 BLK 2185 BRN 17 SENSOR GROUND
SHT12/E4 SHT15/E7
J2B
2630 BLK
SHT12/B4
2455 BLK
SHT14/D6
2710 BLK SP27 2300 BLK

SHT5/B8
2715 BLK
2065 BLK SHT5/C2
SHT3/C6
2505 BLK 2290 BLK
SHT15/G4 SHT13/B8
2045 BLK
SHT12/B8
2035 BLK
SHT8/G8
SP55 SP5
2115 BLK 2105 BLK 2000 BLK
SHT12/D8
2055 BLK 2520 BLK

SHT3/C1 SHT11/D2
2030 BLK 2530 BLK

SHT13/F8 SHT11/F2
2005 BLK
SHT6/G8
2120 BLK
SHT12/E8

S570
T550
T590 S/N ALM418800
AHGM13900
AJZV18500 &&&Above
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 4 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
SHTPrintable
4 / 15
7322231
Version Click Here
814 of 1290
CAN BUS
Z3 C408 C479
GATEWAY CTRLR MFR HARN CONN 1 (BLACK) Z4 LEFT PANEL (BLACK)
120 OHM 0.5 W RESISTOR SP19 SP18 120 OHM 0.5 W RESISTOR
SP31 SP79 SP39 SP35
9260 PUR 9230 PUR 9250 PUR 9270 PUR 9220 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR 9460 PUR
SP30 SP80 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
SP20
J1B
C479
C492
ACS/SJC/AWS-MFR HARN (8 PIN) C503
9290 PUR RH DLX PANEL
7 7
9440 PUR TP-06
9190 PUR/WHT 4 CAN LO
8 8
9340 PUR/WHT
9240 PUR 2 CAN HI
1 1
9140 PUR/WHT C503

4 4
* C450 C460
RIGHT JOYSTICK
AUX CTRLR RIGHT JOYSTICK CONN RIGHT JOYSTICK
9280 PUR SHT3/B1 1 1 1 1
8 CAN LO 2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9180 PUR/WHT 9320 PUR/WHT 9560 PUR/WHT CAN HI
9 CAN HI 3 3 3 3
J2B 4 4 4 4
TELEMATICS USED IN S/N ALM419108-ALM419123,
ALM419126 & ABOVE * C449 C459
LEFT JOYSTICK CONN LEFT JOYSTICK LEFT JOYSTICK
TELEMATICS SHT3/B1 1 1 1 1
S/N ALM419124-ALM419125, ALM419107 & BELOW 2080 BLK 2080 BLK GND
SHT4/G8 2 2 2 2
PWR 10
1305 RED/WHT
SHT2/G1 SEE PREVIOUS SCHEMATIC 9300 PUR/WHT 9540 PUR/WHT CAN HI
2605 BLK 3 3 3 3
GND 11 SHT4/G8 C448 9400 PUR 9640 PUR CAN LO
4 4 4 4
Z5 SP104 MFR HARN CONN 4 (BLACK)
120 OHM 0.5 W RESISTOR 9500 PUR/WHT SUSP SEAT JOYSTICK HARNESS
9515 PUR/WHT 9505 PUR/WHT 7 7
CAN HI 3 9510 PUR/WHT
9 9
9610 PUR
9615 PUR 9605 PUR 10 10
CAN LO 4 9600 PUR Z1 Z2
8 8 ENG ECU CTRLR 120 OHM 0.5W RESISTOR GATEWAY CTRLR
C481 SP103 SP90 120 OHM 0.5W RESISTOR
ENG CAN LO 9200 PUR 9215 PUR 9210 PUR 9205 PUR
47 20 ENG CAN LO
C426
AUX CTRLR SP91
Remote Run Tool, ACD 9100 PUR/WHT 9115 PUR/WHT 9110 PUR/WHT 9105 PUR/WHT
9500 PUR/WHT 9510 PUR/WHT ENG CAN HI 48 14 ENG CAN HI
CAN HI 14 A A CAN HI
J7A J1B
9600 PUR 9610 PUR C169

ENGINE CAN
J2B
1725 RNG/WHT
3615 LBL SHT3/D1 1
CAN SELECT 25 C C CAN SELECT
3095 LBL
REMOTE RUN 24 2715 BLK
SHT4/C6 2
J2A
GATEWAY CTRLR 9155 PUR/WHT

3 ENG CAN HI
3090 LBL 3085 LBL REMOTE RUN KEY
REMOTE RUN KEY 21 D D
SP93 9255 PUR
4 ENG CAN LO
J1B
C169
1735 RNG/WHT
1165 RED/WHT
2710 BLK
SHT4/C6 G G GROUND

S570
T550
T590 S/N ALM418800
AHGM13900&&&Above
AJZV18500
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 5 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
Printable
SHT 5 / 15
7322231
Version Click Here
815 of 1290
ENGINE
T7 STARTER
FRC1 STARTER
RELAY - M SLEEVE
1 R
C111 1
1030 RED
SHT2/B1 M1 87 8200 TAN 8220 TAN
30 M4 A A
85 T9
8210 TAN 3560 LBL
M5 M2 B B SLEEVE B
86
1
FRC1 FRC1
2005 BLK
SHT4/B8 SHT2/E7
SHT3/C1 C C
1015 RED
GATEWAY CTRLR

3560 LBL FOOT THROTTLE
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN
B
GND FOOT THROTTLE HARNESS
SHT4/G3
AIR FILTER C110 ALTERNATOR
7217683 1020 RED
3150 LBL SWITCH (NC) C116 D S
AIR FILTER SENDER SIGNAL 16 A SIG
E
FOOT THROTTLE INTDM F L
C405 5695 YEL
5695 YEL +5V PWR
SHT10/C8 C C C 2015 BLK 1
3695 LBL SHT4/E3
3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A T11
2695 BRN 2695 BRN GND
SHT4/G3 B B B 1
T12
C115
J1A
C355
FUEL HARN
3180 LBL 3180 LBL HAND THROTTLE
FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT10/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
3690 LBL
C406
3690 LBL SIG
2690 BRN GND
SHT10/D5 B
C114
8007 TAN
IGN SW ON 4
J1B FRC1
PREHEATER
RELAY - C
ENG ECU CTRLR
1065 RED/WHT
SHT2/D1 C1 8525 TAN
SP77 8500 TAN 1
2865 BRN GND C100 T14
(FUEL FILTER)
3865 LBL SIG FRC1 FRC1
WIF SENSOR 9 1
8510 TAN
C118 KL87 SHT7/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT7/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT7/G3
8014 TAN
J7A 4 4 SHT7/H7
ENG-CROSSOVER
3420 LBL

S570
T550
T590 S/N ALM418800
AHGM13900
AJZV18500 &&&Above
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 6 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 6 / 15
7322231
816 of 1290
ENGINE CONTROL UNIT
THIS ENGINE SCHEMATIC USED IN S/N ALM418929 & ABOVE
FOR S/N ALM418928 & BELOW SEE PREVIOUS SCHEMATIC
ENG ECU CTRLR
GLOW PLUG FEEDBACK

SHT6/B5 79 GLOW PLUG FEEDBACK
EGR VALVE DC MOTOR
1 64 VREF 3 EGR
OPEN
MAF SENSOR
4 MAF FREQ
SHT6/B5 1
MAF TEMP
C151 SHT6/B5 4
C136
COOLANT TEMP SENSOR
1 45
OIL TEMP SENSOR 4 2
T
C149 T
C137
T
C148

SHIELD-01 BOOST PRESSURE AND TEMP SENSOR
BOOST TEMP SIGNAL 94 2
BOOST PRESSURE PWR 61 3
3 28 ENGINE BLOCK ACCELEROMETER #1 SHIELD T
BOOST PRESSURE SIGNAL 12 4 P
C147
BOOST TEMP/PRESSURE GND 67 1
KNOCK SENSOR 2 SHIELD-02 C150
SHIELD-02

INJECTOR #1

SHIELD-03
INJECTOR #2
CAMSHAFT SENSOR
1 SHT6/B5 FUEL INJECTOR #2 LSD2B 74 2
INJECTOR #3

P
INJECTOR #4
2 19
C143

1 SHT6/C5 C142
C154
J7B
J7B

S570
T550
T590 S/N ALM418800
AHGM13900&&&Above
AJZV18500
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 7 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 7 / 15
7322231
817 of 1290
FRC1
C425 HYDRAULICS
4100 LGN
SHT2/E1 D1 87 4200 LGN 4200 LGN C308
30 D4 A A A
BRAKE
85 GND SOLENOID 9.8
D5 D2 2200 BLK 2200 BLK
C308
2035 BLK
GATEWAY CTRLR
4110 LGN
TRACTION LOCK RELAY SIGNAL 8
3430 LBL
TRACTION LOCK RELAY FEEDBACK 13
2220 BRN GND

SHT4/H3 B
T
500 - 3000 OHM (8 VOLT)
3220 LBL SIG
C108
3320 LBL SIG

2320 BRN GND (NC)
SHT4/H3 B
C112
4010 LGN SIG

1
C446
2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
HYDRAULIC LOCK SOLENOID
J1A
1
C420
2190 BRN GND

SHT4/G3 A
SIG P HYDRAULIC CHARGE
3190 LBL
C PRESSURE 0.5-4.5V
5190 YEL +5V PWR
SHT10/C8 B
C105
4200 LGN
J1B
19
13
4330 LGN GND

PRESS SENDER
TRACTION SOLENOID
HYDRAULIC
HYD LOCK
1
HYD CHARGE
SOLENOID
AUX CTRLR
3.3 OHM PWM
FAN
2330 BRN SIG

OUTPUT
C418
4340 LGN GND
1
GATEWAY CTRLR 3.3 OHM PWM
2340 BRN SIG
J2A C419
J2B
19
13
FRONT BASE
FRONT ROD
SOLENOID
SOLENOID
AUX CTRLR

S570
T550
T590 S/N ALM418800
AHGM13900
AJZV18500 &&&Above
ALJU24500
WARNING Above
csf


SCHEM ELEC CTRL
Sheet 8 of 19
X ± 13 MAT
A
REV
SEE SHEET 1
SHT 8 / 15
7322231
818 of 1290
1940 RNG/WHT
T13
SHT3/E1 1
7040 WHT
1 C499
T2 PTOL CONN

2940 BLK GROUND

SHT4/F8 3
BUZZER C408
10
SHT4/G8 2 20 1 1 2
SHT2/G1 1 19 12 12 4
SHT3/E1 5 C499
GATEWAY CTRLR C500
SHT14/F4 11
SHT14/F4 8 24 2 2 2
1960 RNG/WHT J1A

SHT3/E1
SW9
TRAVEL CONTROL SWITCH(OPTIONAL) 22 14 14

Bobcat s570 6990681 SM 1

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Service Manual

CORRECT CORRECT CORRECT

P-90216 NA1694 NA1693

WRONG WRONG WRONG

NA1674 NA1695 NA1680

NA1682 NA1683 B-6589

3 of 1290 1-1 S570 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

5 of 1290 1-3 S570 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7 of 1290 1-5 S570 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach® attachment

6. Machine signs (decals) must 14. Check all machine fluid

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 1290 1-7 S570 Service Manual

22. Check for any field

10 of 1290 1-8 S570 Service Manual

IMPORTANT • The AEM Safety Manual delivered with the machine

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

The signal word WARNING on the machine and in the

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The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

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Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

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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 nonmetallic parts such as

Know where fire extinguishers and first aid kits are

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Always use the serial number of the loader when Figure 3

Loader Serial Number

The engine serial number (Item 1) [Figure 3] is located

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

Module 1 – Model / Engine

Explanation of loader Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module

2. The five digit Production Sequence Number identifies

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The delivery report [Figure 4] contains a list of items that

The delivery report must be reviewed and signed by the