Bobcat S150 (AL3)

Service Manual
S150 Skid-Steer Loader
S/N A3L111001 - A3L119999
Dealer Copy -- Not for Resale
© Bobcat Company 2009

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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 B-15590 B-15591

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

B-15592 B-15593 B-15599
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
B-15600 B-15601 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.
MSW08-0409
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ALPHABETICAL INDEX
ACCESS PANEL (INSIDE) ..................................... 50-01 ENGINE COOLING SYSTEM .................................70-01

ACCESS PANEL (INSIDE) (SJC) ........................... 50-01 ENGINE INFORMATION .........................................70-01
AIR CLEANER ........................................................70-01 ENGINE SPEED CONTROL ...................................70-01
AIR CLEANER SERVICE .......................................10-01 ENGINE SPEED CONTROL (SJC) .........................70-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 EVAPORATOR ........................................................80-01
ALTERNATOR ........................................................ 60-01 EVAPORATOR/HEATER UNIT................................80-01
EXPANSION VALVE ................................................80-01
BACK-UP ALARM SYSTEM ................................... 60-01
BATTERY................................................................ 60-01 FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01
BLOWER FAN ........................................................ 80-01 FLYWHEEL AND HOUSING ...................................70-01
BOBCAT CONTROLLER (ACS) ............................. 60-01 FLYWHEEL RPM SENSOR ....................................60-01
BOBCAT CONTROLLER (MAIN)............................ 60-01 FRONT AUXILIARY HYDRAULIC
BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 COUPLER BLOCK ...............................................20-01
BOBCAT INTERLOCK CONTROL FUEL SYSTEM.............................................10-01, 70-01
SYSTEM (BICS) ................................................... 60-01 FUEL TANK .............................................................50-01
BOB-TACH (HAND LEVER) ........................ 10-01, 50-01
BOB-TACH (POWER)............................................. 10-01 HEATER COIL .........................................................80-01
BOB-TACH ([POWER-OPTION) ............................. 50-01 HEATER VALVE ......................................................80-01
BOB-TACH (POWER) BLOCK................................ 20-01 HIGH FLOW VALVE ................................................20-01
BRAKE (SINGLE SPEED) ...................................... 40-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BRAKE (TWO-SPEED)........................................... 40-01 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) ..20-01
BUCKET POSITION VALVE ................................... 20-01 HYDRAULIC CONTROL VALVE (STANDARD) ......20-01

HYDRAULIC/HYDROSTATIC FILTERS ..................20-01
CALIBRATION ........................................................ 60-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CAMSHAFT AND TIMING GEARS......................... 70-01 HYDRAULIC/HYDROSTATIC
CASE DRAIN FILTER ............................................. 30-01 FLUID SPECIFICATIONS................................ SPEC-01
CHAINCASE ........................................................... 40-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
CHARGE PRESSURE ........................................... 30-01 HYDRAULIC PUMP (STANDARD)..........................20-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01
CONDENSER ......................................................... 80-01 HYDRAULIC PUMP (SJC) ......................................20-01
CONTROL HANDLE/LEVER .................................. 50-01 HYDRAULIC PUMP (SJC) (HIGH FLOW)...............20-01
CONTROL HANDLE/LEVER (ACS) ....................... 50-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
CONTROL HANDLE/LEVER (SJC) ........................ 50-01 HYDROSTATIC MOTOR .........................................30-01
CONTROL PANEL .................................................. 50-01 HYDROSTATIC MOTOR (TWO SPEED) ................30-01
CONTROL PANEL (SJC)........................................ 50-01 HYDROSTATIC MOTOR CARRIER
CONTROL PANEL SETUP ..................................... 60-01 (SINGLE ANDTWO-SPEED WITH MANUAL
CONTROL PEDALS AND LINKAGE ...................... 50-01 CONTROLS) .........................................................30-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDROSTATIC MOTOR CARRIER
CONTROL SYSTEM (ACS) .................................... 60-01 (SINGLE ANDTWO-SPEED WITH SJC
CONVERSIONS ................................................SPEC-01 CONTROLS) .........................................................30-01
CRANKSHAFT AND PISTONS ............................. 70-01 HYDROSTATIC PUMP ............................................30-01
CYLINDER (BOB-TACH) ........................................ 20-01 HYDROSTATIC PUMP (SJC) ..................................30-01
CYLINDER (LIFT) ................................................... 20-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
CYLINDER (TILT) ................................................... 20-01
CYLINDER HEAD ................................................... 70-01 INSTRUMENT PANELS .........................................60-01
DIAGNOSTICS SERVICE CODES......................... 60-01

DRIVE BELT ........................................................... 30-01
DRIVE COMPONENTS .......................................... 40-01
ELECTRICAL/HYD. CONTROLS ........................... 60-01

ELECTRICAL/HYD. CONTROLS
REFERENCE (SJC).............................................. 60-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM ......................... 10-01
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ALPHABETICAL INDEX (CONT’D)
LIFT ARMS ..............................................................50-01 WHEEL SPEED SENSOR (SJC) ............................ 60-01

LIFT ARM BYPASS CONTROL VALVE...................20-01 WINDOW (FRONT DOOR) ..................................... 50-01
LIFT ARM SUPPORT DEVICE................................10-01 WINDOW (REAR) ................................................... 50-01
LIFTING AND BLOCKING THE LOADER...............10-01 WINDOW (SIDE)..................................................... 50-01
LIGHTS....................................................................60-01 WINDOW (TOP) ...................................................... 50-01
S150 LOADER SPECIFICATIONS .................... SPEC-01
S160 LOADER SPECIFICATIONS .................... SPEC-01
LOADER STORAGE AND RETURN TO SERVICE 10-01
LUBRICATING THE LOADER .................................10-01
LUBRICATION SYSTEM .........................................70-01
MAIN RELIEF VALVE ..............................................20-01

MAINTENANCE CLOCK .........................................60-01
MUFFLER................................................................70-01
OIL COOLER...........................................................20-01
OPERATOR CAB..........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01
PASSWORD SETUP (IF EQUIPPED WITH

KEYLESS START).................................................60-01
PIVOT PINS.............................................................10-01

REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECEIVER/DRIER ..................................................80-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START TOOL KIT-MEL1563 ...................10-01
REMOTE START TOOL (SERVICE TOOL) ‘
KIT - 6689779 ........................................................10-01
SEAT BAR ...............................................................50-01

SEAT BAR SENSOR ...............................................60-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SERVICE SCHEDULE.............................................10-01
SPARK ARRESTOR MUFFLER ..............................10-01
STARTER ................................................................60-01
STEERING DRIFT COMPENSATION .....................60-01
STOPPING THE ENGINE AND
LEAVING THE LOADER .......................................10-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
THERMOSTAT.........................................................80-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACK CARRIAGE COMPONENTS ......................40-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ON A TRAILER ..10-01
TROUBLESHOOTING.............................................80-01
TURBOCHARGER ..................................................70-01
TWO-SPEED VALVE ...............................................30-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

SYSTEM
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL
SYSTEM &
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SERVICE
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER
SPECIFICATIONS
SPECIFICATIONS
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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 wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good

condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.
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.
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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.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM
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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.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

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

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

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
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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.).
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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. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
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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.
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Figure 1
P-48387
The engine serial number is located on the side of the

engine [Figure 2].

P-45263
Loader Serial Number
The loader serial number plate is located on the outside

of the loader frame [Figure 1].
Explanation of loader Serial Number:

XXXX XXXXX
Module 2. - Production
Sequence (Series)
Module 1. - Model / Engine

Combination
1. The four digit Model/Engine Combination Module

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

the order which the loader is produced.
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DELIVERY REPORT
Figure 3
B-16315
The delivery report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure

3].
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BOBCAT LOADER IDENTIFICATION
FRONT
LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS

BUCKET STEPS
STEPS
† BUCKET B-19876A
● OPERATOR CAB
(ROPS / FOPS)
◆ REAR AUXILIARY LIFT ARM

QUICK COUPLERS SUPPORT DEVICE
LIFT ARM
REAR
GRILL LIFT
CYLINDER
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
✽ TIRES B-19877A
◆ Optional or Field Accessory (Not Standard Equipment)

✽ TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
† Bucket - Several different buckets and other attachments are available for this machine.
● ROPS, FOPS - Roll Over Protective Structure, per SAE / ISO 3471, and Falling Object Protective Structure per ISO 3449,
Level I. Level I I is available.
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SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1 DRIVE
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 SYSTEM
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

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . 10-130-1 ELECTRICAL
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 SYSTEM &
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2 SERVICE
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . 10-100-3
SPECIFICATIONS
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . 10-120-1
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
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 . . . . . 10-120-2
Removing And Replacing Hydraulic Case Drain Filters (Single Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter. . . . . . . . . . 10-120-6
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Continued On Next Page
10-01 S150 Service Manual

19 of 861
SAFETY AND MAINTENANCE (CONT’D)
LOADER STORAGE AND RETURN TO SERVICE . . . . . . . 10-190-1

Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit Inspection And Maintenance . . . . 10-30-4
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-180-1
REMOTE START TOOL KIT -MEL1563 . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . 10-60-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . 10-60-2
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . 10-61-1

Computer Service Tool Harness - 6689746 . . . . . . . . . . . . 10-61-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . 10-61-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-5
Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . 10-61-2
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . 10-200-1

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

20 of 861
SAFETY AND MAINTENANCE (CONT’D)
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . 10-40-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD

ITEMS MAY VARY.

21 of 861

22 of 861
LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Figure 10-10-1
P-45481
B-7023A
Put a floor jack under the rear of the loader.
Lift the rear of the loader and install jackstands [Figure

10-10-2].
WARNING
Figure 10-10-3

AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
Procedure
P-45482
Always park the loader on a level surface.
Put the floor jack under the front of the loader.
WARNING Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners
NOTE: Make sure the jackstands do not touch the
of the frame before running the engine for service.
tires. Make sure tires clear the floor and any
Failure to use jackstands can allow the machine to
obstacles.
fall or move and cause injury or death.
W-2017-0286
10-10-1 S150 Service Manual

23 of 861

24 of 861
LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
2
WARNING 3
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 1
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or P-31849 P-45251
with missing parts can cause lift arms to drop

causing injury or death. Put jackstands under the rear corners of the loader frame
W-2572-0407 (Inset) [Figure 10-20-1].
Disconnect the spring (Item 1) from the lift arm support

device retaining pin. Support the lift arm support device
DANGER (Item 2) with your hand and remove the retaining pin

(Item 3) [Figure 10-20-1].
Figure 10-20-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm P-45252
support. Replace if damaged.
D-1009-0409
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure
Remove attachment from the loader. See BOB-TACH 10-20-2] to the lift arm support device so there will be no
(HAND LEVER) on Page 50-40-1. OR See BOB-TACH interference with the support device engagement.
(POWER-OPTION) on Page 50-41-1.
Sit in the operator’s seat, fasten the seat belt and lower
the seat bar. Start the engine.

25 of 861
LIFT ARM SUPPORT DEVICE (CONT’D) Removing
Installing (Cont’d) Remove the pin from the lift arm support device.
Figure 10-20-3 Figure 10-20-4
1 2
P-54470A N-20524B P-45486
Raise the lift arms until the lift arm support device drops Connect the spring (Item 1) [Figure 10-20-4] from the lift
onto the lift cylinder rod (Item 1) [Figure 10-20-3] arm support device to the bracket below the lift arms.
Lower the lift arms slowly until the support device is held

Sit in the operator’s seat fasten the seat belt and lower
between the lift arm and the lift cylinder. Stop the engine. the seat bar.
Raise the seat bar and move both pedals until both
pedals lock. Start the engine.
Install pin (Item 2) [Figure 10-20-3] into the rear of the lift Figure 10-20-5
arm support device below the cylinder rod.
P-45251
Raise the lift arms a small amount. The spring will lift the
support device off the lift cylinder rod. Lower the lift arms.
Stop the engine.
Raise the seat bar, disconnect the seat belt, move pedals
until both pedals lock and exit the cab.
Disconnect the spring from the bracket.
Raise the support device into storage position and insert

pin (Item 1) [Figure 10-20-5] through lift arm support
device and bracket. Connect the spring to the pin.
Remove the jackstands.

26 of 861
OPERATOR CAB
Description
The Bobcat Loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for rollover protection.
ROPS / FOPS - Roll Over protective Structure per ISO

3471, and Falling Object Protective Structure per SAE
J1043 and ISO 3449, Level I. Level II is available.
Level I - Protection from falling bricks, small concrete

blocks, and hand tools encountered in operations
such as highway maintenance, landscaping, and
other construction sites.
Level II - Protection from falling trees, rocks: for

machines involved in site clearing, overhead
demolition or forestry.

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

27 of 861
OPERATOR CAB (CONT’D)
Raising
WARNING
Always stop the engine before raising or lowering the
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
SUPPORT DEVICE on Page 10-20-1.) • STOP ENGINE before raising or lowering cab.
W-2758-0908
Figure 10-30-1
NOTE: On Advanced Control System (ACS) equipped
machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.
Figure 10-30-3

P-43747
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
P-45261
Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the cab is all the way up and
the latching mechanism engages.
P-31288 P-31289
Remove the nuts and plates [Figure 10-30-2] (both

sides) at the front corners of the cab.

28 of 861
OPERATOR CAB (CONT’D)
Lowering
Always stop the engine before raising or lowering the
WARNING
cab.
PINCH POINT CAN CAUSE INJURY
NOTE: Always use the grab handles to lower the cab.
Remove your hand from the latching mechanism
Figure 10-30-4 when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
N-20120 P-45262

Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4]. P-31288 P-31289
NOTE: The weight of the cab increases when
equipped with options and accessories such
Install the plates and nuts (both sides) [Figure 10-30-5].
cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised Tighten the nuts to 40 - 45 ft.-lb. (54 - 61 N•m) torque.
slightly from the latch to be able to release the
latch.
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On Advanced Control System (ACS) equipped

machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.
Support the cab and release the latching mechanism

(Inset) [Figure 10-30-4]. Remove your hand from
latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way.

29 of 861
OPERATOR CAB (CONT’D) Special Applications Kit
Cab Door Sensor Figure 10-30-7
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
B-15551j
B-25286A
2
1
Available for special applications to restrict material from
entering cab openings. Kit includes 1/2 in. polycarbonate
front door, top and rear windows. [Figure 10-30-7].
P-68116 P-68115
See your Bobcat dealer for availability.

The cab door (option) has a sensor (Item 1) [Figure 10- Special Applications Kit Inspection And Maintenance
30-6] installed which deactivates the lift and tilt valves
when the door is open. • Inspect for cracks or damage. Replace if required.
• Pre-rinse with water to remove gritty materials.
CLOSE DOOR TO OPERATE (Item 2) [Figure 10-30-6]
lift and tilt valves. • Wash with a mild household detergent and warm
water.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] • Use a sponge or soft cloth. Rinse well with water and
will be ON when the door is closed and the PRESS TO dry with a clean soft cloth or rubber squeegee.
OPERATE LOADER BUTTON is pressed. • Do not use abrasive or highly alkaline cleaners.
• Do not operate windshield wipers on a dry surface.
• Do not clean with metal blades or scrapers.

30 of 861
TRANSPORTING THE LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
P-31228 P-73276
W-2058-0807
Be sure the transport and towing vehicles are of

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

P-45989 P-45218C
Use the following procedure to fasten the Bobcat Loader

to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].
• Lower the bucket or attachment to the floor.

1
• Stop the engine.
• Engage the parking brake.
P-43631 P-45215C • Install chains at the front and rear loader tie down
positions [Figure 10-40-2]
• Fasten each end of the chain to the transport vehicle.
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1].
The rear of the trailer must be blocked or supported (Item

1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up.

31 of 861

32 of 861
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/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1 & 1/2

times the weight of the loader. (See Performance on
Page SPEC-10-2.)

33 of 861

34 of 861
REMOTE START TOOL KIT -MEL1563 Figure 10-60-2
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool 3
MEL1565 - Service Tool Harness Control 1
MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Figure 10-60-1
P16117
1
The traction lock switch (Item 1) [Figure 10-60-2] is used

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

The maximum flow/variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate maximum flow.
P16114 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF.
The remote start tool (Item 1) [Figure 10-60-1] is The switch is used when checking pressures and flow
required when the service technician is checking the rate.
hydraulic/hydrostatic system or adjusting the steering
linkage. The auxiliary pressure release (Item 3) [Figure 10-60-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.

35 of 861
REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565
Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5
Figure 10-60-3
2
1 1
P16114
P16116
The service tool harness control (Item 1) [Figure 10-60-
5] is used to connect the remote start tool (Item 2)
Figure 10-60-4 [Figure 10-60-5] to the electrical system on the loader.

1 Figure 10-60-6
P16120
N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the plug (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
The panel must be removed from inside the operator cab

and plugged into this connector [Figure 10-60-3].

36 of 861
REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566
Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-60-8
Figure 10-60-7 2
2
1
1
P16119
N-19631
The service tool harness communicator (Item 1) [Figure
10-60-8] is required to connect remote start tool to the
Loaders equipped with an attachment harness (Item 1) Service PC (Item 2) [Figure 10-60-8].
[Figure 10-60-7] must disconnect the attachment

harness from the loader harness (Item 2) [Figure 10-60-
7].
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 Switch.

37 of 861
REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-11
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit

1
Figure 10-60-9
N-19150
Remove the plug (Item 1) [Figure 10-60-10] or

disconnect the attachment control harness (Item 1)
[Figure 10-60-11] if connected.
Figure 10-60-12

P16115
The remote start tool (Item 1) [Figure 10-60-9] is

required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
P13861
Raise the operator cab (if required by the procedure).
Open the rear door of the loader. Connect the remote start tool to the engine harness
connector [Figure 10-60-12].
Figure 10-60-10
NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
1
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
N-19151
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899

38 of 861
REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-14
Remote Start Procedure (Cont'd)
Figure 10-60-13
2
3 1
P16118
The traction lock switch (Item 1) [Figure 10-60-14] is

P16116 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
The remote start tool (Item 1) [Figure 10-60-13] has able to turn.
three rocker switches.

The maximum flow/variable flow switch (Item 2) [Figure
10-60-14] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-14]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.

engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
WARNING
• 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.
• See Service Manual for more instruction.
W-2785-0209

39 of 861
REMOTE START TOOL KIT-MEL1563 (CONT'D)

engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.
Figure 10-60-15

P-34661
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-15].

40 of 861
REMOTE START TOOL (SERVICE TOOL) KIT -
6689779
Description
The Remote Start Tool (Service Tool) Kit is a replacement

tool for MEL 1563 Remote Start Tool and MEL 1400B -
BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 6689779,

can be used to service older loaders with the BOSS®
system using the supplied BOSS® Service Tool Harness
P/N 6689745.
The Remote Start Tool (Service Tool) Kit, P/N 6689779,

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.

41 of 861
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-17
6689779 (CONT'D)
2
Remote Start Tool (Service Tool) - 6689778
Tools that will be needed to complete the following steps

5 3
are:
Order from Bobcat Parts P/N: 6689779 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
6689778 - Remote Start Tool (Service Tool) 1
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-61-16
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-17] has five buttons.
The STOP button (Item 2) [Figure 10-61-17] is used to

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

The RUN button (Item 3) [Figure 10-61-17] is used to
turn the Remote Start Tool (Service Tool) on and
1 activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The START button (Item 4) [Figure 10-61-17] is used to

start the loader engine.
P-76678
The traction lock button (Item 5) [Figure 10-61-17] is

used to turn traction lock ON or OFF. Push the button and
The remote start tool (Item 1) [Figure 10-61-16] is the button will illuminate indicating the traction lock is
required when the service technician is checking the disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system or adjusting the steering
linkage. Loader S/N: xxxx60000 & Below
The auxiliary button (Item 6) [Figure 10-61-17] is used to

activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button once will activate maximum flow. Pressing the
button again will activate variable flow. Pressing the
button a third time will turn the flow OFF. The button is
used when checking pressures and flow rate.
Loader S/N: xxxx60001 & Above
The auxiliary button (Item 6) [Figure 10-61-17] is used to

activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

42 of 861
6689779 (CONT'D)
Loader Service Tool Harness - 6689747 2
Figure 10-61-18
P-76452
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
10-61-20].
The loader service tool harness (Item 1) [Figure 10-61- When the remote start procedure is completed, replace

18] is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-19] or
(Item 2) [Figure 10-61-18] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-20].
Figure 10-61-19
P-76451
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-19] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

43 of 861
REMOTE START TOOL (SERVICE TOOL) KIT - NOTE: The right instrument panel (Key Switch or
6689779 (CONT'D) Keyless) must be in the off position or the
Remote Start Tool (Service Tool) will not
Loader Service Tool Harness - 6689747 (Cont’d) operate.
Figure 10-61-21
2
WARNING
1 AVOID INJURY OR DEATH
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
3 instructions.
1 W-2792-0409
P-76453 Computer Service Tool Harness - 6689746
Figure 10-61-22
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item

1) and (Item 3). The main connector (Item 1)
[Figure 10-61-21] is always used for
connection to the loader harness. 1
The second connector (Item 3) [Figure 10-61-
21] 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 2
ACD harness connector (Item 3) [Figure 10-61-21]. P-76450
The computer service tool harness (Item 1) [Figure 10-

61-22] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-22].

44 of 861
6689779 (CONT'D)
Remote Start Procedure
WARNING
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
Pressing the RUN button on the Remote Start Tool P-76451
disconnects the operator panel from the start circuit.

If the service technician will be working in the engine
Loaders without an attachment control harness, remove
area it is important to remove the operator panel key
the loader harness cap (Item 1) [Figure 10-61-24] and
or lock the keypad with a unique password.
W-2647-0707
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
The tool listed will be needed to do the following Figure 10-61-25

procedure:
6689779: Remote Start Tool (Service Tool) Kit 2
Figure 10-61-23
1
1
P-76452
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76450 disconnected from the loader harness (Item 2) [Figure
10-61-25].
The Remote Start Tool (Service Tool) (Item 1) [Figure 10- When the remote start procedure is completed, replace
61-23] is required when the operator cab is in the raised the loader connector cap (Item 1) [Figure 10-61-25] or
position for service and the service technician needs to reconnect the attachment control harness to the loader
turn on the loader or start the engine. Example: adjusting harness [Figure 10-61-25].
the steering linkage.
Lift and block the loader.

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

45 of 861
6689779 (CONT'D)
2
Figure 10-61-26
5 3
2
6 4
1
P-76439
3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-27] has five buttons.
P-76453
The STOP button (Item 2) [Figure 10-61-27] 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 10-61-27] is used to
[Figure 10-61-26] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
26] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-27] 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 10-61-27] 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 10-61-26]. Loader S/N: xxxx60000 & Below
NOTE: The right instrument panel (Key Switch or The auxiliary button (Item 6) [Figure 10-61-27] is used to
Keyless) must be in the off position or the activate the auxiliary hydraulics. The button will illuminate
Remote Start Tool (Service Tool) will not to indicate the auxiliary hydraulics are active. Pressing
operate.
the button once will activate maximum flow. Pressing the
button again will activate variable flow. Pressing the
button a third time will turn the flow OFF. The button is
WARNING used when checking pressures and flow rate.

• Lift and block the machine. The auxiliary button (Item 6) [Figure 10-61-27] is used to
• Check that wheels or tracks are clear. activate the auxiliary hydraulics. The button will illuminate
• Cab ignition must be in the “STOP” position to to indicate the auxiliary hydraulics are active. Pressing
start the engine with the Service Tool (if the button a second time will turn the flow OFF. The
applicable). button is used when checking pressures and flow rate.
• See machine Service Manual for more
instructions.
W-2792-0409

46 of 861
6689779 (CONT'D)
Figure 10-61-28
1 2
P-34661
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-29].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-28] 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 10-61-28] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
Loader S/N: xxxx60000 & Below
NOTE: To relieve the pressure at the rear or

secondary front auxiliary, (if equipped) press
and hold the AUXILIARY PRESSURE
RELEASE button on the left instrument panel
for three seconds after the engine has
stopped.
NOTE: To relieve the pressure at the rear or

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

47 of 861

48 of 861
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Loader.
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
WARNING 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-2003-0903
SERVICE SCHEDULE HOURS

■ ■ ■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on the sidewall of the tire.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.

Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS) bar raised. See details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
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.
Heater and A/C Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE ❏
MAINTENANCE in this manual.)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲
Drive Belts (Alternator, air Check condition and tension. Adjust or replace as needed.
conditioner, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. ▲ ✶
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ●
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ▲
Engine Valves Adjust the engine valves. ❍
Coolant Replace the coolant Every 2 years
■ Or every 12 months.
▲ Perform at first 50 hours, then as scheduled.
❏ Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
● Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when the transmission warning light
comes ON while operating or as scheduled.
✶ Change oil and filter every 100 hours when operating under severe conditions.
❍ Perform at first 500 hours, then as scheduled.

49 of 861

50 of 861
AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-3
Figure 10-80-1
1
1
P-76732
B-15552G B-15553G
Remove the wing nut (Item 1) [Figure 10-80-3] and

It is important to change the air filter element only when remove the dust cover.
the Air Cleaner Icon in the right panel is ON (Item 1)
[Figure 10-80-1] and you hear three beeps from the Figure 10-80-4

alarm.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
1
Figure 10-80-2
P-76730
1
Remove the wing nut and pull the outer filter element
(Item 1) [Figure 10-80-4] out and discard.
NOTE: Make sure all sealing surfaces are free of dirt

B-15551
and debris. Do not use air pressure to clean.
Press and hold the LIGHT Button (Item 1) [Figure 10-80- Install a new outer element.
2] for two seconds.
Install the dust cover and the wing nut [Figure 10-80-3].
If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER / Check the air intake hose and the air cleaner housing for
CODE DISPLAY (Item 2) [Figure 10-80-2]. damage. Make sure all connections are tight.

51 of 861
AIR CLEANER SERVICE (CONT’D) Figure 10-80-6
Replacing Filter Elements (Cont’d)
Inner Filter
Only replace the inner filter element under the following

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

outer filter is replaced.
• After the outer element has been replaced, start the
engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
P-76732
Figure 10-80-5
Install the dust cover and the wing nut [Figure 10-80-6]

P-76731
Remove the inner filter element (Item 1) [Figure 10-80-

5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install the new inner element.
Install the outer element.

52 of 861
ENGINE COOLING SYSTEM Figure 10-90-2
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage. 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. P-45224D
W-2019-0907
Cleaning NOTE: All access covers (Item 1) [Figure 10-90-2]

(both sides) must be in place to ensure
Open the rear door and remove the rear grill. (See correct air flow through the oil cooler which
Removal And Installation on Page 50-60-1.) will ensure cooling for engine and hydraulic
system.
Figure 10-90-1

1
P-45101
Use low air pressure or water pressure to clean the top of

the oil cooler (Item 1) [Figure 10-90-1].
NOTE: Be careful when raising and lowering the oil

cooler so that the oil cooler does not fall on
the radiator and damage the fins.
Raise the oil cooler (Item 1) and use low air pressure or
water pressure to clean the top of the radiator (Item 2)
[Figure 10-90-3].
Lower the oil cooler.
Lower the air conditioning condenser, if equipped.
Check the cooling system for leaks.
Lower the rear grill and close the rear door.

53 of 861
ENGINE COOLING SYSTEM (CONT’D) Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Checking Level damage.
Open the rear door and raise the rear grill. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Figure 10-90-3 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
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank. See Checking Level.
1
3 One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34° F (-37°C) freeze protection.
2
Fill the tank until it is at the lower marker on the tank and
P-54299 P-76738
replace the coolant fill cap.
NOTE: When installing the coolant fill cap, the cap

Check coolant level. The level markers are on the tank
(Item 2) [Figure 10-90-3]. Coolant must be at the bottom must be tightened until it clicks.
marker when the engine is cold; top marker when hot
Run the engine until it is at operating temperature. Stop
Close the rear door before operating the loader. the engine. Check the coolant level when cool. Use a
refractometer to check the condition of propylene glycol
Removing And Replacing Coolant in your cooling system. Add coolant as needed.
Open the rear door and remove the rear grill. Install the rear grill and close the rear door.
Remove the coolant fill cap (Item 1) [Figure 10-90-3].
Attach a hose to the coolant drain petcock (Item 3)

[Figure 10-90-3] located above the fuel filter. Open the
petcock and drain the coolant into a container. Recycle or
dispose of coolant in an environmentally safe manner.
Close the coolant drain petcock.
Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-4.)
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

54 of 861
FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE F (C) NO. 2 NO. 1 corrosion and plugging of fuel system components.
+15° (9°) 100% 0% • Use of biodiesel blend fuel may result in premature
Down to -20° (-29°) 50% 50% failure of fuel system components, such as plugged
Below -20° (-29°) 0% 100% fuel filters and deteriorated fuel lines.
• Shorter maintenance intervals may be required, such

At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
as cleaning the fuel system and replacing fuel filters
must be used in this machine.
and fuel lines.
The following fuels may be used in this machine:
• Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
deterioration of hoses, tubelines, injectors, injector
pump and seals.

• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low
Apply the following guidelines if biodiesel blend fuel is
sulfur petroleum based diesel. This is commonly
used:
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or
• Ensure the fuel tank is as full as possible at all times
EN590 (EU Standard) specifications.
to prevent moisture from collecting in the fuel tank.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel blend fuel can damage painted surfaces,

remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before

operating the machine.
• Do not exceed engine oil change interval. Extended

oil change intervals can cause engine damage.
• Before vehicle storage; drain the fuel tank, refill with

100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term

stability and should not be stored for more
than three months.

55 of 861
FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Open the rear door. B-15602
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].
1 Install and tighten the fuel fill cap (Item 1) [Figure 10-

100-1].
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
P-76799 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
Remove the fuel fill cap (Item 1) [Figure 10-100-1]. W-2103-0508

56 of 861
FUEL SYSTEM (CONT’D) Figure 10-100-4
Fuel Filter
For the service interval for removing water from, or
replacing the fuel filter (See SERVICE SCHEDULE on 1
Page 10-70-1.)
Removing Water
Figure 10-100-3
3
2
P-76735
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter

housing.
2 Squeeze the hand pump (priming bulb) (Item 2) [Figure

1 10-100-4] until fuel flows from the vent with no air
bubbles.
P-76734

Close the vent (Item 1) [Figure 10-100-4] on the fuel
Loosen the drain (Item 1) [Figure 10-100-3] at the filter housing.
bottom of the filter element to remove water from the
filter. Open the vent (Item 1) [Figure 10-100-4] on the fuel
injection pump.
Replacing Element
Remove the filter element (Item 2) [Figure 10-100-3]. Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until the pump feels solid.
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and Tighten the vent plug (Item 1) [Figure 10-100-4].
hand tighten.
Remove air from the fuel system. (See Removing Air Start the engine.
From The Fuel System below.)
It may be necessary to open the vent (Item 3) [Figure 10-
Removing Air From The Fuel System 100-4] briefly while engine is running. Close the vent
After replacing the filter element or when the fuel tank when the engine runs smoothly.
has run out of fuel, the air must be removed from the fuel
system before starting the engine.
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

57 of 861

58 of 861
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 for the work shift.
Figure 10-110-1
1
B-16320C
P-76736
Use a good quality motor oil that meets API Service
Classification of CI-4 or better See Oil Chart [Figure 10-

Park the machine on level ground. Open the rear door 110-2].
and remove the dipstick (Item 1) [Figure 10-110-1].
Install the dipstick and close the rear door.
Remove the oil fill cap (Item 2) [Figure 10-110-1] and
add oil as necessary.
Keep the oil level between the marks on the dipstick.

59 of 861
ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter

WARNING
For the service interval for replacing the engine oil and
filter. (See SERVICE SCHEDULE on Page 10-70-1.)
Run the engine until it is at operating temperature. Stop
the engine. sparks or lighted tobacco away from fuel and oil.
Figure 10-110-3 explosion or fire.
W-2103-0508
2
3
P-24679

P-76737
Open the rear door and remove the drain hose from its
storage position (Item 1) [Figure 10-110-3].
Remove the drain plug (Item 2) [Figure 10-110-3] and

drain the oil into a container and recycle or dispose of
used oil in an environmentally safe manner.
Reinstall the drain plug.

Remove the oil filter (Item 3) [Figure 10-110-3] and clean
the filter housing surface.
Use genuine Bobcat filter only.

Put oil on the new filter gasket, install the filter and hand
tighten.
Remove the fill cap (Item 3) [Figure 10-110-1].
Put oil in the engine. For the correct quantity (See

Capacities on Page SPEC-10-4). Install the fill cap. Do
not overfill.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 1) [Figure 10-110-1] and
check the oil level.
Add oil as needed if it is not at the top mark on the

dipstick.
Install the dipstick and close the rear door.

60 of 861
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-2
Use only recommended fluid in the hydraulic system.

(See HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-40-1.)
Put the loader on a level surface.
Lower the lift arms and tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-1
P-64023A
Use the correct hydraulic / hydrostatic fluid shown in

1 hydraulic / hydrostatic fluid chart [Figure 10-120-2].
2

P-45224A
P-45224C P-48011
Check the fluid level in the sight gauge (Item 1) [Figure 10-
120-1].
Open the rear door and raise the rear grill. Remove the
fill cap (Item 2) [Figure 10-120-1].
Add fluid as needed to bring the level to the center of the

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

61 of 861
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic / Hydrostatic
Filter
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE
See the SERVICE SCHEDULE for the service interval. SCHEDULE on Page 10-70-1.)
(See SERVICE SCHEDULE on Page 10-70-1.)
Open the rear door.
Replace the fluid if it becomes contaminated or after
major repair.
Figure 10-120-4
Always replace the hydraulic / hydrostatic filter, the
hydraulic case drain filters and the hydraulic charge filter
whenever the hydraulic fluid is replaced. (See Removing
And Replacing Hydraulic / Hydrostatic Filter on Page 10-
120-2.)
Open the rear door and remove the fill cap.
Figure 10-120-3
1
1
P-76800

Remove the filter element (Item 1) [Figure 10-120-4].
Clean the surface of the filter housing where the filter

seal contacts the housing.
P-24751
Put clean oil on the seal of the new filter element.
Raise the cab. (See Raising on Page 10-30-2.) Install and hand tighten the filter element.
Remove the plug from the top of the reservoir (Item 1)

[Figure 10-120-3]. Pump the fluid out of the reservoir
and into a container. WARNING
Recycle or dispose of the used fluid in an
environmentally safe manner. AVOID INJURY OR DEATH
sparks or lighted tobacco away from fuel and oil.
WARNING explosion or fire.
W-2103-0508

Always clean up spilled fuel or oil. Keep heat, flames, Close the rear door before operating the loader.
Failure to use care around combustibles can cause Start the engine and operate the loader hydraulic
explosion or fire. controls.
W-2103-0508
Stop the engine and check for leaks at the filter.
Lower the cab. (See Lowering on Page 10-30-3.)
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-30-1.)

62 of 861
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-6
Removing And Replacing Hydraulic Case Drain

Filters (Single Speed Loaders)
1
See the SERVICE SCHEDULE for the service interval.
Figure 10-120-5
Left Side Shown
P-45499 P-45493
Remove the case drain filter assemblies (Item 1) [Figure

10-120-6] near the hydrostatic motors. Install the fittings
from the old filter assembly onto the new filter assembly.
Install motor covers.
Recycle or dispose of used fluid in an environmentally
P-45492 safe manner.

Start the engine and operate the loader hydraulic
Remove both hydrostatic motor covers (Item 1) [Figure controls.
10-120-5].
Stop the engine and check for leaks at the filter
assemblies.

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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-8

Filters (Two-Speed Loaders)
Raise the lift arms. (See LIFT ARM SUPPORT DEVICE

on Page 10-20-1.) 1
DANGER
P-76168
Remove the case drain filter assembly (Item 1) [Figure

10-120-8]. Install the fittings from the old filter assembly
onto the new filter assembly.
P-90328
AVOID DEATH Install new case drain filter assembly and replace the
• Disconnecting or loosening any hydraulic side access cover.

Recycle or dispose of used fluid in an environmentally
safe manner.
unless supported by an approved lift arm SJC equipped machines skip ahead to [Figure 10-120-
support. Replace if damaged. 10].
D-1009-0409
Figure 10-120-9
Raise the cab. (See Raising on Page 10-30-2.)
Figure 10-120-7
2 2
1
1
1
P-76174
Scribe a mark across the top of the steering linkage bars

P-76171 (Item 1) [Figure 10-120-9] which are connected to the
steering shaft on the control panel.
Remove the left side access cover (Item 1) [Figure 10- Remove the four steering linkage mounting bolts (Item 2)
120-7] near the rear tire. [Figure 10-120-9].

64 of 861
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Filters (Two-Speed Loaders) (Cont’d) WARNING
Figure 10-120-10 AVOID INJURY OR DEATH
1 Use a piece of cardboard or wood to find leaks. Do
W-2072-0807
Stop the engine and check for leaks at the filter

assemblies.

P-76160
Remove the case drain filter assembly (Item 1) [Figure

10-120-10]. Install the fittings from the old filter assembly

onto the new filter assembly.
Install new case drain filter assembly.
WARNING
explosion or fire.
W-2103-0508
Standard Controls and ACS only: Align the marks on the

steering linkage bars. Install the steering linkage
mounting bolts (Item 2) in the proper orientation (two
bolts facing up and two bolts facing down). Tighten the
steering linkage mounting bolts to 35 - 40 ft.-lb. (47,5 -
54,2 N•m).
Recycle or dispose of the used fluid in an

environmentally safe manner.
Remove the lift arm support device and lower the lift arms
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Start the engine and operate the loader hydraulic

controls.

65 of 861
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Lower the operator cab. (See Lowering on Page 10-30-
3.)
Removing And Replacing Hydraulic Charge Filter
Start the engine and operate the loader. Stop the engine
See the SERVICE SCHEDULE for the service interval. and check for leaks at the filter.
Raise the cab. (See Raising on Page 10-30-2.) (See Checking And Adding Fluid on Page 10-120-1.)
Figure 10-120-11
P-64239
Remove the filter (Item 1) [Figure 10-120-11].

Clean the surface of the filter housing where the filter
seal contacts the housing.
Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.
WARNING
explosion or fire.
W-2103-0508
WARNING
W-2072-0807

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

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Raise the cab. (See Raising on Page 10-30-2.)
Figure 10-120-12

P-76673
Remove and discard the hydraulic breather cap (Item 1)

[Figure 10-120-12].
Install new breather.

67 of 861

68 of 861
FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil
Checking And Adding Oil Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the hydraulic / Figure 10-130-2
hydrostatic system (See Hydraulic System on Page
SPEC-10-3.)
Stop the loader on a level surface.
Stop the engine.
Figure 10-130-1
P-31287A
Use a pump to remove the oil from the chaincase [Figure

10-130-2].
Recycle or dispose of the used oil in an environmentally

safe manner.
P-31287
Remove the drain plug (Item 1) [Figure 10-130-1] from

the front of the chaincase housing.
If oil can be reached with the tip of the your finger through
the hole, the oil level is correct.
If the level is low, add lubricant through the check plug

hole until it reaches the desired level.
Install and tighten the plug.

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70 of 861
BOB-TACH (HAND LEVER) Figure 10-140-2
Inspection And Maintenance

1
Figure 10-140-1
Wedge must contact

lower edge of hole in the
attachment.
N-17022 B-15177
The wedges must extend through the holes in the

P-31693 attachment mounting frame (Item 2) [Figure 10-140-2].
The spring loaded wedge (Item 1) [Figure 10-140-2]

Move the Bob-Tach levers to engage the wedges [Figure must contact the lower edge of the hole in the attachment
10-140-1]. (Item 2) [Figure 10-140-2].

The levers and wedges must move freely. If the wedge does not contact the lower edge of the hole
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-140-3
Bob-Tach wedges must extend through the holes in

attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
B-17460
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.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on

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

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

1
Figure 10-141-1 2
Wedge must contact

lower edge of hole in the
attachment.
N-17022 B-15177
The wedges must extend through the holes in the

attachment mounting frame (Item 1) [Figure 10-141-2].
B-15993N
B-15891 The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
141-2].

Push and hold the BOB-TACH “WEDGES UP” switch
until wedges are fully raised. Push and hold the BOB- If the wedge does not contact the lower edge of the hole
TACH “WEDGES DOWN” switch [Figure 10-141-1] until [Figure 10-141-2], the attachment will be loose and can
the wedges are fully down. come off the Bob-Tach.
The levers and wedges must move freely.
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497

73 of 861
BOB-TACH (POWER) (CONT’D)
Inspection And Maintenance (Cont’d)
Figure 10-141-3
B-17460
Inspect the mounting frame on the attachment and the

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.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges. (See SERVICE SCHEDULE on

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

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LUBRICATING THE LOADER Figure 10-150-6
Lubrication Locations
Lubricate the loader as specified for the best

performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.) 3
Record the operating hours each time you lubricate the

Bobcat Loader.
Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader: P-43784
Figure 10-150-4
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-150-6].
Figure 10-150-7

1
P-43782
1. Rod End Lift Cylinder (Both Sides) [Figure 10-150-4].

N-18510
Figure 10-150-5
4. Base End Tilt Cylinder (Both Sides) [Figure 10-150-
7].
2
P-45257A
2. Base End Lift Cylinder (Both Sides) [Figure 10-150-

5].

75 of 861
LUBRICATING THE LOADER (CONT’D) Figure 10-150-10
Lubrication Locations (Cont’d)
Figure 10-150-8
8
5
6
P-45497
8. 250 Hours: Steering Lever Shaft (2) [Figure 10-150-

N-18509 10].
5. Rod End Tilt Cylinder (Both Sides) [Figure 10-150-8].

6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-150-8].
Figure 10-150-9
P-24699
7. Bob-Tach Wedge (Both Sides) [Figure 10-150-9].

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TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-160-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for correct pressure before operating
the loader.
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.
P-45220 The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a

See the SERVICE SCHEDULE for the service interval to rubber lubricant before mounting the tire.
check the wheel nuts [Figure 10-160-1]. (See SERVICE
SCHEDULE on Page 10-70-1.)

Avoid excessive pressure which can rupture the tire and
When installing wheel nuts, tighten to 160 ft.-lb. (217 cause serious injury or death.
N•m) torque.
During inflation of the tire, check the tire pressure
When checking wheel nut torque, set the torque wrench frequently to avoid over inflation.
to 140 ft.-lb. (190 N•m) to prevent over-tightening.
Rotating
WARNING
Check the tires regularly for wear, damage and pressure.
Inflate tires to the maximum pressure shown on the AVOID INJURY OR DEATH
sidewall of the tire.
Do not inflate tires above specified pressure. Failure
Figure 10-160-2 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 loader.
I-2057-0794
B-9976
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].

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SPARK ARRESTOR MUFFLER
Cleaning Procedure
WARNING
Use the correct service interval for cleaning the spark
arrestor muffler. (See SERVICE SCHEDULE on Page
When the engine is running during service, the
10-70-1.)
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Do not operate the loader with a defective exhaust
death.
system. W-2006-0284
Start the engine and run for about 10 seconds while a

second person, wearing safety goggles, holds a piece of
IMPORTANT wood over the outlet of the muffler.
This will force contaminants out through the cleanout

This loader is factory equipped with a U.S.D.A.
hole.
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark Stop the engine.
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping Install and tighten the plug.
the spark chamber every 100 hours of operation.
If this machine is operated on flammable forest,

brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
WARNING
be in violation of California State Law, Section 4442
PRC. AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
Consult local laws and regulations for spark arrestor air must be added to avoid concentration of exhaust
requirements fumes. If the engine is stationary, vent the exhaust
I-2022-0807 outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Stop the engine and open the rear door.
Figure 10-170-1
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
P-76801
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-170-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285

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PIVOT PINS
Figure 10-180-1
P-43783
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-180-1].

Check that the lock nuts are tightened to 35 - 40 ft.-lb. (48
- 54 N•m) torque.

81 of 861

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

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
Loader for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
• 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 place.
• 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 • Remove cover from exhaust pipe opening.
tires.
• Start the engine and let run for a few minutes while
• Put grease on any exposed cylinder rods. observing the instrument panels and systems for
correct operation.
• Put fuel stabilizer in the fuel tank and run the engine
• Operate machine, check for correct function.
a few minutes to circulate the stabilizer to the pump
• Stop the engine and check for leaks. Repair as

and fuel injectors.
needed.
If biodiesel blend fuel has been used, perform the
following:
Drain the fuel tank, refill with 100% petroleum diesel

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

premixed coolant.
• Replace all fluids and filters (engine, hyd. / hydro.).

• Replace air cleaner, heater and air conditioning filters.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is
correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage
condition.

83 of 861

84 of 861
STOPPING THE ENGINE AND LEAVING THE Figure 10-200-3
LOADER
Procedure
Stop the Bobcat Loader on level ground.
Lower the lift arms fully and put the attachment flat on the
ground [Figure 10-200-3].
Figure 10-200-1
P-66667 P-66668
Exit the loader using grab handles, safety tread and

steps (maintaining a 3-point contact) [Figure 10-200-2].
WARNING

P-31864
Before you leave the operator’s seat:

Pull the engine speed control fully backward [Figure 10- • Lower the lift arms, put the attachment flat on the
200-1] to decrease the engine speed. ground.
• Stop the engine.
Figure 10-200-2 • Engage the parking brake.
• Raise seat bar.
• (Foot Pedal Controls) Move pedals until both
lock.
• (Advanced Control System-ACS) Move the
hydraulic controls to the NEUTRAL POSITION to
make sure that both lift and tilt functions are
deactivated.
The seat bar system must deactivate the lift and
tilt control functions when the seat bar is up.
Service the system if hand controls do not
2
deactivate.
• (Selectable Joystick Controls-SJC) Move the
joysticks to the NEUTRAL POSITION to make
1 sure that travel and hydraulic functions are
B-15552G B-15553G
deactivated.
The seat bar system must deactivate these
Engage the parking brake. functions when the seat bar is up. Service the
system if controls do not deactivate.
Turn the key switch to the STOP position (Item 1) (Key W-2463-0603
Switch) or press the STOP button (Item 2) [Figure 10-
200-2] (Keyless).
Lift the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.
Remove the key from the switch (Key Switch) to prevent
operation of the loader by unauthorized personnel.

85 of 861
STOPPING THE ENGINE AND LEAVING THE Front Door (If Equipped)
LOADER (CONT’D)
NOTE: When an Operator Cab Enclosure Kit is
Emergency Exit installed, the window of the front door can be
used as an emergency exit. [Figure 10-200-6]
The front opening on the operator cab and rear window
provide exits. NOTE: If the loader has a Special Application Door
Kit installed, the window of the front door is
Rear Window (If Equipped) NOT an emergency exit.
Figure 10-200-4 Figure 10-200-6

P-64994
N-20171
Pull on the tag on the top of the rear window to remove Pull the plastic loop at the top of the window in the front
the rubber cord [Figure 10-200-4]. door to remove the rubber cord [Figure 10-200-6].
Push the rear window out of the rear of the operator cab. Figure 10-200-7
Figure 10-200-5
X X
X X
P-24472
6707852
P-45260
Push the window out with your foot [Figure 10-200-7] at
any corner of the window.
Exit through the rear of the operator cab [Figure 10-200-
5]. Exit through the front door.

86 of 861
HYDRAULIC SYSTEM
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 HYDRAULIC
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3 SAFETY
SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2 DRIVE
SYSTEM
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

ELECTRICAL
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 SYSTEM &
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3 ANALYSIS
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
ENGINE
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SERVICE
Base End Pivot Pin Removal and Installation . . . . . . . . . . . . . . . . . 20-21-3
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2 SPECIFICATIONS
Rod End Pivot Pin Bushing And Seal Removal And Installation . . . 20-21-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 20-150-2
High Flow Relief Valve Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3

87 of 861
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1

Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . . . . . . . . .20-41-6
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . .20-41-12
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-25
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-24
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-16
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-9
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . .20-41-30
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .20-41-10
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . 20-41-11
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-28
Main Relief Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-31
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-10
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-15
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . 20-41-13
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . .20-41-13
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . .20-41-14

Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-26
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-22
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1

Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . .20-40-9
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-28
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
End Cap/Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . . .20-40-14
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-6
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . .20-40-33
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .20-40-7
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . .20-40-8
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-31
Main Relief Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-33
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-7
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-12
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End) . .20-40-10
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) . . . 20-40-11
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-13
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-25

88 of 861
HYDRAULIC/HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Charge Filter Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 20-80-3
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
HYDRAULIC PUMP (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Pump Test at Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

HYDRAULIC PUMP (STANDARD) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9

89 of 861
HYDRAULIC PUMP (SJC) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-11
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-10
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY

VARY.

90 of 861
HYDRAULIC/HYDROSTATIC
SCHEMATIC
S150 (S/N A3L111001 – A3L119999)
Printable Version Click Here
(PRINTED FEBRUARY 2008)

V-1058legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 44 PILOT ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM CONTROL VALVE - HYDRAULIC
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) POWERED BOB-TACH
2 SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 45 RESTRICTION - 0.089 inch (2,26 mm)
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - BICS CONTROL 32 FILTER - CASE DRAIN (SINTERED
36-44 PSI (2,5-3,0 Bar) BRONZE) 46 RESTRICTION - 0.025 inch (0,6 mm)
17 PILOTED ACTIVATED DIRECTIONAL
Normally Closed
CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE 47 RELIEF VALVE - 2000 PSI (137 Bar)
4 DRIVE MOTOR SHUTTLE VALVE (SCREEN)
5 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - LIFT CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
34 CHECK VALVE - BUCKET POSITION
PRESSURE: 5000 PSI (345 Bar) 19 PULL BUTTON ACTIVATED VALVE
49 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT
6 RELIEF VALVE - CHARGE INLET: 35 RESTRICTION CONTROL VALVE (TWO COIL)
ARM BY-PASS
360 PSI (24,8 Bar) 50 FIXED CAPACITY DISPLACEMENT
at High Engine Idle 20 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
36 VARIABLE CAPACITY DISPLACEMENT HYDRAULIC MOTOR - FAN
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - UNLOADING
BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 51 ANTICAVITATION VALVE
7 FRONT AUXILIARY MANUAL PRESSURE 37 SHUTTLE RELIEF VALVE
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL (Not Adjustable - Factory Set) 52 PROPORTIONAL RELIEF VALVE –
SPOOL 65 PSI (4,5 Bar) (Fan Speed Regulator):
8 HYDRAULIC PUMP . . . . . . . Gear Type 1566 - 1784 PSI (108 - 123 bar)
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT
53 FILTER - BOB-TACH VALVE
BIDIRECTIONAL HYDROSTATIC
9 RELIEF VALVE - MAIN: MOTOR 54
23 SOLENOID ACTIVATED DIRECTIONAL RESTRICTION - 0.343 inch (8,73 mm)
3250-3350 PSI (224-231 Bar)
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
at Front Quick Couplers 55 SENSOR – CHARGE PRESSURE – Fan
24 SOLENOID ACTIVATED DIRECTIONAL Filter
10 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL
PORT 3500 PSI (241,3 Bar) 56 SENSOR – HYD. TEMP. – Hyd. Filter
CONTROL VALVE - BUCKET POSITION
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF)
26 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE

CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
42 CHARGE PUMP -
13 RELIEF/ANTICAVITATION VALVE - 27 PILOT ACTIVATED DIRECTIONAL 12.8 GPM (48,5 L/min) at High Engine Idle
PORT (OPTIONAL) 3500 PSI (241,3 Bar) CONTROL VALVE - REAR AUXILIARY
28 43 CHECK VALVE - With 300 PSI (20,7 Bar)
RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE Spring And With 0.016 inch (0,40 mm) Orifice
29 RESTRICTOR - 0.031 inch (0,8 mm) NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-1058legend (2-7-08)

91 of 861
(REAR QUICK
FEMALE COUPLERS) MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
S150 (S/N A3L111001 - A3L119999)
BASE ROD REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK
(PRINTED FEBRUARY 2008) 23 24 COUPLER BLOCK
V-1058 25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
32 BUCKET POSITION VALVE (OPTIONAL)
38
D
HYDRAULIC FILTER 34
31
OIL
56 2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
13
20
AUXILIARY
CHARGE
54
INLET Dealer Copy -- Not for Resale
12
SPOOL
12
13 B
B A
31
55
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
3 2
8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
52 51 POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
LIFT ARM BY PASS VALVE
32
19
Printed in U.S.A. V-1058 (2-7-08)
92 of 861
WITH 2 SPEED OPTION
S150 (S/N A3L111001 – A3L119999)

V-1059legend
LEGEND
1 RESERVOIR: 15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar) 47 RELIEF VALVE - 2000 PSI (137 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) 48 RELIEF VALVE - 1200 PSI (83 Bar)
2 SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (3,1-3,8 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: BRONZE) CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 Bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE 50 FIXED CAPACITY DISPLACEMENT
Normally Closed
CONTROL VALVE - TILT CONTROL (SCREEN) HYDRAULIC MOTOR - FAN
4 DRIVE MOTOR SHUTTLE VALVE
18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION 51 ANTICAVITATION VALVE
5 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - LIFT CONTROL VALVE
PRESSURE: 5000 PSI (345 Bar) 19 PULL BUTTON ACTIVATED 35 52 PROPORTIONAL RELIEF VALVE –
RESTRICTION
DIRECTIONAL CONTROL VALVE - LIFT (Fan Speed Regulator):
6 RELIEF VALVE - CHARGE INLET: ARM BY-PASS 1566 - 1784 PSI (108 - 123 bar)
VARIABLE CAPACITY DISPLACEMENT
36
360 PSI (24,8 Bar)
at High Engine Idle 20 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not BIDIRECTIONAL
for Resale HYDROSTATIC PUMP 53 FILTER - BOB-TACH VALVE
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - UNLOADING 37 CHECK VALVE - With 5 PSI (0,34 Bar) Spring 54 RESTRICTION - 0.343 inch (8,73 mm)
SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 21 PILOTED ACTIVATED DIRECTIONAL 38 BIDIRECTIONAL HYDROSTATIC 55 SENSOR – CHARGE PRESSURE – Fan
BLEED-OFF VALVE CONTROL VALVE - FLOW CONTROL MOTOR – 2 SPEED Filter
SPOOL 56 SENSOR – HYD. TEMP. – Hyd. Filter
8 HYDRAULIC PUMP . . . . . . . Gear Type 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
16.9 GPM (64 L/min.) at High Engine Idle 22 FLOW DIVIDER ADJUSTMENT VALVE
40 SOLENOID ACTIVATED DIRECTIONAL 57 HIGH PRESSURE SHUTTLE
9 RELIEF VALVE - MAIN: CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 Bar) VALVE (ON/OFF) 58 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BASE
at Front Quick Couplers CONTROL VALVE – WARM UP
41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL 59
10 RELIEF/ANTICAVITATION VALVE - SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD
PORT 3500 PSI (241,3 Bar) 42 CHARGE PUMP - CONTROL VALVE – 2 SPEED
12.8 GPM (48,5 L/min) at High Engine Idle
11 ANTICAVITATION VALVE 25 LOAD SHUTTLE VALVE - BLEED OFF 60 PILOT ACTIVATED DIRECTIONAL
43 CHECK VALVE - With 300 PSI (20,7 Bar) CONTROL VALVE – HIGH / LO SPEED
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL Spring And With 0.016 inch (0,40 mm) Orifice 61 RELIEF VALVE – With 125 PSI (8,6 bar)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL Spring
44 PILOT ACTIVATED DIRECTIONAL
13 RELIEF/ANTICAVITATION VALVE - 27 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC
PORT (OPTIONAL) 3500 PSI (241,3 Bar) CONTROL VALVE - REAR AUXILIARY POWERED BOB-TACH
28 RESTRICTOR - 0.140 inch (3,6 mm) 45 RESTRICTION - 0.089 inch (2,26 mm)
14 LOAD CHECK VALVE
29 RESTRICTOR - 0.031 inch (0,8 mm) 46 RESTRICTION - 0.025 inch (0,6 mm)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-1059legend (2-7-08)
93 of 861
(REAR QUICK
WITH 2 SPEED OPTION
S150 (S/N A3L111001 – A3L119999) BASE ROD REAR AUX VALVE (OPTIONAL)

INTEGRATED QUICK
(PRINTED FEBRUARY 2008) COUPLER BLOCK
23 24
V-1059
25 MALE
26
DRIVE MOTOR MALE
(2 SPEED) 38
29
4 1 30
61 FEMALE
27
57
P-OUT P-IN T

60
D
HYDRAULIC FILTER 34
31
OIL
56 2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
13
20
AUXILIARY
CHARGE
INLET Dealer Copy -- Not for Resale
12
SPOOL
12
13 B
B A
54
31
3
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
55 2
8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
52 51 POWERED 14
BOB-TACH LIFT CYLINDERS
DRIVE MOTOR (OPTIONAL) 10
(2 SPEED) 18
38 39
DR B A
60 13 LIFT
58 37 CYLINDER
43 SPOOL
48 46 15 33 33
47 41 35
49 45
PP
14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
57 DRAIN CIRCUITS
P1 P2
COMPONENTS
44
59 LIFT ARM BY PASS VALVE

32
19
4
61
V-1059 (2-7-08)
Printed in U.S.A.
94 of 861
WITH SJC OPTION
S150 (S/N A3L111001 – A3L119999)

V-1060legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE 50 FIXED CAPACITY DISPLACEMENT
19 PULL BUTTON ACTIVATED HYDRAULIC MOTOR - FAN
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 51 ANTICAVITATION VALVE
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 52 PROPORTIONAL RELIEF VALVE –
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL (Fan Speed Regulator):
BI-DIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 1566 - 1784 PSI (108 - 123 bar)
6 RELIEF VALVE - CHARGE INLET: SPOOL 37
SHUTTLE RELIEF VALVE
360 PSI (24,8 bar) (Not Adjustable - Factory Set) 53 CHARGE PUMP -
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL 65 PSI (4,5 bar) 12.8 GPM (48,5 L/min) at High Engine Idle
CONTROL VALVE - FLOW CONTROL
With 140 degrees F. (60 degrees C.) Fluid
SPOOL 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL with 0.016 inch (0,40 mm) orifice
22 FLOW DIVIDER ADJUSTMENT VALVE BI-DIRECTIONAL HYDROSTATIC
PRESSURE BLEED-OFF VALVE MOTOR 55 SOLENOID ACTIVATED CONTROL
8 VALVE - FORWARD/REVERSE
HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 56 SERVO PISTON -Swash Plate
16.9 GPM (64 L/min.) at High Engine Idle
40 SOLENOID ACTIVATED DIRECTIONAL 57 POSITION SENSOR -Swash Plate
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 bar) 58 CHARGE PRESSURE SENSOR
VALVE (ON/OFF)
at Front Quick Couplers
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE
10 PORT RELIEF/ANTICAVITATION VALVE 59 SENSOR – CHARGE PRESSURE – Fan
3500 PSI (241,3 bar) 26 Filter
SOLENOID ACTIVATED DIRECTIONAL
42 RESTRICTION - 0.343 inch (8,7 mm) 60 SENSOR – HYD. TEMP. – Hyd. Filter
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 FILTER - Bob-Tach Valve
CONTROL VALVE - AUXILIARY
28 RESTRICTOR - 0.140 inch (3,6 mm)
13 PORT RELIEF/ANTICAVITATION VALVE: 44 PILOT ACTIVATED DIRECTIONAL
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) CONTROL VALVE - HYDRAULIC
3500 PSI (241,3 bar) POWERED BOB-TACH
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 45 RESTRICTION - 0.089 inch (2,26 mm)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 46 RESTRICTION - 0.025 inch (0,6 mm)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-1060legend (2-7-08)
Printed in U.S.A.
95 of 861
(REAR QUICK
WITH SJC OPTION
(PRINTED FEBRUARY 2008) INTEGRATED QUICK

(V-1069) 23 24 COUPLER BLOCK
25 MALE
Printable Version Click Here 26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
38 HYDRAULIC FILTER 34
31
B HYDROSTATIC PUMPS A OIL

60 22
2 COOLER
55
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
57 14
36
10 TILT CYLINDERS
59 BICS CONTROL VALVE
31
5 56 5
55
3 2
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
50 LIFT CYLINDERS
52 51 53 10
FAN MOTOR OUTLET 18
HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P2 LIFT ARM BY PASS VALVE
P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-1060 (2-7-08)
96 of 861
WITH SJC & 2 SPEED OPTION
S150 (S/N A3L111001 – A3L119999)

V-1061legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 50 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE) HYDRAULIC MOTOR - FAN
2 SPRING LOADED FILTER BY-PASS 51 ANTICAVITATION VALVE
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 52 PROPORTIONAL RELIEF VALVE –
3 DIFFERENTIAL PRESSURE SWITCH: (Fan Speed Regulator):
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION 1566 - 1784 PSI (108 - 123 bar)
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE
19 PULL BUTTON ACTIVATED 53 CHARGE PUMP -
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION
DIRECTIONAL CONTROL VALVE - 12.8 GPM (48,5 L/min) at High Engine Idle
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 36 VARIABLE CAPACITY DISPLACEMENT 54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
CONTROL VALVE - UNLOADING 37 CHECK VALVE - With 5 PSI (0,34 Bar) Spring 55 SOLENOID ACTIVATED CONTROL
6 RELIEF VALVE - CHARGE INLET: SPOOL VALVE - FORWARD/REVERSE
360 PSI (24,8 bar) 38 BI-DIRECTIONAL HYDROSTATIC 56 SERVO PISTON -Swash Plate
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
Dealer Copy -- NotMOTOR
for Resale
– 2 SPEED
With 140 degrees F. (60 degrees C.) Fluid 57 POSITION SENSOR -Swash Plate
SPOOL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
7 FRONT AUXILIARY MANUAL 22 FLOW DIVIDER ADJUSTMENT VALVE 58 CHARGE PRESSURE SENSOR
PRESSURE BLEED-OFF VALVE 40 SOLENOID ACTIVATED DIRECTIONAL
8 HYDRAULIC PUMP . . . . . . . Gear Type CONTROL VALVE - BUCKET POSITION 59 SENSOR – CHARGE PRESSURE – Fan
23 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
16.9 GPM (64 L/min.) at High Engine Idle Filter
41 CHECK VALVE - BICS CONTROL VALVE 60 SENSOR – HYD. TEMP. – Hyd. Filter
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD
42 RESTRICTION - 0.343 inch (8,7 mm) 61
at Front Quick Couplers HIGH PRESSURE SHUTTLE
25 LOAD SHUTTLE VALVE - BLEED OFF
10 PORT RELIEF/ANTICAVITATION VALVE 43 FILTER - Bob-Tach Valve 62 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,3 bar) 26 CONTROL VALVE – WARM-UP
SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 44 PILOT ACTIVATED DIRECTIONAL 63 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC CONTROL VALVE – 2 SPEED
POWERED BOB-TACH
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 64 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 45 RESTRICTION - 0.089 inch (2,26 mm) CONTROL VALVE – HIGH / LOW SPEED
28 RESTRICTOR - 0.140 inch (3,6 mm)
13 PORT RELIEF/ANTICAVITATION VALVE: 65 RELIEF VALVE – With 125 PSI (8,6 bar) Spring
46 RESTRICTION - 0.025 inch (0,6 mm)
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm)
3500 PSI (241,3 bar)
47 RELIEF VALVE - 2000 PSI (137 bar)
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar)
48 RELIEF VALVE - 1200 PSI (83 bar)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER)
RESTRICT FLOW DURING BOOM 49 SOLENOID ACTIVATED DIRECTIONAL NO significant pressure value.
DOWN BUT NOT DURING BOOM UP CONTROL VALVE (TWO COIL)
V-1061legend (2-7-08)
Printed in U.S.A.
97 of 861
(REAR QUICK
WITH SJC & 2 SPEED OPTION

(V-1061) INTEGRATED QUICK
23 24 COUPLER BLOCK
Printable Version Click Here MALE
25
26
DRIVE MOTOR (2 SPEED) 28 7 (FRONT AUXILIARY

MALE
4 29
65 38 1 30
FEMALE
27
61
P-OUT P-IN T
64 32 BUCKET POSITION VALVE (OPTIONAL)
D
HYDRAULIC FILTER 34
31
B HYDROSTATIC PUMPS A OIL

60 22
2 COOLER
55
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
57 14
36
3 10 TILT CYLINDERS
31 BICS CONTROL VALVE
5 56 5
59 55
2
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
50 LIFT CYLINDERS
52 51
53 OUTLET 10
FAN MOTOR 18
HYDRAULIC
POWERED B A LIFT
DRIVE MOTOR (2 SPEED) BOB-TACH
38 SPOOL
(OPTIONAL)
64 35
39 47
62 37 15
DR
14
54
48 33 41
46 33 16
9
49 45
PP
61 43
P2 LIFT ARM BY PASS VALVE
P1
44 19
63
4
65
32 V-1061 (2-7-08)
Printed in U.S.A.
98 of 861
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.

99 of 861
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).

100 of 861

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

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

RETURN VALVE- It is possible to MANUALLY ACTIVATED
open the valve by pilot pressure. DIRECTION CONTROL VALVE
T
OUT IN
(Variable Position) Joystick
P
Controlled, variable pressure to shift
the pilot activated directional control
SHUTTLE VALVE - The Inlet port
valve spool.
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
FRON T
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.

101 of 861

PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

102 of 861
HYDRAULIC 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
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light come ON when hydraulics are operating. 1, 3
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, 5, 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 is in neutral position 4, 9, 10, 11
Bypass valve stuck 12
Bypass valve stem bent or broke 13

KEY TO CORRECT CAUSE
1. The fluid level is not correct.

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

103 of 861

104 of 861
CYLINDER (LIFT) Figure 20-20-2
Testing
WARNING
Failure to use care around combustibles can cause 2
explosion or fire. 1
W-2103-0508
P-45266
WARNING Install a plug in the hose (Item 1) [Figure 20-20-2] and

tighten.
AVOID INJURY OR DEATH Engage the parking brake. Lower the seat bar. Start the
Diesel fuel or hydraulic fluid under pressure can engine. Press the PRESS TO OPERATE BUTTON. Push
penetrate skin or eyes, causing serious injury or the top (toe) of the lift pedal or move left hand lever

death. Fluid leaks under pressure may not be visible. towards the operator.
not use your bare hand. Wear safety goggles. If fluid If there is any leakage from the base end cylinder port
enters skin or eyes, get immediate medical attention (Item 2) [Figure 20-20-2], remove the lift cylinder for
from a physician familiar with this injury. repair.
W-2072-0807
Repeat the procedure to check the other lift cylinder.
Figure 20-20-1
P-45265
Lower the lift arms. Stop the engine. Pull up on the lift
arm bypass control. Raise the seat bar.
Check only one cylinder at a time.
Disconnect the hose (Item 1) [Figure 20-20-1] from the

lift cylinder base end port.

105 of 861
CYLINDER (LIFT) (CONT’D) Figure 20-20-5
Removal And Installation
Figure 20-20-3
P-45268
Remove the lift arm pivot pin (Item 1) [Figure 20-20-5]

P-45265 (both sides).
Figure 20-20-6
Stop the engine. Pull up on the lift arm bypass control to
release the hydraulic pressure.
1

Disconnect the hoses (Item 1) [Figure 20-20-3] from the
lift cylinder.
Install plugs in the hoses and tighten.

2
Figure 20-20-4
3
1
P-45258
Remove the retainer bolt (Item 1) [Figure 20-20-6] and

nut from the lift cylinder rod end pivot pin (both sides).
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (35

- 38 N•m) torque.
P-45267 Remove the lift cylinder rod end pivot pin (Item 2) [Figure
20-20-6].
Remove the retainer bolt (Item 1) [Figure 20-20-4] and Remove the lift cylinder (Item 3) [Figure 20-20-6] from
nut from the lift arm pin (both sides). the loader.
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (35

- 38 N•m) torque.
NOTE: Remove the air cleaner (See Housing

Removal And Installation on Page 70-40-1) to
remove the left rear pivot pin. The pin must be
driven out from the engine compartment.

106 of 861
CYLINDER (LIFT) (CONT'D)
Parts Identification
1. Plug 9. Spacer
2. O-Ring 10. Seal
3. Cylinder 11. O-Ring
4. O-Ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-Ring

7 8
15
1 6
2
5
14
1 13
3
2 12
11
10
B-13593A
B-13593

107 of 861
CYLINDER (LIFT) (CONT'D) Figure 20-20-8
Disassembly and Assembly

4
Use the following tools to service the cylinder:
3
2
MEL1074 - O-ring Seal Hook
Spanner Wrench 1
MEL1033 - Rod Seal Installation Tool
MEL1396 - Seal Installation Tool
Piston Ring Compressor
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts. P-48036
Always install new O-rings and seals during assembly.

Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Lubricate all O-rings and seals with hydraulic oil during and head (Item 4) [Figure 20-20-8].
installation.
Assembly: Tighten the nut (Item 1) [Figure 20-20-8] to
Hold the hydraulic cylinder over a drain pan and move 600 ft.-lb. (814 N•m) torque.
the rod in and out slowly to remove the fluid from the

cylinder. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Put the base end of the cylinder in a vise.
Figure 20-20-9
Figure 20-20-7
2 2
1
P-48038
P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

Use a spanner wrench to loosen the head (Item 1) 20-9] from the piston.
[Figure 20-20-7] from the cylinder case.
NOTE: If the fiber surface (Item 3) [Figure 20-20-9] on
Assembly: Tighten the head with a spanner wrench until the piston head, becomes damaged, the
the head is seated all of the way into the cylinder (Item 2) complete piston head must be replaced.
[Figure 20-20-7].

108 of 861
Disassembly and Assembly (Cont'd)
Figure 20-20-10
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-12] from

P7424 the cylinder head.
Figure 20-20-13
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-10]. Allow

the seal to stretch for 30 seconds before installing it on
the piston. 2
Once the seal is installed on the piston, a piston ring

compressor can be used on the piston for 3 minutes to
compress the seal into place.
1
Figure 20-20-11
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-20-
2 13].
P-48039
Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-11] from the cylinder head.

109 of 861
Figure 20-20-14
P7425
Assembly: Install the rod seal in the head. Rotate the

P-48042 handles to collapse the rod seal.
Reverse the disassembly procedure to assemble the lift

Remove the rod seal (Item 1) [Figure 20-20-14] from the cylinder.
cylinder head.

Figure 20-20-15
P-48043A P7427
Assembly: Install the rod seal on the rod seal tool

[Figure 20-20-15].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-15] must be installed
toward the inside of the cylinder.

110 of 861
CYLINDER (TILT) Figure 20-21-2
Testing
WARNING 1
Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
N-18802
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar. Install a cap (Item 1) [Figure 20-21-2] on the fitting and
tighten.
Figure 20-21-1
Engage the parking brake. Lower the seat bar.
Start the engine and push the Press to Operate button.

Push the bottom (heel) of the tilt pedal.
If there is leakage from the open port, remove the tilt

cylinder for repair.
N-18801
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the base end of the tilt cylinder.

111 of 861
CYLINDER (TILT) (CONT'D) Figure 20-21-4
WARNING 1

explosion or fire.
W-2103-0508
N-18545
Figure 20-21-3
Use a drift pin and hammer, remove the rod end pivot pin
(Item 1) [Figure 20-21-4].
Figure 20-21-5

1
N-18544 3 2
Remove the attachment. Roll the Bob-Tach forward. Stop

the engine. Raise the seat bar.
Remove the retainer bolt (Item 1) [Figure 20-21-3] and P-34137

nut from the rod end pin.
Installation: Tighten the bolt and nut to standard torque. Remove the retainer bolt (Item 1) [Figure 20-21-5] from
the tilt cylinder rod end pivot pin.
Installation: Tighten the bolt and nut to 125 - 140 ft.-lb.

(170 - 190 N•m) torque.
Remove the step (Item 2) [Figure 20-21-5].

cylinders.

112 of 861
CYLINDER (TILT) (CONT'D) Base End Pivot Pin Removal and Installation
Removal And Installation (Cont’d) Figure 20-21-7
Figure 20-21-6
2
P-68534
P-34228
Remove the tilt cylinder from the Bob-Tach. (See
Removal And Installation, Page 20-21-2.)
cylinder. Loosen the retainer bolt (Item 1) [Figure 20-21-7] from

the tilt cylinder rod base end pin.
Remove the cylinder (Item 2) [Figure 20-21-6] from the
rod end pivot pin. Installation: Tighten the retainer bolt to 175 - 190 ft.-lb.
(240 - 260 N•m) torque.
Remove the cylinder from the loader.
Strike the head of the bolt (Item 1) [Figure 20-21-7] to
push the pivot pin out.
Reverse the removal procedure to install the pivot pin.

113 of 861
Rod End Pivot Pin Bushing And Seal Removal And

Installation
Figure 20-21-8
1
1 N-18554
Reverse the removal procedure to install the pivot pin

bushing and seal.
N-18556
Remove the rod end of the tilt cylinder from the Bob-

Tach. (See Removal And Installation, Page 20-21-2.)
Use a seal pick to remove the seals (Item 1) [Figure 20-

21-8] on both sides of the pivot bushing.
Figure 20-21-9
N-18555
Remove and replace bushing with a driver tool and

hammer [Figure 20-21-9].

114 of 861
CYLINDER (TILT) (CONT'D)
1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal MC-1688B
8. O-ring 16. Bushing
3
MC-01688A

9
4
10
7
12
6 13
5 11
MC-01688D
14
MC-01688C
15
16
15
PE-1056A

115 of 861
Disassembly And Assembly

3
Use the following tools to service the cylinder: 2

1
Spanner Wrench

damage. Replace any damaged parts.
P-48071
Lubricate all O-rings and seals with hydraulic oil during Remove the nut (Item 1), piston (Item 2) and head (Item
installation. 3) [Figure 20-21-12].
Hold the hydraulic cylinder over a drain pan and move Assembly: Tighten the nut (Item 1) [Figure 20-21-12] to
the rod in and out slowly to remove the fluid from the 100 ft.-lb. (136 N•m) torque.
cylinder.

NOTE: Clean and dry the threads before installing the
Put the base end of the cylinder in a vise. nut. Install the new nut from the kit.
Figure 20-21-11 Figure 20-21-13
P-48034 P-48088 P-48089
Use a spanner wrench to loosen the head (Item 1) Assembly: Mark the end of the shaft and nut. Tighten
[Figure 20-21-11] from the cylinder case. the nut an additional 135 degrees or 2-1/4 flats [Figure
20-21-13].
Assembly: Tighten the head with a spanner wrench until
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-21-11].

116 of 861
Disassembly And Assembly (Cont'd)

1
Figure 20-21-14
2
2
P-48039

P-48073 (Item 2) [Figure 20-21-16] from the cylinder head.
Figure 20-21-17
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-14] from the piston.

Figure 20-21-15
1
P-48040


stretch it until it fits the piston [Figure 20-21-15]. Allow
the seal to stretch for 30 seconds before installing it on
the piston.


117 of 861
Figure 20-21-18
1
P-48043 P7427

P-48041 P-48042 [Figure 20-21-20].

Install the wiper seal, with the wiper side of the seal (Item (Item 1) [Figure 20-21-20] must be installed
1) toward the outside of the head (Item 2) [Figure 20-21- toward the inside of the cylinder.

18].
Figure 20-21-21
Figure 20-21-19
P7425
P-48042

Remove the rod seal (Item 1) [Figure 20-21-19] from the handles to collapse the rod seal [Figure 20-21-21].
cylinder head.

118 of 861
CYLINDER (BOB-TACH) Figure 20-22-2
Testing
WARNING
explosion or fire.
W-2103-0508 1
P16330
WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the

Bob-Tach cylinder base end port.
AVOID INJURY OR DEATH Figure 20-22-3


from a physician familiar with this injury. 2
W-2072-0807
Figure 20-22-1
1 P16332
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
Engage the parking brake. Lower the seat bar. Start the
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
N-21401
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the Bob-Tach cylinder
Tilt the Bob-Tach forward, so it is parallel to the floor
for repair.
[Figure 20-22-1].

119 of 861
CYLINDER (BOB-TACH) (CONT’D)
Figure 20-22-4
1 2
N-21401
Disconnect the hoses from the cylinder fittings (Item 1 &

2) [Figure 20-22-4].

Install plugs and cap on fittings.
NOTE: Connect the hose with the 45 degree end (Item

1) [Figure 20-22-4] to the base end fitting on
the cylinder.
Figure 20-22-5
1 1
N-21400
Remove the bolts (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the washers and cylinder from the lever pivots.

120 of 861
CYLINDER (BOB-TACH) (CONT’D)
1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod
1

3
2
14
13 12
11
10
9
8 7 6
5
4
15
PE1064

121 of 861
CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-7

4 3 2
Use the following tools to service the cylinder:
1
Spanner Wrench

damage. Replace any damaged parts.
P16294

Remove the head and rod assembly from the cylinder
Lubricate all O-rings and seals with hydraulic oil during [Figure 20-22-7]. Put the rod end in a vise.
installation.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Hold the hydraulic cylinder over a drain pan and move and head (Item 4) [Figure 20-22-7] from the rod.
the rod in and out slowly to remove the fluid from the

cylinder. Assembly: Grease the piston where the nut contacts the
piston. do not get grease on the threads. Install the new
Put the base end of the cylinder in a vise. nut (Item 1) [Figure 20-22-7].
Figure 20-22-6 Assembly: Tighten the nut to 90 ft.-lb. (122 N•m) torque.
Figure 20-22-8
2
3
2
1
4
1
P-43212
P16295
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-22-6].
Remove the O-ring (Item 1), and seal (Item 2) from the
Assembly: Tighten the head with a spanner wrench until piston (Item 3) [Figure 20-22-8].
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-22-6]. NOTE: The piston center hole (Item 4) [Figure 20-22-
8] has a bevel on one end. The bevel goes
toward the rod when assembling.

122 of 861
Disassembly and Assembly (Cont’d)
Figure 20-22-9
1
P-48040

Figure 20-22-12
stretch it until it fits the piston [Figure 20-22-9]. Allow the

seal to stretch for 30 seconds before installing it on the
piston. 2

1
Figure 20-22-10
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2 12].
P-48039

(Item 2) [Figure 20-22-10] from the cylinder head.

123 of 861
Figure 20-22-13
P7425

P-48042 handles to collapse the rod seal [Figure 20-22-15].
Reverse the disassembly procedure to assemble the

Remove the rod seal (Item 1) [Figure 20-22-13] from the Bob-Tach cylinder.
cylinder head.

Figure 20-22-14
P-48043A P7427

[Figure 20-22-14].

(Item 1) [Figure 20-22-14] must be installed
toward the inside of the cylinder.

124 of 861
MAIN RELIEF VALVE Lift and block the loader. (See Procedure on Page 10-10-
1.)
Description
Figure 20-30-1
The main relief valve limits the hydraulic system pressure
by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader. 2
Testing 1
IMPORTANT
P-34480
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284 Connect the IN port (Item 1) [Figure 20-30-1] of the
hydraulic tester to the bottom (female) quick coupler on
the loader.

Connect the OUT port (Item 2) [Figure 20-30-1] of the
WARNING hydraulic tester to the top (male) quick coupler on the
loader.
When the engine is running during service, the Figure 20-30-2

steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
WARNING
1
W-2017-0286 N-18409
The tools listed will be needed to do the following • Press the AUXILIARY HYDRAULICS Button (Item 1)
procedure: [Figure 20-30-2] Maximum Flow.
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position. To release the

hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds.

125 of 861
MAIN RELIEF VALVE (CONT’D) Turn the restrictor control, on the tester, until the main
relief valve opens. Check the relief pressure.
Testing (Cont’d)
Figure 20-30-3
Right
Steering
Lever
Control
1
P-31833
Figure 20-30-4

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

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

switch (Item 1) [Figure 20-30-3] & [Figure 20-30-4] a
second time.
Watch the flow meter on the hydraulic tester to make

sure the flow is correct. Increase the engine speed to full
RPM.
Refer to Specifications, (See Hydraulic System on Page

SPEC-10-3.) for both flow and pressure specifications of
the hydraulic system.
Check the free flow specification.

126 of 861
MAIN RELIEF VALVE (CONT’D)
Adjusting
Figure 20-30-5
O-ring
Back-up
B-6764
If the pressure is not correct, adjust the main relief valve.

Remove the end cap (Item 1) [Figure 20-30-5].

Turn the adjusting screw in or out until the pressure is
correct.
NOTE: If the correct pressure can not be reached,

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

127 of 861
MAIN RELIEF VALVE (CONT’D) Figure 20-30-7
Removal and Installation
Figure 20-30-6
1
1
P-48874
1
Clean the area around the control valve. Loosen and

P-48872 remove the main relief valve (Item 1) [Figure 20-30-7].
Remove the O-rings and back-up washers [Figure 20-

Remove the four motor cover mounting screws (Item 1) 30-5].
[Figure 20-30-6].

Clean the main relief valve in clean solvent. Use air
Installation: Tighten the mounting screws to 15 - 20 ft.- pressure to dry the valve.
lb. (20 - 27 N•m) torque.
Install new O-rings and back-up washers. Install the main
relief valve (Item 1) [Figure 20-30-7] and tighten. Check
the pressure again. (See Testing on Page 20-30-1.)
Installation: Tighten the main relief valve to 35 - 40 ft.-lb.

(47 - 54 N•m) torque.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

128 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Removal And Installation
Description
Figure 20-40-1
DANGER
P-90328
AVOID DEATH
P-68012
unless supported by an approved lift arm
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operators cab. D-1009-0409

The hydraulic control valve [Figure 20-40-1] 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 are operated using mechanical
linkages to connect the foot pedals to the lift and tilt Never work on a machine with the lift arms up unless
spools. the lift arms are secured by an approved lift arm
The auxiliary function is operated by pilot pressure. support device can allow the lift arms or attachment
There is one solenoid located by each side of the spool. to fall and cause injury or death.
Only one solenoid at a time is activated by the switch on W-2059-0598
the right side control handle/lever. The activated solenoid
sends pilot pressure oil to one side of the spool and
forces the spool to shift.
The hydraulic control valve contains a main relief valve

which is adjustable. IMPORTANT
damage the system.
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10-

1.)
Raise the lift arms and install an approved lift arm support
device (See Installing on Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-2.)

129 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-4
(CONT’D)
Removal And Installation (Cont’d)

1
Clean the area around the control valve.
Drain the hydraulic reservoir. (See Removing And 1

Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the control panel. (See Removal and Installation

on Page 50-100-2.)
Figure 20-40-2
2
P-66964
Disconnect and cap the tubelines (Item 1) [Figure 20-40-

4] from the lift arm bypass valve to the hydraulic control
valve.
Disconnect and cap the hose (Item 2) [Figure 20-40-4]

from the lift arm bypass valve to the drive motor case
1

drain.
Figure 20-40-5
P-34004
1
Remove the right rear tire.
Locate and remove the access covers (Item 1) [Figure

20-40-2] on the right side of the machine.
Figure 20-40-3
1
P-66967
2 Remove the connector pins (Item 1) [Figure 20-40-5].

1
P-66963
Mark and disconnect the five electric solenoid connectors

for correct installation (Item 1) [Figure 20-40-3].
Disconnect and cap the supply hose (Item 2). Remove
the supply hose clamp (Item 3) [Figure 20-40-3].

130 of 861
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-40-6 1
P-66968
Remove tubeline clamp screw (Item 1) [Figure 20-40-8]

from the auxiliary tubelines in the left rear upright.
P-66969
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m)
torque.
Remove the crossbar linkage bolt (Item 1) [Figure 20-40-
6].

Figure 20-40-9
Remove the control pedal crossbar linkage and tilt

linkage. (See Linkage Removal And Installation on Page
50-90-2.) 3
5
Figure 20-40-7
4
2 1
1
1
P-66970
Remove and cap both tubelines (Item 1) [Figure 20-40-

9] from the auxiliary section of the control valve.
P-66965 Disconnect and cap the drain hose (Item 2) [Figure 20-
40-9] from the control valve.
Remove the two lift arm bypass valve bracket mounting Remove and cap the outlet tubeline (Item 3) [Figure 20-
bolts (Item 1) [Figure 20-40-7]. 40-9] from the control valve to the hydraulic oil cooler.
Remove the lift arm bypass valve and mounting bracket. Remove and cap the charge tubeline (Item 4) [Figure 20-
40-9] from the control valve to the charge filter.
Remove the throttle rod (Item 5) [Figure 20-40-9] from

the engine, then pull the throttle rod out of the loader from
the rear.

131 of 861
(CONT’D)

1
Figure 20-40-10
2
1
P-66971
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-40-12] from the tilt section of the control
P-66961 valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-40-

Disconnect and cap the supply tubeline (Item 1) [Figure 12] from the lift section of the control valve.

20-40-10] from the hydraulic control valve.
Figure 20-40-13
Figure 20-40-11
1
2
P-66957
P-66973
Mark all tubelines and hoses for correct installation.

Remove the supply tubeline clamp screw (Item 1)
[Figure 20-40-11]. The fixed end main valve hose (Item 1) [Figure 20-40-
13] is connected to a fixed end fitting on the control valve.
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m) The hose is routed to the back upright where the hose is
torque. connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
Remove supply tubeline (Item 2) [Figure 20-40-11] from fitting, located in the right side upright.
loader.
NOTE: Remember the hose routing for ease of
control valve installation.

132 of 861
(CONT'D)
Figure 20-40-14
1
1
P-66974
Connect a hoist to the lifting brackets (Item 1) [Figure 20-

40-16] on the control valve.
P-66962
Figure 20-40-17
Remove any tie-straps (Item 1) [Figure 20-40-14]

securing the fixed end main valve hose.

1
Figure 20-40-15
P-66972P-
P-66972
P-51713
34004P-
1 51713
Remove the two mounting bolts (Item 1) [Figure 20-40-

17] fastening the control valve and bracket to the side of
P-66960 the loader.
Remove the control valve from the loader.

Remove the fixed-end main valve hose (Item 1) [Figure
20-40-15] from the main control valve fitting. Reverse removal procedure to install the hydraulic
control valve.

133 of 861
HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-18
J2
C2 J4 C3
D5 E3 B3
E3
G1 G2
F2 B2 A3 D3
D4 F4 E2
C4
A2
D1
D2
A1
E1
F1 H2 B1
F3

H3
MR C1
H1 J3
J1 MS1937
ITEM S150/S160 LOADER ITEM S150/S160 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Lift 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 Valve Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End) J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Rod End)
MR Main Relief Valve – 3300 PSI
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

134 of 861
(CONT'D)
Mount Bracket Removal And Installation
Remove the control valve and mount bracket from the

loader. 1
Figure 20-40-19
2
1
2
P-68014
Remove the fitting (Item 1) [Figure 20-40-21] from the

check valve.
Remove the lift load check valve (Item 2) [Figure 20-40-

3 21].
P-68011

Installation: Lubricate the O-ring and tighten the valve to
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Remove the two mount bolts (Item 1) [Figure 20-40-19]
and lift eyes (Item 2) from the hydraulic control valve. Figure 20-40-22
Remove the mount bracket (Item 3) from the hydraulic

control valve.
Lift Load Check Valve Removal And Installation

1
Figure 20-40-20
1
P-51439
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-22].
P-68013
Remove the tubeline (Item 1) [Figure 20-40-20] from the

control valve.

135 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Load Check Valve Removal And Installation (Tilt &
(CONT'D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-40-24

(Cont’d)
Figure 20-40-23
1
1
P-68007
P-51440 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-24].
Check for free movement of the load check valve (Item 1)

At the front side of the control valve locate the auxiliary
[Figure 20-40-23]. section load check valve (Item 2) [Figure 20-40-24].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
Figure 20-40-25
1
3
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-25].
Check the orifice (Item 3) [Figure 20-40-25] in the

poppet to be sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-40-

25] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.

136 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Installation: Always use new O-ring (Item 1) [Figure 20-
(CONT'D) 40-27] on the anti-cavitation valve plug. Tighten the plug
to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Anti-Cavitation Valve Removal And Installation
(Lift, Rod End) Figure 20-40-28
Figure 20-40-26
1
3
2
P-51453
P-68015
20-40-28].
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-40-26]. Check the orifice (Item 3) [Figure 20-40-28] in the

IMPORTANT installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.

damage the system.
I-2003-0888
Figure 20-40-27
P-51693

137 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Port Relief/Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Base End)
Port Relief/Anti-Cavitation Valve Removal And Figure 20-40-31

Installation (Lift, Base End)
Figure 20-40-29
P-68015
P-68015 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-40-31] from the base end of the tilt section.
Loosen the lift circuit port relief/anti-cavitation valve (Item

Figure 20-40-32
1) [Figure 20-40-29].
Figure 20-40-30
P-51454
1
P-51451 Replace the O-ring (Item 1) [Figure 20-40-32] before

installation.
Replace the O-ring (Item 1) [Figure 20-40-30] before Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)
installation. torque.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)

torque.

138 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Port Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-35
Port Relief/Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Figure 20-40-33
P-68015
Remove the port relief plug (Item 1) [Figure 20-40-35]

P-68015 from the auxiliary circuit of the control valve.
Figure 20-40-36
Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-40-33] from the rod end of the tilt section.
Figure 20-40-34
P-51695
1
Installation: Always use new O-rings (Item 1) [Figure

P-51694 20-40-36]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
Replace the O-ring (Item 1) [Figure 20-40-34] before

installation.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)

torque.

139 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Plug Removal And Installation
(CONT'D)
Figure 20-40-39
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-37
1
1
P-68016
P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-39].
The control valve may be equipped with an optional Figure 20-40-40

auxiliary port relief valve (Item 1) [Figure 20-40-37].

Remove the auxiliary port relief valve.
Figure 20-40-38
P-51460

20-40-40]. Tighten to 40 ft.-lb. (54 N•m) torque.
P-51640

20-40-38]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.

140 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Rubber Boot Removal And Installation
(CONT'D)
Figure 20-40-43
Plug Removal And Installation (Cont’d)
1
Figure 20-40-41
P-51506
1
P-51461 Remove the three screws (Item 1) [Figure 20-40-43] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
(Item 1) [Figure 20-40-41].

11,3 N•m) torque.
Figure 20-40-42 Figure 20-40-44
1
2
1
P-51462
P-51701
Installation: Always use new O-rings (Item 1) [Figure Remove the rubber boots (Item 1) from the retainer plate
20-40-42]. Tighten to 40 ft.-lb. (54 N•m) torque. (Item 2) [Figure 20-40-44].

141 of 861
(CONT'D)
End Cap/Spool Lock Block Removal And Installation
Figure 20-40-45
1 1
P-51699A
1
Remove the four end cap/spool lock block mount screws

(Item 1) [Figure 20-40-47].
P-51697
Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
11,3 N•m) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-45] from the

Remove the rubber boots and retainer plate from the lift
end cap/spool lock block. and tilt spools.
Figure 20-40-46 Figure 20-40-48
1 1
P-68017
P-51700
Disconnect the tube line (Item 1) [Figure 20-40-46] from Remove the end cap/spool lock block (Item 1) [Figure
the end cap/spool lock block. 20-40-48] from the control valve.

142 of 861
(CONT'D)
Lift Spool And Detent Removal And Installation

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
Remove the end cap/spool lock block from the control

valve.
Figure 20-40-49
P-51513
Remove the end cap (Item 1) [Figure 20-40-51].
Figure 20-40-52
1

P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-49]. 2
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap/spool lock block.
P-51514
Figure 20-40-50
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-52].
Remove the washer (Item 2) [Figure 20-40-52].
P-51512A
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-50] from the lift spool.

143 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Put a rag around the detent assembly [Figure 20-40-54].
(CONT'D) This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
(Cont'd) Figure 20-40-55
Figure 20-40-53
2 1
3
1
1 2 P-51517
2
P-51515
Remove the detent sleeve (Item 1), detent balls (Item 2)

Remove the screws (Item 1) [Figure 20-40-53] from the and spring (Item 3) [Figure 20-40-55].

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-53].
Installation: Lubricate the screws and tighten to 90 - 100

in.-lb. (10 - 11,3 N•m) torque.
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-54
P-51516

144 of 861
(CONT'D)

(Cont'd)
Figure 20-40-56
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-58].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-59
Remove the lift spool assembly and seal (Item 1) [Figure

20-40-56] from the control valve. 2
Figure 20-40-57
1
3
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-59] over the

P-51519A centering spring.
NOTE: Be careful when removing the detent adapter

Remove the lift spool seal (Item 1) [Figure 20-40-57] (Item 2) [Figure 20-40-59] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-59]

is white on all 700 series loaders.

145 of 861
(CONT'D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-60
N-19009
Remove spring tool (Item 1) [Figure 20-40-62] from the

1 spring assembly.
2
N-18916 Figure 20-40-63
Put a rag around the detent assembly [Figure 20-40-60]. 1

2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3
Remove the detent adapter with an Alan wrench.

4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-60].
Figure 20-40-61
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-63].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-61]

from the spring assembly.

146 of 861
(CONT'D)

(Cont'd)
2
Figure 20-40-64
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-66].
N-18918 NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
this O-ring. Always replace the o-ring and
Remove the stud from the end of the spool [Figure 20-

recheck the lift spool before the control valve
40-64]. is replaced.
Figure 20-40-65 Figure 20-40-67
N-18920
N-18963
Removal of the plastic plug: Install the plastic plug and O-ring in the spool [Figure 20-
40-67].
Make a center point in the plug using a 1/16 in. drill.
Drill a hole all the way through the plug using a 7/64 in.
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-65] into the plug.

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

THREADS.

147 of 861
(CONT'D)

(Cont'd)
2
Figure 20-40-68
O-Ring
1 3
2
N-18958
Plastic
Plug
0.60 in. Apply grease on all the detent component surfaces
(15,2 mm)
before assembly [Figure 20-40-70].
B-14712 Install the spring (Item 1) and detent balls (Item 2) into
the adapter (Item 3) [Figure 20-40-70] and compress
with the detent pliers (Item 1) [Figure 20-40-71].
Install the stud and tighten until the other end of the stud

is out about 0.600 in. (15,2 mm) from the spool [Figure Figure 20-40-71
20-40-68].
Figure 20-40-69
N-18968
N-18967 Install the detent adapter to the collar [Figure 20-40-71].
NOTE: The collar and the detent adapter are held

Clamp the collar (Item 1) [Figure 20-40-69] in a vice. together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

148 of 861
(CONT'D)

(Cont'd)
Figure 20-40-72
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-74].
N-19004 Remove the spring tool.
Check the alignment of the detent adapter and the


washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 90 - 100 in.-lb. (10 - 11,3 N•m).
Figure 20-40-73
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-74].
Figure 20-40-75
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-73].
CD-15051
Install the detent balls and spring [Figure 20-40-75].

149 of 861
(CONT'D)

(Cont'd)
Figure 20-40-76
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-78].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-78].
Install the mounting screws (Item 2) [Figure 20-40-78].

Hold the detent balls in place with the detent pliers

[Figure 20-40-76]. Installation: Lubricate the screws and tighten to 90 - 100
in.-lb. (10 - 11,3 N•m) torque.
Figure 20-40-77
Figure 20-40-79
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-77] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-79].

150 of 861
(CONT'D)

(Cont'd)
Figure 20-40-80
2
1
P-51512A
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-82] on the lift spool.
P-51513 Figure 20-40-83
Install the end cap (Item 1) [Figure 20-40-80].

Figure 20-40-81
1
P-51511A
Install the O-ring (Item 1) [Figure 20-40-83] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-81] on the

linkage end of the valve.

151 of 861
(CONT'D)

(Cont'd)
Figure 20-40-84
2
1
P-51697
3
Use an ohm meter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 5.5 ± 0.28 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap/spool lock block (Item 1) and the

(Item 2) [Figure 20-40-86] lock solenoids and tighten to
mount bolt (Item 2) [Figure 20-40-84]. 35 - 45 ft.-lb. (52 - 61 N•m) torque.
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-84].

11,3 N•m) torque.
Figure 20-40-85
P-68017
Connect the tubeline (Item 1) [Figure 20-40-85].

152 of 861
(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap/spool lock block. (See
End Cap/Spool Lock Block Removal And Installation on
Page 20-40-14.)
2
Figure 20-40-87
1
P-68023
Remove the spool centering block (Item 1) [Figure 20-

1 2 40-89] from the control valve.
Check and replace the O-ring (Item 2) [Figure 20-40-89]

before replacing the spool centering block.

P-51521A Figure 20-40-90

20-40-87] from the tilt spool.
Figure 20-40-88
1
1 P-51544A
Remove the tilt spool, centering spring, back-up washer

2
and spool seal [Figure 20-40-90].
P-68019 Installation: Always use a new spool seal.
Remove the two tubelines (Item 1) [Figure 20-40-88].
Remove the three bolts (Item 2) [Figure 20-40-88] from

the spool centering block.
Installation: Tighten the bolts to 90 - 100 in.-lb. (10 - 11,3

N•m) torque.

153 of 861
(CONT'D)
Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-91
3
4
1
N-18944A
N-18942
Figure 20-40-94
Put the linkage end of the spool in the vice [Figure 20-
40-91]. 2

1
Install the spool tool (Item 1) [Figure 20-40-91] over the
centering spring.
Figure 20-40-92
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

Installation: Always use a new spool seal.
N-19014
Remove the bolt (Item 1) [Figure 20-40-92] holding the

centering spring to the spool.
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3

N•m) torque.
Remove spring tool from the spring assembly.

154 of 861
(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-95
2
2
1
1
P-68022

1
20-40-97] from the auxiliary spool.
P-68020
Figure 20-40-98
Remove the three screws (Item 1) [Figure 20-40-95]

from the spool centering block.

N•m) torque.

2 1
Figure 20-40-96
P-51549A
Remove the spring (Item 1) and center spring retainer

2 (Item 2) [Figure 20-40-98] from the auxiliary spool.
1 NOTE: If the centering spring retainer (Item 2) [Figure

20-40-98] must be replaced, replace the
retainer on the opposite end also.
P-68021

(Item 2) [Figure 20-40-96] from the auxiliary spool.
Note: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end also.

155 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Auxiliary Solenoid Removal And Installation
(CONT'D)
Figure 20-40-101
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-99
1
1
1 2
P-68007
P-51550A Remove the nut (Item 1) [Figure 20-40-101] from both

solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)

torque.
Figure 20-40-100 Figure 20-40-102
1
2
P-51551A
P-51553
Remove the spool (Item 1) [Figure 20-40-100]. Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-40-102].
Use an ohm meter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.9 ± 0.25 ohm.

156 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Solenoid Removal And Installation
(CONT'D)
Figure 20-40-105
Auxiliary Solenoid Removal And Installation (Cont’d)
Figure 20-40-103
1
2
P-68006
P-68008 Remove the nut (Item 1) [Figure 20-40-105] from the

solenoid stem.
Remove the solenoid stem (Item 1) [Figure 20-40-103]. Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19 Remove the solenoid coil (Item 2) [Figure 20-40-105].
N•m) torque.
Figure 20-40-106
Figure 20-40-104
N-18693A
P-51555
Remove the O-rings (Item 1) [Figure 20-40-106] from

Remove the O-rings (Item 1) [Figure 20-40-104] from both ends of the solenoid coil.
the solenoid stem.
Use an ohm meter to measure the solenoid coil
Check and clean the screen (Item 2) [Figure 20-40-104]. resistance.
The correct resistance for the coil is 9.79 ± 0.29 ohm.

157 of 861
(CONT'D)
Solenoid Removal And Installation (Cont’d)
Figure 20-40-107 3
2
1
1
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-108] from the cartridge.
P-68009
Clean all parts in solvent and dry with compressed air.
Remove the solenoid stem (Item 1) [Figure 20-40-107]. Inspect all parts for wear and replace any showing

excessive wear.
Installation: Lubricate the O-rings and tighten the stem
to 20 - 24 ft.-lb. (27 - 33 N•m) torque. NOTE: The screen (Item 3) [Figure 20-40-108] may be
cleaned with solvent. If it is torn or worn it
needs to be replaced.
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-106] &

[Figure 20-40-108] and new back-up rings (Item 2)
[Figure 20-40-108] on the solenoid stem.

158 of 861
(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-109 1
1
1
1 2
1
2
2
2
P-51564

[Figure 20-40-111] from the lift lock valve, and replace
P-68010 with new.
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-109] is for the lift

circuit.
Figure 20-40-110
P-51443
Remove the lift lock valve (Item 1) [Figure 20-40-110]

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

tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.

159 of 861
(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-112
1
1
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-40-114]

from the front of the control valve.
P-51705
Installation: Lightly lubricate the lock valve O-rings and
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-
112].

Figure 20-40-115
Figure 20-40-113
2 1
1
1
1 2
2
2
P-51564
P-51697P-
51504
[Figure 20-40-115] from the tilt lock valve, and replace
Remove the lift spool lock solenoid (Item 1) [Figure 20- with new.
40-113].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

40-113].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 38 - 45 ft.-lb. (52 - 61 N•m) torque.

160 of 861
HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-118
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-116
1
P-51707
2
P-68010 Remove the main relief valve (Item 1) [Figure 20-40-
118].
Remove the tubeline (Item 1) and fitting (Item 2) [Figure Figure 20-40-119
20-40-116] from the valve.

Figure 20-40-117
P-51463
P-51437 Remove the O-rings (Item 1) [Figure 20-40-119] from the

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

casting.

161 of 861
(CONT'D)
Check Valve Removal And Installation
Figure 20-40-120
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

122] and tighten the fitting to 20 - 24 ft.-lb. (27 - 33 N•m)
P-68013 torque.
Figure 20-40-123
Remove the tubeline (Item 1) [Figure 20-40-120].

Figure 20-40-121
P-68870
P-68010 Inspect the screen (Item 1) [Figure 20-40-123].
Remove the BICS check valve fitting (Item 1) [Figure 20-

40-121] from the top of the lift load check valve.
Installation: Lubricate the O-ring and tighten the fitting to

20 - 24 ft.-lb. (27 - 33 N•m) torque.

162 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P-68027
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operators cab. D-1009-0409

The hydraulic control valve [Figure 20-41-1] 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 ACS or the SJC hydraulic
control valve are operated using electronic control Never work on a machine with the lift arms up unless
handle/levers or foot pedals that send an electronic the lift arms are secured by an approved lift arm
signal to the electronic actuators to move the lift and tilt support device. Failure to use an approved lift arm
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 handle/lever. The activated solenoid
sends pilot pressure oil 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

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

163 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-4
(CONT’D)

1
Clean the area around the control valve.
1
Drain the hydraulic reservoir. (See Removing And

on Page 50-100-2.)
2
Figure 20-41-2
P-68206
Disconnect and cap the tubelines (Item 1) [Figure 20-41-

4] from the lift arm bypass valve to the hydraulic control
valve.

from the lift arm bypass valve to the drive motor case
1

drain.
Figure 20-41-5
P-34004
Remove the right rear tire.
Locate and remove the access covers (Item 1) [Figure

20-41-2] on the right side of the machine.
Figure 20-41-3
1
3
P-68205
2 Disconnect the connectors for the hydraulic control valve

actuators (Item 1) [Figure 20-41-5].
1
1
P-68204
Mark and disconnect the three electric solenoid

connectors for correct installation (Item 1) [Figure 20-41-
3].
Disconnect and cap the supply hose (Item 2). Remove
the supply hose clamp (Item 3) [Figure 20-41-3].

164 of 861
(CONT’D)
Removal And Installation (Cont'd) 3

5
Figure 20-41-6
2
1 1 4
P-68203
Remove and cap both tubelines (Item 1) [Figure 20-41-

8] from the auxiliary section of the control valve.
P-66965
Disconnect and cap the drain hose (Item 2) [Figure 20-
Remove the two lift arm bypass valve bracket mounting
bolts (Item 1) [Figure 20-41-6].

Remove and cap the outlet tubeline (Item 3) [Figure 20-
41-8] from the control valve to the hydraulic oil cooler.
Remove the lift arm bypass valve and mounting bracket.
Remove and cap the charge tubeline (Item 4) [Figure 20-
Figure 20-41-7 41-8] from the control valve to the charge filter.
Remove the throttle rod (Item 5) [Figure 20-41-8] from

the engine, then pull the throttle rod out of the loader from
the rear.
1
P-66968
Remove tubeline clamp screw (Item 1) [Figure 20-41-7]

from the auxiliary tubelines in the left rear upright.

torque.

165 of 861
(CONT’D)

1
Figure 20-41-9
2
1
P-66971
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-41-11] from the tilt section of the control
P-66961 valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-41-

Disconnect and cap the supply tubeline (Item 1) [Figure 11] from the lift section of the control valve.

20-41-9] from the hydraulic control valve.
Figure 20-41-12
Figure 20-41-10
1
2
P-66957
P-66973
Mark all tubelines and hoses for correct installation.

Remove the supply tubeline clamp screw (Item 1)
[Figure 20-41-10]. The fixed end main valve hose (Item 1) [Figure 20-41-
12] is connected to a fixed end fitting on the control valve.
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m) The hose is routed to the back upright where the hose is
torque. connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
Remove supply tubeline (Item 2) [Figure 20-41-10] from fitting, located in the right side upright.
loader.
NOTE: Remember the hose routing for ease of
control valve installation.

166 of 861
(CONT’D)
Figure 20-41-13
1 1
P-68202
Connect a hoist to the lifting brackets (Item 1) [Figure 20-

41-15] on the control valve.
P-66962
Figure 20-41-16
Remove any tie-straps (Item 1) [Figure 20-41-13]

securing the fixed end main valve hose.

1
Figure 20-41-14
P-66972P-
P-66972
P-51713
34004P-
1 51713

16] fastening the control valve and bracket to the side of
P-66960 the loader.

Remove the fixed-end main valve hose (Item 1) [Figure
20-41-14] from the main control valve fitting. Reverse removal procedure to install the hydraulic
control valve.

167 of 861
(CONT’D)
Actuator Removal And Installation (Out of Loader)
Figure 20-41-17
P-68030
Using a drift pin and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-41-19] from the actuator
1 and the lift spool.
P-68028 Remove the actuator and linkage pin from the valve.

Figure 20-41-20
from the lift actuator.
Installation: Tighten the mounting bolts to 90 - 100 in.-lb.

(10 - 11,3 N•m) torque.
1
Figure 20-41-18
P-68031
1
Inspect the O-ring (Item 1) [Figure 20-41-20] on the nose

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

P-68029 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-41-

18] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-18].

168 of 861
(CONT’D)

(Cont’d)
Figure 20-41-21
P-68034
Using a drift pin and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-41-23] from the actuator
1 and the tilt spool.
P-68032
Remove the actuator and linkage pin from the valve.

Figure 20-41-24
from the tilt actuator.

(10 - 11,3 N•m) torque.
Figure 20-41-22 1
P-68031
Inspect the O-ring (Item 1) [Figure 20-41-24] on the nose

of the actuator, and replace as needed.
P-68033 Check the linkage pin (Item 2) [Figure 20-41-24] and

replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-41-

22] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-22].

169 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)

(Cont’d)
Figure 20-41-25
1
2
P-68035
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2) to
the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator (Item 4) [Figure 20-
41-25] to the end cap.

(10 - 11,3 N•m) torque (Item 1) [Figure 20-41-25]

170 of 861
(CONT’D)
Figure 20-41-26
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3
B2 D3
D4 E2
C4
A2
D1
D2
A1
E1
F1 H2 B1
H3

MR C1
H1 J3
J1 MS1972
ITEM S150/S160 LOADER ITEM S150/S160 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Lift Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS Valve Solenoid
C3 Load Check Valve Auxiliary Function H2 BICS Lock Valve (Tilt)
C4 Check Valve
H3 BICS Lock Valve (Lift)
D1 Anti-Cavitation Valve
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm Bypass Orifice
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Base End) Main Relief Valve – 3300 PSI
MR
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

171 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Mount Bracket Removal And Installation Figure 20-41-28
Remove the control valve and mount bracket from the

loader.
Figure 20-41-27
1 1
P-68013

3 control valve.
P-68011
Figure 20-41-29

and lift eyes (Item 2) from the hydraulic control valve.
Remove the mount bracket (Item 3) from the hydraulic 1

control valve.
P-68014

check valve.
Remove the lift load check valve (Item 2) [Figure 20-41-

29].
Installation: Lubricate the O-ring and tighten the valve to

55 - 65 ft.-lb. (75 - 88 N•m) torque.

172 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt &
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation
(Cont’d) Figure 20-41-32
Figure 20-41-30
1
2
2
P-68007
P-51439
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-32].
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-41-30]. At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-41-32].
NOTE: The tilt and auxiliary load check valves are

Figure 20-41-31 interchangeable.
Figure 20-41-33
1
1
3
2
P-51440
P-51453
Check for free movement of the load check valve (Item 1)
[Figure 20-41-31].
20-41-33].
Check the orifice (Item 3) [Figure 20-41-33] in the


installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.

173 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Always use new O-ring (Item 1) [Figure 20-41-35] on the
(CONT’D) anti-cavitation valve plug.
Anti-Cavitation Valve Removal And Installation (Lift,
Rod End) Figure 20-41-36
Figure 20-41-34
1
3
2
1
P-51453
P-68037
20-41-36].
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-41-34]. Check the orifice (Item 3) [Figure 20-41-36] in the

IMPORTANT installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.

damage the system.
I-2003-0888
Figure 20-41-35
P-51452

174 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief/Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Base End)
Port Relief/Anti-Cavitation Valve Removal And
Installation (Lift, Base End) Figure 20-41-39
Figure 20-41-37
P-68037
P-68037
Remove the tilt port relief/anti cavitation valve (Item 1)
[Figure 20-41-39] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item

1) [Figure 20-41-37]. Figure 20-41-40
Figure 20-41-38
1
1
P-68039
P-68038
installation.
installation. Installation: Lightly lubricate with oil and tighten to 38 -
45 ft.-lb. (52 - 61 N•m) torque.
Installation: Lightly lubricate with oil and tighten to 38 -
45 ft.-lb. (52 - 61 N•m) torque.

175 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief Valve Removal And Installation
(CONT’D)
Port Relief/Anti-Cavitation Valve Removal And Figure 20-41-43
Installation (Tilt, Rod End)
Figure 20-41-41 1
P-68037
Remove the port relief plug (Item 1) [Figure 20-41-43]

P-68037
from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-41-44

[Figure 20-41-41] from the rod end of the tilt section.
Figure 20-41-42
P-51801
1

P-51455 20-41-44]. Lightly lubricate with oil and tighten to 38 - 45
ft.-lb. (52 - 61 N•m) torque.
installation.
Installation: Lightly lubricate with oil and tighten to 38 -

45 ft.-lb. (52 - 61 N•m) torque.

176 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Plug Removal And Installation
(CONT’D)
Port Relief Valve Removal And Installation (Cont’d) Figure 20-41-47
Figure 20-41-45
1
1
P-68016
P-51743
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-47].
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-41-45]. Figure 20-41-48

Remove the auxiliary port relief valve.
Figure 20-41-46
1
P-51460

P-51640

20-41-46]. Lightly lubricate with oil and tighten to 38 - 45

177 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) End Cap Block Removal And Installation
(CONT’D)
Plug Removal And Installation (Cont’d) Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (Out of Loader)
Figure 20-41-49 on Page 20-41-6.)
Figure 20-41-51
1 P-51461
P-68040
At the bottom side of the control valve remove the plug
(Item 1) [Figure 20-41-49].

Disconnect the tube line (Item 1) [Figure 20-41-51] from
Figure 20-41-50 the end cap block.
Remove the two end cap block mount screws (Item 2)

[Figure 20-41-51].

11,3 N•m) torque.
1 Figure 20-41-52
P-51462
1

P-68041
Remove the end cap block (Item 1) [Figure 20-41-52]

from the control valve.

178 of 861
(CONT’D)
Lift Spool And Detent Removal And Installation 1

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-41-53
1
P-68043
1
Remove the two screws (Item 1) [Figure 20-41-55] from
the lift spool end cap.
Installation: Lubricate the screws and tighten to 90 - 100

in.-lb. (10 - 11,3 N•m) torque.

Figure 20-41-56
P-68042
Remove the O-ring (Item 1) [Figure 20-41-53].
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
Figure 20-41-54 1
P-68044
2 Remove the lift spool end cap (Item 1) [Figure 20-41-56]

1 from the control valve.
P-68047

20-41-54] from the lift spool.

179 of 861
(CONT’D)
(Cont'd)
Figure 20-41-57
P-51772
1
Clamp the linkage end of the spool in a vise [Figure 20-
41-59].
P-68045
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-41-60

20-41-57] from the control valve.
Figure 20-41-58
1
P-51773

P-68046
centering spring.
Remove the lift spool seal (Item 1) [Figure 20-41-58]

from the linkage end of the valve.

180 of 861
(CONT’D)
(Cont'd)
Figure 20-41-61
1
1
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1/16 in. drill.
N-190146
Drill a hole all the way through the plug using a 7/64 in.
tap drill

centering spring to the spool. Turn a 6-32 tap (Item 1) [Figure 20-41-63] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3 break the tap.
N•m) torque.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD
Figure 20-41-62 THREADS.
Figure 20-41-64
3
2 2
1 1
4
P-51776
P-74183
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-41-64].
NOTE: Check the O-ring for damage. The lift spool

will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
recheck the lift spool before the control valve
is replaced.

181 of 861
(CONT’D)

(Cont'd) 1
Figure 20-41-65
2
3
3
P-68044
Install the lift spool assembly (Item 1) [Figure 20-41-67]

in the spool bore.
P-74184 Install the end cap (Item 2) [Figure 20-41-67].
Install the mounting screws (Item 3) [Figure 20-41-67].

Install the plastic plug and O-ring in the spool [Figure 20-

41-65]. Installation: Lubricate the screws and tighten to 90 - 100
in.-lb. (10 - 11,3 N•m) torque.
Figure 20-41-66
2
1
P-51771 P-51775


182 of 861
(CONT’D)
(Cont'd) 1
Figure 20-41-68
P-68042
Install the O-ring (Item 1) [Figure 20-41-70] on the

control valve.
P-68048
Figure 20-41-71
Install the spool seal (Item 1) [Figure 20-41-68] on the

actuator end of the valve.
Figure 20-41-69 3
1
P-68040
2 Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-41-71].
P-68049
11,3 N•m) torque.
Install the O-ring (Item 1) and spacer (Item 2) [Figure 20-
41-69] on the lift spool. Connect the tube line (Item 3) [Figure 20-41-71] to the
end cap block.
Install the lift and tilt actuators to the control valve.

183 of 861
(CONT’D)
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-41-16.)
Figure 20-41-72
2
P-68051

1 2
Check and replace the O-ring (Item 2) [Figure 20-41-74]
before replacing the spool centering block.
P-68049

Figure 20-41-75
20-41-72] from the tilt spool.
Figure 20-41-73
1
1
2 1
P-68052
2 Remove the tilt spool, centering spring, back-up washer

and spool seal (Item 1) [Figure 20-41-75].
P-68050

Disconnect the tubeline (Item 1) [Figure 20-41-73].


N•m) torque.

184 of 861
(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
2 1
Figure 20-41-76
3
4
1
N-18944A
N-18942
Figure 20-41-79
Put the linkage end of the spool in the vice [Figure 20-
41-76]. 2

1
centering spring.
Figure 20-41-77
1
1
P-51545 N-18943

N-19014

centering spring to the spool.

N•m) torque.

185 of 861
(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-80
1 1
2
P-68054
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

P-68050
Figure 20-41-83
Disconnect the tubelines (Item 1) [Figure 20-41-80] from
the spool centering block.


N•m) torque.
2
Remove the spool centering block from the control valve. 1
Figure 20-41-81
P-68076

2 NOTE: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end of the spool,
also.
1
P-68053

NOTE: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end of the spool also.

186 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d) Figure 20-41-86
Figure 20-41-84
1 1
2
P-68082
P-68077
Remove the nut (Item 1) [Figure 20-41-86] from both
solenoids.
20-41-84] from the auxiliary spool. Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)

torque.
Figure 20-41-85
Figure 20-41-87
P-68078
P-51553
Remove the auxiliary spool (Item 1) [Figure 20-41-85].

Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-41-87].
Use an Ohm meter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.9 ± 0.25 Ohms.

187 of 861
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Solenoid Removal And Installation
(CONT’D)
Auxiliary Solenoid Removal And Installation (Cont’d) Figure 20-41-90
Figure 20-41-88
1
2
P-68084
P-68083
Remove the nut (Item 1) [Figure 20-41-90] from the
solenoid stem.
Remove the solenoid stem (Item 1) [Figure 20-41-88].
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19
N•m) torque. Remove the solenoid coil (Item 2) [Figure 20-41-90].
Figure 20-41-89 Figure 20-41-91
N-18693A
P-51555
Remove the O-rings (Item 1) [Figure 20-41-89] from the Remove the O-rings (Item 1) [Figure 20-41-91] from
solenoid stem. both ends of the solenoid coil.
Check and clean the screen (Item 2) [Figure 20-41-89]. Use an Ohm meter to measure the solenoid coil
resistance.
The correct resistance for the coil is 9.79 ± 0.29 Ohms.

188 of 861
(CONT’D)
Solenoid Removal And Installation (Cont’d)
Figure 20-41-92
3
2
1
1
N-18694

[Figure 20-41-93] from the stem.
P-68085
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any showing

Installation: Lubricate the O-rings and tighten the stem excessive wear.
to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
NOTE: The screen (Item 3) [Figure 20-41-93] may be
cleaned with solvent. If it is torn or worn it
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-91] & [Figure

20-41-93] and new back-up rings (Item 2) [Figure 20-41-
93] on the solenoid stem.

189 of 861
(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-94
1
1
1
2
1
1
2
2
2
P-51564

[Figure 20-41-96] from the lift lock valve, and replace
P-68079
with new.
Locate the two BICS lock valves, (Item 1) is for the tilt Figure 20-41-97
circuit, and (Item 2) [Figure 20-41-94] is for the lift circuit.

Figure 20-41-95
1
P-68080
Remove the tilt lock valve (Item 1) [Figure 20-41-97]

P-68081
from the back of the control valve.
Remove the lift lock valve (Item 1) [Figure 20-41-95] Installation: Lightly lubricate the lock valve o-rings and
from the back of the control valve. tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Installation: Lightly lubricate the lock valve o-rings and


190 of 861
(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-98
1
1
1
1
2
2
2
P-51564

[Figure 20-41-98] from the tilt lock valve, and replace

with new.

191 of 861
(CONT’D)
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-99
P-68087

valve.

Figure 20-41-100
P-51437
Check the lift arm bypass orifice (Item 1) [Figure 20-41-

100].
NOTE: This orifice is not removable from the valve

casting.

192 of 861
(CONT’D)
Main Relief Valve Removal And Installation
Figure 20-41-101
P-68088
Remove the main relief valve (Item 1) [Figure 20-41-

101].

Figure 20-41-102
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

[Figure 20-41-102].
Installation: Always use new O-rings. Tighten to 38 - 45


193 of 861
(CONT’D)
Check Valve Removal And Installation
Figure 20-41-103
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

105] and tighten the fitting to 20 - 24 ft.-lb. (27 - 33 N•m)
P-68081
torque.
Remove the tubeline (Item 1) [Figure 20-41-103]. Figure 20-41-106

Figure 20-41-104
P-68870
P-68010
Inspect the screen (Item 1) [Figure 20-41-106].
Remove the check valve fitting (Item 1) [Figure 20-41-

104] from the hydraulic control valve.

194 of 861
LIFT ARM BYPASS CONTROL VALVE Removal and Installation
Description
The lift arm bypass control valve is located on the right

side of the machine close to the engine speed control.
DANGER
The lift arm bypass control valve is manually operated by
pulling up on the valve knob (Item 1) [Figure 20-50-1]
and turning the knob clockwise a 1/4 turn. 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.
Testing P-90328
Figure 20-50-1 AVOID DEATH

1 unless supported by an approved lift arm
D-1009-0409

WARNING
P-68159 the lift arms are secured by an approved lift arm
support device can allow the lift arms or attachment
Raise the lift arms 6 feet (2 m) off the ground. Stop the to fall and cause injury or death.
engine. Turn the Lift Arm Bypass Control Knob (Item 1) W-2059-0598
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms
Install jack stands under the rear corners of the loader.
slowly lower.
Start the engine. Raise the lift arms and install an
The knob should return to its original position.
approved lift arm support device. (See Installing on Page
10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)

195 of 861
LIFT ARM BYPASS CONTROL VALVE (CONT'D) Remove the two mounting bolt/nuts (Item 4) [Figure 20-
50-3].
Installation: Tighten the mounting bolts to 180 - 200 in.-
Figure 20-50-2 lb. (21 - 23 N•m) torque.
Remove the lift arm bypass control valve.
1 Disassembly And Assembly
3 Figure 20-50-4
2
P-68160
Hold the Lift Arm Bypass Control knob (Item 1) and

loosen the jam nut (Item 2) on the Lift Arm Bypass valve

shaft [Figure 20-50-2].
P-26065
Remove the Lift Arm Bypass Control knob (Item 1) and
the jam nut (Item 2) from the Lift Arm Bypass valve shaft
[Figure 20-50-2]. Remove the bypass valve (Item 1) [Figure 20-50-4] from
the valve block. Inspect the bypass valve for damage and
Remove the rubber washer (Item 3) [Figure 20-50-2]. replace if necessary.
Figure 20-50-3 Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50

N•m) torque.
Inspect the hydraulic fittings on the valve block for

damage and replace if necessary.
2
3
1
P-68160
Disconnect the base end lift tubeline (Item 1) [Figure 20-

50-3] from the Lift Arm Bypass valve.
Disconnect the drain tubeline (Item 2) [Figure 20-50-3]

from the Lift Arm Bypass valve.
Disconnect the motor case drain hose (Item 3) [Figure

20-50-3].

196 of 861
HYDRAULIC PUMP (STANDARD) Install a hydraulic tester (Item 1) [Figure 20-60-1] onto
the front auxiliary quick couplers.
Description
This procedure will require a operator in the cab and one
The hydraulic gear pump is attached to the end of the operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle RPM. Press the Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
The hydraulic gear pump has a dedicated charge pump. RPM*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 140° F (60° C) by turning the restrictor
control clockwise on the tester so it reads about a 1000
A seal kit is available to service the hydraulic pump. If PSI (69 bar).
any of the main components of the pump are damaged,
the entire pump must be replaced. NOTE: DO NOT EXCEED 3300 PSI.
Pump Test at Quick Couplers Turn the restrictor control (Item 2) [Figure 20-60-1] on
the tester counterclockwise to obtain free flow, the flow
The tools listed will be needed to do the following should be approximately 16 - 17 GPM. Start turning the
procedure: restrictor clockwise, causing more restriction on the flow.

The GPM should drop off slightly until the pressure
MEL10003 - In-Line Hydraulic Tester reaches approximately 2800 PSI. At approximately 2800
MEL10006 - Flowmeter Fitting Kit PSI the flow should start decreasing rapidly until the
pressure reaches 3250 - 3300 PSI. At 3250 - 3300 PSI
Figure 20-60-1 the flow should be at 0 GPM. Turn the restrictor (Item 2)
[Figure 20-60-1] counterclockwise to free flow. Shut the
front auxiliary hydraulics off.
1
If flow and pressure specs are not obtained, go to Direct
Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full RPM.
P-16903 P-66894
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 3/4 in. in diameter and
connected directly to the hydraulic tester
without using any type of “quick coupler” on
the connection to the tester. Also make sure
your hydraulic tester is capable of at least 50
GPM.

197 of 861
HYDRAULIC PUMP (STANDARD) (CONT'D) Figure 20-60-2
Direct Pump Test (Standard Section)
The tools listed will be needed to do the following

procedure: 2
MEL1563 or 6689779 - Remote Start Tool

WARNING 1
P-68163
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
tubeline on the control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

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

P-48256
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Open the rear door of the loader. of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-3] from the tester to the tubeline (Item 2) [Figure
Connect the remote start tool. (See REMOTE START 20-60-2] on the control valve.
TOOL KIT -MEL1563 on Page 10-60-1.)
IMPORTANT
I-2024-0284

198 of 861
HYDRAULIC PUMP (STANDARD) (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Figure 20-60-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In Hydraulic Control
Valve

BH-196
Sample tester connection shown [Figure 20-60-4].
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
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor

control (Item 1) [Figure 20-60-4] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM*.
Push the maximum/variable flow switch (on the remote

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X 100

FREE FLOW (GPM)
A low percentage may indicate a failed pump.


199 of 861
Direct Pump Test (Charge Section)

procedure:

MEL10103 - Hydraulic Tester 2
MEL10106 - Hydraulic Test Kit 1
WARNING
P-69182
Failure to use jackstands can allow the machine to Disconnect the proportioning valve electrical connector
fall or move and cause injury or death. (Item 1) [Figure 20-60-5].
W-2017-0286
Remove the tie-strap (Item 2) [Figure 20-60-5] from the

Lift and block the loader. (See Procedure on Page 10-10- electrical harness.
1.)

Figure 20-60-6
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
P-69184
NOTE: The fluid from the charge pump must be
filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1)[Figure 20-60-6].
Hydrostatic Pumps.
Raise the operator cab. (See Raising on Page 10-30-2.) for system relief pressure and full RPM.
Connect the remote start tool. (See REMOTE START


200 of 861
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-60-7
4 3
P-48256A
2 1 Be sure all connections are tight and that the hoses are
P-69185 not touching any moving parts before starting the loader
[Figure 20-60-8].
Connect the filter inlet hose (Item 1) to the inlet side of

the tester (Item 2) [Figure 20-60-7].

Connect the OUTLET hose (Item 3) from the hydraulic
tester to the inlet fitting (Item 4) of the charge filter
IMPORTANT
[Figure 20-60-7].
I-2024-0284
RPM*.

600 PSI (41,4 bar). DO NOT exceed 1200 PSI (82,7 bar).
Open the restrictor control and record the free flow
(GPM) at full RPM*.
Turn the restrictor down to system operating pressure

approximately 1000 PSI (69 bar). DO NOT EXCEED
1200 PSI (82,7 bar). Refer to Hydraulic Schematics for
flow. The high pressure flow must be at least 80% of free
flow.
HIGH PRESSURE FLOW (GPM)
%= X 100
FREE FLOW (GPM)
*Refer to the Hydraulic Schematics for pump flow and

RPM.

201 of 861
DANGER
1
P-66880
P-90328
AVOID DEATH Disconnect and cap the outlet hoses (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 60-9] from the back of the hydraulic pump.
support. Replace if damaged. WARNING

D-1009-0409
IMPORTANT to fall and cause injury or death.
W-2059-0598

Figure 20-60-10
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Installing on

Page 10-20-1.) 1
device. (See Procedure on Page 10-10-1.)
Drain the hydraulic fluid from the reservoir. (See P-66882

Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
Disconnect and cap the inlet hoses (Item 1) [Figure 20-
Open the rear door of the loader. 60-10] from the front of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See

202 of 861
Figure 20-60-11
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-13] on the

P-66897 hydraulic pump.
Reverse the removal procedure to install the hydraulic

Figure 20-60-12 pump.

1
P-66898

11] and [Figure 20-60-12] from the hydraulic pump.
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb.

(75 - 85 N•m) torque.
Remove the hydraulic pump from the loader.

203 of 861
Hydraulic Pump Start Up
NOTE: This procedure to prevent a dry start up of the

hydraulic pump.
Figure 20-60-14
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Disconnect the pump inlet hose connection at the front of
the hydrostatic pump. Fill the pump inlet and hose Connect the starter bypass tool to the starter solenoid
completely with hydraulic fluid. Reconnect the hose battery terminal and S terminal. Crank the engine for 15
[Figure 20-60-14]. seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
Figure 20-60-15 tool [Figure 20-60-16].
Momentary Switch
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
After operating the engine at low idle, Remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
Starter Bypass Tool Check for hydraulic leaks.
P-59354
[Figure 20-60-15] To crank the engine without starting,

the machine key switch can be bypassed. Obtain a
starter bypass tool from a local source which can be used
as a universal connection to remotely crank the engine
without starting.
The starter bypass tool consists of two wires, each with a

clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.

204 of 861
HYDRAULIC PUMP (STANDARD) (CONT'D)
15
14
7 5
13
8
5 6
4
12 3

9
8
7
11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
12. Pump Center Section
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)
B-21259A

205 of 861
Disassembly And Assembly 1
Figure 20-60-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-60-
P-64508 18].
Mark the pump sections for correct assembly [Figure 20-

60-17].

Remove the eight pump housing bolts (Item 1) [Figure
20-60-17].
Installation: Tighten the bolts (Item 2) [Figure 20-60-17]

to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888

206 of 861
Figure 20-60-19 1
P-64511
2
Figure 20-60-22
P-64509
1
Figure 20-60-20

3
4
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 60-21] & [Figure 20-60-22] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-60-19] & [Figure 20-60-20] from the pump 60-22]. If excessive wear or damage is visible,
end section. the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-60-20]

inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-60-20] and bushings (Item 4) [Figure 20-60-
20]. If excessive wear or damage is visible, the
pump must be replaced.

207 of 861
Figure 20-60-23
P-64515
Figure 20-60-26
P-64513
Figure 20-60-24

1
P-64516
Remove the idler gear (Item 1) [Figure 20-60-25] &

P-64514 [Figure 20-60-26] from the pump center section.
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

Remove the drive gear (Item 1) [Figure 20-60-23] & 26]. If excessive wear or damage is visible, the
[Figure 20-60-24]. pump must be replaced.
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-


208 of 861
Figure 20-60-27
1
P-64519
1
2 Figure 20-60-30
P-64517
2
Figure 20-60-28

1
2 1
P-64520
Remove the load seal (Item 1) [Figure 20-60-29] &

P-64518 [Figure 20-60-30]. Inspect for damage and replace as
needed.
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-60-30].
[Figure 20-60-27] & [Figure 20-60-28] from the pump
center section. Inspect for damage and replace as
needed.

toward gears.

209 of 861
Figure 20-60-31
2
1
1
P-64526
Figure 20-60-34
P-64521
3
Inspect the pre-load seal (Item 1) [Figure 20-60-31] for

damage and replace as needed. 4

NOTE: Inspect the pump center section (Item 2) and
bushings (Item 3) [Figure 20-60-31]. If
excessive wear or damage is visible, the
pump must be replaced. 1
Figure 20-60-32
2
1
P-64527
Remove the wear plate (Item 1) and O-ring (Item 2)

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-60- pump must be replaced.
32].

210 of 861
Figure 20-60-35
1
P-64530
1
Remove the drive gear (Item 1) [Figure 20-60-37] from
P-64528 the pump flange section.
Figure 20-60-38
Figure 20-60-36

1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
60-35] & [Figure 20-60-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

60-36]. If excessive wear or damage is visible,
the pump must be replaced.

211 of 861
Figure 20-60-39
2
P-64535
Figure 20-60-42
P-64532
Remove the spline shaft (Item 1) [Figure 20-60-39] from

the end of the drive gear.

Remove the idler gear (Item 2) [Figure 20-60-39].
Figure 20-60-40
2
P-64536

1 [Figure 20-60-41] & [Figure 20-60-42] from the pump
flange section. Inspect for damage and replace as
needed.

P-64534 inlets and traps as shown with bronze side
toward gears.


212 of 861
Figure 20-60-43
3
2
1
P-64540

P-64537 damage and replace as needed.
NOTE: Inspect the pump flange section (Item 2) and

Figure 20-60-44 bushings (Item 3) [Figure 20-60-45]. If

Figure 20-60-46
1
2
2
1 P-30188A
P-64538

[Figure 20-60-44]. Inspect for damage and replace as
P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-60-44]. Remove the shaft seal (Item 1) [Figure 20-60-46] from
the pump flange section.
Installation: The shaft seal flush surface (Item 2)

[Figure 20-60-46] must be facing out away from the
pump.

213 of 861

214 of 861
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) NOTE: When testing the hydraulic flow of a machine,
Description connected directly to the hydraulic tester
The hydraulic gear pump is attached to the end of the the connection to the tester. Also make sure
hydrostatic pumps and is located on the right side of the your hydraulic tester is capable of at least 50
loader between the hydraulic control valve and the GPM.
engine.
Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
The hydraulic gear pump is a combination of gear pumps the front auxiliary quick couplers.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. operator running the tester.
pressure to the hydrostatic pump. Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
The high flow hydraulic pump has an additional pump trigger on the right handle. Make sure the tester is
section that provides an additional amount of flow that is connected correctly. If no flow is indicated on the tester,
controlled by an external valve. The valve is switched the hoses are connected wrong. With the hoses
from a button on the panel in the cab. connected correctly, increase the engine speed to full
RPM*.
A seal kit is available to service the hydraulic pump. If
any of the main components of the pump are damaged, Warm the fluid to 140° F (60° C) by turning the restrictor
the entire pump must be replaced. control clockwise on the tester so it reads about a 1000

PSI (69 bar).
Pump Test At Quick Couplers
NOTE: DO NOT EXCEED 3300 PSI.
procedure: Turn the restrictor control (Item 2) [Figure 20-61-1] on
MEL10003 - In-Lin Hydraulic Tester should be approximately 16 - 17 GPM. Start turning the
MEL10006 - Flow Meter Fitting Kit restrictor clockwise, causing more restriction on the flow.
Figure 20-61-1 reaches approximately 2800 PSI. At approximately 2800
PSI the flow should start decreasing rapidly until the
1 the flow should be at 0 GPM. Turn the restrictor (Item 2)

on Page 20-61-2.)

P-16903 P-66894

215 of 861
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Figure 20-61-2
(CONT'D)
The tools listed will be needed to do the following 2

procedure:

1
WARNING
P-68163

Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
that comes from the gear pump, and connects to the
W-2017-0286
Figure 20-61-3

1.)
2
WARNING 1

to fall and cause injury or death. P-48256
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-61-3] from

Raise the operator cab. (See Raising on Page 10-30-2.) the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Open the rear door of the loader. 20-61-3] from the tester to the tubeline (Item 2) [Figure
20-61-2] on the control valve.

216 of 861
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)
(CONT'D)
Figure 20-61-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
RPM*.


80% of free flow.

%= X 100
FREE FLOW (GPM)


217 of 861
(CONT'D)

procedure:
MEL1563 or 6689779 - Remote Start Tool 2

WARNING
P-69182

Disconnect the proportioning valve electrical connector
(Item 1) [Figure 20-61-5].
W-2017-0286
electrical harness.

1.) Figure 20-61-6
WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-69184

filtered after it passes through the Hydraulic Disconnect the filter inlet hose (Item 1)[Figure 20-61-6].
Tester, to prevent any contamination to the
Hydrostatic Pumps.


218 of 861
(CONT'D)
Figure 20-61-7
4 3
P-48256A
Be sure all connections are tight and that the hoses are
2 1 not touching any moving parts before starting the loader
P-69185 [Figure 20-61-8].


IMPORTANT
[Figure 20-61-7]. The hydraulic tester must be in the fully open
I-2024-0284
RPM*.

(GPM) at full RPM*.

flow.
%= X 100
FREE FLOW (GPM)

RPM.

219 of 861
(CONT'D)
Direct Pump Test (High Flow Section)
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-61-9] onto the

front auxiliary quick couplers.
the lift arms are secured by an approved lift arm Raise the lift arms and install an approved lift arm support
support device. Failure to use an approved lift arm device. (See Installing on Page 10-20-1.)

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)


220 of 861
(CONT'D)
EXAMPLE: TESTER
Direct Pump Test (High Flow Section) (Cont'd) CONNECTION
Reservoir
Figure 20-61-10
Hydraulic Pump
Out In
High Flow Valve
1
1 B-16277

2
P-48235 Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
Disconnect the high flow pump OUTLET hose (Item 1) coupler. Make sure the tester is connected correctly. If no
from the high flow valve INLET fitting (Item 2) [Figure 20-

flow is indicated on the tester, the hoses are connected
61-10]. wrong. With the hoses connected correctly, increase the
engine speed to full RPM*.
Figure 20-61-11
1000 PSI (6895 kPa).
2 1 Open the restrictor control and record the free flow

(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure. (See Adjusting
on Page 20-30-3.)
P-48256
Record the highest pressure (PSI) and flow (GPM). The
high pressure flow must be at least 80% of free flow.
the tester, to the high flow pump OUTLET hose (Item 1) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-61-10]. Connect the OUTLET hose (Item 2) FREE FLOW (GPM)
[Figure 20-61-11] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-61-10] on the High Flow A low percentage may indicate a failed pump.
valve.
*Refer to Hydraulic Schematics Legend for system relief
Lower the cab. pressure and full RPM.

221 of 861
(CONT'D)
DANGER
1
P-64545
P-90328
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
AVOID DEATH 61-13] from the back of the hydraulic pump.
tubeline, hose, fitting, component or a part failure Remove the Power Bob-Tach block if equipped. (See
can cause lift arms to drop. Removal And Installation on Page 20-130-1.)

D-1009-0409
WARNING
IMPORTANT support device. Failure to use an approved lift arm
When repairing hydrostatic and hydraulic systems, W-2059-0598
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-61-14
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)
Raise the lift arms and install an approved lift arm support 1
Drain the hydraulic fluid from the reservoir. (See

Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
P-66882

61-14] from the front of the hydraulic pump.

222 of 861
(CONT'D)
Figure 20-61-15
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-61-17] on the

hydraulic pump.
P-66897
pump.
Figure 20-61-16

1
P-66898

15] and [Figure 20-61-16] from the hydraulic pump.

(75 - 85 N•m) torque.
Remove the hydraulic pump from the loader.

223 of 861
(CONT'D)
Hydraulic Pump Start Up
NOTE: This procedure to prevent a dry start up of the

hydraulic pump.
Figure 20-61-18 Starter

Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Connect the starter bypass tool to the starter solenoid
the hydrostatic pump. Fill the pump inlet and hose
battery terminal and S terminal. Crank the engine for 15
completely with hydraulic fluid. Reconnect the hose
seconds, then stop for at least 30 seconds. Again, crank
[Figure 20-61-18].
tool [Figure 20-61-20].
Figure 20-61-19
Momentary Switch Start the loader from the operators cab and run the
hydraulics.
of cylinder stroke.

Check for hydraulic leaks.
Starter Bypass Tool
P-59354

without starting.


224 of 861
(CONT'D)
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7

12
7
8
7
9 6
5
3 4
6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
11. Auxiliary Center Section
12. Splined Shaft
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

225 of 861
(CONT'D)
1
Figure 20-61-21
1
P-64553
P-64554
1
1 Remove the high flow end section (Item 1) [Figure 20-
61-22].
P-64552

61-21].

20-61-21].

IMPORTANT
damage the system.
I-2003-0888

226 of 861
(CONT'D)

1
Figure 20-61-23
P-64556
2 Figure 20-61-26
P-64554
1
Figure 20-61-24

3
4
1 P-64557
2 Remove the high flow pump section (Item 1) [Figure 20-

61-25] & [Figure 20-61-26] from the charge center
P-64555 section.
NOTE: Inspect the high flow pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-26]. If excessive wear or
[Figure 20-61-23] & [Figure 20-61-24] from the high flow damage is visible, the pump must be
end section. replaced.

toward gears.
NOTE: Inspect the high flow end section (Item 3) and


227 of 861
(CONT'D)
Figure 20-61-27
P-64560
Figure 20-61-30
P-64558
Figure 20-61-28

1
P-64561

[Figure 20-61-30] from the charge center section.
P-64559
Remove the drive gear (Item 1) [Figure 20-61-27] & pump must be replaced.
[Figure 20-61-28].


228 of 861
(CONT'D)
Figure 20-61-31
1
P-64564
2 Figure 20-61-34
P-64562
2
Figure 20-61-32

1
2 1
P-64565

P-64563 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-34].

[Figure 20-61-31] & [Figure 20-61-32] from the charge
needed.

toward gears.

229 of 861
(CONT'D)

2
Figure 20-61-35
3
1
1 P-64569
Figure 20-61-38
P-64567 3

4
damage and replace as needed.

NOTE: Inspect the charge center section (Item 2) and
Figure 20-61-36
2
P-64571
1

needed.

toward gears.

P-64568 bushings (Item 4) [Figure 20-61-38]. If
Remove the charge center section (Item 1) [Figure 20-
61-36].

230 of 861
(CONT'D)
Figure 20-61-39
1
1
P-64574

the auxiliary center section.
P-64572
Figure 20-61-42
Figure 20-61-40

1
P-64575
P-64573
Remove the charge pump section (Item 1) [Figure 20- pump must be replaced.
61-39] & [Figure 20-61-40] from the auxiliary pump
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-61-40]. If excessive wear or
damage is visible, the pump must be
replaced.

231 of 861
(CONT'D)
Figure 20-61-43
1
2
1
2
P-64578
Figure 20-61-46
P-64576

the end of the drive gear. Inspect for damage and replace

as needed.
1
2
Figure 20-61-44
P-64579
1 Remove the wear plate (Item 1) and O-ring (Item 2)

[Figure 20-61-45] & [Figure 20-61-46] from the auxiliary
needed.

toward gears.
P-64577


232 of 861
(CONT'D)
2
Figure 20-61-47
1 1
P-64521

P-64519
NOTE: Inspect the auxiliary center section (Item 2)
and bushings (Item 3) [Figure 20-61-49]. If
Figure 20-61-48 excessive wear or damage is visible, the

2 Figure 20-61-50
1
P-64520

P-64525
needed.
Remove the auxiliary center section (Item 1) [Figure 20-
Remove the pre-load seal (Item 2) [Figure 20-61-48]. 61-50].

233 of 861
(CONT'D)
Figure 20-61-51
P-64528
1
Figure 20-61-54
P-64526
Figure 20-61-52

3
4 1
1 P-64529
Remove the auxiliary pump section (Item 1) [Figure 20-

2
61-53] & [Figure 20-61-54] from the pump flange
P-64527 section.
NOTE: Inspect the auxiliary pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-54]. If excessive wear or
[Figure 20-61-51] & [Figure 20-61-52] from the auxiliary damage is visible, the pump must be
center section. Inspect for damage and replace as replaced.
needed.

toward gears.


234 of 861
(CONT'D)
Figure 20-61-55
1
2
P-64532

P-64530
Remove the drive gear (Item 1) [Figure 20-61-55] from Figure 20-61-58

Figure 20-61-56
1
1
P-64534
P-64531 Remove the idler gear (Item 1) [Figure 20-61-58] from

NOTE: Inspect the drive gear (Item 1) [Figure 20-61- NOTE: Inspect the idler gear (Item 1) [Figure 20-61-
56]. If excessive wear or damage is visible, the 58]. If excessive wear or damage is visible, the
pump must be replaced. pump must be replaced.

235 of 861
(CONT'D)
Figure 20-61-59
P-64537
Figure 20-61-62
P-64535
Figure 20-61-60

2
P-64538
1

2 [Figure 20-61-62]. Inspect for damage and replace as
P-64536 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-62].

Remove the wear plate (Item 1) and section seal (Item 2)
needed.

toward gears.

236 of 861
(CONT'D)
Figure 20-61-63
3
2
1
P-64540


Figure 20-61-64
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-61-64] from


pump.

237 of 861

238 of 861
HYDRAULIC PUMP (SJC) Install a hydraulic tester (Item 1) [Figure 20-70-1] onto
the front auxiliary quick couplers.
Description
The hydraulic gear pump is attached to the end of the operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle RPM. Press the Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
The hydraulic gear pump has a dedicated charge pump. RPM*.
pressure to the hydrostatic pump. Warm the fluid to 140° F (60° C) by turning the restrictor
control clockwise on the tester so it reads about a 1000
A seal kit is available to service the hydraulic pump. If PSI (69 bar).
any of the main components of the pump are damaged,
the entire pump must be replaced. NOTE: DO NOT EXCEED 3300 PSI.
Pump Test At Quick Couplers Turn the restrictor control (Item 2) [Figure 20-70-1] on
The tools listed will be needed to do the following should be approximately 16 - 17 GPM. Start turning the
procedure: restrictor clockwise, causing more restriction on the flow.

MEL10003 - In-Line Hydraulic Tester reaches approximately 2800 PSI. At approximately 2800
MEL10006 - Flow Meter Fitting Kit PSI the flow should start decreasing rapidly until the
Figure 20-70-1 the flow should be at 0 GPM. Turn the restrictor (Item 2)
1
on Page 20-70-2.)

P-16903 P-66894
NOTE: When testing the hydraulic flow of a machine,

connected directly to the hydraulic tester
the connection to the tester. Also make sure
your hydraulic tester is capable of at least 50
GPM.

239 of 861
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-70-2

procedure: 2

WARNING 1
P-68163
W-2017-0286
1.)

WARNING 2
1

P-48256
W-2059-0598

240 of 861
HYDRAULIC PUMP (SJC) (CONT'D)
Figure 20-70-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
RPM*.


80% of free flow.

FREE FLOW (GPM)


241 of 861

procedure:

WARNING
P-69182
W-2017-0286

1.)

Figure 20-70-6
WARNING
W-2059-0598
P-69184
Hydrostatic Pumps.
Raise the operator cab. (See Raising on Page 10-30-2.) for system relief pressure and full RPM.


242 of 861
Figure 20-70-7
4 3
P-48256A
[Figure 20-70-8].


IMPORTANT
[Figure 20-70-7].
I-2024-0284
RPM*.

(GPM) at full RPM*.

flow.
%= X 100
FREE FLOW (GPM)

RPM.

243 of 861
HYDRAULIC PUMP (SJC) (CONT'D) Raise the lift arms and install an approved lift arm support
Drain the hydraulic fluid from the reservoir. (See
DANGER Removing And Replacing Hydraulic Fluid on Page 10-
120-2.)
Disconnect and cap the outlet hose (Item 1) [Figure 20-
70-9] from the back of the hydraulic pump.
Remove the Power Bob-Tach block (Item 2) [Figure 20-
70-9] if equipped. (See Removal And Installation on
Page 20-130-1.)
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
WARNING

D-1009-0409
W-2059-0598
Figure 20-70-10
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888
Figure 20-70-9 1
P-64547

70-10] from the front of the hydraulic pump.
1
P-64546

Page 10-10-1.)

244 of 861
HYDRAULIC PUMP (SJC) (CONT'D) Remove the hydraulic pump (Item 3) [Figure 20-70-12]
from the hydrostatic pump.
Figure 20-70-13
Figure 20-70-11
P-64446
P-64549
Replace the O-ring (Item 1) [Figure 20-70-13] in the

11] from the hydraulic pump. hydrostatic pump.

Installation: Tighten the mounting bolts to 55 - 60 ft.-lb. Reverse the removal procedure to install the hydraulic
(75 - 85 N•m) torque. pump.
Figure 20-70-12
3
1
P-64343
Remove the bracket mounting bolt (Item 1) from the

pump mounting bracket (Item 2) [Figure 20-70-12].
Note: The mounting bolt is a special purpose bolt.

Only replace with original Bobcat Parts.
Installation: Apply a medium strength threadlocker to

mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-70-

12].

245 of 861
Hydraulic Pump Startup
NOTE: This procedure to prevent a dry startup of the

hydraulic pump.
Figure 20-70-14
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Momentary Switch
hydraulics.
of cylinder stroke.

P-59354

without starting.


246 of 861
HYDRAULIC PUMP (SJC) (CONT'D)
15
14
7 5
13
8
5 6
4
12 3

9
8
7
11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
11. Spline Shaft
12. Pump Center Section
14. Pump End Section
15. Bolt (8)
B-21259A

247 of 861
Figure 20-70-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-70-
P-64508 18].

70-17].

20-70-17].

IMPORTANT
damage the system.
I-2003-0888

248 of 861
Figure 20-70-19 1
P-64511
2
Figure 20-70-22
P-64509
1
Figure 20-70-20

3
4
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 70-21] & [Figure 20-70-22] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-70-19] & [Figure 20-70-20] from the pump 70-22]. If excessive wear or damage is visible,
end section. the pump must be replaced.

toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-70-20] and bushings (Item 4) [Figure 20-70-

249 of 861
Figure 20-70-23
P-64515
Figure 20-70-26
P-64513
Figure 20-70-24

1
P-64516

P-64514 [Figure 20-70-26] from the pump center section.



250 of 861
Figure 20-70-27
1
P-64519
1
2 Figure 20-70-30
P-64517
2
Figure 20-70-28

1
2 1
P-64520

needed.
needed.

toward gears.

251 of 861
Figure 20-70-31
2
1
1
P-64526
Figure 20-70-34
P-64521
3


NOTE: Inspect the pump center section (Item 2) and
Figure 20-70-32
2
1
P-64527

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-70- pump must be replaced.
32].

252 of 861
Figure 20-70-35
1
P-64530
1
P-64528 the pump flange section.
Figure 20-70-38
Figure 20-70-36

1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
70-35] & [Figure 20-70-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

70-36]. If excessive wear or damage is visible,
the pump must be replaced.

253 of 861
Figure 20-70-39
2
P-64535
Figure 20-70-42
P-64532


Figure 20-70-40
2
P-64536

1 [Figure 20-70-41] & [Figure 20-70-42] from the pump
needed.

P-64534 inlets and traps as shown with bronze side
toward gears.


254 of 861
Figure 20-70-43
3
2
1
P-64540


Figure 20-70-44 bushings (Item 3) [Figure 20-70-45]. If

Figure 20-70-46
1
2
2
1 P-30188A
P-64538

P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-70-44]. Remove the shaft seal (Item 1) [Figure 20-70-46] from

pump.

255 of 861

256 of 861
HYDRAULIC PUMP (SJC) (HIGH FLOW) NOTE: When testing the hydraulic flow of a machine,
Description connected directly to the hydraulic tester
The hydraulic gear pump is attached to the end of the the connection to the tester. Also make sure
hydrostatic pumps and is located on the right side of the your hydraulic tester is capable of at least 50
loader between the hydraulic control valve and the GPM.
engine.
Install a hydraulic tester (Item 1) [Figure 20-71-1] onto
The hydraulic gear pump is a combination of gear pumps the front auxiliary quick couplers.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. operator running the tester.
pressure to the hydrostatic pump. Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
The high flow hydraulic pump has an additional pump trigger on the right handle. Make sure the tester is
section that provides an additional amount of flow that is connected correctly. If no flow is indicated on the tester,
controlled by an external valve. The valve is switched the hoses are connected wrong. With the hoses
from a button on the panel in the cab. connected correctly, increase the engine speed to full
RPM*.
A seal kit is available to service the hydraulic pump. If
any of the main components of the pump are damaged, Warm the fluid to 140° F (60° C) by turning the restrictor
the entire pump must be replaced. control clockwise on the tester so it reads about a 1000

PSI (69 bar).
Pump Test At Quick Couplers
procedure: Turn the restrictor control (Item 2) [Figure 20-71-1] on
MEL10003 - In-Line Hydraulic Tester should be approximately 16 - 17 GPM. Start turning the
MEL10006 - Flow Meter Fitting Kit restrictor clockwise, causing more restriction on the flow.
Figure 20-71-1 reaches approximately 2800 PSI. At approximately 2800
PSI the flow should start decreasing rapidly until the
1 the flow should be at 0 GPM. Turn the restrictor (Item 2)

on Page 20-71-2.)

P-16903 P-66894

257 of 861
HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D) Figure 20-71-2

procedure: 2

WARNING 1
P-68163
W-2017-0286
1.)

WARNING 2
1

P-48256
W-2059-0598

258 of 861
HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D)
Figure 20-71-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
RPM*.


80% of free flow.

FREE FLOW (GPM)


259 of 861

procedure:

WARNING
P-69182
W-2017-0286

1.)

Figure 20-71-6
WARNING
W-2059-0598
P-69184
Hydrostatic Pumps.


260 of 861
HYDRAULIC PUMP (SJC) (HIGH FLOW)(CONT'D) Figure 20-71-8
Figure 20-71-7
4 3
P-48256A
[Figure 20-71-8].


IMPORTANT
[Figure 20-71-7].
I-2024-0284
RPM*.

(GPM) at full RPM*.

flow.
%= X 100
FREE FLOW (GPM)

RPM.

261 of 861
Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-71-9] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)


262 of 861
Direct Pump Test (High Flow Section) (Cont'd) EXAMPLE: TESTER

CONNECTION
Reservoir
Figure 20-71-10
Hydraulic Pump
Out In
High Flow Valve
1 1
B-16277
2 Sample tester connection shown [Figure 20-71-12].

P-48235
Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
Disconnect the high flow pump OUTLET hose (Item 1) button (on the right control lever) for fluid flow to the quick
from the high flow valve INLET fitting (Item 2) [Figure 20- coupler. Make sure the tester is connected correctly. If no

71-10]. flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
Figure 20-71-11 engine speed to full RPM*.

1000 PSI (6895 kPa).

2 1
(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Adjustment on Page 20-150-2.)
P-48256
Record the highest pressure (PSI) and flow (GPM). The

high pressure flow must be at least 80% of free flow.
the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-71-10]. Connect the OUTLET hose (Item 2) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-71-11] from the tester, to the high flow valve FREE FLOW (GPM)
INLET fitting (Item 2) [Figure 20-71-10] on the High Flow
valve. A low percentage may indicate a failed pump.
Lower the cab. *Refer to Hydraulic Schematics Legend for system relief
pressure and full RPM.

263 of 861
DANGER
P-64545
P-90328
AVOID DEATH Figure 20-71-14


D-1009-0409
1
2
Page 10-10-1.)
P-64546
Drain the hydraulic fluid from the reservoir. (See Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Removing And Replacing Hydraulic Fluid on Page 10- 71-13] and [Figure 20-71-14] from the back of the
120-2.) hydraulic pump.
Open the rear door of the loader. Remove the Power Bob-Tach block (Item 2) [Figure 20-
71-14] if equipped. (See Removal And Installation on
Page 20-130-1.)
WARNING
W-2059-0598

264 of 861
Figure 20-71-15
3
1
1
2
1 P-64343
Remove the bracket mounting bolt (Item 1) from the

P-64544 pump mounting bracket (Item 2) [Figure 20-71-17].
NOTE: The mounting bolt is a special purpose bolt.
Disconnect and cap the inlet hoses (Item 1) [Figure 20- Only replace with original Bobcat Parts.
71-15] from the front of the hydraulic pump. Installation: Apply a medium strength threadlocker to

mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
Figure 20-71-16 N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-71-
17].
Remove the hydraulic pump (Item 3) [Figure 20-71-17]
from the hydrostatic pump.
Figure 20-71-18
1
P-64549

16] from the hydraulic pump.

(75 - 85 N•m) torque.
P-64446
Replace the O-ring (Item 1) [Figure 20-71-18] in the

hydrostatic pump.

pump.

265 of 861
Hydraulic Pump Startup
NOTE: This procedure to prevent a dry startup of the

hydraulic pump.
Figure 20-71-19
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Momentary Switch
hydraulics.
of cylinder stroke.

P-59354

without starting.


266 of 861
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7
12

7
8
7
9 6
5
3 4
6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
11. Auxiliary Center Section
12. Splined Shaft
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

267 of 861
Figure 20-71-22
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 71-23].

71-22].

20-71-22].

IMPORTANT
damage the system.
I-2003-0888

268 of 861
Figure 20-71-24 1
P-64556
2
Figure 20-71-27
P-64554
1
Figure 20-71-25

3
4
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 71-26] & [Figure 20-71-27] from the charge center
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-71-24] & [Figure 20-71-25] from the high flow [Figure 20-71-27]. If excessive wear or
end section. damage is visible, the pump must be
replaced.
toward gears.
NOTE: Inspect the high flow end section (Item 3) and


269 of 861
Figure 20-71-28
P-64560
Figure 20-71-31
P-64558
Figure 20-71-29

1
P-64561

P-64559 [Figure 20-71-31] from the charge center section.



270 of 861
Figure 20-71-32
P-64564
2
Figure 20-71-35
P-64562
2
Figure 20-71-33

1
2
1
P-64565

needed.
needed.

toward gears.

271 of 861
Figure 20-71-36 2
3
1
1
P-64569
Figure 20-71-39
P-64567
3


1
Figure 20-71-37
2
1 P-64571

needed.

toward gears.
P-64568 NOTE: Inspect the charge center section (Item 3) and

Remove the charge center section (Item 1) [Figure 20- pump must be replaced.
71-37].

272 of 861
Figure 20-71-40
1 1
P-64574

P-64572 the auxiliary center section.
Figure 20-71-43
Figure 20-71-41

1
P-64575
P-64573

Remove the charge pump section (Item 1) [Figure 20- 43]. If excessive wear or damage is visible, the
71-40] & [Figure 20-71-41] from the auxiliary pump pump must be replaced.
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-71-41]. If excessive wear or
damage is visible, the pump must be
replaced.

273 of 861
Figure 20-71-44
1 2
2
P-64578
Figure 20-71-47
P-64576

the end of the drive gear. Inspect for damage and replace

as needed.
Remove the idler gear (Item 2) [Figure 20-71-44]. 1
Figure 20-71-45 2
P-64579
1
[Figure 20-71-46] & [Figure 20-71-47] from the auxiliary
needed.

P-64577 toward gears.


274 of 861
Disassembly And Assembly (Cont'd) 2
Figure 20-71-48
1
1
P-64521


Figure 20-71-49 and bushings (Item 3) [Figure 20-71-50]. If

2
Figure 20-71-51
1
P-64520

P-64525
needed.
Remove the pre-load seal (Item 2) [Figure 20-71-49]. Remove the auxiliary center section (Item 1) [Figure 20-
71-51].

275 of 861
Figure 20-71-52
P-64528
1
Figure 20-71-55
P-64526
Figure 20-71-53

3
4
1
1
P-64529
2 Remove the auxiliary pump section (Item 1) [Figure 20-

P-64527 71-54] & [Figure 20-71-55] from the pump flange
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-71-52] & [Figure 20-71-53] from the auxiliary [Figure 20-71-55]. If excessive wear or
center section. Inspect for damage and replace as damage is visible, the pump must be
needed. replaced.

toward gears.


276 of 861
Figure 20-71-56
1
1
P-64532

P-64530 the end of the drive gear.

the pump flange section. Figure 20-71-59

Figure 20-71-57
1
1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-71-59] from
57]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-71-
pump must be replaced. 59]. If excessive wear or damage is visible, the

277 of 861
Figure 20-71-60
P-64537
Figure 20-71-63
P-64535
Figure 20-71-61

2
1 P-64538

2
needed.
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-71-63].
needed.

toward gears.

278 of 861
Figure 20-71-64
3
2
1
P-64540


Figure 20-71-65
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-71-65] from


pump.

279 of 861

280 of 861
HYDRAULIC/HYDROSTATIC FILTERS Disconnect the tubeline (Item 3) [Figure 20-80-1] from
the filter housing.
Description
Figure 20-80-2
The hydraulic/hydrostatic filters help to remove
contaminants from the hydraulic fluid when the hydraulic/
hydrostatic systems are operating.
The hydraulic/hydrostatic filter system consists of one

gear pump filter and one charge pressure filter.
The gear pump hydraulic/hydrostatic filter removes 1

contaminants after the oil cooler.
2
The charge pressure filter removes contaminants after
the hydraulic cooling fan before the oil enters the
hydrostatic pump.
P-68220
IMPORTANT Disconnect the temperature sender connector (Item 1)

[Figure 20-80-2] from the filter housing.

Disconnect the wire connector (Item 2) [Figure 20-80-2]
from the differential pressure switch on the filter housing.
damage the system.
I-2003-0888
Housing Removal And Installation
Figure 20-80-1
2
P-68234
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.)
Remove the mounting bolt (Item 1) and remove the

hydraulic filter drip pan (Item 2) [Figure 20-80-1].

281 of 861
HYDRAULIC/HYDROSTATIC FILTERS (CONT’D) Figure 20-80-4
Housing Removal And Installation (Cont’d)
Figure 20-80-3 1
P-48258
Remove the two mounting screws (Item 1) [Figure 20-

P-48257 80-4] from the filter housing mounting bracket.
Installation: Tighten the mounting screws to 15 - 20 ft.-

Using MEL 1558 tool disconnect the oil cooler tubeline lb. (20 - 27 N•m) torque.
(Item 1) [Figure 20-80-3] from the filter housing.

Remove the hydraulic filter housing and filter.
Reverse the removal procedure to install the filter

housing and filter.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.)

282 of 861
HYDRAULIC/HYDROSTATIC FILTERS (CONT’D) Figure 20-80-7
Charge Filter Housing Removal And Installation
Figure 20-80-5 2
2 1
2
1 P-68127
Remove filter inlet hose (Item 1) [Figure 20-80-7].

P-66884
Remove the four mounting screws (Item 2) [Figure 20-
80-7].
Remove filter outlet hose (Item 1) [Figure 20-80-5].
Installation: Tighten the mount screws to 15 - 20 ft.-lb.

Disconnect the electrical connector (Item 2) [Figure 20- (20 - 27 N•m) torque.
80-5] from the charge pressure sender.
Remove filter assembly from the loader.
Figure 20-80-6
Figure 20-80-8
2
1
P-66884
P-66609
Disconnect the charge pressure tubeline (Item 1) [Figure

20-80-6] that connects to the control valve. Remove the four mounting bolts (Item 1) [Figure 20-80-
8].
Disconnect the electrical connector from the filter sensor
(Item 2) [Figure 20-80-6]. Installation: Tighten the mount bolts to 25 ft.-lb. (34
N•m) torque.

283 of 861

284 of 861
HYDRAULIC FLUID RESERVOIR
Description
The hydraulic fluid reservoir is a storage container for the

IMPORTANT
loaders hydraulic/hydrostatic fluid. The reservoir contains
a vented fill cap with a fluid screen to prevent When repairing hydrostatic and hydraulic systems,
contaminants from entering the reservoir while adding clean the work area before disassembly and keep all
fluid. parts clean. Always use caps and plugs on hoses,
The hydraulic fluid reservoir is located below the damage the system.
I-2003-0888
operators cab on the left side of the loader.
Removal And Installation Stop the engine.
Lift and block the loader. (See Procedure on Page 10-10- Raise the operator cab. (See Raising on Page 10-30-2.)
1.)
Remove the fluid from the hydraulic reservoir.
Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page Remove the control panel. (See Removal and Installation
10-20-1.) on Page 50-100-2.)
Remove Bucket position valve if so equipped. (See

DANGER

Remove the control panel, if so equipped. (See Removal
and Installation on Page 50-100-2.)
Figure 20-90-1
P-90328 2
AVOID DEATH
support. Replace if damaged. 1
D-1009-0409
P-34113
Remove the left rear tire assembly (Item 1) [Figure 20-

WARNING 90-1].
Remove the two access panels (Item 2) [Figure 20-90-

Never work on a machine with the lift arms up unless 1].
W-2059-0598

285 of 861
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-90-4
Figure 20-90-2
1 3
1 2
2 P-68132
Remove the drive motor drain hose (Item 1) [Figure 20-

P-68130 90-4] at the drain filter
Remove the auxiliary pressure relief drain hose (Item 2)

Remove the two mounting screws (Item 1) and remove [Figure 20-90-4] at the drain filter.
the plate (Item 2) [Figure 20-90-2] from the loader.

Remove the drive motor supply hose (Item 3) [Figure 20-
Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27 90-4] from the drive motor and the hydrostatic pump.
N•m) torque.
Figure 20-90-5
Figure 20-90-3
2
1
1
P-68131
P-66831
Remove the control valve drain hose (Item 1) [Figure 20-

Remove the hose clamp (Item 1) [Figure 20-90-3] from 90-5].
the fill hose.
Remove the hydraulic fill hose (Item 2) [Figure 20-90-3] reservoir.
from the hydraulic reservoir.

286 of 861
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-90-8
Figure 20-90-6
2
P-34044
Remove the hose clamp (Item 1) [Figure 20-90-8] from

P-34042 the fitting.
Remove the breather hose (Item 2) [Figure 20-90-8]

Remove the hose clamp (Item 1) [Figure 20-90-6] from from the hydraulic reservoir.
the tank outlet.

Figure 20-90-9
Remove the hydrostatic supply hose (Item 2) [Figure 20-
90-6] from the bottom of the reservoir.
Figure 20-90-7
1
1
2
P-34052
Remove the hydraulic reservoir (Item 1) [Figure 20-90-9]

P-34043 from the loader.
Remove the bolt and nut (Item 1) [Figure 20-90-7].
Loosen the bolt and nut (Item 2) [Figure 20-90-7] to

allow the hydraulic reservoir mount to drop down.

287 of 861
HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Figure 20-90-10
P-68128

Remove the hose clamp (Item 1) and remove the
hydraulic fill hose (Item 2) [Figure 20-90-10] from the
hydraulic reservoir.
Figure 20-90-11
P-68129
Remove the hydraulic fluid screen (Item 1) [Figure 20-

90-11] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

288 of 861
OIL COOLER Figure 20-100-2
Description
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
The oil cooler is located underneath the rear grill between

the A/C condenser (if so equipped) and the radiator.
N-19346
IMPORTANT Figure 20-100-3

damage the system.

I-2003-0888
Remove the rear grill from the loader. (See Removal And
Installation on Page 50-60-1.)
Figure 20-100-1
P-45242
1
2
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 20-100-2] & [Figure 20-
100-3].
N-19345
Install tool MEL 1558 (Item 1) to outside of rubber sleeve

(Item 2) [Figure 20-100-1].

289 of 861
OIL COOLER (CONT’D)
Removal and Installation (Cont’d)
Figure 20-100-4
1
2
1
P-45101
Disconnect the inlet and outlet hoses (Item 1) from the oil
cooler (Item 2) [Figure 20-100-4].

NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.

290 of 861
BUCKET POSITION VALVE Figure 20-110-2
Description
The Bucket Position Valve is an option that allows the

loader to meter the lift and tilt circuits. The metering of the
lift and tilt circuits allows the operator to hold the
attachment at the same angle from the ground to 2
maximum lift height without using the tilt function.
The bucket position valve is located below the operators

cab on the right side of the hydraulic fluid reservoir.
See Hydraulic Schematic for more circuit information. 1

(See HYDRAULIC SYSTEM INFORMATION on Page
20-10-1.) P-26311A
Solenoid Removal And Installation

Remove the solenoid nut (Item 1) [Figure 20-110-2].
Figure 20-110-1
Installation: Tighten the solenoid nut to 4 - 6 ft.-lb. max.
(5 - 8 N•m max.) torque. Overtightening may cause valve
failure.

Remove the solenoid coil (Item 2) [Figure 20-110-2].
Figure 20-110-3
1 2
P-68162
Disconnect the wire harness connector (Item 1) [Figure

20-110-1] from the bucket position shut-off solenoid.
NOTE: Loosening the two mounting screws (Item 2) 1

[Figure 20-110-1] on the Bucket Positioning P-26312A
Valve Bracket may aid in the solenoid
removal.
Remove the solenoid stem (Item 1) [Figure 20-110-3]
from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.

291 of 861
BUCKET POSITION VALVE (CONT'D) Solenoid Testing
Solenoid Removal And Installation (Cont’d) Figure 20-110-5
Figure 20-110-4
1
2
P9175
N-18191
Use a test meter to measure coil resistance [Figure 20-
110-5]. Coil wires do not have polarity. Correct resistance
Inspect the solenoid stem and replace the O-rings (Item for the coil is 9.8 ohm.
1) and the back-up washer (Item 2) [Figure 20-110-4].

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

292 of 861
BUCKET POSITION VALVE (CONT'D) Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
Removal And Installation 10-20-1.)
Stop the engine.
DANGER Raise the operator cab. (See Raising on Page 10-30-2.)
Disconnect the electric solenoid connector (Item 1)

[Figure 20-110-6].
Figure 20-110-7
P-90328
AVOID DEATH
2

1
D-1009-0409
P-26311A

W-2059-0598
1
Figure 20-110-6
P-26312A

1
Installation: Tighten the nut to 4 - 6 ft.-lb. max. (5 - 8
N•m max.) torque. Overtightening may cause valve
failure.
Remove the solenoid (Item 2) [Figure 20-110-7] and the

solenoid stem (Item 1) [Figure 20-110-8].
P-68162
Installation: Put oil on the O-rings and back-up washers

and tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.

293 of 861
BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 20-110-11

Figure 20-110-9
N-19069
P-68158

Disconnect the tubeline (Item 1) [Figure 20-110-9] from
the fitting under the solenoid on the bucket position valve. Assembly: Tighten the nut to 6 ft.-lb. max. (8 N•m max.)
torque. Overtightening may cause valve failure.

Figure 20-110-10
Figure 20-110-12
1 4
2
3 P-68157
N-19070
Remove the tubeline (Item 1) [Figure 20-110-10] from

the B port to the control valve. Remove the solenoid (Item 1) and the solenoid stem
(Item 2) [Figure 20-110-12].
the C port (tilt rod end) on the BPV. Installation: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 30 - 40 ft.-lb. (40,7 - 50,2
Disconnect the tubeline (Item 3) [Figure 20-110-10] from N•m) torque.
the D port (tilt base end) on the BPV.
Remove the mounting screws (Item 4) [Figure 20-110-

10].
Installation: Tighten the mounting screws to 15 - 20 ft.-

Remove the bucket position valve and bracket from the

loader.

294 of 861
BUCKET POSITION VALVE (CONT'D) Figure 20-110-15
Figure 20-110-13
N-18339
1 Remove the plug (Item 1), and flow control spool (Item 2)
N-19072 [Figure 20-110-15].
Assembly: Tighten the plug to 56 - 64 ft.-lb. (75,9 - 86,8

Remove the flow adjustment valve and O-ring (Item 1) N•m) torque.
[Figure 20-110-13].

Check the flow control spool for wear, check the O-ring
Installation: Tighten the flow adjustment valve to 15 - 30 on the plug and replace as needed.
ft.-lb. (20,3 - 40,7 N•m) torque.
Figure 20-110-16
NOTE: Always install new O-rings before any parts
are installed into the valve. Check the parts
for wear or damage and replace as needed.
Figure 20-110-14
3
N-19042
Remove the tilt cylinder check valve (item 1) spring (Item

1 2) and plug (Item 3) [Figure 20-110-16]. Check for wear,
N-19041 check the O-ring and replace as needed.

Remove the plug (Item 1) [Figure 20-110-14]. N•m) torque.

N•m) torque.

295 of 861
BUCKET POSITION VALVE (CONT'D)
Figure 20-110-17
N-19045
Remove the plug [Figure 20-110-17].

N•m) torque.
Figure 20-110-18
N-19046
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-110-18].
Check all parts and replace as needed. Install a new O-

ring on the plug before installing.

N•m) torque.

296 of 861
REAR AUXILIARY DIVERTER VALVE
Description
WARNING
The rear auxiliary diverter valve is an optional valve that
diverts oil from the front auxiliary circuit to two sets of rear
auxiliary couplers or the right side auxiliaries. The AVOID INJURY OR DEATH
couplers are used for rear mounted attachments.The Always clean up spilled fuel or oil. Keep heat, flames,
right side auxiliaries are used for older attachments. sparks or lighted tobacco away from fuel and oil.
The rear couplers are located, one set on each side of explosion or fire.
the rear frame uprights. W-2103-0508
The right side auxiliaries are located on the inside of the

right side lift arm at the front of the machine. Lift and block the loader. (See Procedure on Page 10-10-
1.)
The rear auxiliary valve is located on the right side of the
machine behind the blower housing. The valve is Raise the lift arms and install an approved lift arm support
accessed by remove a panel on the right side of the device. (See Installing on Page 10-20-1.)
machine.
See Hydraulic Schematic for more circuit information.
(See HYDRAULIC SYSTEM INFORMATION on Page Disconnect the negative battery cable. (See Removal
20-10-1.) And Installation on Page 60-20-1.)

Remove the speed control lever. (See Removal And
DANGER Remove the control panel. (See Removal and Installation

on Page 50-100-2.)
Remove the right rear tire. (See TIRE MAINTENANCE

on Page 10-160-1.)
Figure 20-120-1
P-90328
AVOID DEATH
• Keep out of this area when lift arms are raised 1
D-1009-0409
P-48301
WARNING The rear auxiliary valve (Item 1) [Figure 20-120-1] is

located between the control valve and the gear pump on
the right side of the loader.
W-2059-0598

297 of 861
REAR AUXILIARY DIVERTER VALVE (CONT'D) Remove the three access covers (Item 1) [Figure 20-
120-3] on the right side of the machine.
Figure 20-120-4
IMPORTANT
damage the system. 1
I-2003-0888
Figure 20-120-2
P-48300
Disconnect the four solenoid connectors (Item 1) [Figure

20-120-4] from the rear auxiliary valve.

Figure 20-120-5
1
2
P-48302 1
Disconnect the base and rod end tubelines (Item 1)

[Figure 20-120-2].
Remove the fittings (Item 2) [Figure 20-120-2] from the

valve.
P-48304
Figure 20-120-3
Disconnect the drain tubeline (Item 1) [Figure 20-120-5]
from the lift arm by pass valve.
P-48872

298 of 861
REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-120-8
Figure 20-120-6
1
P-48869
Loosen and remove the two bolts and nuts (Item 1)

P-48303 [Figure 20-120-8] that hold the rear auxiliary valve.
Figure 20-120-9
Disconnect and remove the drain tubeline (Item 1)
[Figure 20-120-6] from the rear auxiliary valve.

Figure 20-120-7
2
P-48870
1
Remove the rear auxiliary valve (Item 1) [Figure 20-120-
P-48305 9] by moving the valve to the rear access hole which
allows enough room for the valve to be removed from the
loader.
Disconnect the pump outlet hose (Item 1) [Figure 20-
120-7] from the rear auxiliary valve. The valve needs to be tilted as shown in [Figure 20-120-
9] for it to be removed through the hole.
the bottom of the control valve and the rear auxiliary
valve.

299 of 861
IMPORTANT
clean the work area before disassembly and keep all 1
I-2003-0888
P-76791
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct There are 11 #4 SAE hex head plugs (Item 1) [Figure 20-
assembly. 120-11] located on all sides of the diverter valve and can
be removed for clean out purposes.
Figure 20-120-10
Assembly: Put oil on O-rings. Tighten to 10 ft.-lb. (13,6
N•m) torque.

2 Figure 20-120-12
1
P-76747
Remove the two mount bolts (Item 1) from the diverter

valve mount plate (Item 2) [Figure 20-120-10] and
P-48752
remove the mount plate.
Inspect O-ring (Item 1) [Figure 20-120-12].
Assembly: Put oil on O-ring.

300 of 861
Disassembly And Assembly (Cont’d)
Figure 20-120-13
1
1
P-76789A
Remove the differential sensing valve (Item 1) [Figure

P-76789A 20-120-15].
Assembly: Put oil on O-rings and back-up washers.

Remove the shuttle valve (Item 1) [Figure 20-120-13]. Tighten to 85 ft.-lb. (115,25 N•m) torque.

Assembly: Put oil on the O-rings and back-up washers. Figure 20-120-16
Tighten to 8 ft.-lb. (10,8 N•m) torque.
Figure 20-120-14
1
1 1
2 P-48757
P-48756 Inspect the O-rings (Item 1) and back-up washers (Item

2) [Figure 20-120-16] for damage.
Inspect the O-rings (Item 1) and back-up washers (Item


301 of 861

1
Figure 20-120-17
1 P-76794
NOTE: Before removing the solenoid coils, mark the

P-48753 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-120-19] from the

Remove the relief valve (Item 1) [Figure 20-120-17]. solenoid valve stem.

Assembly: Put oil on O-rings and back-up washers. Assembly: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)
Tighten to 25 ft.-lb. (34 N•m) torque. torque.
Figure 20-120-18 Figure 20-120-20
2
2
1
P-48754 P-76796
Inspect the O-rings (Item 1) and back-up washer (Item 2) Remove the metal shields (Item 1) and solenoid valve
[Figure 20-120-18] for damage. coils (Item 2) [Figure 20-120-20].

302 of 861
Figure 20-120-21
1
P-48761
NOTE: Before removing the solenoid coils, mark the

P-48763A coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-120-23] from the

Remove the solenoid valve stem (Item 1) [Figure 20- solenoid valve stems.
120-21]

Assembly: Tighten the nut to 4 - 6 ft.-lb. (5-8 N•m)
Assembly: Put oil on the O-rings and back-up washers. torque.
Tighten to 25 ft.-lb. (34 N•m) torque.
Figure 20-120-24
Figure 20-120-22
1
1
P-48762
2 P-48764
Remove the solenoid valve stems (Item 1) [Figure 20-

Inspect the O-rings (Item 1) and back-up washers (Item 120-24].
Assembly: Put oil on the O-rings and back-up washers.
Tighten to 25 ft.-lb. (34 N•m) torque.

303 of 861
Figure 20-120-25
1 1
P-48752
2

P-76833
Assembly: Put oil on O-ring.
Inspect the O-rings (Item 1) and back-up washer (Item 2) Figure 20-120-28
[Figure 20-120-25].

Figure 20-120-26
1
P-48766
P-48765 Remove and inspect the orifice (Item 1) [Figure 20-120-

28] for dirt and debris.
Remove the #8 SAE hex head plug (Item 1) [Figure 20- Assembly: Tighten the orifice to 22 ft.-lb. (29,8 N•m)
120-26]. torque.
Assembly: Tighten the plug to 38 ft.-lb. (51,5 N•m)

torque.

304 of 861

1
Figure 20-120-29
1
2
P-76798
Remove the #4 SAE hex head plug (Item 1) and the #6

P-48765 SAE hex head plugs (Item 2) [Figure 20-120-31].
Assembly: Tighten the #4 SAE hex head plug to 10 ft.-

Remove the #4 SAE hex head plug (Item 1) [Figure 20- lb. (13,6 N•m) torque.
120-29].

Assembly: Tighten the #6 SAE hex head plugs to 14 ft.-
Assembly: Tighten the plug to 10 ft.-lb. (13,6 N•m) lb. (19 N•m) torque.
torque.
Figure 20-120-32
Figure 20-120-30
P-48752
P-48786

Remove the orifice (Item 1) [Figure 20-120-30] and
inspect for dirt and debris. Assembly: Put oil on O-ring.
Assembly: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m)

torque.

305 of 861
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Solenoid Testing
Figure 20-120-33
P9137

120-33]. Coil wires do not have polarity. Correct

resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.

306 of 861
BOB-TACH (POWER) BLOCK
Description
The power Bob-Tach block is an option that allows the

IMPORTANT
operator to hydraulically control the Bob-Tach levers for
mounting and dismounting the attachments. When repairing hydrostatic and hydraulic systems,
The power Bob-Tach is operated by a switch on the front parts clean. Always use caps and plugs on hoses,
console. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The power Bob-Tach block is mounted on the right side
of the machine in front of the engine on the backside of
the hydraulic gear pump. Figure 20-120-1

3
WARNING 1


support device can allow the lift arms or attachment 3
W-2059-0598 2
P-66869
DANGER Lift and block the loader. (See Procedure Page 10-10-1.)
device. (See Installing Page 10-20-1.)
Raise the operator cab. (See Raising Page 10-30-2.)
Open the rear door.

P-90328 Replacing Hydraulic Fluid Page 10-120-2.)
AVOID DEATH Remove the nut from the speed control linkage (Item 1)
• Disconnecting or loosening any hydraulic and unplug the rear lights electrical connector (Item 2)
tubeline, hose, fitting, component or a part failure [Figure 20-120-1].
• Keep out of this area when lift arms are raised Remove the fuel fill bracket mounting bolts (Item 3)
unless supported by an approved lift arm [Figure 20-120-1].
D-1009-0409

307 of 861
BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-130-4
Figure 20-130-2
P-48227
Remove the four mounting bolts (Item 1) [Figure 20-130-

P-48230 4].

Installation: The harness connectors are marked with (34 - 38 N•m) torque.
Red or Black tie straps. Be sure the connectors with the

same color are connected. Remove the power Bob-Tach block.
Disconnect the power Bob-Tach harness from the NOTE: There is an O-ring in-between the power Bob-
solenoid connectors (Item 1) [Figure 20-130-2] by the Tach block and the hydraulic pump. Inspect
hydraulic pump. and replace as needed.
Figure 20-130-3
P-48226

“DR” port fitting on the block.

power Bob-Tach cylinder rod end fitting on the block.

power Bob-Tach cylinder base end fitting on the block.
Disconnect the outlet hose (Item 4) [Figure 20-130-3]

from the fitting on top of the block.

308 of 861
Figure 20-130-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-130-6].
Check the O-ring (Item 4) [Figure 20-130-6] on the plug

Clean the block (Item 1) [Figure 20-130-5] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-130-7
Remove the plug (Item 2) [Figure 20-130-5].
Assembly: Tighten the plug to 25 - 30 ft.-lb. (34 - 40,6

N•m) torque.
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly P-48116
damage the system.

I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-7].
Assembly: Tighten the plug to 12 - 14 ft.-lb. (16,3 - 19

N•m) torque.

309 of 861
Figure 20-130-8
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-130-10].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-130-8]. will be altered.

Assembly: Oil the check valve and O-rings and tighten Figure 20-130-11
the check valve to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.
Figure 20-130-9
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-130-11], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Assembly: Tighten the plug (Item 1) [Figure 20-130-11]
(Item 2) [Figure 20-130-9]. to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
Check the O-rings and back up washers (Item 3) [Figure

20-130-9] on the check valve and piston assembly and
replace as needed.

310 of 861
Figure 20-130-12 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-130-14].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.
plug (Item 1) [Figure 20-130-11] & [Figure 20-130-12].

Figure 20-130-15
Assembly: Tighten the orifice screw (Item 2) [Figure 20-
130-12] to 6 - 8 ft.-lb. (8,1 - 10,8 N•m) torque.
Figure 20-130-13
1
1
2
P-48386

P-48127
Assembly: Tighten the solenoid stem to 20 - 25 ft.-lb.
(27,1 - 34 N•m) torque.
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-13].
Assembly: Tighten the solenoid valve stem nut to 15 -

45 in.-lb. (1,7 - 5,1 N•m) torque.

311 of 861
Figure 20-130-16
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 130-18].
Assembly: Tighten the screened orifice plug to 11 - 12

Remove the armature rod assembly (Item 1) [Figure 20- ft.-lb. (14,9 - 16,3 N•m) torque.
130-16].

Figure 20-130-19
Figure 20-130-17
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 130-19] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
130-17].
Check the O-ring (Item 2) [Figure 20-130-19] and
NOTE: If the solenoid stem is damaged (Item 1) check replace as needed.
the armature assembly (Item 2) for damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-130-
17].

312 of 861
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Description Figure 20-140-2
The front auxiliary hydraulic coupler block is the

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers 1
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm. 2
Removal and Installation 4

3
IMPORTANT P-34661
When repairing hydrostatic and hydraulic systems, Figure 20-140-3


I-2003-0888
Figure 20-130-1
6 2
4
5 3
2
1
P-34760
3
Remove the male coupler (Item 1) [Figure 20-140-2] &

[Figure 20-140-3].
Assembly: Tighten the male coupler (Item 1) [Figure 20-

140-2] & [Figure 20-140-3] to 59 ft.-lb. (80 N•m)
P-48464
Remove the drain coupler (Item 2) [Figure 20-140-2] &
[Figure 20-140-3].
Disconnect the auxiliary tubelines (Item 1) and drain
tubeline (Item 2) from the coupler block [Figure 20-130- Assembly: Tighten the drain coupler (Item 2) [Figure
1]. 20-140-2] & [Figure 20-140-3] to 37 ft.-lb. (50 N•m)
Remove the two mounting bolts (Item 3) [Figure 20-130- Remove the female coupler (Item 3) [Figure 20-140-2] &
1]. [Figure 20-140-3].
Assembly: Tighten the female coupler (Item 3) [Figure

20-140-2] & [Figure 20-140-3] to 59 ft.-lb. (80 N•m)
Remove the fittings (Item 4) [Figure 20-140-2] & [Figure

20-140-3] check the O-rings (Item 5) [Figure 20-140-3]
and replace as needed.
Remove the springs (Item 6) [Figure 20-140-3].

313 of 861
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-140-6
(CONT’D)

1
Figure 20-140-4
1
2
P-34665
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-140-6].
P-34663
Figure 20-140-7
Check the O-ring (Item 1) [Figure 20-140-4] for damage

and replace as needed.

1
Figure 20-140-5
P-34664
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-140-7].
P-34701
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-140-5] for damage and replace as
needed.

314 of 861
HIGH FLOW VALVE
Description
WARNING
The high flow valve is an optional valve with a 12 volt
solenoid that diverts flow from a dedicated high flow
section on the gear pump.
The valve is in plumbed in series with the female coupler
side on the front auxiliary circuit. W-2017-0286
High Flow Relief Valve Testing

Figure 20-150-2
Figure 20-150-1
3
1
1
2

N-18409
P-34480
Start the engine and run at low idle RPM. Push the flow
The tools listed will be needed to do the following switch (Item 1) once (on the instrument panel) to engage
procedure: the front auxiliary hydraulics variable flow, the light (Item
2) will come ON [Figure 20-150-2].
MEL10006 - Hydraulic Test Kit Push the high flow switch (Item 3) [Figure 20-150-2] and
the High Flow light will come ON.
1.)
NOTE: Check the Main Relief Valve See MAIN RELIEF

VALVE on Page 20-30-1 for proper flow and
pressure before checking the High Flow Relief
Valve.
Connect the IN port of the hydraulic tester to the female

quick coupler (Item 1) [Figure 20-150-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-150-1] on the loader.
IMPORTANT
I-2024-0284

315 of 861
HIGH FLOW VALVE (CONT'D) High Flow Relief Valve Adjustment
High Flow Relief Valve Testing (Cont’d) NOTE: The high flow relief valve is located between
the control valve and the hydraulic reservoir.
Figure 20-150-3
Figure 20-150-4
Right
Steering
Lever
Control
1
P-31833
P-48231
• Push the front switch (Item 1) [Figure 20-150-3] to

give the front quick couplers a constant flow of fluid. If the relief pressure is not correct, stop the engine and

raise the operator cab.(See Raising on Page 10-30-2.)
• To release from continuous operation, press the front
switch (Item 1) [Figure 20-150-3] a second time. Remove the high flow relief valve adjustment plug (Item
1) [Figure 20-150-4].
Watch the flow meter on the hydraulic tester to make
sure the flow is correct. Increase the engine speed to full
RPM.

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure.
Turn the restrictor control on the tester counter clockwise,

to obtain free flow, the flow should be at 27 GPM. Start
turning the restrictor clockwise, causing more restriction
on the flow. The GPM should drop off slightly until the
pressure reaches approximately 3100 PSI. At
approximately 3100 PSI the flow should start decreasing
rapidly until the pressure reaches 3250-3350 PSI. At
3250-3350 PSI the flow should be at 0 GPM. Turn the
restrictor control counter clockwise to free flow. Shut the
If the specs from above are reached, the high flow relief
valve is OK.
If the high flow relief pressure is not correct, stop the

engine and adjust the high flow relief valve. (See High
Flow Relief Valve Adjustment on Page 20-150-2.)

316 of 861
HIGH FLOW VALVE (CONT'D) Solenoid Testing
High Flow Relief Valve Adjustment (Cont’d) Figure 20-150-6
Figure 20-150-5
P9175
P-45469
150-6]. Coil terminals do not have polarity. Correct
To increase the high flow relief valve PSI turn the screw resistance for the pressure relief coil is 7.5 ohms.
(Item 1) [Figure 20-150-5] clockwise a 1/4 turn and

recheck the high flow relief valve. (1/4 turn equals Replace the test meter with 12 volt power. You can see
approximately 200 PSI.) and hear the spool shift.
To decrease the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-150-5] counterclockwise a 1/4 turn
and recheck the high flow relief valve. (1/4 turn equals
approximately 200 PSI.)
NOTE: If the relief screw (Item 1) [Figure 20-150-5]

has been turned in 1/4 turn and the pressure
remains the same, remove and inspect the
high flow relief valve, replace as needed.
Install the plug into the high flow relief valve.

317 of 861
HIGH FLOW VALVE (CONT'D) Figure 20-150-8
Figure 20-150-7
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
P-48235 150-8] from the solenoid.
Figure 20-150-9
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 20-150-7] which are connected to the

Remove the four steering linkage mounting bolts (Item 2)

[Figure 20-150-7].
2
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 25 -
28 ft.-lb. (34 - 38 N•m) torque.
The high flow valve is located between the control valve

1
and the hydraulic reservoir.
P-48238
IMPORTANT Mark all tubelines and hoses for correct installation.

from the pump outlet to the high flow valve.
from the high flow valve to the pump inlet.
damage the system.
I-2003-0888

318 of 861
HIGH FLOW VALVE (CONT'D) Disassembly And Assembly
Figure 20-150-10
2 1
1
2
P-48108
P-48232
Remove the solenoid nut (Item 1) and solenoid (Item 2)
[Figure 20-150-11] from the solenoid valve.
Disconnect and cap the tubelines (Item 1) [Figure 20-
150-10] to the tilt cylinders. Assembly: Tighten to 4 - 6 ft.-lb. (5 - 8 N•m) torque.

Remove the two mounting bolts (Item 2) [Figure 20-150- Figure 20-150-12
10].

(34 - 38 N•m) torque.
P-48109
Remove the solenoid valve (Item 1) [Figure 20-150-12]

from the valve.
Assembly: Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.

319 of 861
HIGH FLOW VALVE (CONT'D) Figure 20-150-15
Figure 20-150-13
2 2
P-48112
1 Inspect the relief valve and replace the two O-rings (Item
P-48110 1) and washer (Item 2) [Figure 20-150-15].
Figure 20-150-16
Inspect O-rings (Item 1) and back-up washer (Item 2) on
the solenoid stem [Figure 20-150-13].

Assembly: Put oil on O-rings and back-up washer.
Install and tighten to 25 ft.-lb. (39,9 N•m) torque.
Figure 20-150-14
1
P-45469
Inspect the O-ring (Item 1) [Figure 20-150-16] on the

relief valve adjustment plug for damage and replace as
needed.
P-48111 Assembly: Tighten to 20 ft.-lb. (27,1 N•m) torque.
Remove the relief valve (Item 1) [Figure 20-150-14].
Assembly: Apply to oil to the O-rings and back-up

washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.

320 of 861
HIGH FLOW VALVE (CONT'D)
Figure 20-150-17
P-48113
Remove the check valve (Item 1) [Figure 20-150-17]

from the high flow valve.

Figure 20-150-18
P-48114
Inspect the check valve, O-rings & back-up washers for

wear and replace as needed [Figure 20-150-18].
Assembly: Apply oil to the O-rings (Item 1) and back-up

washers (Item 2) [Figure 20-150-18]. Tighten to 30 - 35

321 of 861

322 of 861
HYDROSTATIC SYSTEM
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 SAFETY &
MAINTENANCE
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 HYDROSTATIC
Sender Removal And Installation. . . . . . . . . . . . . . . . . . . . 30-40-3 SYSTEM
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 DRIVE

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 SYSTEM
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 30-60-3
Belt Tensioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-7
Belt Tensioner Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 30-60-6
Belt Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . 30-60-5
Belt Tensioner Removal And Installation . . . . . . . . . . . . . . 30-60-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-60-1

ELECTRICAL
SYSTEM &
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 ANALYSIS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 ENGINE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 SERVICE
HYDROSTATIC MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . 30-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1 SPECIFICATIONS
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-8
Removal And Installation (Left Side) . . . . . . . . . . . . . . . . . 30-21-2
Removal And Installation (Right Side) . . . . . . . . . . . . . . . . 30-21-5
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED

WITH MANUAL CONTROLS) . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-30-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . 30-30-1

323 of 861
HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH

SJC CONTROLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-3
Shaft Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 30-31-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . 30-50-1
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1

Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-10
High Pressure Relief and Bypass Valve. . . . . . . . . . . . . . . . . . . 30-51-8
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . 30-51-29
Hydraulic Controller Removal And Installation. . . . . . . . . . . . . . 30-51-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-6
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-7
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
TWO-SPEED VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS

MAY VARY.

324 of 861
HYDROSTATIC SYSTEM INFORMATION
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 the service code appears in the left instrument panel,

refer to the Electrical Service Manual for the probable
cause.
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.

325 of 861
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Description
The hydrostatic system consists of a tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of 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 due to internal leakage in the components
of the hydrostatic system.

326 of 861
HYDROSTATIC MOTOR Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

DANGER
the hydrostatic pumps.
In this system there is a case drain filter for each motor to

filter the excess low pressure oil before the oil enters the
hydraulic reservoir.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission tub which houses the drive chains. P-90328
The hydrostatic motors do not have an internal brake. AVOID DEATH

Inside the endcap of the hydrostatic motor, there is a tubeline, hose, fitting, component or a part failure
shuttle valve. The shuttle valve helps to keep the motor can cause lift arms to drop.
cool by mixing case drain oil with cooled low pressure oil • Keep out of this area when lift arms are raised
from the charge circuit. The shuttle valve is shifted by the unless supported by an approved lift arm
high pressure oil coming from the hydrostatic pumps. If support. Replace if damaged.
the shuttle valve sticks, a delay or lack of drive may or D-1009-0409
may not be felt in the controls and/or an overheated

hydrostatic motor will result.
Figure 30-20-1
WARNING
W-2059-0598
WARNING
P-68211 AVOID INJURY OR DEATH
explosion or fire.
W-2103-0508

1.)
Remove the front and rear wheel/tire assemblies. (See

TIRE MAINTENANCE on Page 10-160-1.)

327 of 861
HYDROSTATIC MOTOR (CONT’D) Mark the two hoses (Item 1) [Figure 30-20-3] before
disconnecting them from the hydrostatic motor for correct
Removal And Installation (Cont’d) installation.
Figure 30-20-2 Remove the two hoses (Item 1) [Figure 30-20-3] from
the hydrostatic motor.
Remove the drain hose and case drain filter (Item 2)

[Figure 30-20-3] from the hydrostatic motor.
NOTE: The hydraulic fitting (Item 3) [Figure 30-20-3]

on the hydrostatic motor must be tightened to
115 - 125 ft.-lb. (156 - 170 N•m) torque.
Figure 30-20-4
1
P-34004
Remove the four motor cover mounting screws (Item 1)

[Figure 30-20-2].

Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
P-68208
IMPORTANT Remove the four hydrostatic motor mounting bolts (Item

When repairing hydrostatic and hydraulic systems, 1) [Figure 30-20-4] that fasten the hydrostatic motor to
clean the work area before disassembly and keep all the hydrostatic motor carrier.
tubelines and ports to keep dirt out. Dirt can quickly Installation: Tighten the hydrostatic motor mounting
damage the system. bolts to 90 - 100 ft.-lb. (122 - 136 N•m) torque.
I-2003-0888
Figure 30-20-3
2
1
P-68208

328 of 861
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-5
P-68209
Remove the hydrostatic motor from the access hole in

the loader frame [Figure 30-20-5].

Inspect hydrostatic motor O-ring (Item 1) and carrier shaft
seal (Item 2) [Figure 30-20-5].
Reverse the removal procedure to install the hydrostatic

motor.

329 of 861
HYDROSTATIC MOTOR (CONT’D)
16
14
20 3
15
14
19 14
16 18
3 13
18
19
17 3 5
12
11
10
5
9

8
7 10
6 3
3
5
4
2
1
PE2620T
Ref. Description Ref. Description

1. SHAFT, drive 11. GEROLER
2. SEAL, face 12. PLATE, valve
3. O-RING 13. END CAP
4. FLANGE, mounting 14. POPPET
5. SEAL, square cut 15. SPRING
6. RING, back-up 16. PLUG
7. SPRING, belleville
8. PLATE, outer balance 17. BOLT
9. PLATE, inner balance 18. SLEEVE
10. BALL 19. SPRING
20. VALVE, shuttle

330 of 861
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-7

1
IMPORTANT
damage the system.
I-2003-0888
P-68211
Figure 30-20-6
Remove the nine tie bolts (Item 1) [Figure 30-20-7] from
the motor.
Figure 30-20-8
3
8

6
5
9
2
P-64267 1
7
4
Drain the oil from the motor.
Seal all open ports and clean the motor with solvent. P-68211
Put a mark across the sections of the motor for correct

assembly [Figure 30-20-6]. Assembly:
1. Tighten the bolts to 45 - 55 ft.-lb. (61 - 75 N•m) torque

in the order shown in figure [Figure 30-20-8].
2. Re-tighten the bolts to 55 - 65 ft.-lb. (75 - 88 N•m)

torque in the order shown in figure [Figure 30-20-8].
NOTE: To prevent damage to the balance plate, never

lift or support the motor by the drive shaft.

331 of 861
Figure 30-20-9
3
1
2
1
P-63785
Remove the plug (Item 1) spring (Item 2) and poppet

P-64267 (Item 3) [Figure 30-20-11] that make up the relief valve
assembly. Inspect for scoring on poppet. Ensure it can
operate freely in the bore. Inspect O-ring on plug.
Once the tie bolts have been removed and the motor
begins to separate, the drive shaft (Item 1) [Figure 30- Installation: Lubricate relief valve assembly with

20-9] can be removed. hydraulic oil and tighten plug to 260 in.-lb. (41 N•m)
torque.
Assembly: Install drive shaft before tightening tie bolts.
Figure 30-20-12
Figure 30-20-10
2
1
P-68213
P-68212
Remove the plug (Item 1) and shuttle valve assembly

Lift and remove the end cap (Item 1) [Figure 30-20-10] (Item 2) [Figure 30-20-12]. Inspect for scoring on shuttle
from the motor. valve. Ensure it can operate freely in the bore. Inspect O-
ring on plug.
NOTE: Do not scratch or damage the surfaces of the
motor sections. Always put them on a soft Installation: Lubricate shuttle valve assembly with
surface. hydraulic oil and tighten plug to 260 in.-lb. (41 N•m)
torque.

332 of 861

3
Figure 30-20-13
2
P-64274
Remove and inspect/replace seal (Item 1) [Figure 30-20-

P-39897 15].
Remove the gerolor section as an assembly (Item 2)

Remove the remaining pieces to the shuttle valve [Figure 30-20-15].
assembly (Item 1) [Figure 30-20-13] from the inside of

the end cap. Inspect for broken or damaged parts. Parts NOTE: There are two check balls on the backside of
should move freely in bore. the gerolor section. Be careful not to lose
these check balls. See [Figure 30-20-16]. Note
Assembly: Apply grease to shuttle valve parts to help location of case drain hole (Item 3) [Figure 30-
hold in place during assembly. 20-15]. Align hole with other sections on
hydrostatic motor.
Figure 30-20-14
2 3
P-39898
Remove and inspect/replace seals (Item 1) [Figure 30-

20-14].
Remove the valve plate (Item 2) [Figure 30-20-14].
Assembly: Apply grease to seals. Note location of case

drain hole (Item 3) [Figure 30-20-14]. Align hole with
other sections on hydrostatic motor.

333 of 861

1
4
Figure 30-20-16 2
3
1
P-64268
Remove the center piece of the balance plate (Item 1)

P-39901 [Figure 30-20-17].
Remove and inspect/replace the seal (Item 2) [Figure

Remove the two check balls (Item 1) [Figure 30-20-16] 30-20-17].
from the gerolor.

Remove the balance plate (Item 3) [Figure 30-20-17].
Assembly: Check for scoring and wear on the gerolor
assembly. Apply grease to check balls to keep them from Assembly: Apply grease to seals. Note location of case
falling out of there seats when assembling. drain hole (Item 4) [Figure 30-20-17]. Align hole with
other sections on hydrostatic motor.
NOTE: Care should be taken to keep the gerolor
assembly together.
NOTE: If rollers are removed, put them back in their

original bore.

334 of 861

1
Figure 30-20-18
1
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-20].

P-64270
Assembly: If the belleville spring is no longer cone
shaped, replace with new.
Remove the back up ring (Item 1) [Figure 30-20-18].
Figure 30-20-21

Assembly: Apply grease to back up ring. One side of the
back up ring is grooved to fit against the o-ring
underneath.
Figure 30-20-19
1
1
P-64273
1
Carefully turn the mounting flange over and remove the

1 seal (Item 1) [Figure 30-20-21].
P-64271
Assembly: Replace the seal.
Remove and inspect/replace the seals (Item 1) [Figure

30-20-19] from the gerolor.
Assembly: Apply grease to seals.

335 of 861

336 of 861
HYDROSTATIC MOTOR (TWO-SPEED)
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
In this system there is a case drain filter for filtering the

excess low pressure oil before the oil enters the hydraulic
reservoir.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing drive
loop return oil with cooled low pressure oil from the
charge circuit. The shuttle valve is shifted by the high
pressure oil 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.

337 of 861
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D) Remove the front and rear wheel/tire assemblies. (See
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
DANGER Page 50-101-1.)
Remove the linkage on foot control loaders. (See

Linkage Removal And Installation on Page 50-90-2.)
Drain the hydraulic reservoir. (See Removal And

Figure 30-21-1
P-90328
AVOID DEATH
unless supported by an approved lift arm 1 1

D-1009-0409
WARNING P-45492
Never work on a machine with the lift arms up unless Remove the motor cover mount bolts (Item 1) [Figure
the lift arms are secured by an approved lift arm 30-21-1].
support device can allow the lift arms or attachment Remove the motor cover from the loader.
W-2059-0598 Figure 30-21-2
IMPORTANT
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10- P-73665
1.)
Raise the lift arms and install an approved lift arm support Loosen the bolts (Item 1) [Figure 30-21-2] holding the
device. (See Installing on Page 10-20-1.) lower motor bolt access panel and swing the panel open.
The panel is located under the loader frame directly
Raise the operator cab. (See Raising on Page 10-30-2.) below the motor.

338 of 861
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D) Figure 30-21-5
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-3 1
P-73664
Remove the lower mounting bolt (Item 1) [Figure 30-21-

P-76164 5] from the motor.
Installation: Tighten the mounting bolt to 210 ft.-lb. (285

Mark the hoses and tubeline for correct installation. N•m) torque.

Disconnect both high pressure hydraulic tubelines (Item Figure 30-21-6
1) [Figure 30-21-3] from the motor.
Disconnect the pre-warming tubeline (Item 2) [Figure 30-

21-3] from the motor. 1
Figure 30-21-4
P-76146
1
Remove two mounting bolts (Item 1) [Figure 30-21-6]
from the motor.
3
P-76159 Installation: Tighten the mounting bolts to 210 ft.-lb.
(285 N•m) torque.
Mark the hose and tubelines for correct installation. Remove the motor from the access hole in the loader
frame.
Disconnect the case drain tubeline (Item 1) [Figure 30-
21-4] from the motor.
Disconnect the shift pressure tubeline (Item 2) [Figure

30-21-4] from the motor.

motor.

339 of 861
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D)
Removal And Installation (Left Side) (Cont'd)
Figure 30-21-7
1
2
P-76139
Lubricate and install a new hydrostatic motor O-ring (Item

1) [Figure 30-21-7].

Inspect the hydrostatic motor carrier shaft seal (Item 2)
[Figure 30-21-7].
Figure 30-21-8
CORRECT WRONG
P-73542
Installation: Ensure you have correctly installed a new

shaft seal (Item 1) [Figure 30-21-8] in the mounting
flange cavity with the convex surface facing outward.
Reverse the removal procedure to install the two speed

hydrostatic motor.

340 of 861
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D) Remove the front and rear wheel/tire assemblies. (See
Wheel Nuts on Page 10-160-1.)
Removal And Installation (Right Side)
Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.) or (See CONTROL PANEL (SJC) on
DANGER Page 50-101-1.)
Remove the linkage on foot control loaders. (See

Linkage Removal And Installation on Page 50-90-2.)
Drain the hydraulic reservoir. (See Removal And

Figure 30-21-9
P-90328
AVOID DEATH
unless supported by an approved lift arm 1 1

D-1009-0409
WARNING P-45492
Never work on a machine with the lift arms up unless Remove the motor cover mount bolts (Item 1) [Figure
the lift arms are secured by an approved lift arm 30-21-9].
support device can allow the lift arms or attachment Remove the motor cover from the loader.
W-2059-0598 Figure 30-21-10
IMPORTANT
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10- P-73665
1.)
Raise the lift arms and install an approved lift arm support Loosen the bolts (Item 1) [Figure 30-21-10] holding the
device. (See Installing on Page 10-20-1.) lower motor bolt access panel and swing the panel open.
The panel is located under the loader frame directly
Raise the operator cab. (See Raising on Page 10-30-2.) below the motor.

341 of 861
Removal And Installation (Right Side) (Cont'd)
Figure 30-21-11 2
2 P-76127
Mark the hose and tubelines for correct installation.

P-76153
Disconnect the case drain tubeline (Item 1) [Figure 30-
Mark the hoses and tubeline for correct installation.
Disconnect the shift pressure tubeline (Item 2) [Figure

Disconnect both high pressure hydraulic tubelines (Item 30-21-13] from the motor.
1) [Figure 30-21-11] from the motor.
Figure 30-21-14
Disconnect the pre-warming tubeline (Item 2) [Figure 30-
Figure 30-21-12 1
P-73664
Remove the lower mounting bolt (Item 1) [Figure 30-21-

P-76152 14] from the motor.

Mark the hose and tubelines for correct installation. N•m) torque.
Disconnect the hoses (Item 1) [Figure 30-21-12] from

the motor.

342 of 861
Removal And Installation (Right Side) (Cont'd)
Figure 30-21-15 1
CORRECT WRONG
P-73542
Installation: Ensure you have correctly installed a new

P-76145 shaft seal (Item 1) [Figure 30-21-17] in the mounting
flange cavity with the convex surface facing outward.
Remove two mounting bolts (Item 1) [Figure 30-21-15] Reverse the removal procedure to install the two speed
from the motor. hydrostatic motor.

Installation: Tighten the mounting bolts to 210 ft.-lb.
(285 N•m) torque.
Remove the motor from the access hole in the loader

frame.
Figure 30-21-16
1
2
P-76139
Lubricate and install a new hydrostatic motor O-ring (Item

1) [Figure 30-21-16].
Inspect the hydrostatic motor carrier shaft seal (Item 2)

[Figure 30-21-16].

343 of 861
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D)
Ref. Description
1. Shaft Seal 10
2. Mounting Flange 11
12 15
3. O-Ring 13 14
4. Main Drive
5. Geroler® 16
6. O-Ring
7. Valve Drive
8. Selector Plate
9. Gasket 17
9 18
10. Plug
11. Compression Spring
12. Compression Spring 8
13. Control Spool
14. Plug
15. Cap Screw 7
16. Spool Housing 6
17. Plug
18. O-Ring
19. Valve 5
20. Outer Balance Ring

21. Backup Ring
22. O-Ring
23. Backup Ring 3 4
24. Inner Balance Ring
25. Backup Ring
26. O-Ring 2
27. Dowel Pin
28. Plug
29. Compression Spring
30. Plug
31. Valve Housing 33
32. Shuttle Valve Assembly
33. 12 Point Screw 28
34. Plug 32
35. Plug 31
36. Ball Seat
37. Ball
1
32
28
34
35
27
25 37 36
24 29
23
20 21 26 30
19
22
MS2315SA

344 of 861
HYDROSTATIC MOTOR (TWO-SPEED) (CONT'D) Place the mounting flange (Item 1) [Figure 30-21-19] on
a protective material built up two and one-fourth inches to
Disassembly allow room for main drive.
Figure 30-21-18 Figure 30-21-20
1
P-76142 P-73524
Remove the tubeline (Item 1) and relief valve (Item 2) Remove the nine mounting bolts (Item 1) [Figure 30-21-
[Figure 30-21-18] from the motor. 20] from the valve housing.

Remove the fittings [Figure 30-21-18] from the motor. Figure 30-21-21
Figure 30-21-19
1 P-73529
P-73525
Remove the valve housing from the motor assembly and
place on a clean work surface.
NOTE: The motor is connected to the carrier for
photo purposes [Figure 30-21-19]. Install a Remove and discard the O-ring (Item 1) [Figure 30-21-
mark on the valve housing, selector plate, 21].
Geroler®, and mounting flange for correct
assembly.
NOTE: Always protect any sealing surfaces. Any
scratches or marks will cause premature
failure.
NOTE: It is not recommended to remove any plugs
unless they are leaking.
Drain the oil from the motor casing.

345 of 861
Disassembly (Cont'd)
1
Figure 30-21-22
P-73532
Remove four compression springs (Item 1) [Figure 30-

P-73530 21-24] and inspect for damage.
Figure 30-21-25
Remove the dowel pin (Item 1) [Figure 30-21-22] and
inspect for wear.
1

Figure 30-21-23
P-73534
Remove the outer balance ring (Item 1) [Figure 30-21-

P-73531 25] from the valve housing. Tap the ring lightly with a
wooden dowel or hammer handle if binding. Inspect the
face of the outer balance ring for wear.
Remove the inner balance ring (Item 1) [Figure 30-21-
23] from the valve housing and inspect face for wear.

346 of 861
Figure 30-21-26
P-73539
1 Remove and discard the backup ring (Item 1) [Figure 30-

P-73535 21-28] from the valve housing.
Figure 30-21-29
Remove and discard the O-ring and two backup rings
(Item 1) [Figure 30-21-26] from the outer balance ring.

Figure 30-21-27
P-73538
Remove and discard the O-ring (Item 1) [Figure 30-21-

P-73536 29] from the valve housing.
Remove the six compression springs (Item 1) [Figure

30-21-27] and inspect for damage.

347 of 861
Figure 30-21-30
1 1
P-76390
Remove the plug (Item 1) [Figure 30-21-32] from the

P-76387 valve housing.
Figure 30-21-33
valve housing.

Figure 30-21-31
P-76389
1
Remove O-ring (Item 1) [Figure 30-21-33] on plug.

P-76389

348 of 861
Figure 30-21-34
2
1
P-76395

P-76392 valve housing.
Figure 30-21-37
Remove the ball seat (Item 1) and ball (Item 2) [Figure
30-21-34] from the valve housing.

NOTE: To remove the ball seat, use a long allen
wrench to reach down into the valve housing.
Figure 30-21-35
P-76389

1
P-76394A

349 of 861
Figure 30-21-38
1
1
1
1
1 1
1
1 P-76400
1 Remove the shuttle valve assembly (Item 1) [Figure 30-

P-76397 21-40] from the valve housing.
Figure 30-21-41
Remove the plugs (Item 1) [Figure 30-21-38] from both
sides of the valve housing.

Figure 30-21-39
P-73526
1
Remove the valve (Item 1) [Figure 30-21-41] and inspect

P-76389 for wear.
Remove O-ring (Item 1) [Figure 30-21-39] on plugs.

350 of 861
Figure 30-21-42
1 2
P-73528

P-73527 44].
Remove the Geroler® assembly (Item 2) [Figure 30-21-

Remove the selector plate (Item 1) [Figure 30-21-42] 44] and inspect for wear.
and inspect for wear.

Figure 30-21-45
Figure 30-21-43
1 1
2
P-73540
P-73543
Remove the main drive (Item 1) [Figure 30-21-45] and

Remove the valve drive (Item 1) [Figure 30-21-43] and inspect for wear.
inspect for wear.
45].

351 of 861
Figure 30-21-46
1
1
P-73549
Mount the spool housing in a vise taking care to protect it

P-73546 from damage. Remove the spool retaining plug (Item 1)
[Figure 30-21-48].
Remove the ten screws (Item 1) [Figure 30-21-46] from NOTE: The plug is under slight spring pressure.
the selector spool housing. Remove the plug carefully.

Figure 30-21-47 Figure 30-21-49
2 1
P-73547 P-73550
Remove and discard the gasket (Item 1) [Figure 30-21- Remove the two nested springs (Item 1) [Figure 30-21-
47]. 49] from the spool housing.
Inspect the selector plate (Item 2) [Figure 30-21-47] for

wear.
NOTE: Clean any old thread sealer from the threaded

holes before assembly.

352 of 861
Figure 30-21-50
P-73552
Inspect the spool for wear or damage [Figure 30-21-52].

P-73523
Clean the spool and spool housing.
Inspect springs for wear and deformation [Figure 30-21- Figure 30-21-53
50].

Figure 30-21-51
P-73550A
1
P-73551 Remove the plug (Item 1) [Figure 30-21-53] from the
spool housing.
Remove the spool (Item 1) [Figure 30-21-51] from the

spool housing.

353 of 861
Figure 30-21-54
P-76389
1
Remove O-ring (Item 1) 23 on plug.

P-76389

Figure 30-21-55
P-76438

spool housing.

354 of 861
Assembly
NOTE: Always use new O-rings and back up washers

during assembly and lubricate them with
clean petroleum jelly.
Figure 30-21-57
P-76389
Install new O-ring (Item 1) [Figure 30-21-59] on plug.
1 Figure 30-21-60
P-76389

Figure 30-21-58
1
P-73550A
Install the plug (Item 1) [Figure 30-21-60] in the spool

housing with a light coat of oil.
Tighten the plug to 14 - 18 ft.-lb. (19 - 24 N•m) torque.
P-76438
Install the plug (Item 1) [Figure 30-21-58] in the spool

housing with a light coat of oil.

355 of 861
Assembly (Cont’d)
Figure 30-21-61
1
1 P-73549
Install the plug (Item 1) [Figure 30-21-63] with a light

P-73551 coat of oil.

Lubricate with hydraulic oil and insert the spool (Item 1)
[Figure 30-21-61] into the spool housing.

Figure 30-21-62
P-73550
Install two nested springs (Item 1) [Figure 30-21-62] on

the spool shaft.

356 of 861
Assembly (Cont'd)
Figure 30-21-64
Apply Loctite® 262 Here
P-73774
Install the new gasket (Item 1) [Figure 30-21-65] onto

P-73775 the selector plate.
Figure 30-21-66
NOTE: Before assembling the new gasket, the spool
housing, or the screws, remove any old

thread sealer from the threaded holes.
Put a VERY SMALL amount of Loctite® 262 into each of

the ten threaded holes of the selector plate. DO NOT put
Loctite® on the screw threads [Figure 30-21-64].
Remove any trapped air from below the Loctite®. Wipe

any excess Loctite® from the selector plate surface.
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
prevent the screws from reaching full thread P-73776
contact and the correct torque may not be
reached.
Install the ten screws [Figure 30-21-66] through the
NOTE: Installing the screws can force some of the spool housing and into the selector plate.
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.

357 of 861
Assembly (Cont'd)
Figure 30-21-67 2 1
10 4 1 6 7
3
P-73528
9 5 2 3 8
Install the Geroler® assembly (Item 1) with the groove in
MS2316S the ring facing up. The star groove (Item 2) must be
facing up. Take care to line up the shuttle flow hole (Item
3) [Figure 30-21-69].
Tighten the ten screws to 70 - 80 in.-lb. (8 - 9 N•m) torque
using the sequence shown [Figure 30-21-67]. Lubricate and install the new O-ring (Item 4) [Figure 30-

21-69].
Repeat the tightening sequence to insure the correct
torque. Motor Timing
Put the selector plate assembly aside until needed for Figure 30-21-70
installation. Let the Loctite® cure for six hours after
assembly.
4
Figure 30-21-68
2
1
2
3
1
P-73544
Locate a tooth (Item 1) [Figure 30-21-70] that lines up

P-73540 with a star tip.
Install the main drive (Item 1) [Figure 30-21-68]. Ensure Install the valve drive (Item 2) [Figure 30-21-70] in the
it is supported from beneath until assembly is complete. Geroler®.
Lubricate and install the new O-ring (Item 2) [Figure 30- Mark the spline (Item 3) in the Geroler® star that is 11.25
21-68]. degrees counter-clockwise. Mark the corresponding
tooth (Item 4) on the small end of the valve drive that
NOTE: Two eight inch long steel rods installed in the aligns with the spline mark (Item 3) [Figure 30-21-70].
mounting bolt holes will help align the bolt
holes in each section of the motor during
assembly.

358 of 861
Assembly (Cont’d)
Motor Timing (Cont’d)
Figure 30-21-71
1 1
P-76389
2
Install new O-rings (Item 1) [Figure 30-21-73] on both
plugs.
P-73527 Figure 30-21-74

Install the selector plate (Item 1) with the slotted holes
facing up. Be sure to line up the shuttle flow hole (Item 2)
[Figure 30-21-71].
1
Figure 30-21-72
1
1
1
1
1
1
1 P-76400
3
2 Assemble the shuttle valve assembly (Item 1) [Figure
30-21-74] and insert into the valve housing.
P-73545
Install the valve (Item 1) [Figure 30-21-72] on the valve

drive. The round holes and four grooves must be facing
up.
Align any one of the four grooves (Item 2) in the valve

with the marked tooth on the valve drive (Item 3) [Figure
30-21-72].

359 of 861
Assembly (Cont’d)
Figure 30-21-75
2
1
1
P-76392
1 Install the ball (Item 1) and ball seat (Item 2) [Figure 30-
P-76397 21-77] into the valve housing.
Tighten the ball seat to 18 - 22 in.-lb. (2 - 3 N•m) torque.

Install the plugs (Item 1) [Figure 30-21-75] with a light
coat of oil on both sides of the valve housing. NOTE: To install the ball seat, use a long allen

wrench to reach down into the valve housing.
Figure 30-21-78
Figure 30-21-76
1
1
P-76389
P-76394A


360 of 861
Assembly (Cont’d)
Figure 30-21-79
P-76395
1 Install the plug (Item 1) [Figure 30-21-81] with a light

P-76390 coat of oil.

coat of oil. Figure 30-21-82

Tighten the plug to 2 7 -33 ft.-lb. (37 - 45 N•m) torque.
Figure 30-21-80
P-76389
1

P-76389

361 of 861
Assembly (Cont’d)
Figure 30-21-83
1
1
P-73539
Lubricate and install the backup ring (Item 1) [Figure 30-

P-76387 21-85] on the valve housing.
Figure 30-21-86
coat of oil.

1
Figure 30-21-84
P-73536
Install the six compression springs (Item 1) [Figure 30-

1 21-86].
P-73538
Lubricate and install new O-ring (Item 1) [Figure 30-21-

84] on the valve housing.

362 of 861
Assembly (Cont’d)
1
Figure 30-21-87
P-73532
1 Install four compression springs (Item 1) [Figure 30-21-

P-73535 89].
Figure 30-21-90
Lubricate and install the O-ring and two backup rings
(Item 1) [Figure 30-21-87] on the outer balance ring.

Figure 30-21-88
1 1
P-73531
Install the inner balance ring (Item 1) [Figure 30-21-90]

P-73534 in the valve housing.
Install the outer balance ring (Item 1) [Figure 30-21-88]

in the valve housing.

363 of 861
Assembly (Cont’d)
Figure 30-21-91 1
P-73773
Install the valve housing (Item 1) [Figure 30-21-93] on

P-73529 the assembly taking care to maintain correct alignment.
NOTE: Be careful when installing the valve housing

Install the dowel pin (Item 1) [Figure 30-21-91]. so the balance rings and springs remain in
position.

Figure 30-21-92
Figure 30-21-94
P-73529
P-73525
Lubricate and install new O-ring (Item 1) [Figure 30-21-

92]. Verify correct assembly with the marks that were made
prior to disassembly [Figure 30-21-94].

364 of 861
Assembly (Cont'd)
Figure 30-21-95
2
P-76142
Install the relief valve (Item 1) and tubeline (Item 2) and

P-73524 [Figure 30-21-97] on the motor.
Install the fittings [Figure 30-21-97] on the motor.

Lubricate the nine bolts (Item 1) [Figure 30-21-95] with
hydraulic oil and install them into the assembly. Hand

tighten the bolts.
Figure 30-21-96
5 8
2 3
7 6
4 9
1 MS2317S
Tighten the nine bolts to 50 - 70 ft.-lb. (68 - 95 N•m)

torque using the sequence shown in [Figure 30-21-96].
Perform a final tightening of the nine bolts to 110 ft.-lb.

(149 N•m) torque using the same sequence shown in
[Figure 30-21-96].

365 of 861

366 of 861
HYDROSTATIC MOTOR CARRIER (SINGLE AND Shaft Seal Removal And Installation
TWO-SPEED WITH MANUAL CONTROLS)
The tool listed is necessary for the following procedure:
Description
MEL1420 - Carrier Seal Tool
The hydrostatic motor carrier is the mating connection
from the hydrostatic drive motor to the transmission case. Remove the hydrostatic motor. (See HYDROSTATIC
MOTOR on Page 30-20-1.) or (See HYDROSTATIC
The hydrostatic motor carrier contains a shaft that rotates MOTOR (TWO-SPEED) on Page 30-21-1.)
on two tapered roller bearings. the shaft has two
sprockets that turn the drive chains. Damaged or
severely worn bearings can destroy a drive motor.
The hydrostatic motor carrier is sealed to the

WARNING
transmission case with a polyurethane sealant. A gasket
is not used. Replacement sealant can be ordered AVOID INJURY OR DEATH
through Bobcat Parts part number 6685372. Wear safety glasses to prevent eye injury when any
of the following conditions exist:
The hydrostatic motor carrier has a seal which isolates • When fluids are under pressure.
the chain case oil from the hydrostatic motor case drain • Flying debris or loose material is present.
oil. • Engine is running.
• Tools are being used.
A brake disk is installed on each hydrostatic motor W-2019-0907
carrier. The brake disk is mounted to the shaft in the

motor carrier. Figure 30-20-1
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.
Figure 30-30-1
1
Single Speed Two-Speed
P-68214
The motor carrier seal (Item 1) [Figure 30-20-1] is

located on the outside of the motor carrier shaft.
1 1
P-73920
P-68214
The motor carrier hydrostatic motor mounting holes (Item

1) [Figure 30-30-1] are the only difference between the
single and two-speed motor carriers with manual
controls. The disassembly and assembly procedures are
the same.

367 of 861
HYDROSTATIC MOTOR CARRIER (SINGLE AND Figure 30-30-4
TWO-SPEED WITH MANUAL CONTROLS) (CONT’D)
Shaft Seal Removal And Installation (Cont’d)
Figure 30-30-2
P-4454A
Installation: Install a new seal over the motor carrier

P-39783A
Figure 30-30-5
Drill a 0.125 in. (3 mm) hole in the motor carrier seal

[Figure 30-30-2].

Figure 30-30-3
P-39786A
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-30-5].
P-39784A
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-30-5].
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-30-3].

368 of 861
HYDROSTATIC MOTOR CARRIER (SINGLE AND Removal And Installation
Figure 30-30-6
WARNING
W-2059-0598
1
2 Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)

1.)
P-54286A Raise the loader operator cab. (See Raising on Page 10-
30-2.)
Photo [Figure 30-30-6] shows the motor carrier seal
Drain the fluid from the chaincase. (See Removing And
correctly installed.

Replacing Oil on Page 10-130-1.)
Inspect the O-ring (Item 1) [Figure 30-30-6] and replace
Remove the engine speed control. (See Removal And
if needed.
NOTE: Before reinstalling the hydrostatic motor,
check the plug (Item 2) [Figure 30-30-6]
on Page 50-100-2.) or (See Removal And Installation on
located in the center of the carrier shaft for
Page 50-101-1.)
tightness. If the plug becomes loosened, case
drain lubrication oil from the hydrostatic
Remove the lift arm bypass control valve. (See Removal
motor can leak into the chaincase.
Remove the traction lock assembly. (See Removal And

Remove the center chaincase cover. (See Center Cover

Remove the front chaincase cover. (See Front Cover

Remove the front axle and sprocket. (See Axle Sprocket

And Bearings Removal And Installation on Page 40-20-
4.)
Remove the hydrostatic motor. (See HYDROSTATIC

MOTOR (TWO-SPEED) on Page 30-21-1.)

369 of 861
Figure 30-30-7
P-54235A
Slide the motor carrier out of the chaincase [Figure 30-

30-9].
P-54227
Installation: Ensure both motor carrier sealing surface
and transmission sealing face is clean and apply
Remove the parking brake disc (Item 1) [Figure 30-30- polyurethane sealant to both surfaces.
7]. (See BRAKE (SINGLE SPEED) on Page 40-10-1.) or

(See BRAKE (TWO-SPEED) on Page 40-11-1.) Figure 30-30-10
Remove the six motor carrier mounting bolts (Item 2)

[Figure 30-30-7] from the inside of the chaincase.
1
Installation: Tighten the motor carrier mounting bolts to
125 - 140 ft.-lb. (170 - 190 N•m) torque.
Figure 30-30-8
2 P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-30-10] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

P-54226 remove the carrier from the loader.
Reverse the removal procedure to install the motor

For ease of removal, fasten the front drive chain carrier.
(previously removed) to the chaincase as shown (Item 1)
[Figure 30-30-8].
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-30-
8] from the sprocket.

370 of 861
HYDROSTATIC MOTOR CARRIER (SINGLE AND
SINGLE SPEED
1
5
2
6
3
7
8

TWO-SPEED
1
5
6 2
7
8 3
4
P-76446
P-76445
1. SHAFT 5. RACE
2. BEARING 6. BEARING
3. RACE 7. SNAP RING
4. HOUSING 8. SEAL

371 of 861
Figure 30-30-11
3.000” O.D. Diameter

(76,2 mm)
2.530” I.D. Diameter

(64,26 mm)
7.000”
Length
P-39816
(177,8 mm)
Put the motor carrier in the hydraulic press as shown

[Figure 30-30-13].
MC-2102
Use 2-1/4 in. driver tool and press the sprocket shaft out
of the motor carrier housing [Figure 30-30-13].
It is necessary to locate or fabricate a press tool for this
procedure. Refer to [Figure 30-30-11] for the correct

NOTE: The outer bearing will now be free from the
dimensions of the tool needed. sprocket shaft.
Figure 30-30-12 Figure 30-30-14
2
1
1
P-39815
P-4365
A hydraulic press, slide hammer with puller end and snap Remove the housing from the press and install a bearing
ring pliers are also recommended for this procedure. puller (Item 1) [Figure 30-30-14] on the sprocket shaft.
Remove the motor carrier shaft seal. (Refer to Shaft Seal Put the assembly in the hydraulic press. Use the same
Removal And Installation on Page 30-20-1). tool driver and remove the bearing (Item 2) [Figure 30-
30-14] from the shaft.
Remove the snap ring (Item 1) [Figure 30-30-12] from
the motor carrier shaft using the snap ring pliers.

372 of 861
Figure 30-30-15
P-39820
Put the motor carrier housing in the press as shown

[Figure 30-30-17].
P-39817
Use 4-5/16 in. driver tool and press the new inner bearing
race into the motor carrier housing [Figure 30-30-17].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30-

Press the bearing race in until it is fully seated in the
30-15] facing up. carrier housing.
Install the slide hammer with puller end (Item 2) [Figure Figure 30-30-18
30-30-15] on the bottom side of the bearing race.
Remove the bearing race from the carrier housing

[Figure 30-30-15].
Figure 30-30-16
P-39819
Turn the motor carrier housing over as shown [Figure

30-30-18].
P-39818 Use 4-5/16 in. driver tool and press the new outer
bearing race into the motor carrier housing [Figure 30-
30-18].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-30-16]. Press the bearing race in until it is fully seated in the
carrier housing.
Use a 3-7/8 in. driver tool and press the outer bearing
race from the housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

373 of 861
Figure 30-30-19

P-4371
P-4366 Put the motor carrier housing (Item 1) [Figure 30-30-20]

over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 in. driver Put the outer bearing over the end of the sprocket shaft
tool, install the new inner bearing (Item 2) [Figure 30-30- and press the bearing on with the press tool and driver
19] on the sprocket shaft as shown. tool [Figure 30-30-20].
Remove the press and drive tools from the sprocket Remove the press and driver tools from the sprocket
shaft. shaft.

374 of 861
Figure 30-30-21
P-39814
Put the snap ring (Item 1) [Figure 30-30-21] over the end P-4375
of the sprocket shaft.

Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-30-
NOTE: Use the snap ring pliers to spread the snap 23] and install the shaft seal.
ring so it will fit over the sprocket shaft.
Using the press and driver tools, press the snap ring the carrier shaft [Figure 30-30-23].
(Item 1) [Figure 30-30-21] over the sprocket.
Figure 30-30-24
Press the snap ring on until it snaps into the groove on
the shaft.
Figure 30-30-22
P-39821
Use a rubber mallet [Figure 30-30-24], tap down on the

P-4376 cluster shaft.
Put a new shaft seal (Item 1) [Figure 30-30-22] on the

sprocket shaft.

375 of 861
Figure 30-30-25

N-15087
Install a dial indicator as shown in Photo [Figure 30-30-

25].
Use a pry bar (Item 1) [Figure 30-30-25] to lift the carrier

shaft and read the end play on the dial indicator.
The carrier shaft must turn freely with end play not to
exceed 0.007 in. (0,17 mm).

376 of 861
HYDROSTATIC MOTOR CARRIER (SINGLE AND Shaft Seal Removal And Installation
TWO-SPEED WITH SJC CONTROLS)
The tool listed is necessary for the following procedure:
Description
MEL1420 - Carrier Seal Tool
The hydrostatic motor carrier is the mating connection
from the hydrostatic drive motor to the transmission case. Remove the hydrostatic motor. (See HYDROSTATIC
The hydrostatic motor carrier contains a shaft that rotates MOTOR on Page 30-20-1.) or (See HYDROSTATIC
on two tapered roller bearings. the shaft has two MOTOR (TWO-SPEED) on Page 30-20-1.)
sprockets that turn the drive chains. Damaged or
severely worn bearings can destroy a drive motor.
The hydrostatic motor carrier is sealed to the
transmission case with a polyurethane sealant. A gasket
WARNING
is not used. Replacement sealant can be ordered
through Bobcat Parts part number 6685372. AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
The hydrostatic motor carrier has a seal which isolates of the following conditions exist:
the chain case oil from the hydrostatic motor case drain • When fluids are under pressure.
oil. • Flying debris or loose material is present.
Loaders equipped with Selectable Joystick Controls • Engine is running.
(SJC) use a speed sensor installed in the motor carrier • Tools are being used.
W-2019-0907
housing. The speed sensor senses a disk that is fixed to
the shaft in the motor carrier. If the loader does not have

(SJC), a plate covers the hole where the sensor would Figure 30-21-1
be.
A brake disk is installed on each hydrostatic motor
carrier. The brake disk 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. 1
Figure 30-31-1
Single Speed Two-Speed P-68214
The motor carrier seal (Item 1) [Figure 30-21-1] is

located on the outside of the motor carrier shaft.
1 1
P-73920
P-68214
The motor carrier hydrostatic motor mounting holes (Item

1) [Figure 30-31-1] are the only difference between the
single and two-speed motor carriers with SJC controls.
The disassembly and assembly procedures are the
same.

377 of 861
TWO-SPEED WITH SJC CONTROLS) (CONT’D)
Figure 30-31-2
P-4454A
Installation: Install a new seal over the motor carrier

P-39783
Figure 30-31-5
Drill a 0.125 in. (3 mm) hole in the motor carrier seal

[Figure 30-31-2].

Figure 30-31-3
P-39786
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-31-5].
P-39784
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-31-3].

378 of 861
HYDROSTATIC MOTOR CARRIER (SINGLE AND Removal And Installation
Figure 30-31-6
WARNING
W-2059-0598
Raise the loader lift arms and install an approved lift arm
1

1.)
P-39780 Raise the loader operator cab. (See Raising on Page 10-
30-2.)
Photo [Figure 30-31-6] shows the motor carrier seal
correctly installed.

Replacing Oil on Page 10-130-1.)
NOTE: Before reinstalling the hydrostatic motor,
check the plug (Item 1) [Figure 30-31-6]
located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
drain lubrication oil from the hydrostatic
on Page 50-100-2.)
motor can leak into the chaincase.
Remove the lift arm bypass control valve. (See Removal


Remove the front chaincase cover. (See Front Cover

Remove the front axle and sprocket. (See Axle Sprocket

And Bearings Removal And Installation on Page 40-20-
4.)
Remove the hydrostatic motor. (See HYDROSTATIC

MOTOR (TWO-SPEED) on Page 30-21-1.)

379 of 861
Figure 30-31-7
P-54235A
1
Slide the motor carrier out of the chaincase [Figure 30-
31-9].
P-39781
Installation: Ensure both motor carrier sealing surface
and transmission sealing face is clean and apply
Remove the parking brake disc (Item 1) [Figure 30-31- polyurethane sealant to both surfaces.
7]. (See BRAKE (SINGLE SPEED) on Page 40-10-1.) or

(See BRAKE (TWO-SPEED) on Page 40-11-1.) Figure 30-31-10
Remove the six motor carrier mounting bolts (Item 2)

[Figure 30-31-7] from the inside of the chaincase.
1
Installation: Tighten the motor carrier mounting bolts to
125 - 140 ft.-lb. (170 - 190 N•m) torque.
Figure 30-31-8
2 P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-31-10] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

P-54226 remove the carrier from the loader.
Reverse the removal procedure to install the motor

For ease of removal, fasten the front drive chain carrier.
(previously removed) to the chaincase as shown (Item 1)
[Figure 30-31-8].
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 2) [Figure 30-31-
8] from the sprocket.

380 of 861
SINGLE SPEED
1
6
2
7 3
4
8
9

TWO-SPEED
1
6
7
2
8 4 3
9
5
P-76448
P-76447
1. SHAFT 6. RACE
2. SENSOR DISC 7. BEARING
3. BEARING 8. SNAP RING
4. RACE 9. SEAL
5. HOUSING

381 of 861
Figure 30-31-11
3.000” O.D. Diameter

(76,2 mm)
2.530” I.D. Diameter

(64,26 mm)
7.000”
Length
P-39816
(177,8 mm)
Put the motor carrier in the hydraulic press as shown

[Figure 30-31-13].
MC-2102
Use 2-1/4 in. driver tool and press the sprocket shaft out
of the motor carrier housing [Figure 30-31-13].
It is necessary to locate or fabricate a press tool for this
procedure. Refer to [Figure 30-31-11] for the correct

NOTE: The outer bearing will now be free from the
dimensions of the tool needed. sprocket shaft.
Figure 30-31-12 Figure 30-31-14
1
P-39815
P-76462
A hydraulic press, slide hammer with puller end and snap Remove the housing from the press and install a bearing
ring pliers are also recommended for this procedure. puller on the sprocket shaft.
Remove the motor carrier shaft seal. (See Shaft Seal Put the assembly in the hydraulic press. Use the same
Removal And Installation on Page 30-21-1). tool driver and remove the bearing (Item 1) [Figure 30-
31-14] from the shaft.
the motor carrier shaft using the snap ring pliers.

382 of 861
Figure 30-31-15
P-39820
Put the motor carrier housing in the press as shown

[Figure 30-31-17].
P-39817
Use 4-5/16 in. driver tool and press the new inner bearing
race into the motor carrier housing [Figure 30-31-17].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30-

Press the bearing race in until it is fully seated in the
31-15] facing up. carrier housing.
Install the slide hammer with puller end (Item 2) [Figure Figure 30-31-18
30-31-15] on the bottom side of the bearing race.
Remove the bearing race from the carrier housing

[Figure 30-31-15].
Figure 30-31-16
P-39819
Turn the motor carrier housing over as shown [Figure

30-31-18].
P-39818 Use 4-5/16 in. driver tool and press the new outer
bearing race into the motor carrier housing [Figure 30-
31-18].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-31-16]. Press the bearing race in until it is fully seated in the
carrier housing.
Use a 3-7/8 in. driver tool and press the outer bearing
race from the housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

383 of 861
Figure 30-31-19
2 1
P-76462
Use the fabricated press tool and 3.0 in. driver tool, install
the new inner bearing (Item 1) [Figure 30-31-21] on the
P-76464 sprocket shaft as shown.
Remove the press and drive tools from the sprocket

Figure 30-31-20 shaft.

2
1
P-76466
Install the sensor disc (Item 1) on the shaft (Item 2)

[Figure 30-31-19] and [Figure 30-31-20].
NOTE: Protrusion on disc to be aligned with pin area

on sprocket.

384 of 861
Figure 30-31-22
1 P-39814
Put the snap ring (Item 1) [Figure 30-31-23] over the end
of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap

ring so it will fit over the sprocket shaft.

Using the press and driver tools, press the snap ring
(Item 1) [Figure 30-31-23] over the sprocket.
Press the snap ring on until it snaps into the groove on

the shaft.
P-4371 Figure 30-31-24
Put the motor carrier housing (Item 1) [Figure 30-31-22]

over the sprocket shaft as shown.
Put the outer bearing over the end of the sprocket shaft
and press the bearing on with the press tool and driver
tool [Figure 30-31-22]. 1
Remove the press and driver tools from the sprocket

shaft.
P-4376
Put a new shaft seal (Item 1) [Figure 30-31-24] on the

sprocket shaft.

385 of 861
Figure 30-31-25
P-76467
1 Install a dial indicator as shown in Photo [Figure 30-31-

27].
Use a pry bar (Item 1) [Figure 30-31-27] to lift the carrier

shaft and read the end play on the dial indicator.

The carrier shaft must turn freely with end play not to
exceed 0.007 in. (0,17 mm).
P-4375
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-31-

25] and install the shaft seal.
Figure 30-31-26
P-76463
Use a rubber mallet [Figure 30-31-26], tap down on the

cluster shaft.

386 of 861
CHARGE PRESSURE support device can allow the lift arms or attachment
Description W-2059-0598
Charge pressure is a supply of oil to the hydrostatic

Figure 30-40-2
pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed 1
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is obtained from the standard section

on the hydraulic gear pump.
Charge pressure is also used to operate other hydraulic 3

functions, such as shifting the auxiliary spool in the main 2
hydraulic control valve.
The charge pressure sender is located on the charge

filter housing mounted next to the blower housing.
P-43197
Charge pressure alarm settings are pre-programmed into
the main controller and are based on loader type and
options installed. Connect the gauge (Item 1), to the adapter fitting (P/N
93F5) (Item 2) [Figure 30-40-2].

Testing
Connect the hydraulic hose (Item 3) [Figure 30-40-2] to
Figure 30-40-1 the adapter fitting. Tighten all connections.
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
2 4
1 3
P-43196
The tools needed to check charge pressure, hydraulic

hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge (1000 PSI) (Item 3) and adapter fitting (P/N 93F-5)
(Item 4) [Figure 30-40-1].
WARNING

387 of 861
CHARGE PRESSURE (CONT’D) Figure 30-40-4
Testing (Cont’d)
Figure 30-40-3
3 2
1
P-68256
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4].

P-66884
Install a hose (Item 2) [Figure 30-40-4], to replace the
tubeline that was there.
Remove the hydraulic tubeline (Item 1) [Figure 30-40-3]
from the charge pressure sender adapter fitting and the Install the hose (Item 3) [Figure 30-40-4], that is

hydraulic control valve. attached to the pressure gauge, to the T fitting.
Tighten the hydraulic fittings.
Start the loader and warm the hydraulic fluid to 140° F

(60° C).
The charge pressure at high idle, with the fluid

temperature of 140° F (60° C) is 335-385 PSI (23,1 - 26,5
bar) with the pump in neutral.

388 of 861
CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-40-5
P-66884
Disconnect the charge pressure sender connector (Item

1) [Figure 30-40-5] from the sender.

Remove the sender (Item 2) [Figure 30-40-5] from the
adapter fitting.
Installation: Tighten the charge pressure sender to 7.4 -

8.1 ft.-lb. (10 - 11 N•m) torque.

389 of 861
CHARGE PRESSURE (CONT’D) Figure 30-40-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system. N-17231
I-2003-0888
Remove the plug, spring and poppet [Figure 30-40-7].

Figure 30-40-6
Check the poppet and spring for wear or damage.
1
Inspect the seat inside the hydrostatic pump case for
wear or damage.

Figure 30-40-8
N-19567
If the charge pressure is not correct loosen the charge 1

relief valve plug (Item 1) [Figure 30-40-6].
Assembly: Always use a new O-ring. Tighten the plug to

N-19568
30 - 50 ft.-lb. (41 - 68 N•m) torque.
There are several different thickness of the shims (Item

1) [Figure 30-40-8] and are used to adjust the charge
pressure.
NOTE: 0.010 in. (0,254 mm) is 8 PSI (0,55 bar)

increase in pressure.
The charge pressure should be set at 335 - 385 PSI (23,1

- 26,5 bar).

390 of 861
CHARGE PRESSURE (CONT'D) Figure 30-40-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
1
damage the system. P-64435
I-2003-0888
Check the poppet and spring for wear or damage.

Figure 30-40-9
Inspect the seat inside the hydrostatic pump case for
wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-40-10] used to adjust the charge pressure.
NOTE: 1.0 mm shim (Item 1) [Figure 30-40-10] = 43.5

1 PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
The charge pressure should be set at 335 - 385 PSI (23,1

- 26,5 bar).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-9].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

30 - 50 ft.-lb. (41 - 68 N•m) torque.

391 of 861

392 of 861
HYDROSTATIC PUMP Figure 30-50-2
Description
1
The hydrostatic pump is composed of two hydrostatic
piston pumps connected together. The pumps provide bi-
directional flow to two separate hydrostatic 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 2
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure P-66670
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump contains the charge pressure Remove the replenishing/high pressure relief valve (Item
relief. The charge pressure relief is adjustable with 1) [Figure 30-50-1] from the pump.
shims.
Assembly: Tighten the plug to 30 - 50 ft.-lb. (41 - 68
The hydrostatic pump is located in the center of the N•m) torque.
mainframe mounted to the engine flywheel housing.

Check for damage and replace as needed.
Replenishing/High Pressure Relief Valve
Check the O-ring (Item 2) [Figure 30-50-2] for damage
Figure 30-50-1 and replace as needed.
If the replenishing/high pressure relief valve must be

1 replaced, it must be replaced as a complete unit.
The pressure setting for a new replenishing/high

pressure relief valve is 5000 PSI (345 bar).
N-19565
There are four replenishing/high pressure relief valves

(Item 1) [Figure 30-50-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.

393 of 861
HYDROSTATIC PUMP (CONT’D) Figure 30-50-4

1
IMPORTANT
clean the work area before disassembly and keep all 2
damage the system.
I-2003-0888
P-34567B
Remove the engine/hydrostatic pump assembly from the

loader. (See Engine Removal And Installation on Page Loosen the drive belt tensioner (Item 1) [Figure 30-50-4]
70-10-9.) and remove the drive belt.
Remove the control handle linkage from the hydrostatic Remove the hydrostatic pump drive pulley mounting nut
pump. (See Linkage Removal And Installation on Page (Item 2) [Figure 30-50-4] and washer.
50-100-7.)

Installation: Tighten the pump pulley mounting nut to
Remove the hydraulic pump from the hydrostatic pump. 175 - 200 ft.-lb. (237 - 271 N•m) torque.
(See HYDRAULIC PUMP (STANDARD) on Page 20-60-
1.) Figure 30-50-5
Figure 30-50-3
P-34567A
1
P-34568
Install a puller on the hydrostatic pump drive pulley and
remove the pulley from the pump shaft [Figure 30-50-5].
Remove the hydrostatic pump mounting bolt (Item 1)
[Figure 30-50-3] and washer(s).
Installation: Tighten the mounting bolt to 90 - 100 ft.-lb.

(125 - 135 N•m) torque.
NOTE: Mounting bolt (Item 1) [Figure 30-50-3] is a

special purpose bolt, replace with genuine
Bobcat parts only.

394 of 861
HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Follow the hydraulic pump startup procedure. (See
Hydraulic Pump Start Up on Page 20-60-8.)
Figure 30-50-6
1
WARNING
explosion or fire.
W-2103-0508
P-48650
Installation: Install the key in the hydrostatic pump shaft

(Item 1) [Figure 30-50-6] before installing the pump drive

pulley.
Figure 30-50-7
P-28850
Hold the nut (Item 1) [Figure 30-50-7] on the two

hydrostatic pump mounting bolts (Item 2) [Figure 30-50-
6].
Remove the two hydrostatic pump mounting bolts from

the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 65 - 70

Reverse the removal procedure to install the hydrostatic

pump assembly.

395 of 861
HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

396 of 861
Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash plate
17. Housing 10

18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

397 of 861
HYDROSTATIC PUMP (CONT'D) Figure 30-50-10
Disassembly
1
Figure 30-50-8
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-50-10].

N-19550
Check the valve plate for wear. (Both Sides.)
Remove the four bolts (Item 1) [Figure 30-50-8] from the

pump housing end cap.

Figure 30-50-9
N-19551
Remove the pump housing end cap (Item 1) [Figure 30-

50-9].
Remove the gasket (Item 2) [Figure 30-50-9].

398 of 861
1
Figure 30-50-11
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-50-13] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-50-13] for wear

Check the valve plate locating pin (Item 1) [Figure 30-50- and replace the rotating group as needed.
11] for wear and replace if needed.

Figure 30-50-14
Check the needle bearing (Item 2) [Figure 30-50-11] for
wear and replace if needed. 1
Figure 30-50-12
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-50-

N-17197 14] from the cylinder block.
Remove the rotating group (Item 1) [Figure 30-50-12]

from the pump.

399 of 861
Figure 30-50-15
1
3 3
2
3 3 2 1
3
N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2)

N-17200 and the support washer (Item 3) from the drive shaft end
of the pump [Figure 30-50-17].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-50-18
2) for wear and replace as needed [Figure 30-50-15].

Remove the four pins (Item 3) [Figure 30-50-15] from the
cylinder block. 1
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-50-15] to see if they are

all the same length.
Figure 30-50-16
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-50-18] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-50-16] from

the pump housing.

400 of 861
Figure 30-50-19 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-50-21] for

N-17240 wear and replace if needed.
Figure 30-50-22
the pump housing and remove the driveshaft and bearing

from the housing.
Figure 30-50-20
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-50-22]
from the lower trunnion cover. Remove the cover.
N-17241

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

401 of 861
Figure 30-50-23
2
2
1 1
1 N-17246
Remove the four mount bolts (Item 1) from the pump

N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-50-25].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-50-26
from the pump housing [Figure 30-50-23].

Figure 30-50-24
1
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-50-

26].
Check the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-24] for wear and replace as needed.

402 of 861
Figure 30-50-27
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-50-29] and replace as needed.
Figure 30-50-30
Inspect the seal (Item 1) [Figure 30-50-27] in the upper
trunnion cover and replace if needed.

Figure 30-50-28
1 N-17251
2
Slide the swash plate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-50-30] from
the swash plate shaft.
Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-50-28] from the pump housing.

403 of 861
Assembly
Figure 30-50-31
N-17252
Install the swash plate and bearing into the pump

N-17252 housing [Figure 30-50-33].
Tilt the swash plate (Item 1) [Figure 30-50-31] and

remove the swash plate and lower bearing from the

pump housing.
Figure 30-50-32
N-17253
Install the lower bearing (Item 1) [Figure 30-50-32] on

the swash plate.

404 of 861
Assembly (Cont'd)
Figure 30-50-34
1 1
2
N-17247
3
Install the upper trunnion seal (Item 1) [Figure 30-50-36]
N-17249 and cover.
Figure 30-50-37
Install the tapered bearing (Item 1) [Figure 30-50-34] on
the swash plate shaft.

Figure 30-50-35
2
N-17246
3
Install the linkage bracket (Item 1) [Figure 30-50-37] and
N-17248 the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 -
30 N•m) torque.
Install the bearing race (Item 2) and O-ring (Item 3) as

shown in [Figure 30-50-34] & [Figure 30-50-35].

405 of 861
Assembly (Cont'd)
Figure 30-50-38
2
N-17243
Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-50-40].
Install the four mounting bolts and tighten to 18 - 22 ft.-lb.

Figure 30-50-39 (24 - 30 N•m) torque.

Figure 30-50-41
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-50-38] and O-
ring (Item 2) [Figure 30-50-38] at the lower trunnion as
shown in [Figure 30-50-39]. Install the snap ring (Item 1) [Figure 30-50-41] on the
pump shaft.

406 of 861
Assembly (Cont'd) 1 1
Figure 30-50-42
3
2
1 1
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-50-44]

N-17241 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the bearing and snap ring (Item 1) [Figure 30-50- and install into the ball guide retainer (Item 3) [Figure 30-
42] on the pump shaft. 50-44].

Figure 30-50-43 Figure 30-50-45
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
50-43]. 30-50-45] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-50-43].

407 of 861
Assembly (Cont'd)
1
2
Figure 30-50-46
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-50-48] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-50-49
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
50-46].
Figure 30-50-47
2 1
N-17196
The bearing cage (Item 1) [Figure 30-50-49] will

protrude from 0.08 - 0.10 in. (2,0 - 2,5 mm) from the
N-17197 surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

Lay the pump housing on its side and install the cylinder 50-49] will protrude from 1.65 - 0.185 in. (4,19 - 4,70 mm)
block, piston assembly into the housing. from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-50-47].

408 of 861
Assembly (Cont'd)
1 1
Figure 30-50-50
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-50-52] to 35 - 45 ft.-
Coat the backside of the valve plate with petroleum jelly Figure 30-50-53
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-50-50].
The notch (Item 1) [Figure 30-50-50] on the valve plate

must engage the locating pin.
Figure 30-50-51 1
2
1
N-19571
1 Install the two small O-rings (Item 1) [Figure 30-50-53].
Install the large new O-ring (Item 2) [Figure 30-50-53].
N-19551 Install the pump coupler (Item 3) [Figure 30-50-53].
Coat a new end cap gasket (Item 1) [Figure 30-50-51]

with petroleum jelly and install onto the end cap.

409 of 861
Assembly (Cont'd)
Figure 30-50-54
N-19570
Install the two pumps together [Figure 30-50-54].

Figure 30-50-55
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-50-55] to 35 -

45 ft.-lb. (47 - 61 N•m) torque.

410 of 861
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 endcaps 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 Ports are labeled on the hydrostatic pump casting.
a spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1

P-64943
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 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

411 of 861
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
removed when the hydrostatic pump is separated from
the engine/hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the 1

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Raise the lift arms and install and approved lift arm P-64460
Place the loader on jack stands. (See Procedure on Page Disconnect all of the electrical harness connectors (Item
10-10-1.) 1) [Figure 30-51-3] from the loader harness.
Removal:
WARNING

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
damage the system.
I-2003-0888
Figure 30-51-2
1 Figure 30-51-4
P-64425
P-64426
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.

412 of 861
Hydraulic Controller Removal And Installation 1

(Cont'd)
Figure 30-51-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 7.7
ft.-lb. (10,4 Nm) torque. Ensure bolts are tight to
P-64427 specifications.
NOTE: When a hydraulic controller is replaced, the

Remove the controller (Item 1) [Figure 30-51-5] from the hydrostatic pumps must be calibrated. (See

pump. Hydraulic Controller Neutral Adjustment on
Page 30-51-29.)
Remove the controller gaskets (Item 2) [Figure 30-51-5]
from the pump. Figure 30-51-8
Installation:
Figure 30-51-6
P-64978
With the engine running and the loader on jack stands:

P-64444 Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-51-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in out of the set screw. Tighten set screw to 18 in.-lb. (2
the center of the servo piston groove (Item 1) [Figure 30- N•m) torque.
51-6].
Repeat the bleeding procedure for all of the solenoids.
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-51-5].
Be sure the pump surface is clean.

413 of 861
Remove the hydrostatic pump/engine assembly from the

loader. (See Engine Removal And Installation on Page
70-10-9.)
1
IMPORTANT
parts clean. Always use caps and plugs on hoses, P-64345

damage the system.
I-2003-0888
Loosen the washer and nut (Item 1) [Figure 30-51-10] on
the hydrostatic pump drive shaft.
Figure 30-51-9 Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271
N•m) torque

Figure 30-51-11
1
1
P-64344
Loosen the tensioner mount bolt (Item 1) [Figure 30-51-

P-64346
9].
Remove the drive belt (Item 2) [Figure 30-51-9]. Use a puller (Item 1) [Figure 30-51-11] to loosen the
pulley from the pump drive shaft.
Installation: (See Belt Removal And Installation on Page
30-60-3.) NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.

414 of 861
Figure 30-51-12
1 1 1 P-64343
Remove the mounting bolt (Item 1) [Figure 30-51-14] at

P-64348 the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 90 - 100 ft.-lb. (125

Figure 30-51-13 - 135 N•m)

NOTE: The mounting bolt is a special purpose bolt.
Only replace with original Bobcat Parts.
1 1 Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-41-6.)
P-64337 P-64338

12] and nuts (Item 1) [Figure 30-51-13].
Installation: Tighten the mounting bolts and nuts to 65 -

70 ft.-lb. (88 - 95 N•m) torque.
Make sure the key (Item 2) [Figure 30-51-12] is installed.

415 of 861
HYDROSTATIC PUMP (SJC) (CONT'D)
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 30-51-15

1
P-64458
Remove the air bleed plugs (Item 1) [Figure 30-51-15].
BEFORE STARTUP: Fill one of the air bleed ports with

new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before startup.
Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.

416 of 861
3
1. O-ring 5 1
2. Bolt 4
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt 14
15
16
19 17
21 25
24 23 22 26
20

18
26
18
27 29
19
32 28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
6 21. Bolt
2 7 22. Plug
23. Screen
24. Plug
25. Plug
30 26. Dowel Pin
4 27. Charge Pressure Relief
28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
P-90241

417 of 861
High Pressure Relief and Bypass Valve
Figure 30-51-16
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-51-18]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-18] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-16] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-16].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 111 - 125 ft.-lb. (150 - 170 replacement is required, replace as an assembly.
N•m) torque.
Factory setting on the relief valve is 5075 PSI (350 bar).
Figure 30-51-17
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-17], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-17]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-51-17] to

ensure it is not broken or flattened.

418 of 861
Charge Relief Valve
Figure 30-51-19 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-51-21] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-51-19] is Inspect the sealing ring (Item 3) [Figure 30-51-21] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or

foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 52 ft.-lb. (70 shims (Item 5) [Figure 30-51-21].
N•m) torque.
NOTE: 1.0 mm shim (Item 5) [Figure 30-51-21] = 43.5
Figure 30-51-20 PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
1
P-64435
Check and replace the O-ring (Item 1) [Figure 30-51-20].

419 of 861
Remove the hydrostatic pump/engine assembly from the

2
70-10-9.)
Figure 30-51-22
1
1
1
P-64439
Remove the bolts (Item 1) mounting the steel covers

(Item 2) [Figure 30-51-24].
Assembly: Tighten bolts to 38 ft.-lb. (51 N•m) torque.
P-64458 Figure 30-51-25

Remove the hydraulic controllers (Item 1) [Figure 30-51-
22]. (See Hydraulic Controller Removal And Installation 1
on Page 30-51-2.)
Figure 30-51-23
2 2
1 1
1
P-64440
Remove the mounting bolts and washers for the

swashplate angle sensor (Item 1) [Figure 30-51-25].
Assembly: Tighten bolts to 27.4 in.-lb. (3,1 N•m) torque.

P-64438
Swashplate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-23].
Note the connectors facing each other.
Note the steel covers facing direction.

420 of 861
Figure 30-51-26
P-64442
Both swashplate angle sensors and associated hardware

P-64441 removed from the hydrostatic pump. [Figure 30-51-28].
Assembly: Note the slotted portion (Item 1) of the

positioning pin tightly fits the machined section on the

swashplate angle sensor shaft (Item 2) [Figure 30-51-
26].
Note the machined section of the swashplate angle

sensor shaft faces the center of the hydrostatic pump.
Figure 30-51-27
P-64453
NOTE: Improperly installing the swashplate angle

sensor, with the shaft facing toward the
outside of the hydrostatic pump, will make it
hard to install the sensor mounting bolts and
also destroy the seal (Item 1) [Figure 30-51-
27].

421 of 861
Right End Housing
Figure 30-51-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
51-31].
1
P-64445

Left End Housing
Figure 30-51-30
3 1
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
[Figure 30-51-29] and [Figure 30-51-30].
Assembly: Alternately, tighten mount bolts to 96 ft.-lb.

(130 N•m) torque.

422 of 861
Figure 30-51-32
1 2
1
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole

P-64465 in case housing (Item 2) [Figure 30-51-34] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-32].

Figure 30-51-33
P-64466
Ensure servo follower (Item 2) [Figure 30-51-32] is

swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-33].

423 of 861
Figure 30-51-35
RIGHT SIDE
P-64454
Figure 30-51-36

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-51-35] and

[Figure 30-51-36] 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

30-51-35] and [Figure 30-51-36] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

424 of 861

LEFT SIDE
Figure 30-51-37 1
2
RIGHT SIDE
1 P-64503
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
P-64455 37] and [Figure 30-51-38] in the case housing with the
notch (Item 1) [Figure 30-51-39] and [Figure 30-51-40]
that does not go through the valve plate.
Figure 30-51-38
Align the shoulder of the roller bearing (Item 2) [Figure

LEFT SIDE 30-51-37] and [Figure 30-51-38] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-39] and [Figure
30-51-40].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.
1
2
P-64502
Figure 30-51-39
RIGHT SIDE
1
2
P-64456

425 of 861
Figure 30-51-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-43].

B25012
Figure 30-51-44
Right Side Rotating Group [Figure 30-51-41].

Figure 30-51-42
1
P-64475
Remove the pistons (Item 1) [Figure 30-51-44] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-42].

426 of 861

1
Figure 30-51-45
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64476 47].
Figure 30-51-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-45] in the
1

slippers, are not plugged.
Figure 30-51-46
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-48]. 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 30-51-46].

427 of 861

3
Figure 30-51-49
1
1
P-64479
Inspect mating surface for the slippers on the swashplate

P-64474 (Item 1) [Figure 30-51-51].
Remove the swashplate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-51].
1) [Figure 30-51-49].

Remove the slide ring (Item 3) [Figure 30-51-51], ensure
Figure 30-51-50 it pivots freely.
Figure 30-51-52
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-50] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-52].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-51-50] are not bent or damaged.

428 of 861
Disassembly and Assembly (Cont'd) 2

1 1
Figure 30-51-53
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-

P-64481 55].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-55] on them. The edges face towards
swashplate (Item 1) [Figure 30-51-53]. the outside of the endcap housing

Figure 30-51-54 Inspect bearing surfaces for scratches or scoring.
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-54].
Inspect individual roller bearings and machined surfaces

(Item 2) [Figure 30-51-54] on swashplate.

429 of 861
Disassembly and Assembly (Cont'd) LEFT SIDE

Figure 30-51-56
1
2
1
P-64486
Figure 30-51-59
P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-51-56].

Figure 30-51-57
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-51-58] and

[Figure 30-51-59] from the end housing.
Figure 30-51-60
P-64485
Pull the positioning pin from the end housing.
Replace O-ring (Item 1) [Figure 30-51-57].
Inspect wear surfaces (Item 2) [Figure 30-51-57] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
1
P-64524
The pump seal (Item 1) [Figure 30-51-60] is removed by

inserting a screw into the seal and prying out.

430 of 861
HYDROSTATIC PUMP (SJC) (CONT'D) The Servo Piston Assembly [Figure 30-51-62] cannot be
removed unless the hydraulic controller and rotating
Disassembly and Assembly (Cont'd) group is removed first.
Figure 30-51-61 Figure 30-51-63
1 1 1
P-64488 P-64489
The drive shaft can be tapped out of the end housing with Remove servo piston mounting bolts (Item 1) [Figure 30-
a rubber mallet. 51-63].

Inspect wear surfaces for scratches, and inspect splines Installation: Tighten bolts to 7.7 ft.-lb. (10,4 N•m) torque.
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-51-61] and remove
bearing.
Figure 30-51-62
B25013
Servo Piston Assembly [Figure 30-51-62].

431 of 861
Figure 30-51-64
P-64492
Slide the servo piston assembly out of the bore. [Figure

P-64490 30-51-66].
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-64].

Figure 30-51-65
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-65].

432 of 861
Figure 30-51-67 1
2
1
P-64493
Remove the bushings (Item 1), seals and O-rings (Item

P-64467 2) [Figure 30-51-69] from the pump housing.
Figure 30-51-70
Figure 30-51-68

1
3
P-64494
P-64466
Each servo has a pair of bushings (Item 1), O-rings (Item

Assembly: Align the servo piston so the guide slot 2) and square-cut seals (Item 3) [Figure 30-51-70].
(Item 1) [Figure 30-51-68] is parallel to the driveshaft
centerline. Measure with a straight-edge [Figure 30-51-
67].

433 of 861
Figure 30-51-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-73] from the
P-64495 servo piston.
Figure 30-51-74
Remove the lock nut (Item 1) [Figure 30-51-71] from the
servo piston.
1

Assembly: Tighten lock nut to 22 ft.-lb. (30 N•m) torque. 2
Figure 30-51-72
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-51-74] from the servo piston.
P-64496 Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-51-74]

Remove the servo cover (Item 1) [Figure 30-51-72] from
the servo piston.

434 of 861
Figure 30-51-75
1
1
2 1
3
P-64499
Remove the four control pressure plugs (Item 1) [Figure

P-64461 30-51-77] at the top of the case housing.
Replace O-rings on plugs.

Remove the plug (Item 1) from the top center of the case
housing. Replace O-ring (Item 2) [Figure 30-51-75]. Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.

Assembly: Tighten plug to 45 ft.-lb. (10 N•m) torque.
Remove internal screen (Item 3) [Figure 30-51-75].
Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m)

torque.
Figure 30-51-76
P-64462
Ensure screen is clean [Figure 30-51-76].

435 of 861
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 swashplate relative
Figure 30-51-78 to the hydraulic controller. This procedure should be
followed if the hydrostatic pump has been disassembled
for servicing the servo piston and the setting has been
disrupted.
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
2
1
WARNING
P-64502
W-2017-0286
Bearings (Item 1) [Figure 30-51-78] in case housing are
replaced by using a press and bearing driver. Raise the lift arms, and install an approved lift arm

Inspect center coupler (Item 2) [Figure 30-51-78].

Disconnect the swashplate angle sensors in the electrical

harness. This prevents unwanted swashplate 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 find an
accessible connector to disconnect.
Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
WARNING
immediately.
W-2145-0290

436 of 861
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-79
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-81] from the

P-64973 MA ports on the bottom of the pump, and install 7500 PSI
pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-79] Figure 30-51-82

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 30-51-80
1
1
1 1
P-64977
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-82]. Plug the ports with metal caps. The
P-64425 caps must be able to handle at least 7500 PSI. Plugging
the A and B ports eliminates leakage at the drive motors
from causing errors in the pump mechanical neutral
Remove the plugs (Item 1) [Figure 30-51-80] from the setting.
MB ports on the front side of the pump, and install 7500
PSI (241 bar) pressure gauges.

437 of 861
Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-83
1
P-64457
Turn the adjustment screw (Item 1) [Figure 30-51-85]

P-64457 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-51-83]. Figure 30-51-86

Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-84
P-64457

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-64457

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

438 of 861
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 30-51-87 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.
NOTE: Procedure is shown for the left side hydraulic

2
controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
right side hydraulic controller and connect
1 pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-64457
Place the loader on jack stands. (See Procedure on Page
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-51-87] to 22 ft.-lb.

(30 N•m) torque.
Shut loader OFF. WARNING
Remove the hydraulic hose from the X1 and X2 ports on
the pump. Install the plugs and tighten to 18 ft.-lb. (25 Put jackstands under the front axles and rear corners
N•m) torque. of the frame before running the engine for service.
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 18 ft.-lb. (25 W-2017-0286
N•m) torque.
NOTE: The Hydraulic Controller Neutral Adjustment Raise the lift arms, and install an approved lift arm
must be performed whenever the Mechanical support device. (See Installing on Page 10-20-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Raise the operator cab. (See Raising on Page 10-30-2.)
29.)
WARNING
immediately.
W-2145-0290

439 of 861
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-88
2
1
P-64975
1
Install 500 PSI pressure gauges in the X1 and X2 ports

P-64460 pertaining to the side of the hydrostatic pump you are
adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-51-91

[Figure 30-51-88] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-51-89
1 1
P-64459
Loosen the locking screw (Item 1) [Figure 30-51-91].

P-64458
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-51-89] 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

440 of 861
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-92
P-64459

P-64459 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 30-51-95

in system pressure. Mark the position of the adjustment
screw.
2
Figure 30-51-93
P-64459
While holding the adjustment screw (Item 1) in position,

P-64459 tighten the locking screw (Item 2) [Figure 30-51-95] to
4.5 ft.-lb. (6,1 N•m) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-93] 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 18 ft.-lb. (25
N•m) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

441 of 861

442 of 861
DRIVE BELT Adjusting
Description To adjust the drive belt, between the flywheel and the
hydrostatic pump pulley, use the following procedure:
The drive belt makes the mechanical connection from the
engine flywheel to the hydrostatic pump pulley. Stop the engine.
The belt is a cord-reinforced rubber design. Open the rear door and disconnect the negative (-)
battery cable.
Constant tension is applied to the drive belt by the use of
a spring-loaded belt tensioner. Remove the belt shield. (See Shield Removal And
Installation Page 30-60-1.)
The drive belt is protected by a plastic shield fastened to
the flywheel housing by metal clips. The shield is also in Figure 30-60-3
place to protect the operator.
Shield Removal And Installation

1
Figure 30-60-1

1 P-66813
Loosen the bolt (Item 1) [Figure 30-60-3] on the spring

loaded belt tensioner.
P-66811
NOTE: The pointer will be at the 1 o'clock position
(Item 2) [Figure 30-60-3] when the belt
Remove the three drive belt shield mounting clips tensioner is not under spring tension.
(Item 1) [Figure 30-60-1].
Figure 30-60-2
P-66812
Remove the belt shield (Item 1) [Figure 30-60-2].

443 of 861
DRIVE BELT (CONT’D) Figure 30-60-5
Adjusting (Cont’d)
Figure 30-60-4
1
P-66814
Raise the belt tensioner slightly so that the pulley is

P-66814 operating on spring tension and not against the stop.
Tighten the mounting bolt (Item 1) [Figure 30-60-5] to 25

Using the Belt Tensioner Bar (MEL1405) or a pry bar - 28 ft.-lb. (34 - 38 N•m) torque.
push the belt tensioner against the belt, the pointer (Item

1) [Figure 30-60-4] will be at the 3 o'clock position when NOTE: Do not set the belt tensioner against the travel
the belt tensioner stop is bottomed out. Do not pry stop in the 3 o'clock position.
directly on the pulley, pry on the belt tensioner bracket
the pulley is mounted on. Run the engine for a few minutes.
Note: If the pointer does not move when prying on Stop the engine and recheck the pointer position.
the belt tensioner mounting bracket, manually
move the arrow towards the 3 o’clock position Readjust if necessary.
with a screwdriver while putting tension on
the bracket to help get it started. After the belt tensioner has been in service, readjust
when the pointer reaches the 1 o'clock position.
Install the belt shield using the fasteners.
Reconnect the negative (-) battery cable.
Close the rear door.

444 of 861
Belt Removal And Installation
Figure 30-60-6
P-66813
Remove the air conditioner belt if so equipped.

P-48000
The belt tensioner is located between the flywheel and
pump pulley. Loosen and remove the bolt (Item 1)
Stop the engine. Open the rear door. [Figure 30-60-7] from the belt tensioner.
Raise the operator cab. (See Raising Page 10-30-2.)

Remove the belt tensioner assembly.
Remove the negative (-) cable from the battery. The Figure 30-60-8
battery may be removed for additional working clearance.
(See Removal And Installation Page 60-20-1.)
Remove the belt shield [Figure 30-60-6]. (See Shield

Removal And Installation Page 30-60-1.)
P-48481
Remove the drive belt from the pump pulley and flywheel.
Remove the drive belt from the loader [Figure 30-60-8].
Install the new drive belt. Install the belt tensioner

assembly.
Adjust the drive belt. (See Adjusting Page 30-60-1.)
Reinstall belt shield and connect the negative (-) cable to

the battery.

445 of 861
Belt Tensioner Removal And Installation
Figure 30-60-9
P-66813
Loosen and remove the belt tensioner mounting bolt

P-48000 (Item 1) [Figure 30-60-10].
Installation: Tighten the bolt to 25 - 28 ft.-lb. (34 - 38

Stop the engine. Open rear door. N•m) torque.

Remove the negative (-) cable from the battery. the Remove the belt tensioner from the flywheel housing.
battery may be removed for additional working clearance.
(See Removal And Installation Page 60-20-1.) Reverse the removal procedure to install the belt
tensioner.
Remove the belt shield [Figure 30-60-9]. (See Shield
Removal And Installation Page 30-60-1.)

446 of 861
DRIVE BELT (CONT’D)
Belt Tensioner Parts Identification
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring

19. Shaft 6 13
20. Bracket
NOTE: Belt tensioner parts are not all 5 14

available individually. Consult
parts catalog for available 15
sub-assemblies. 7
8 16
17
9
18
10
19
20
E-2296

447 of 861
Belt Tensioner Disassembly
Figure 30-60-11
3
1
1
4
P-8861
Remove the two pins (Item 1) from the hub assembly

P-8858 (Item 2) [Figure 30-60-13] only if they have been
damaged.
Remove the grease cover (Item 1) [Figure 30-60-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-60-13] with a plastic hammer.

Figure 30-60-12
Figure 30-60-14
2
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-60-14].
assembly (Item 5) [Figure 30-60-12].

448 of 861
Belt Tensioner Assembly
Figure 30-60-15
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-60-17] into the hub.
Figure 30-60-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-60-15] as shown.

Figure 30-60-16
2
3
P-8874
Install a punch as shown and turn clockwise while

P-8872 applying down pressure on the pulley.
Turn until the pulley snaps down into place; this

Install the shaft from the bracket assembly (Item 1) into procedure winds the spring and retains the end of the
the pulley assembly (Item 2) and align the spring (Item 3) spring in proper location [Figure 30-60-18].
[Figure 30-60-16] over the alignment pin on the bracket.

449 of 861
Belt Tensioner Assembly (Cont'd)
Figure 30-60-19
1
1
P-8877
Press the grease cap (Item 1) onto the pulley assembly

P-8875 (Item 2) [Figure 30-60-21]. Press on the outer formed
edge of the grease cap.
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-60-19] over the roll pins. assembly, do not press down on the arrow

indicator plate. Support the hub assembly so
Figure 30-60-20 that it contacts only the hub and not the arrow
indicator plate.
2
1
P-8876
Install the second retainer washer (Item 1), the washer

(Item 2) and the bolt (Item 3) [Figure 30-60-20].
Tighten the bolt to 28 - 32 ft.-lb. (38 - 45 N•m) torque.
Fill the grease cap 1/4 full (approximately 1/2 - 3/4 oz.) of
grease.

450 of 861
TWO-SPEED VALVE
Description
Figure 30-70-1
P-76175
The two-speed valve (Item 1) [Figure 30-70-1] is located

on top of the chaincase in front of the hydrostatic pump.

The high range is selected by a switch located on the
right handle for manual loaders and on the left joystick for
SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.
The two-speed valve also contains a two-speed pre-

warming solenoid, which provides warm hydraulic oil to
preheat the drive motors preventing damage in cold
conditions. When the hydraulic oil reaches a pre-
determined temperature, the pre-warming solenoid is
turned off and the two-speed is engaged.
The case drain filter for the drive motors is mounted to

the top of the two-speed valve.

451 of 861
TWO-SPEED VALVE (CONT'D) Mark all hydraulic hoses and tubelines for proper
installation.
Valve Removal And Installation
Figure 30-70-2
DANGER
2 2
1 1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-76174

can cause lift arms to drop. Scribe a mark across the top of the steering linkage bars
• Keep out of this area when lift arms are raised (Item 1) [Figure 30-70-2] which are connected to the
unless supported by an approved lift arm steering shaft on the control panel.

D-1009-0409 Remove the four steering linkage mounting bolts (Item 2)
[Figure 30-70-2].

WARNING bars. Tighten the steering linkage mounting bolts to 35 -
40 ft.-lb. (47,5 - 54,2 N•m) torque. Verify linkage neutral
adjustment. (See Linkage Neutral Adjustment on Page
Never work on a machine with the lift arms up unless 50-100-13.)
support device. Failure to use an approved lift arm Figure 30-70-3
W-2059-0598
2
WARNING 1

W-2017-0286
P-76161
1.)
Raise the lift arms and install an approved lift arm support 30-70-3] from the two-speed pre-warming solenoid.
Raise the operator cab. (See Raising on Page 10-30-2.) 30-70-3] from the two-speed solenoid.

452 of 861
TWO-SPEED VALVE (CONT'D) Figure 30-70-6
Valve Removal And Installation (Cont'd)
Figure 30-70-4
1
1
2
1
P-76148

1 P-76160 6] from the valve bracket.
Remove the two-speed valve assembly from the loader.

Disconnect the three hydraulic tubelines (Item 1) [Figure
30-70-4] from the two-speed valve.

Disconnect the hydraulic hose (Item 2) [Figure 30-70-4]
from the two-speed valve.
Figure 30-70-5
2
2
P-76155
Disconnect the hydraulic hose (Item 1) and the three

tubelines (Item 2) [Figure 30-70-5] from the two-speed
valve.

453 of 861
TWO-SPEED VALVE (CONT'D) Figure 30-70-8
Valve Disassembly And Assembly
Figure 30-70-7
1 6 1
3
4
2
7
5
P-76185
Check the O-rings (Item 1) [Figure 30-70-8] on the two-

P-76134 speed solenoid stem for wear and replace as needed.
Figure 30-70-9
Mark all hydraulic tubelines and fittings for proper
installation.

Remove the two-speed solenoid nut (Item 1), two-speed
solenoid (Item 2), and two-speed solenoid stem (Item 3)
[Figure 30-70-7] from the valve block.
Assembly: Tighten the two-speed solenoid nut to 5 ft.-lb. 1

(6,8 N•m) torque.
Assembly: Tighten the two-speed solenoid stem to 20

ft.-lb. (27,1 N•m) torque.
Remove the pre-warming solenoid nut (Item 4), pre-

warming solenoid (Item 5), and pre-warming solenoid 2 P-76188
stem (Item 6) [Figure 30-70-7] from the valve block.
Assembly: Tighten the pre-warming solenoid nut to 5 ft.- Check the O-rings (Item 1) and back-up washers (Item 2)
lb. (6,8 N•m) torque. [Figure 30-70-9] on the pre-warming solenoid stem for
wear and replace as needed.
Assembly: Tighten the pre-warming solenoid stem to 20
ft.-lb. (27,1 N•m) torque.

valve fittings.

454 of 861
TWO-SPEED VALVE (CONT'D)
Valve Disassembly And Assembly (Cont’d)
Figure 30-70-10
P-76136A
Remove the two bolts and nuts (Item 1) [Figure 30-70-

10] fastening the two-speed valve and case drain filter

clamp to the valve mounting bracket.
Remove the two-speed valve (Item 1) and case drain

filter clamp (Item 2) [Figure 30-70-10] from the valve
mounting bracket.
Assembly: Tighten the two mounting bolts to 80 - 90 in.-


455 of 861

456 of 861
CASE DRAIN FILTER Figure 30-80-3
Description
The case drain filter is an external filter assembly in the

case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete 1
assembly or disassembled to replace the element with an
element kit and/or the spring kit purchased from Bobcat
Parts.
Remove the case drain filter(s) from the machine. (See

Removing And Replacing Hydraulic Case Drain Filters
(Two-Speed Loaders) on Page 10-120-4.)
P-76218
Figure 30-80-1
Remove the filter element and spring assembly (Item 1)
[Figure 30-80-3]
NOTE: Remember the orientation of the filter element

and spring assembly for correct assembly.
Figure 30-80-4

2
1
3
P-76212
1
Remove the filter housing nut (Item 1) from the filter
housing (Item 2) [Figure 30-80-1].
2
Figure 30-80-2
P-76216
The larger taper spring (Item 1) slides over the end of the
2
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-80-4] slides into the filter element.
P-76214
Remove the packing (Item 1) and O-ring (Item 2) [Figure

30-80-2] from the filter housing nut.

457 of 861

458 of 861
DRIVE SYSTEM
BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1 SAFETY &
MAINTENANCE
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-11-1
Disc Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 40-11-2
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-11-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . 40-30-2 DRIVE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 SYSTEM
Front Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-1
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-3
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 SYSTEM &
ANALYSIS
OTHERWISE SPECIFIED. ENGINE
SERVICE

ITEMS MAY VARY.
SPECIFICATIONS

459 of 861

460 of 861
BRAKE (SINGLE SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-2.)
Description
Disconnect and remove the engine speed control. (See
The brake is used to hold the machine in place. The Removal And Installation on Page 70-20-1.)
brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the front accessory panel. Remove the control panel from the loader. (See Removal
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier Remove the center chaincase cover. (See Center Cover
shafts. An electric solenoid is sent power from a relay to Removal And Installation on Page 40-30-2.)
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the Remove the traction lock assembly. (See Removal And
discs. Installation on Page 60-120-2.)
The hold signal will be interrupted and the wedge will Figure 40-10-2
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 1

LOCK on Page 60-120-1.)
Figure 40-10-1

1
N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.
1 Figure 40-10-3
P-76419
Disc Removal And Installation
WARNING
1
N-19105
support device can allow the lift arms or attachment Inspect the traction lock guides (Item 1) [Figure 40-10-3]
to fall and cause injury or death. and the brake disc for damage or wear and replace as
W-2059-0598
necessary. (See Inspecting on Page 60-120-6.)

461 of 861
BRAKE (SINGLE SPEED) (CONT’D)
Disc Removal And Installation (Cont’d)
Figure 40-10-4
N-19082A
Figure 40-10-5

1
N-19083A
A snap ring pliers with 90 degree tips are necessary for

removing the parking brake disc.
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.

462 of 861
BRAKE (TWO-SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-2.)
Description
Disconnect and remove the engine speed control. (See
The brake discs on two-speed loaders have a rubber Removal And Installation on Page 70-20-1.)
isolator riveted to the side of the brake discs.
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 40-11-1]
located on the front accessory panel.
The brake is applied by a spring-loaded wedge that drops Removal And Installation on Page 40-30-2.)
into two notched brake discs attached to the motor carrier
shafts. An electric solenoid is sent power from a relay to Remove the traction lock assembly. (See Removal And
pull the wedge away from the discs. A signal from the Installation on Page 60-120-2.)
main Bobcat controller holds the wedge away from the
discs. Figure 40-11-2
The hold signal will be interrupted and the wedge will

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
1
brake solenoid.
For more information on the brake. (See TRACTION

LOCK on Page 60-120-1.)

Figure 40-11-1
N-19081A
The parking brake discs (Item 1) [Figure 40-11-2] are

located beneath the center chaincase cover.
Figure 40-11-3
P-76419
Disc Removal And Installation
WARNING 1
N-19105
support device. Failure to use an approved lift arm Inspect the traction lock guides (Item 1) [Figure 40-11-3]
support device can allow the lift arms or attachment and the brake disc for damage or wear and replace as
to fall and cause injury or death. necessary. (See Inspecting on Page 60-120-6.)
W-2059-0598

463 of 861
BRAKE (TWO-SPEED) (CONT’D) Disc Disassembly and Assembly
Disc Removal And Installation (Cont’d) Figure 40-11-6
Figure 40-11-4
1
2 1
P-76405
P-73918
Remove the four rivets (Item 1) from the isolator (Item 2)
[Figure 40-11-6] fastened to the disc.
Figure 40-11-5
Remove the isolator (Item 2) [Figure 40-11-6] from the

disc.
NOTE: Make sure rubber isolator is seated tight

1
against disc after rivets are installed.
P-73917
A snap ring pliers with 90 degree tips are necessary for

removing the parking brake disc.
Remove the snap ring (Item 1) [Figure 40-11-4] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-11-4] off the sprocket

(Item 1) [Figure 40-11-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.
NOTE: When installing the two-speed brake discs,

make sure the discs isolators are facing each
other towards the center of the loader. The
rivets fastening the isolator to the disc are
orientated so the disc can be slid between the
two sprockets without interfering with the
rivets.

464 of 861
DRIVE COMPONENTS
Description

P-66933
The drive components consist of the chaincase, drive

chains, sprockets, axleshafts, hubs 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.

465 of 861
DRIVE COMPONENTS (CONT’D) Installation: Support the flange of the axle hub and
install the two studs with a hammer. A hydraulic press
Axle Seal Removal And Installation can also be used to install the studs.
2
2
2 1
P-4157 P-4159
The tools listed are needed for the following procedure: Install the puller tool (Item 1) [Figure 40-20-2] on the
axle hub.

Axle Hub Puller Tool
MEL1399 - Seal Driver Tool A driver tool (Item 2) [Figure 40-20-2] can be used for
MEL1242 - Power Ram (may be used if desired) centering the threaded rod of the puller.
To loosen the axle hub mounting bolt (Item 1) [Figure 40-

20-1], use the following procedure:
Before lifting and blocking the loader, loosen the hub WARNING
mounting bolt (Item 1) [Figure 40-20-1].
NEVER STAND IN-LINE OF THE HUB WHEN
NOTE: If the axle and bearings are being replaced, REMOVING A HUB FROM AN AXLE. The hub has a
also loosen the sprocket mounting bolt inside tapered fit on the axle end and can come off the axle
the chaincase before lifting and blocking the with great force and cause serious injury.
loader. (See Axle Sprocket And Bearings W-2186-0395
Removal And Installation on Page 40-20- 4.)
Use a wrench with the puller and remove the axle hub
from the axle tube. A spacer and a power ram can be
1.)
used between the axle and the tool if available, instead of
the wrench, threaded rod and driver tool.
Remove the front tire/wheel assembly.
Remove the hub mounting bolt (Item 1) [Figure 40-20-1]

and washer from the axle.
Installation: Tighten the hub mounting bolt to 725 - 800

ft.-lb. (983 - 1085 N•m) torque.
Remove two of the wheel mounting studs (Item 2)

[Figure 40-20-1].
Use a wheel mounting nut on each stud and remove the

two studs with a hammer.

466 of 861
DRIVE COMPONENTS (CONT’D) Figure 40-20-5
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for
P-4161 the following procedure:
Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair

Figure 40-20-4 sleeve kit is available from Bobcat Parts.
Place the new axle seal over the axle and into the axle
tube.
Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is
flush with the edge of the axle tube [Figure 40-20-5].
1 Reverse removal procedure to install the axle hub and

wheel assembly.
P-4181
Drill a small hole in the axle seal.
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end in the axle seal.
Remove the axle seal.

467 of 861
Axle Sprocket And Bearings Removal And

Installation
The tools listed are needed for the following procedure:
MEL1242 - Power Ram

MEL1202B - Axle Bearing Service Set
NOTE: The procedure shown is for removing the 2

front axle, bearings and sprocket. This
procedure can also be used for the rear axle, 1
bearings and sprocket. (See Rear Cover
P-34255
Use jackstands to support the rear of the loader. (The
loader wheels should remain on the ground.)
Remove the eight front cover mounting bolts (Item 1) and
the front cover (Item 2) from the chaincase [Figure 40-
20-6]. (See Front Cover Removal And Installation on
WARNING Page 40-30-1.)
Figure 40-20-7

W-2059-0598
Remove the control panel. (See Removal and Installation 1

on Page 50-100-2.)
P-4147A
Loosen the axle sprocket mounting bolt (Item 1) [Figure

40-20-7].

1.)
Remove the fluid from the chaincase. (See Removing

And Replacing Oil on Page 10-130-1.)
Remove the axle hub. (See Axle Seal Removal And

Remove the sprocket mounting bolt (Item 1) [Figure 40-

20-7].
Installation: Tighten the sprocket mounting bolt to 300 -

330 ft.-lb. (407 - 447 N•m) torque.

468 of 861

Installation (Cont’d)
Figure 40-20-8
2
1
P-4162A
Remove the drive chain from the sprocket (Item 1)

1 [Figure 40-20-9] and remove the sprocket from the
P-4158A chaincase.
Remove the inner bearing (Item 2) [Figure 40-20-9] and

Install the MEL1242 power ram (Item 1) [Figure 40-20-8] remove the axle from the axle tube. (See Axle Sprocket

between the two sprockets. And Bearings Removal And Installation on Page 40-20-
4.)
Put a spacer between the power ram and axle. Push the
axle out to the end of the power ram stroke. Add another
Installation: Pack both axle bearings with grease before
spacer and push the axle again. Repeat this procedure
installing them.
until the axle is free from the sprocket and inner bearing.
Figure 40-20-10
P-4170
A bearing puller (Item 1) [Figure 40-20-10] is needed for

the following procedure:
Put the axle/outer bearing assembly in the bearing puller

as shown and put in the hydraulic press [Figure 40-20-
10].

469 of 861

4
3
Figure 40-20-11
P-4169
Installation: A piece of round tubing (Item 1) [Figure 40-

20-12] is needed to install the bearing on the axle shaft.
P-4171 The tubing needs to measure approximately 0.500 in.
(12,7 mm) to 1.0 in. (25,4 mm) in length. The inside
diameter of the tubing should not be under 2.100 in. (53,3
Be sure the bearing puller makes good contact with the mm) and the outside diameter should not be over 2.400

inner race of the bearing and press the bearing off the in. (60 mm),
mounting surface of the axle.
A bearing puller (Item 2) [Figure 40-20-12] is also
Be sure to hold onto the axle during removal as it will needed to install the bearing on the axle.
slide freely along the axle shaft after removal from the
bearing mounting surface and until the bearing contacts Put the tubing (Item 1) on the bearing puller (Item 2)
the spline on the shaft. [Figure 40-20-12].
Press the splined end of the axle free from the bearing Put the bearing (Item 3) [Figure 40-20-12] on the tube as
[Figure 40-20-11]. shown.
Put the spline end of the axle shaft (Item 4) [Figure 40-
20-12] in the bearing and press the bearing onto the axle.
Be sure to hold onto the axle during installation, as it will

slide freely along the axle shaft after the spline end has
passed through the bearing and until it reaches the
bearing mounting surface on the axle.

470 of 861

Figure 40-20-13
2
1
P-4179
To remove the outer bearing cup, place the bearing cup

tool (Item 1) [Figure 40-20-15] on the slide hammer.
P-4175
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].
When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated After the bearing cup tool is inside the axle tube, pull the
[Figure 40-20-13]. tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-15] on the tool.
Figure 40-20-14
Figure 40-20-16
P-4172
P-4180
Use the tools provided in the MEL1202B Axle Bearing

Service Set for bearing cup removal and installation. A Use the slide hammer and remove the bearing cup from
slide hammer is also necessary for this procedure. the axle tube [Figure 40-20-16].
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-14].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].

471 of 861
DRIVE COMPONENTS (CONT’D) Put the installation tool (Item 1) [Figure 40-20-18] in the
axle tube with the threaded rod through the hole in the
Axle Sprocket And Bearings Removal And tool.
Secure the tool to the threaded rod with a nut [Figure 40-
Figure 40-20-17 20-18].
Hold the inside nut (Item 3) [Figure 40-20-17] with a

1 wrench and tighten the outside nut as shown in photo
2 [Figure 40-20-18].
Tighten the nut until the bearing cup is seated.
Figure 40-20-19
P-4174A
Figure 40-20-18

1
P-4173
To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.
Put the bearing cup tool on the short rod.

2
Put the bearing cup in the axle tube and put the tool into
the tube over the bearing cup [Figure 40-20-19].
P-4164
Hit the short rod with a hammer until the bearing cup is
seated inside the axle tube.
Use the bearing cup installation tools (Item 1) [Figure 40-
20-17] and (Item 1) [Figure 40-20-18] and the long
threaded rod (Item 2) [Figure 40-20-18] from the service
set to install the inner and outer bearing cups.
Put the inner bearing cup in the axle tube (Item 2)

[Figure 40-20-17].
Put the installation tool (Item 1) [Figure 40-20-17] in the

axle tube.
Install the long threaded rod (Item 2) [Figure 40-20-18]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-17].
Secure the tool to the threaded rod with a nut (Item 3)

[Figure 40-20-17].

472 of 861
Chain Removal And Installation 2
WARNING
1
W-2059-0598
P-54227
support device.(See Installing on Page 10-20-1.)
Remove the parking brake disc (Item 1) [Figure 40-20-
Lift and block the loader. (See Procedure on Page 10-10- 20]. (See Disc Removal And Installation on Page 40-10-
1.) 1.) or (See Disc Removal And Installation on Page 40-11-
1.)
Raise the loader operator cab. (See Raising on Page 10-
30-2.) Remove the six carrier mounting bolts (Item 2) [Figure

40-20-20] from inside the chaincase.
Replacing Oil on Page 10-130-1.) Installation: Tighten the motor carrier mounting bolts to
125 - 140 ft.-lb. (170 - 190 N•m) torque.
Installation on Page 70-20-1.) Figure 40-20-21

on Page 50-100-2.)

Installation on Page 60-120-2.) 1
Remove the front (or rear) chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)
Remove the front (or rear) axle and sprocket. (See Axle
Sprocket And Bearings Removal And Installation on P-54226
Page 40-20-4.)
Tip the end of the sprocket on the motor carrier toward

the rear of the loader and remove the rear drive chain
from the sprocket.
NOTE: It may be necessary to tie the front drive chain

up as shown in photo [Figure 40-20-21], so the
carrier/motor assembly can be moved enough
to free the rear drive chain (Item 1) [Figure 40-
20-21] from the sprocket.
Remove the front drive chain from the chaincase.

473 of 861
DRIVE COMPONENTS (CONT’D)
Chain Removal And Installation (Cont’d)
Figure 40-20-22
B-13504A
The tool listed is needed for the following procedure:

MEL1037 - Chain Link Tool
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use MEL1037 Chain Link Tool and #80 chain adapter.
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22]. Tighten the
threaded rod of the chain link tool to 130 ft.-lb. (176 N•m)
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

474 of 861
CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

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

30-2.) 3
3
P-34255
DANGER
Remove the front chaincase cover mounting screws
(Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.

NOTE: There are machined recesses (Item 3) [Figure
40-30-1] on the bottom side of the cover to
P-90328 help pry the covers off.
AVOID DEATH Installation: Apply polyurethane sealer to mating
• Disconnecting or loosening any hydraulic surfaces. Polyurethane sealant should be applied to the
tubeline, hose, fitting, component or a part failure screw threads to stop oil leakage. Tighten the mounting
can cause lift arms to drop. screws to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
D-1009-0409
WARNING
W-2059-0598

475 of 861
CHAINCASE COVERS (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
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
unless supported by an approved lift arm 1
2
D-1009-0409
3 3
on Page 50-100-2.)
1
Figure 40-30-2 3 3
P-66980
4
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
1 Remove the center chaincase cover (Item 2) [Figure 40-

30-3] from the loader.
2
3 NOTE: There are machined recesses (Item 3) [Figure
40-30-3] on the bottom side of the cover to
help pry the covers off.
P-66969
Installation: Apply polyurethane sealer to mating
surfaces. Polyurethane sealant should be applied to the
If loader is equipped with SJC, skip to [Figure 40-30-3]. screw threads to stop oil leakage. Tighten the mounting
screws to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

476 of 861
CHAINCASE COVERS (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
support device. (See Installing on Page 10-20-1.) 3 3
1
Raise the loader operator cab. (See Raising on Page 10- 2
30-2.)
DANGER 3 3
P-66959
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-4].
Remove the rear chaincase cover (Item 2) [Figure 40-

P-90328 30-4].
AVOID DEATH

NOTE: There are machined recesses (Item 3) [Figure
• Disconnecting or loosening any hydraulic 40-30-4] on the bottom side of the cover to
tubeline, hose, fitting, component or a part failure help pry the covers off.
• Keep out of this area when lift arms are raised Installation: Apply polyurethane sealer to mating
unless supported by an approved lift arm surfaces. Polyurethane sealant should be applied to the
support. Replace if damaged. screw threads to stop oil leakage. Tighten the mounting
D-1009-0409 screws to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Removal And Installation on
Page 30-70-2.)
If loader is equipped with high flow, remove the high flow

valve. (See Removal And Installation on Page 20-150-4.)
Disconnect the front steering linkage bars from the rear

linkage bars. (See Linkage Removal And Installation on
Page 50-100-7.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.

477 of 861

478 of 861
MAIN FRAME
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . 50-120-1 SAFETY &
MAINTENANCE
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . 50-121-2
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . 50-40-2 DRIVE
Pivot Pin Bushing And Seal Removal And Installation . . . . . . 50-40-4 SYSTEM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
BOB-TACH (POWER-OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1 MAIN FRAME
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . 50-41-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . 50-41-4

ELECTRICAL
SYSTEM &
CONTROL HANDLE/LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 ANALYSIS
Boot Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 50-110-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 ENGINE
SERVICE
CONTROL HANDLE/LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Boot Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 50-111-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . 50-111-5 SPECIFICATIONS
Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-111-1
Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Mount Removal And Installation . . . . . . . . . . . . . . . 50-112-3
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-112-2
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

479 of 861
MAIN FRAME (CONT’D)
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-13
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-100-7
Linkage Travel Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-17
Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 50-100-11
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-2
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-91-1
Foot Pedal Linkage Disassembly And Assembly. . . . . . . . . . . . . .50-91-3
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .50-91-2

Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . . .50-91-1
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . .50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-4
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1

Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . .50-80-3
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . .50-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . . .50-20-3
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . .50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

480 of 861
MAIN FRAME (CONT’D)
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . 50-31-4
Lower Cushion Removal And Installation . . . . . . . . . . . . . . . . 50-31-2
Seat Belt Removal and Installation . . . . . . . . . . . . . . . . . . . . . 50-31-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-2
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . 50-31-5
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . 50-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
WINDOW (FRONT DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1

Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . 50-133-2
Removal (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1
Removal And Installation (Special Applications Window) . . . 50-133-4
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1


ITEMS MAY VARY.

481 of 861

482 of 861
SEAT BAR Figure 50-10-3
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
The seat bar is located in the operator cab.
Figure 50-10-1
P10564 P10563
Loosen the nut (both sides) at the front corners of the

1 operator cab [Figure 50-10-3].
Remove the nuts and plates (both sides) [Figure 50-10-

3].

Installation: Tighten the nuts to 40 - 50 ft.-lb. (54 - 68
N•m) torque.
N-19225 Figure 50-10-4
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2
1
P-45261
Lift on the grab handle and bottom of the operator cab

slowly until the cab is all the way up and the latching
N-18463 mechanism engages [Figure 50-10-4].
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

from the cab harness.
Lower the seat bar.

483 of 861
SEAT BAR (CONT’D) Disassembly And Assembly
Figure 50-10-5
4 6
5
7
1
2 9 8
10
1
N-19383
N-18572
Figure 50-10-8
Remove the seat bar mounting nuts (Item 1) [Figure 50-

4
10-5] (both sides).
5

9 8
Installation: Tighten the nuts to 28 ft.-lb. (38 N•m) 3
torque. 6
2 10
Lower the operator cab. (See Raising on Page 10-30-2.)
Figure 50-10-6 7
1
N-19219
1
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Seat Bar Mount (Item 1)

Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
N-19224 Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Remove the seat bar (Item 1) [Figure 50-10-6] from the Sensor Mounting Nut (Item 8)
operator cab. Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Reverse the above procedure to install the seat bar into
the operator cab. Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.

484 of 861
SEAT BAR (CONT’D)
Figure 50-10-9
5
4 6
2 7
1
N-19340
Figure 50-10-10

4
5
3 6
2
7
1
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
10].
Seat Bar Mount (Item 1)

Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7) [Figure

50-10-9] & [Figure 50-10-10] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.

485 of 861
SEAT BAR (CONT’D) Figure 50-10-12
Compression Spring Disassembly And Assembly 1
Figure 50-10-11
6 7
5
4 6
N-19222
3
2
1 Turn the bolt (Item 1) [Figure 50-10-12] & [Figure 50-10-
N-19384 11] out of the clevis.
Assembly: Apply Loctite® #518 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.

NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.
Disassemble and assemble the seat bar compression

spring and parts as shown in Fig. [Figure 50-10-11].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)

486 of 861
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
P-66826 P-66827
1 Remove the cab nut and holddown plate (Item 1) [Figure

50-20-2] (both sides).
Installation: Tighten the nut to 40 - 50 ft.-lb. (54 - 68

N•m) torque.

Figure 50-20-3
P-66825
Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1].
WARNING
P-48265
support device. Failure to use an approved lift arm Raise the operator cab (See Raising on Page 10-30-2) to
support device can allow the lift arms or attachment release the tension on the gas cylinder.
W-2059-0598 Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Raise the lift arms.
Install an approved lift arm support device. (See Installing

on Page 10-20-1.)

487 of 861
OPERATOR CAB (CONT’D) Figure 50-20-6
Gas Cylinder Removal And Installation (Cont’d)
Figure 50-20-4
SINGLE GAS CYLINDER
N-19184
1
P-48262A Rotate the mounting bracket forward to relieve any

remaining tension on the gas cylinder(s) [Figure 50-20-
6].
Figure 50-20-5
Remove the front screw (Item 1) [Figure 50-20-6] from

DUAL GAS CYLINDER the gas cylinder mounting bracket.
Installation: Tighten the screws to 100 - 130 in.-lb. (11,3

- 14,7 N•m) torque.
1 2
P-43354A
Loosen the front screw (Item 1) and remove the rear

screw (Item 2) [Figure 50-20-4] and [Figure 50-20-5]
from the gas cylinder mounting bracket.

488 of 861
OPERATOR CAB (CONT’D) Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont’d) Figure 50-20-9
Figure 50-20-7
SINGLE GAS CYLINDER
2
1
P1008
P-66830
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.

DUAL GAS CYLINDER
Assembly: Install a replacement cylinder inside the
cylinder housing.
1 Figure 50-20-10
P-66829
Remove the retaining pin(s) (Item 1) [Figure 50-20-7]

and [Figure 50-20-8] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-7]

P1006
and [Figure 50-20-8] from the operator cab.
Reverse the above procedure to install the gas cylinders Apply a small amount of thread-locker on the threads of
onto the operator cab. the cylinder rod [Figure 50-20-10].
Reinstall the washer and clevis on the cylinder rod.

489 of 861
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
2
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796 P-66831
Remove the operator cab gas cylinder(s). (See Gas

Remove screw (Item 1) [Figure 50-20-12] from the cab
Cylinder Removal And Installation on page 50-20-1.)
ground.
Figure 50-20-11
torque.

Remove any tie-straps connected to the harness [Figure
50-20-12].
Disconnect the cab harness connector screw (Item 2)

[Figure 50-20-12].
Installation: Tighten the connector screw to 30 - 35 in.-

lb. (3,39 - 3,96 N•m) torque.
Figure 50-20-13
P-48265A
Use the hoist connected to the operator cab grab handles

to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-11].
P-66829
Remove the bolt (Item 1) [Figure 50-20-13] from the cab

ground.

490 of 861
Removal And Installation (Cont’d) 2
Figure 50-20-14 1
P-48266A
Connect the slings (Items 1 & 2) [Figure 50-20-15] to a

P-66832 chain hoist.
Lift the operator cab up and forward.

Remove the rear mounting bolt (Item 1) [Figure 50-20-
14] (both sides) and nut from the operator cab. Remove the operator cab from the loader.

Installation: Tighten the bolt and nut to 25 - 35 ft.-lb. (34 Reverse the above procedure to install the operator cab.
- 47 N•m) torque.

491 of 861

492 of 861
OPERATOR SEAT Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
Figure 50-30-1
1 1
1 2
N-20729
N-20729
Raise the operator cab. (See Raising on Page 10-30-2.) Locate the seat belt bolts under seat pan insulation (Item
1 & 2) [Figure 50-30-3] and peel back or cut insulation to

Remove the four seat mounting nuts (Item 1) [Figure 50- gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Item 1 & 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54

ft.-lb. (73 N•m) torque. Tighten nut (Item 2) [Figure 50-
P10564 P10563 30-4] to 34 ft.-lb. (46 N•m) torque.
Repeat for other half of seat belt and guide

Lower the cab and install one of the mounting washers
and a nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.

493 of 861

494 of 861
OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Figure 50-31-1
1 2
N-20974
NOTE: Assure seat tethers are securely fastened to

N-20647 seat belt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising on Page 10-30-2.) Figure 50-31-4

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
Figure 50-31-2
N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P10564 P10563
Lower the cab and install one of the mounting washers

and a nut [Figure 50-31-2].
NOTE: With the seat removed, the cab will raise.

seat.

495 of 861
OPERATOR SEAT (SUSPENSION) (CONT’D) Seat Belt Removal and Installation
Slide Rail Removal And Installation Figure 50-31-6
Figure 50-31-5
1 1
2 1
2
1
1
N-20974
N-18587
Remove the nut (Item 1) [Figure 50-31-6] from the seat
belt mount.
Remove the seat belt.

Remove the operator seat. (See Removal And
Installation on Page 50-31-1.) Installation: Tighten the mounting nuts to 58 - 62 ft.-lb.
(78,6 - 84 N•m) torque.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5]. Lower Cushion Removal And Installation
Remove the slide rail (Item 2) [Figure 50-31-5] from the Figure 50-31-7
bottom of the seat frame.

seat slide rail. 1
N-18579
Press the two buttons (Item 1) [Figure 50-31-7] &

[Figure 50-31-8] and lift the seat cushion.

496 of 861
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-10
Lower Cushion Removal And Installation (Cont’d)
Figure 50-31-8
1 1
N-18580
Inspect the seat ride adjustment [Figure 50-31-10].

N-18582
seat back.
Figure 50-31-9

1
N-18581
Remove the cushion (Item 2) [Figure 50-31-8] from the

seat frame (Item 1) [Figure 50-31-9].

497 of 861
OPERATOR SEAT (SUSPENSION) (CONT’D) Shock Removal And Installation
Back Cushion Removal And Installation Figure 50-31-13
Figure 50-31-11
2
1
P-43118
N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50- Remove the operator seat. (See Removal And
31-11] and tilt the seat back all the way forward. Installation on Page 50-31-1.)

Figure 50-31-12 Remove the seat shock mounting bolts (Item 1) [Figure
50-31-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-13].

seat shock.
1 1
N-18578

31-12] from the seat back and remove the back.

seat back.

498 of 861
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation
Remove the operator seat. (See Removal And

Installation on Page 50-31-1.) 2
Figure 50-31-14
1
2 3
P16284
Remove the mounting nut (Item 1) [Figure 50-31-15]
1 Remove the seat belt retractor (Item 2) [Figure 50-31-

15]
3
Installation: Be sure tether strap (Item 3) [Figure 50-31-

P16285 15] is on the seat belt stud behind the seat belt retractor.
Remove the end release buckle (Item 2) [Figure 50-31-

14]
Installation: Be sure tether strap (Item 3) [Figure 50-31-

14] is on the seat belt stud behind the end release
buckle.

499 of 861
OPERATOR SEAT (SUSPENSION) (CONT’D)
3-Point Seat Belt Removal And Installation (Cont’d)
Figure 50-31-16
OUTSIDE OF CAB
P16131
Remove the mounting bolt (Item 1) [Figure 50-31-16]

Figure 50-31-17
1 2
P16126
INSIDE OF CAB
P16128
Remove the shoulder harness retractor (Item 1) [Figure

50-31-17]
Installation: Line up the bolt (Item 1) [Figure 50-31-16]

with the mounting bracket (Item 2) [Figure 50-31-17] on
the inside of the cab.

500 of 861
BOB-TACH (HAND LEVER) Figure 50-40-2
Description
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach uses two
manually operated, spring assisted, locking wedge and
lever assemblies to secure the attachment the Bob-Tach. 1
2
The Bob-Tach is located on the front of the loader
connected to the loader lift arms.
Figure 50-40-1
N-18545
Remove the pivot pin (Item 1) [Figure 50-40-2] from the

tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
1 Loosen the bolt (Item 2) [Figure 50-40-2] at the Bob-

Tach pivot pin.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -

260 N•m) torque.
Figure 50-40-3
N-18544
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 3 in.) under each side of the Bob-
Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.
Remove the retainer bolt (Item 1) [Figure 50-40-1] and 1

nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25 - 30

P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-40-3] out of the Bob-Tach frame. This allows
grease to escape when driving the pivot pins into the
Bob-Tach frame.

501 of 861
BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-6
Figure 50-40-4
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)

N-18547 [Figure 50-40-6] from the Bob-Tach Wedge and spring
clevis.
Strike the head of the bolt (Item 1) [Figure 50-40-4] to Figure 50-40-7
push the pivot pin into the Bob-Tach frame.

Remove the bolt.
Use a long punch to push the pivot pin all the way into the
1
Bob-Tach.
Remove the Bob-Tach from the lift arms.
Remove the Bob-Tach pivot pin (both sides).
Lever And Wedge Disassembly And Assembly
Figure 50-40-5
N-18560
Remove the Wedge (Item 1) [Figure 50-40-7].
Always replace bent or broken wedges.
N-18558
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.

502 of 861
BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-10

(Cont’d)
Figure 50-40-8
3 N-18563
2 Use a punch and hammer to drive the roll pin (Item 1)

1 [Figure 50-40-10] flush with the face of the Bob-Tach.
N-18561
Reverse the removal procedure to install the Bob-Tach
lever and wedge [Figure 50-40-10].
Remove the lever mounting nut (Item 1), washer (Item 2),

spring (Item 3) and lever (Item 4) [Figure 50-40-8].

N•m) torque.
Figure 50-40-9
2 4
3
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-9] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as

needed.

503 of 861
BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-11
2 1
N-18557
Remove the Power Bob-Tach. (See Removal And


Use a seal pick to remove seal (Item 1) [Figure 50-40-
11] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-11]

with a driver tool and hammer.

504 of 861
BOB-TACH (POWER-OPTION) 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
2 3
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
lever assemblies by pressing a switch on the front
accessory 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. 1
The Power Bob-Tach block is located on the rear of the

P-48131
gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. blocks (approximately 3 in.) under each side of the Bob-
Tach [Figure 50-41-1].

Lower the Bob-Tach onto the blocks.
Remove the hoses to the cylinder fittings

[Figure 50-41-1].
NOTE: The hose with the 45 degree end (Item 1)

[Figure 50-41-1] is connected to the base end
fitting on the cylinder.
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.
Remove the retainer bolt (Item 3) [Figure 50-41-1] and

nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25 - 28


505 of 861
BOB-TACH (POWER-OPTION) (CONT’D) Figure 50-41-4
Figure 50-41-2
N-18547
2
Strike the head of the bolt (Item 1) [Figure 50-41-4] to

P-48185 push the pivot pin into the Bob-Tach frame.
Remove the bolt.

Remove the pivot pin (Item 1) [Figure 50-41-2] from the
tilt cylinder rod end (both sides). Use a long punch to push the pivot pins all the way into

the Bob-Tach frame.
Remove the tilt cylinder rod end from the Bob-Tach (both
sides). Remove the Bob-Tach from the lift arms.
Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob- Remove the Bob-Tach pivot pin (both sides).
Tach pivot pin.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -

260 N•m) torque.
Figure 50-41-3
P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-41-3] out of the Bob-Tach frame. This allows
the grease to escape when driving the pivot pins in to the
Bob-Tach frame.

506 of 861
BOB-TACH (POWER-OPTION) (CONT’D) Figure 50-41-7
Figure 50-41-5
N-18560
1
Remove the Wedge (Item 1) [Figure 50-41-7].

P-48135
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-41-8
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and

wedge.
Figure 50-41-6
1
2
1
3
5
4
P-48135
Remove the washers and bolts (Item 1) [Figure 50-41-

N-18559 8].

Use a punch and hammer, remove the roll pin (Item 1) N•m) torque.
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis. Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].

N•m) torque.

507 of 861
BOB-TACH (POWER-OPTION) (CONT’D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-11

(Cont’d)
Figure 50-41-9
2 1
4
N-18557
3 2
N-20625 Remove the Power Bob-Tach. (See Removal And

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), Use a seal pick to remove seal (Item 1) [Figure 50-41-

or clevis (Item 4) [Figure 50-41-9] are damaged, put the 11] on the Bob-Tach.
assembly in a vise.
Remove and replace bushing (Item 2) [Figure 50-41-11]
Remove the bolt and replace the damaged parts as with a driver tool and hammer.
needed.
Figure 50-41-10
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-41-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge [Figure 50-41-10].

508 of 861
LIFT ARMS Figure 50-50-3
NOTE: When installing new lift arms, It may be

necessary to spread the lift arms apart or pull
them closer together to get all of the pivot 1
pins in place.
2
Roll the Bob-Tach fully forward. Stop the engine.
Figure 50-50-1
P-45258
Remove the retainer bolt and nut (Item 1) [Figure 50-50-

3] from the left side, rod end, lift cylinder pin.
1 Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb.
(34 - 38 N•m) torque.

Remove the lift cylinder rod pin (Item 2) [Figure 50-50-3].
P-45367 Figure 50-50-4
At the right side of the loader, mark the two tilt hoses for
proper installation.
Disconnect and cap the two tilt hoses (Item 1) [Figure

50-50-1] from the tubelines (right side of machine).
Figure 50-50-2
1
1
P-45365
Remove the tubeline clamp (Item 1) [Figure 50-50-4].

2
P-45363

2] from the right side, rod end lift cylinder.
Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb.

(34 - 38 N•m) torque.
Remove the lift cylinder rod pin (Item 2) [Figure 50-50-2].

509 of 861
LIFT ARMS (CONT'D) Figure 50-50-7
Figure 50-50-5
P-45366
Install a floor jack (Item 1) [Figure 50-50-7] under the

P-45364 front of the lift arms, and raise the lift arms 3 - 4 in.
Figure 50-50-8
Remove the tubeline clamp (Item 1) [Figure 50-50-5].

Figure 50-50-6
P-45422
P-34360 Install two lift straps (Item 1) [Figure 50-50-8] on the lift
arms as shown.
Remove the front auxiliary coupler mounting bolts (Item NOTE: Position the lift straps as shown in [Figure 50-
1) [Figure 50-50-6] 50-8] to balance the lift arms for removal and
installation.

510 of 861
LIFT ARMS (CONT'D)
Figure 50-50-9
P-45259

9]. (Both sides.)

Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb.
(34 - 38 N•m) torque.
Remove the lift arm pivot pin (Item 2) [Figure 50-50-9].

(Both sides.)
Remove the lift arms from the loader.
Remove the bob-tach. (See Removal And Installation on

Page 50-40-1.)
Remove the tilt cylinders from the lift arms. (See


511 of 861

512 of 861
REAR GRILL Figure 50-60-3
Figure 50-60-1
2
P-48130
Installation: Line up the tab (Item 1) on the grill with the

P-48251 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
Open the rear door. Reverse the removal procedure to install the grill.

Figure 50-60-2
P-48252
Lift up on the rear grill (Item 1) [Figure 50-60-1] and

[Figure 50-60-2].
Lift the grill away from the loader.

513 of 861

514 of 861
REAR DOOR Figure 50-70-3

1
Figure 50-70-1
2
3
2
P-34606
1
Remove the top and bottom door hinge mounting bolts
P-68264 (Item 1) [Figure 50-70-3] and nuts.
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) in the top hinge as shown
50-70-1] from the engine harness. [Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from
Installation: Tighten the mounting bolts and nuts to 25 -
the door. (See Rear Removal And Installation on Page
28 ft.-lb. (34 - 38 N•m) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
P-34588
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.

515 of 861
REAR DOOR (CONT’D) Striker (Adjusting)
Striker Removal and Installation
Figure 50-70-4 WARNING

1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-31126
Remove the two striker mount bolts (Item 1) [Figure 50-

70-4].

Remove the striker assembly from the loader. 1
Striker Disassembly and Assembly

P-31126
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 2
3 Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P-31320
Tighten both striker mount bolts (Item 1) [Figure 50-70-6]
to 90 - 100 ft.-lb. (125 - 135 N•m) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Close the rear door.
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-5].
Check the parts for wear and replace as needed.

516 of 861
REAR DOOR (CONT’D) Figure 50-70-9
Latch Removal and Installation
Figure 50-70-7
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-9] from

P-31125 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-7] from
the latch.
Figure 50-70-8
1
P-31127
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

517 of 861

518 of 861
FUEL TANK Figure 50-80-3

2
Figure 50-80-1
P-28143

P1616
Remove the cover (Item 1) [Figure 50-80-1] which is 70-10-9.)
installed over the fuel drain near the rear of the

chaincase. Remove the two mounting bolts (Item 1) [Figure 50-80-
3] from the battery holder.
Installation: Tighten the cover mounting bolts to 190 -
240 in.-lb. (21,5 - 27 N•m) torque. Installation: Tighten the battery holder mounting bolts to
190 - 240 in.-lb. (21,5 - 27 N•m) torque.
Figure 50-80-2
Remove the battery holder (Item 2) [Figure 50-80-3]
from the loader.
Figure 50-80-4
1 1
P1619
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
P-28144
Remove the mounting bolts (Item 1) [Figure 50-80-4]

from the fuel tank retainer bracket.
Installation: Tighten the mounting bolts to 190 - 240 in.-

lb. (21,5 - 27 N•m) torque.

519 of 861
FUEL TANK (CONT’D) Fuel Level Sender Removal And Installation
Figure 50-80-5
P13870
P13876
Loosen the fuel level sender (Item 1) [Figure 50-80-6]
with a wrench.
Disconnect fuel sender.
Turn the fuel level sender out and remove it from the fuel

Disconnect fuel vent hose. tank. Check the fuel level sender for damage and replace
if necessary.
Disconnect fuel fill hose.
Installation: tighten the fuel level sender to 50 - 60 in.-lb.
Lift the fuel tank up and remove the tank from the loader (5,7 - 6,8 N•m) torque.
[Figure 50-80-5].

520 of 861
FUEL TANK (CONT’D)
Fuel Fill Screen Removal And Installation
Figure 50-80-7
2
1
P13874
Remove the clamp (Item 1) [Figure 50-80-7] and remove

the fuel fill hose (Item 2) [Figure 50-80-7] from the tank.

Figure 50-80-8
P13875
Remove the fuel fill screen (Item 1) [Figure 50-80-8]

from the tank. Check the screen for damage and replace
if necessary.

521 of 861

522 of 861
CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
The control pedals and linkages are connected to the 1

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 operators feet.
Pedal Removal And Installation
WARNING P-26008
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 Check the rubber bushing in the pedal for wear and
to fall and cause injury or death. replace as needed.
W-2059-0598

Figure 50-90-2
Raise the operator cab. (See Raising on Page 10-30-2.) 1
DANGER
P-34375
P-90328 Remove the two mounting bolts (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

523 of 861
CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
2
1
P-34376
Remove the crossbar from the pivot [Figure 50-90-5].

P-66969A
Installation: Check the nylon bushing (Item 1) [Figure
50-90-5] for wear and replace as needed.
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.

Remove the crossbar pivot bolt (Item 2) [Figure 50-90-
3].
Figure 50-90-4
P-34260
Remove the hairpin clip and cross-pin (Item 1) [Figure

50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

524 of 861
Linkage Removal And Installation (Cont’d)
Figure 50-90-6
P-34258
Remove the hairpin clip and cross-pin (Item 1) [Figure

P-66969 50-90-8] from the control valve tilt spool.
Figure 50-90-9
disconnect the lift foot pedal linkage from the crossbar

linkage.
Figure 50-90-7
1
P-26008

disconnect the lift foot pedal.
P-24759

disconnect the lift foot pedal.

525 of 861
Pedal (Adjusting)
After installing the pedal, adjust the pedal angle so that 2

there is clearance under the rear of the pedal. The valve 1
spool must travel full stroke without the pedal hitting the
floor panel.
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.
Figure 50-90-10
P-26008
1
Loosen the bolt (Item 2) [Figure 50-90-11] and nut on the
pedal linkage.
Check the rubber 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 mounting bolts (Item 1) and pivot bolt

P-34375 (Item 2) [Figure 50-90-11] on the pedal assembly to
standard torque.
Loosen the two mounting bolts (Item 1) [Figure 50-90-

10] from the pedal mounting bracket.

526 of 861
CONTROL PEDALS (ACS) Figure 50-91-2
Description
The control pedals 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. 1
The control pedals are located on the lower mainframe at

the operators feet.
Foot Sensor Removal And Installation
Figure 50-91-1
P-21935
2
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
P-21936
Remove the foot pedal and sensor assembly from the

loader.

Figure 50-91-3
1
P-21938
Pull the pin (Item 1) [Figure 50-91-1] holding the foot

pedal linkage to the sensor. 1
Disconnect the two connectors (Item 2) [Figure 50-91-1]

from the sensor and lock solenoid.
P-21927
Remove the two bolts (Item 1) [Figure 50-91-3] from the

foot sensor shield.
Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2

N•m) torque.

527 of 861
CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Cont’d) Figure 50-91-5
Figure 50-91-4
1
P-21940
P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6

Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque. 1
Remove the two bolts (Item 2) [Figure 50-91-4] from the
bracket and sensor assembly.
P-21935A

N•m) torque.
Remove the sensor assembly.
NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See P-21934
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.

528 of 861
CONTROL PEDALS (ACS) (CONT'D)
Foot Pedal Linkage Disassembly And Assembly
Figure 50-91-7
P-21931
Remove the bolt (Item 1) holding the linkage (Item 2) to

the side of the foot pedal [Figure 50-91-7].

Figure 50-91-8
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) from the foot pedal [Figure 50-91-8].

529 of 861

530 of 861
CONTROL PANEL
Description
Figure 50-100-1

P-54658
The steering system [Figure 50-100-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the 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. The returning force of the torsion bushings.
bellcranks have grease fittings.
NOTE: Torsion bushings need to be replaced if torn
The forward travel is adjusted by drift adjustment bolts. or rotating in the housing. Loosen torsion
bushing bolts slightly before adjustments are
The bellcranks are attached to steering linkage bars with made. Do not fully tighten torsion bushing
rubber torsion bushings pressed into the bellcranks. bolts again until all steering adjustments have
Bellcranks mount to the control panel. been made first.
Steering linkage bars are a two-piece design. Steering Sequence of steering adjustments:
linkage bars are adjustable in length for “full travel
adjustment”. 1. Set neutral of pintle arms, “creep”
2. Set linkage travel at steering linkage bars
Steering linkage bars attach to the pintle arms where a 3. Set drift at drift adjustment bolts
rubber torsion bushing is pressed into the pintle arms.

531 of 861
CONTROL PANEL (CONT'D) Figure 50-100-2
2 1
DANGER 3
P-48462
P-90328
AVOID DEATH Raise the lift arms and install an approved lift arm support
• Disconnecting or loosening any hydraulic device. (See Installing on Page 10-20-1.)
can cause lift arms to drop. Raise the operator cab. (See Raising on Page 10-30-2.)
unless supported by an approved lift arm Remove the engine speed control. (See Removal And

D-1009-0409
Loosen the jam nut (Item 1) from the bypass control knob
(Item 2) [Figure 50-100-2].
WARNING Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-2].
Never work on a machine with the lift arms up unless Figure 50-100-3
W-2059-0598
WARNING
P-48277
W-2017-0286
Disconnect the control harness connectors (Item 4)

[Figure 50-100-2] & [Figure 50-100-3] from the control
levers.

532 of 861
Removal and Installation (Cont'd)
Figure 50-100-4 2
1 1
2 2
3
P-26323
1 1
Remove the fuse cover mount screws (Item 1) [Figure

P-54609 50-100-5].
Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)

Scribe a mark across the top of the steering linkage bars torque.

steering shaft on the control panel. Remove the fuse/relay cover (Item 2) [Figure 50-100-5].
Remove the four steering linkage mounting bolts (Item 2) Remove the fuse/relay shield mounting screws (Item 3)
[Figure 50-100-4]. [Figure 50-100-5].
Installation: Align the marks on the steering linkage Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
bars. Tighten the steering linkage mounting bolts to 35 - N•m) torque.
40 ft.-lb. (47,5 - 54,2 N•m) torque.
Remove the fuse/relay shield (Item 4) [Figure 50-100-5]
Figure 50-100-6
P-26325
Remove the fuse/relay block [Figure 50-100-6].

533 of 861

1
Figure 50-100-7
11
P-26329
P-26328 P-26329
1
Remove the control panel mounting bolts (Item 1)

P-26326 [Figure 50-100-7], [Figure 50-100-8] & [Figure 50-100-
9] from both sides of the control panel.
Figure 50-100-8 Installation: Tighten the control panel mounting bolts to

15 - 20 ft.-lb. (20 - 27 N•m) torque.

Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
1
1
P-26327

534 of 861
CONTROL PANEL (CONT’D) Shaft Removal And Installation
Shock Removal And Installation NOTE: The steering shaft can be removed without
removing the control panel from the loader.
Figure 50-100-10 Photo [Figure 50-100-11] shows the control
panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-100-10].
1
Remove the steering shock mounting nuts (Item 2)
3 [Figure 50-100-10].
Figure 50-100-11
P-48275

from the end of the shock connected to the steering

linkage. 3

from the other end of the shock connected to the bracket 1 2
on the control panel.
P-48278

(34 - 38 N•m) torque. Remove Control Handle Lever (Item 1) [Figure 50-100-
11]. (See Lever Removal And Installation on Page 50-
110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

100-11] from both sides of the control panel.
Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 -

38 N•m) torque.
Remove the steering shaft from the control panel.

535 of 861
CONTROL PANEL (CONT’D) Figure 50-100-13
Shaft Disassembly And Assembly

1
Figure 50-100-12
2
2
1 1
P-26331
2
To remove the steering shaft mounting bracket (Item 3)

P-4154 [Figure 50-100-11], remove the three mounting bolts
(Item 1) [Figure 50-100-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks
(Item 1) from the cross shaft assembly [Figure 50-100- Remove the steering shaft mounting bracket.

12].
Assembly: Install new nylon bushings (Item 2) [Figure (20 - 27 N•m) torque.
50-100-12] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left bellcranks.
NOTE: The bellcranks should pivot freely on the

cross shaft when assembled correctly.

536 of 861
Linkage Removal And Installation
WARNING 2 2
support device can allow the lift arms or attachment 1 1
W-2059-0598
P-54609
WARNING Scribe a mark across the top of the steering linkage bars
Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-100-14].

W-2017-0286
bars. Tighten the steering linkage mounting bolts to 35 -
Raise the lift arms and install an approved lift arm support 40 ft.-lb. (47,5 - 54,2 N•m) torque.
NOTE: After removal and installation of the linkage,
Lift and block the loader. (See Procedure on Page 10-10- the linkage neutral adjustment procedure
1.) must be performed. See Page 50-100-13 for
Linkage Neutral Adjustment procedure.

537 of 861

7
Figure 50-100-15 6 8
3 1 4
1
2
5
2
P-48630
The centering plate/centering spring assembly consists

2 of the following parts:
P-48631
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-15]. 1 Bolt

2 Bushings
Remove the bolt/spring assembly.
3 Washer
Installation: Tighten the centering spring bolt and a 4 Bushing Spacer
NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
5 Spring
Figure 50-100-16 6 Lock Nut
7 Centering Plate
8 Guide Bushings
1
P-48632
Slide the centering plate (Item 1) [Figure 50-100-16] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operators seat.

538 of 861
Linkage Removal And Installation (Cont’d) SOLID CAMS
Figure 50-100-18
2
1
3
2 3
6
5
1
1 4
2
1
P-48627
2
If the surface of any of the four solid pintle cams (Item 1)

P-48629 are worn, loosen the bolt (Item 2) and rotate the cams 1/4
turn [Figure 50-100-19].
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-18]. 19] from the pintle.

If the centering blocks need replacement, remove the Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
bolts (Item 2) [Figure 50-100-18]. Remove the centering 54,2 N•m) torque.
blocks.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Installation: Tighten the centering block bolts to 35 - 40 100-19].
ft.-lb. (47,5 - 54,2 N•m) torque.
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-19].
centering plate.
NOTE: If the centering blocks are worn, they can be

removed and rotated 180 degrees and
reinstalled. If the solid cams are worn, they
can be loosened and rotated 90 degrees and
reinstalled.

539 of 861
Figure 50-100-20
ROLLER CAMS 2
2
1
P-54615
3
Loosen the bolt (Item 1) and remove the pintle base (Item
P-54617 2) [Figure 50-100-22].
Remove the bolts and washers (Item 1) [Figure 50-100-

20] from the pintle.

Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
54,2 N•m) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-20].
Figure 50-100-21
4
3
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-100-21].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering linkage bar (Item 4) for damage and replace as
needed [Figure 50-100-21].
NOTE: The washers (Item 2) [Figure 50-100-21] are

hardened, and should only be replaced
through Bobcat Parts.

540 of 861
CONTROL PANEL (CONT’D) Pintle Arm Disassembly and Assembly
Linkage Removal And Installation (Cont’d) Figure 50-100-24
Figure 50-100-23 2
1
3
1
P-54625
P-48659
Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-24] and inspect the pintle solid cams
NOTE: When installing the pintle base (Item 1) onto for damage or excessive wear.
the pump shaft, the cutouts on the pump shaft

will not line up with the bolt (Item 3) [Figure Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
50-100-23]. 54,2 N•m) torque.
Installation: Install the pintle base (Item 1) onto the Figure 50-100-25
pump shaft (Item 2) [Figure 50-100-23]. The top of the
pintle base should be level with the top of the pump shaft. 2
Tighten the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque. 3
NOTE: After installing the linkage onto the
hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
See Page 50-100-13 for Linkage Neutral
Adjustment procedure. 2
1
P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-100-

25] are used on ACS loaders only.
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-25].
Inspect the torsion bushing (Item 3) [Figure 50-100-25]

for damage and replace as needed.
Installation: Tighten the nuts to 35 - 40 ft.-lb. (47,5 - 54,2

N•m) torque.

541 of 861
Pintle Arm Disassembly and Assembly (Cont’d)
Figure 50-100-26
4 1 3
2 2
3 P-48619
Using a bushing driver (Item 1) remove the torsion

P-54626 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-27].
Remove the base pintle (Item 1) [Figure 50-100-26] from
the pump shaft. Installation: Install the torsion bushing (Item 2) [Figure

50-100-27] into the pintle arm using the same procedure
Remove the retaining bolt (Item 2), adjusting screw (Item as the removal.
3) and neoprene dampener (Item 4) [Figure 50-100-26]
from the base pintle. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Inspect parts for wear and damage, replace as needed arm should be the same.
[Figure 50-100-26].
NOTE: Anti-seize should be used on the adjusting

screw to prevent corrosion and allow free
movement while adjusting.

542 of 861
Linkage Neutral Adjustment
The following tool listed will be needed to do the following 1

procedure:
MEL1563 or 6689779 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See

REMOTE START TOOL KIT -MEL1563 on Page 10-60-
1.)

1.)
P-48448
Figure 50-100-28
Loosen the bolt/nut (Item 1) [Figure 50-100-29] only until

3
the tension is released from the torsion bushing.
Figure 50-100-30

1
P-48450
2
Tool that may assist in the neutral adjustment [Figure 50-

100-28].
P-54612
To make this tool use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-28] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-100-30].
A steering centering block (Item 3) [Figure 50-100-28] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-100-30] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

543 of 861
Linkage Neutral Adjustment (Cont’d)
Figure 50-100-31
2
P16121
2 Using the remote start tool, turn the key (Item 1) [Figure
P-54614 50-100-33] to the run position.
Move the traction lock override switch (Item 2) [Figure

Loosen the two bolts (Item 1) holding the right centering 50-100-33] so the traction function is unlocked. (The
block. Move the right hand centering block (Item 2) traction lock override switch light will be ON.) On a

[Figure 50-100-31] until both pintle cams contact the standard loader the wedge brake will unlock.
centering block.
NOTE: When the engine is started, the wheels/tracks
NOTE: The left centering block is not adjustable. By may begin to move.
adjusting the right centering block the left
centering block will also become aligned NOTE: In loaders equipped with manual steering and
properly. hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-32 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
3 release the hydraulic brake.
Using the remote start tool, turn the key (Item 1) [Figure
50-100-33] and start the engine and run at low idle.
1
Tighten bolts (Item 3) [Figure 50-100-32] to 35 - 40 ft.-lb.
(47,5 - 54,2 N•m).
2
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-31] & [Figure 50-
100-32].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-28] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-100-
32] around both centering blocks.
Lock the C-Clamp in place.

544 of 861
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 50-100-34
2 1
1
P-54610
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

P-48632
adjustment on the left side of the loader. The

procedure is the same for the right side
neutral adjustment.
Loosen the left pump pintle adjustment lock bolts
(Item 1). (The right pump pintle adjustment lock bolts are Turn the adjustment screw (Item 1) [Figure 50-100-35]
(Item 2) [Figure 50-100-34].) Loosen the bolts enough to counterclockwise until forward creep is seen.
allow free movement between the pintle arm and the
pintle base. Turn the adjustment screw (Item 1) [Figure 50-100-35]
counterclockwise to a point between forward and reverse
NOTE: If the bolts are too loose or too tight, the where there is zero creep.
neutral adjustment may be affected.
Stroke the left steering lever to forward and allow the
lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.

545 of 861
CONTROL PANEL (CONT’D)
Figure 50-100-36
1
2 2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-36] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-36] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels/

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-36] at a time and apply Loctite® 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). 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 pre applied
Loctite®.
Remove the loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Page 50-100-17.)

546 of 861
Linkage Travel Adjustment
NOTE: When the linkage travel adjustment procedure 2

is being done as part of the loader neutral
adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
2
1
WARNING
P-48448
support device. Failure to use an approved lift arm Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
support device can allow the lift arms or attachment (Item 2). The bolt (Item 2) [Figure 50-100-37] must be
to fall and cause injury or death. loosened enough to allow the torsion bushing to turn
W-2059-0598
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm support Figure 50-100-38

1
WARNING
Put jackstands under the front axles and rear corners 2
W-2017-0286

1.) P-54613

Loosen the nut (Item 1) only until the tension is released
Pre-load tension in the torsion bushings must be from the torsion bushing (Item 2) [Figure 50-100-38].
removed before adjusting the steering linkage.
The bolt must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-38] to turn freely
between the torsion bushing and the linkage bar.

547 of 861
Linkage Travel Adjustment (Cont’d)

2
Figure 50-100-39
1 3 4
P-51174
Move the right side steering lever forward and install a

P-37574 15/16 in. (24 mm) thick spacer (Item 1) between the
center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-41].
Remove access plug from the top of the control panel.
This will allow the pintle arms to move freely while

Turn the control lever drift adjustment bolts (Item 1) adjusting the steering linkage for full forward travel
[Figure 50-100-39] (one on each control lever) out until it speed.
is flush with the bottom of the nut.
Remove the 3/8 in. (10 mm) thick spacer (Item 4) [Figure
Figure 50-100-40 50-100-41].
Figure 50-100-42
3 2
4
1
P-51173
1
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) Before adjusting the linkage, check that the base pintle
[Figure 50-100-40]. arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-42] and tighten to 35
- 40 ft.-lb. (48 - 54 N•m) torque. There should be no play
between the pintle arm and the square pump shaft.
Also check that the cam mounting nuts or bolts (Item 4)

[Figure 50-100-40] are tight, 35 - 40 ft.-lb. (48 - 54 N•m)
torque.

548 of 861
Linkage Travel Adjustment (Cont'd)
Figure 50-100-43
1 1 1
P-51175
Remove the spacer (Item 1) [Figure 50-100-45].

P-54609
Disconnect the remote start tool. (See REMOTE START
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
43] on each steering linkage bar.
Figure 50-100-46

Figure 50-100-44
2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35 - 40

ft.-lb. (47,5 - 54,2 N•m) [Figure 50-100-46].
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 50-100-44]. Use a locking plier, clamp the two
linkage bars together.
Installation: Tighten the nuts and bolts to 35 - 40 ft.-lb.

(47,5 - 54,2 N•m) torque.
Check 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.

549 of 861
Linkage Travel Adjustment (Cont'd)
Figure 50-100-47 1
1
P-37574
Push the control lever to full stroke and turn drift

P-48448 adjustment bolt (Item 1) [Figure 50-100-48] in until it
touches the U-bolt holding the control lever.
Tighten the two bolts and nuts (Items 1 & 2) [Figure 50- Repeat steps on the other control lever.
100-47] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque at the

steering bell cranks. Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 10 ft. of

“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-48] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.

550 of 861
CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm support
Description
The SJC control panel has two electronic handles that
control the steering, lift, and tilt functions. There is no
mechanical linkages connecting to the hydrostatic pumps
or the control valve. Figure 50-101-1
The control panel is connected to the lower main frame
and wraps around and underneath the operator seat.
WARNING 1

W-2017-0286
P-73451

Remove the lift arm bypass control knob and rubber
DANGER washer (Item 1) [Figure 50-101-1].
Figure 50-101-2
2
1
1
P-90328
AVOID DEATH 4
can cause lift arms to drop. 3 3
unless supported by an approved lift arm P-64319
D-1009-0409 Remove the fuse cover mount screws (Item 1) [Figure
50-101-2].
Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)

torque.
WARNING Remove the fuse/relay cover (Item 2) [Figure 50-101-2].
Remove the fuse/relay shield mounting screws (Item 3)

Never work on a machine with the lift arms up unless [Figure 50-101-2].
support device. Failure to use an approved lift arm Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
support device can allow the lift arms or attachment N•m) torque.
W-2059-0598
Remove the fuse/relay shield (Item 4) [Figure 50-101-2]

551 of 861
CONTROL PANEL (SJC) (CONT’D)
Figure 50-101-3
1 1
P-64309
Remove the control panel mount screws (Item 1) [Figure

50-101-3] from the both sides of the control panel.

Installation: Tighten the control panel mounting screws
to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Figure 50-101-4
P-73293
Disconnect the right and left joystick wire harness

connectors (Item 1) [Figure 50-101-4].
Remove the control panel from the loader.

552 of 861
CONTROL HANDLE/LEVER Figure 50-110-2
Description
The control handles/levers are used to control the

forward and reverse travel.
The control handles/levers are mounted to the control

panel.
Lever Removal And Installation

1 1
Figure 50-110-1 2
N-22658
Remove the nuts from the two U-bolts (Item 1) [Figure

50-110-2] used to mount the control lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 2) [Figure 50-110-2] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-3] on the front of the control panel.
1
P-48462 Installation: Tighten the U-bolts so the lever can not be
moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
Disconnect the electrical connectors from the control operator cab when lowering or raising the cab.
lever [Figure 50-110-1].

553 of 861
CONTROL HANDLE/LEVER (CONT’D)
Boot Removal And Installation
Figure 50-110-3
N-18884
To replace the rubber boot (Item 1) [Figure 50-110-3] on

the control panel, remove the control lever (See above

procedure).
Drill out the four rivets (Item 2) [Figure 50-110-3] located

on the flange of the rubber boot and remove the old boot.
Install the new boot and reinstall the control lever.

554 of 861
CONTROL HANDLE/LEVER (ACS) Handle Sensor Removal And Installation

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
located in the base of the control handle/levers.

panel.
1
Figure 50-111-1
P-21864
1 Loosen the nuts (Item 1) [Figure 50-111-2].
Installation: Tighten the u-bolts so the lever can not be


seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-111-3
P-21879
Handle Sensor (Item 1) [Figure 50-111-1]. 2

sensor, actuator or ACS Controller. (See
P-21837
Tilt the control handle (Item 1) [Figure 50-111-3] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-3].

555 of 861
CONTROL HANDLE/LEVER (ACS) (CONT'D) Figure 50-111-6
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-4
1
P-21860
2
Remove the handle lock solenoid connector (Item1)
P-21836 [Figure 50-111-6] from the clip.
NOTE: Pry out with a small screw driver and push the
Disconnect the harness connector (Item 1) [Figure 50- connector down.
111-4] from the handle sensor connector.

Figure 50-111-7
Disconnect the harness connector (Item 2) [Figure 50-
111-4] from the handle lock solenoid connector. 1
Figure 50-111-5
5
2
1 4
1
P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-7] from the handle sensor.
Installation: Tighten screws to 32 - 38 in.-lb. (3,6 - 4,3

Remove the handle sensor connector (Item 1) [Figure N•m) torque.
50-111-5] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screw driver and push the handle sensor, remove the one plastic spacer (Item 3),
connector down. the spring (Item 4) and washer (Item 5) [Figure 50-111-
7].

556 of 861
Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-8 2
P-21878
1
Figure 50-111-11
P-21880
3
2
Remove one of the two mounting screws (Item 1) [Figure
50-111-8] from the handle sensor.

Installation: Tighten bolt to 32 - 38 in.-lb. (3,6 - 4,3 N•m)
torque.
Figure 50-111-9
4 1
3 8
P-21799
1
Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-10] & [Figure 50-
3 7 111-11] to assure proper return of the control handle to
neutral and minimize harness movement.
5 6
NOTE: Route wires (Item 2) [Figure 50-111-10] &
2
P-21882 [Figure 50-111-11] as shown away from stop
strap (Item 3) [Figure 50-111-10] & [Figure 50-
111-11] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-9]
from the handle assembly. NOTE: The calibration procedure must be followed
NOTE: The handle sensor (Item 1) [Figure 50-111-9] sensor, actuator or ACS Controller. (See
can only be replaced as a complete assembly. CALIBRATION on Page 60-160-1.)
Check the spacer (Item 2) and screws (Item 3), mounting

pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
(Item 7), stop strap (Item 8) and replace as needed
[Figure 50-111-9].

557 of 861
Handle Removal and Installation
Figure 50-111-12
1
1 N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-14] from the handle.
Figure 50-111-15
Remove the handle sensor (Item 1) [Figure 50-111-12].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-13 1
1 2 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure
P16534 50-111-15] from the handle assembly.
Installation: Tighten the allen head screws to 35 in.-lb.

Remove the switch handle (Item 1) [Figure 50-111-13]. (4 N•m) torque.
(See Switch Handle Removal on Page 60-130-4.)

558 of 861
CONTROL HANDLE/LEVER (ACS) (CONT'D) Lever Removal and Installation
Handle Disassembly and Assembly Figure 50-111-18
Figure 50-111-16
1
1
1
2
1 N-22667
N-17394
Disconnect the electrical connectors (Item 1) [Figure 50-
111-18] from the control lever switch handle.
Remove the handle sleeve (Item 1) and bushings (Item
2) from the handle [Figure 50-111-16]. Remove the electrical connectors from the control lever

switch handle. (See Handle Sensor Connector
Check all parts for wear and replace as needed. Disassembly And Assembly on Page 60-130-3.)
Figure 50-111-17
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-17] that

connects the handle to the handle sensor for wear,
replace as needed.

559 of 861
Lever Removal And Installation (Cont'd)
Figure 50-111-19
2
1
P13734
2
The control lever (Item 1) [Figure 50-111-21] must be
N-22658 replaced as a complete unit.
The connector clip (Item 2) [Figure 50-111-21] can be

Figure 50-111-20 replaced separately from the control lever.

18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-111-19]

nuts.
Installation: Tighten the u-bolts so the lever can not be

seat. Control lever end (Item 2) [Figure 50-111-19]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 in. [Figure 50-111-20].
Remove the control lever from the cross shaft and control
panel.

560 of 861
CONTROL HANDLE/LEVER (ACS) (CONT'D)
Boot Removal And Installation
Figure 50-111-22
N-22659
To replace the rubber boot (Item 1) [Figure 50-111-22]

on the control panel, remove the control lever. (See Boot

Drill out the four rivets (Item 2) [Figure 50-111-22]

located on the flange of the rubber boot and remove the
old boot.
Install the new boot and reinstall the control lever. (See
Boot Removal And Installation on Page 50-110-2.)

561 of 861

562 of 861
CONTROL HANDLE / LEVER (SJC) Figure 50-112-2
Description

forward and reverse travel and the lift and tilt functions.

panel.
1
Joystick Testing
Figure 50-112-1
P-64298
At the back side of the control panel, locate the left

joystick wire connector (Item 1) [Figure 50-112-2].
Figure 50-112-3

1
P-28301
The tools listed will be needed to do the following 3

procedure:
2
MEL1608-Joystick Test Harness [Figure 50-112-1]
MEL1563 or 6689779-Remote Start Tool
Multi meter
P-28312
Disconnect the joystick harness connector (Item 1) from
Raise the operator cab. (See Raising on Page 10-30-2.) the loader wiring harness (Item 2) [Figure 50-112-3].
Connect the remote start tool to the loader. (See Install the test harness (Item 3) [Figure 50-112-3]
REMOTE START TOOL KIT -MEL1563 on Page 10-60- between the two connectors.
1.)
Turn the remote start key to ON position without starting
the loader.
Check the voltage between pin 3 and pin 5 on the joystick

test harness (Item 3) [Figure 50-112-3].
The voltage should be between 2.45 and 2.55 volts.

563 of 861
CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Removal And Installation
Joystick Testing (Cont’d) When replacing joystick assemblies, they are available
as a complete assembly with the boot and lever already
Figure 50-112-4 attached. This procedure is shown so the electrical
connections can be checked at the bottom of the joystick,
if suspected to be loose or disconnected.

1
Figure 50-112-5
P-64328
Repeat the procedure at the right joystick wiring harness

connector (Item 1) [Figure 50-112-4]. (If needed.)

1
P-73247
Lift the rubber boot (Item 1) [Figure 50-112-5].
Figure 50-112-6
1
1
P-73248
Remove the four screws (Item 1) [Figure 50-112-6] to lift

the joystick control from the base.

564 of 861
CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Mount Removal And Installation
Joystick Removal And Installation (Cont’d) Figure 50-112-8
Figure 50-112-7
P-64328
P-73240
Disconnect the joystick wiring harness connectors (Item
1) on both the right and left hand joysticks [Figure 50-
Disconnect the joystick connector (Item 1) [Figure 50- 112-8].
112-7] from the harness connector.

Figure 50-112-9
P-64303
Remove the two control lever mounting bolts (Item 1)

[Figure 50-112-9].
The mounting bolts are secured with lock-nuts on the

back of the control panel. Once removed, they need to be
replaced with new.

565 of 861
CONTROL HANDLE / LEVER (SJC) (CONT'D)
Joystick Mount Removal And Installation (Cont’d)
Figure 50-112-10
P-76992
Remove the control lever from the loader [Figure 50-

112-10].

566 of 861
ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-120-3
Figure 50-120-1
2 1
1
2
P-66819
P-66818
Remove the top mounting screw (Item 1), and loosen the
two bottom mounting screws (Item 2) [Figure 50-120-3]
Remove the top mounting screw (Item 1), and loosen the from the front access panel.
two bottom mounting screws (Item 2) [Figure 50-120-1]

from the front access panel. Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
N•m) torque. Remove the front access panel from the loader.
Remove the front access panel from the loader. Figure 50-120-4
Figure 50-120-2
2
1 1
1
1
1 P-66821
1
P-66820
Remove the seven mount screws (Item 1) [Figure 50-
120-4] from the rear access panel.
120-2] from the rear access panel. Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
N•m) torque. Remove the throttle lever assembly (Item 2) [Figure 50-
120-4]from the access panel.
Remove the rear access panel from behind the steering
panel, remove the panel from the loader. Remove the rear access panel from behind the steering
panel, remove the panel from the loader.

567 of 861

568 of 861
ACCESS PANEL (INSIDE) (SJC) Figure 50-121-2
Removal And Installation (Left)
device. (See Installing on Page 10-20-1.) 1 1
Figure 50-121-1
1 P-64310
2

121-2]
Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27

N•m) torque.

P-64299 Move the lever assembly a slight amount toward the
center of the loader, to allow clearance for the panel to be
removed.
Remove the top mounting screw (Item 1) and loosen the
two bottom screws (Item 2) [Figure 50-121-1]. Remove the inside rear access panel from the loader.

N•m) torque.
Remove the inside front access panel from the loader.

569 of 861
ACCESS PANEL (INSIDE) (SJC) (CONT’D) Figure 50-121-5
Removal And Installation (Right)

2
1
Figure 50-121-3
P-64327
Loosen the two bottom mount screws (Item 1) [Figure

50-121-5] from the front inside access panel.
Remove the top mount screw (Item 2) [Figure 50-121-5]

from the front inside access panel.

P-64300 Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
Remove the two mounting screws (Item 1) [Figure 50- Remove the inside front access panel from the loader.
121-3], from the foot throttle assembly.

N•m) torque.
Figure 50-121-4
P-64313
Disconnect the foot operated speed control linkage (Item

1) [Figure 50-121-4] from the hand operated speed
control lever arm.
Remove the foot operated speed control assembly from

the loader.

570 of 861
Removal And Installation (Right) (Cont’d)
Figure 50-121-6
1 2
P-34553A
Lift the speed control pin (Item 1) from the notch (Item 2)
P-34548 [Figure 50-121-8] in the speed control rod.
Figure 50-121-9
Remove the two mount screws (Item 1) [Figure 50-121-
6] from the hand operated speed control lever.

N•m) torque.
Figure 50-121-7
P-34549
At the bottom right side of the control panel, remove the

keeper and pin (Item 1) [Figure 50-121-9] that connects
the speed control linkage arm to the speed control rod.
P-34551
Lift slightly on the speed control handle and move it

toward the front of the loader [Figure 50-121-7].

571 of 861
Removal And Installation (Right) (Cont’d)
Figure 50-121-10
1
1
1
2
P-64309
Remove the five mount screws (Item 1) [Figure 50-121-

P-34550 11] from the access panel.

Remove the mount bolt and nut (Item 1) [Figure 50-121- N•m) torque.
10] from the speed control linkage arm.

Move the lever assembly a slight amount toward the
Remove the speed control linkage arm (Item 2) [Figure center of the loader, to allow clearance for the panel to be
50-121-10] from the access panel. removed.
Remove the inside rear panel from the loader.

572 of 861
WINDOW (REAR) Installation
Removal Clean the area before installing the rubber molding.
Figure 50-130-1 Figure 50-130-2
P-64994 P16014
Pull on the tag (Item 1) [Figure 50-130-1] on the rear Install the rubber molding (Item 1) [Figure 50-130-2]
window to remove the rubber cord. around the edge of the rear opening in the operator cab.

Using gloves, push the rear window out the rear of the If replacing the rubber molding (Item 1) [Figure 50-130-
operator cab. 2] cut off the excess molding.
NOTE: If rear window was broke, remove all glass Figure 50-130-3
fragments from the rubber molding before
installing a new window.
P16015A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-3]
into the molding on the inside of the operator cab.
Install the safety tag in the top center of the cord.

573 of 861
WINDOW (REAR) (CONT’D) Figure 50-130-6
Figure 50-130-4
1 1
P16013
Use the plastic stick (Item 1) [Figure 50-130-6] to

P-64997 position the locking tab into the groove to secure the
window in the molding.
Apply liquid soap in the rubber molding (Item 1) [Figure Tapping the window corners will help seat the window in
50-130-4] to make installation easier. the molding.

Install the window from the outside of the operator cab.
Install a lower corner of the rear window into the corner of

the molding. [Figure 50-130-4].
Align the other lower corner of the window in the molding.
Work the window downward until the window is fully

seated in the lower portion of the molding.
Figure 50-130-5
P-64998
Use a plastic stick (Item 1) [Figure 50-130-5] under the

molding lip to guide the window into the molding groove.

574 of 861
WINDOW (TOP)
Figure 50-131-1
1 1
P-24378
Position the window in the recess area.

Install the bolts (Item 1) [Figure 50-131-1] through the
window grommets, the nylon bushings and through the
cab holes.
Figure 50-131-2
1
1
1
1
N-20950
From inside the operator cab, install and tighten the

knobs (Item 1) [Figure 50-131-2] on the window bolts.

575 of 861

576 of 861
WINDOW (SIDE) Figure 50-132-3
Figure 50-132-1
2
N-20814
NOTE: [Figure 50-132-3] is shown with the washer

P-66024 and knob removed to illustrate the direction of
movement.
Release the latch (Item 1) [Figure 50-132-1] and slide Move the window slide rail using the two thumb pads
the front window back towards the rear of the operator (Item 2) [Figure 50-132-2] and [Figure 50-132-3]

cab. towards the rear of the operator cab and then down
towards the bottom of the operator cab.
Figure 50-132-2
NOTE: The top of the window should come out of the
top slide rail at this time. Make sure the
window is secure and does not fall. Make sure
the slide rails are in alignment and the window
is positioned in the top track during
1 1 installation.
Remove the front side window from the operator cab.
2 2
P-66019
From inside the operator cab, loosen the knobs (Item 1)

[Figure 50-132-2] and [Figure 50-132-3] on the window
slide rail bolts.

577 of 861
WINDOW (SIDE) (CONT’D)
Figure 50-132-4
2
1
P-66021
Installation: When installing the window make sure the

slide rail (Item 1) adjoins the front stationary slide rail

(Item 2) [Figure 50-132-4].
Figure 50-132-5
P-66020
The rear side window sets in a recessed groove.
NOTE: The window should be secured to prevent

damage when the bolt (Item 1) [Figure 50-132-
5] is loosened.
Loosen the bolt (Item 1) [Figure 50-132-5] on the rear

side window.
Remove the rear side window.

578 of 861
WINDOW (FRONT DOOR) Figure 50-133-3
Removal (Standard Window)

1
Figure 50-133-1
1
3 1 1
2
1 P-24472
Push the window out at any corner of the window (Item 1)

P-66051 [Figure 50-133-3].
NOTE: The window may fall when pushing on the

Remove the wiper arm assembly (Item 1) [Figure 50- corners. Have a second technician assist you
133-1]. during the removal of the window.

Remove the two screws (Item 2) and the nut (Item 3)
[Figure 50-133-1].
Secure the wiper motor inside the cab.
Figure 50-133-2
N-20171
Pull the plastic loop (Item 1) [Figure 50-133-2] at the top

of the window to remove the rubber cord.

579 of 861
WINDOW (FRONT DOOR) (CONT’D) Figure 50-133-6
Installation (Standard Window)
Clean the area before installing the rubber molding.
Figure 50-133-4
1
P-66059
Apply liquid soap in the rubber molding to make

installation easier.
P-66058 Install the window from the outside of the door frame.
Install a lower corner of the rear window (Item 1) [Figure

Install the rubber molding (Item 1) [Figure 50-133-4] 50-133-6] into the corner of the molding.
around the edge of the front door frame starting at the
bottom of the door frame. Align the other lower corner of the window in the molding.
If replacing the rubber molding (Item 1) [Figure 50-133- Work the window downward until the window is fully
4] cut off the excess molding. seated in the lower portion of the molding.
Figure 50-133-5 Figure 50-133-7
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-133-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-133-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.

580 of 861
WINDOW (FRONT DOOR) (CONT’D)
Installation (Standard Window) (Cont’d)
Figure 50-133-8
P-66049A
Use the plastic stick (Item 1) [Figure 50-133-8] to

position the locking tab into the groove to secure the

window in the molding.
Tapping the window corners will help seat the window in

the molding.
Figure 50-133-9
P-66051
Install the wiper motor (Item 1) and wiper arm assembly

(Item 2) [Figure 50-133-9].

581 of 861
WINDOW (FRONT DOOR) (CONT’D) Figure 50-133-10
Removal And Installation (Special Applications

Window)
1
Replace the Lexan glazing under the following
conditions:
• When the glazing is four years old;

• When the glazing becomes yellow or hazed;
• Is scratched on either side with scratches that can be
felt with the fingernail;
• Has cracks coming from the edges or mounting holes.
or fine cracks on the surface area;
P-66101
• Has contacted any fluids that have caused
cloudiness.
Remove window from loader.
NOTE: The Special Applications window is held on by

the brackets only, it does not sit in the rubber
molding. During Removal the window may fall
as the mounting bolts are loosened.

Remove the five mounting brackets and bolts (Item 1)
[Figure 50-133-10].

582 of 861
ELECTRICAL SYSTEM & ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 SAFETY &
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2 MAINTENANCE
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Adjusting Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2 DRIVE
Alarm Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5 SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Troubleshooting (Standard and ACS) . . . . . . . . . . . . . . . . . . . . . . 60-210-3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 ELECTRICAL

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 SYSTEM &
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2 ANALYSIS
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . 60-20-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1 ENGINE

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-3 SERVICE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-4
BOBCAT CONTROLLER (MAIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 SPECIFICATIONS

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

583 of 861
ELECTRICAL SYSTEM (CONT’D)
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS Controller (Engine Stopped - Key ON). . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC) 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING). . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . 60-160-7
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-3
Lift And Tilt Calibration (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5

CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Attachment Control Information (Keyless) . . . . . . . . . . . . . . . . . . . 60-180-2
Right Panel Setup (Keyless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Actuator Connector Disassembly And Assembly. . . . . . . . . . . . . . 60-130-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Foot Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . 60-130-11
Handle Lock Solenoid Disassembly And Assembly. . . . . . . . . . . 60-130-10
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . 60-130-10
Handle Sensor Connector Disassembly And Assembly . . . . . . . . 60-130-3
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes (Keyless) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Viewing Service Codes (Key Switch) . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
ELECTRICAL/HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
ELECTRICAL/HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . 60-141-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

584 of 861
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . 60-10-1

Cab Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . 60-10-8
Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Alarm Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 60-50-11
Bulb Removal And Installation (Left Only) . . . . . . . . . . . . . . . . . 60-50-9
Front Accessory Panel Removal And Installation . . . . . . . . . . 60-50-11
Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . 60-50-10
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Removal And Installation (Left And Right) . . . . . . . . . . . . . . . . . 60-50-6
Right Panel (Keyless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Key Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Side And Front Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . . 60-60-2
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
MAINTENANCE CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-6
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2

585 of 861
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) . . . . 60-190-1

Changing The Owner And User Passwords . . . . . . . . . . . . . . . . . 60-190-2
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-3
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Bobcat Interlock Control System (BICS) Circuit Test . . . . . . . . . . . 60-110-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . 60-150-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING DRIFT COMPENSATION. . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Exiting And Saving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-2
Selecting And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6
WHEEL SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.

MAY VARY.

586 of 861
587 of 861
588 of 861
WIRING SCHEMATIC
STD CAB HARNESS
S150 (S/N A3L111001 – A3L119999)
V-1040
C479 C480
LEFT PANEL CONN RIGHT PANEL CONN
PROTECTED POWER
PROTECTED POWER
COMPUTER POWER
COMPUTER POWER
RUN/ENTER SW
CLOCK/LATCH
CLOCK/LATCH
HEADLIGHTS
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
STSTEM Tx
GROUND
GROUND
BUZZER
START
START
DATA
DATA
OPEN
C G E F H K D A B J C J B A G D K H F E
C G E F H K D A B J C J B A G D K H F E
9330
1920
1220
1910
9310
9110
9340
9300
9320
9330
9310
1210
2910
9210
9300
9220
9120
2920
9350
S1
BUZZER (+)
S2 2910
BUZZER (-) 2930 2920
39
31
39
31
9340
2900 2900
2770 Dealer Copy -- Not for Resale
40 40 9350
35 35 9210
8 8 9200 9200 9220
1 1 9110
7 7 9100 9100 9120
37 37 1910
41 41 1900 1900 1920
48 48 1220
42 42 1200 1200 1210
4 4 4500
C482
45 45 3910 A A GND
SEATBAR
C408 CAB MNFR HARNESS CONN
46 46 3920 B B SIG SENSOR

44 44 3900 C C PWR
C212
12 12 2795 1 1_
POWER
34 34 1160 2 2
+ PLUG
33 33 2730
1100
27 27 A A C209
24 24 2790 B B DOME LIGHT
2710
13 13 SWITCH
30 30
17 17
9 9
10 10
22 22
16 16 C434
28 28 2765 2765 2750 B B LEFT
20 20 6110 A A HEADLIGHT
4500
2770
14 14
25 25 6100 6100 6120 A A C435
47 47 2760 B B RIGHT
15 15 HEADLIGHT
19 19
18 18
6 6 3 1 4 6 SW1
11 11 BRAKE
38 38 2 5 SWITCH
21 21
1770
26 26
23 23 1100
43 43 1770
32 32 1700
3 3
5 5
1170
1700
2730
2 2
36 36
29 29 A B C
RED = RED BATTERY FEED 1000-1999 RED, RED/WHT, RNG
WIRES CONNECT BY
A B C RNG = ORANGE
LETTER ACROSS
GROUND 2000-2999 BLK
BLK = BLACK MONITORING 3000-3999 LBL
CONNECTORS
C129 LBL = LIGHT BLUE
DBL = DARK BLUE A B
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORY LGN = LIGHT GREEN
DGN = DARK GREEN
B A ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
CONNECTOR STANDARD CAB HARNESS 7143070 YEL = YELLOW
PNK = PINK
SOME CONNECTOR COMMUNICATION 9000-9999 PUR
589 of 861 WHT = WHITE

BRN = BROWN
BODIES NOT SHOWN
FOR DRAWING CLARITY
TAN = TAN
PUR = PURPLE
GRY = GRAY
V-1040 (2-6-08)
590 of 861
591 of 861
592 of 861
LEFT TAILLIGHT
POWER BOB-TACH RIGHT TAILLIGHT
TO MAINFRAME SOLENOID
WIRING SCHEMATIC 7100 C
TO OPTIONS BACK-UP
ALARM
C606
A 7000 A A 9.8 ohms
2650 F
OPTIONS D 2760 B B
C601
C103
6600 G
C
S150 (S/N A3L111001 – A3L119999) BACK-UP
6400 E
C607
B 7010 B B POWER BOB-TACH TO ENGINE OR
ALARM 6310 A SOLENOID A B C D E F REGISTRATION MAINFRAME RIGHT WORK A B C D E F
E 2770 A A LEFT WORK
6500 D ACCESSORY STOP LIGHT
(PRINTED FEBRUARY 2008) C604 C103 C605
6200 H 9.8 ohms
V-1041 A B C D E F A B B A A B C A B C D E F G H A B C D E F
2600 B
POWER BOB-TACH HARNESS -
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
6410
6810
6640
2540
2540
2530
6240
1720
2720
1740
2730
1730
6600
2530
2520
7100
6370
6310
2500
7100
6500
6400
6200
6250
2520
2510
6240
6230
6510
6710
6610
2550
6340
2620
2610
6610
6320
6620
6330
2640
Printable Version Click Here 7112290
2630 6210
E F C A B D F E D C B A
C604 C605 REGISTRATION LEFT WORK RIGHT WORK
E F C A B D F E D C B A LAMP
(TO "D" PIN) 46 C C 6430 A A 6520
(TO "B" PIN)

C410
C431
41 B B 6730 B B 6720
4640
DELUXE TAILGATE 40 A A 2660 OPEN C C 6620
HARNESS 6713993 2630 D D 2620
HARNESS - 7109404 40 A A 2640 OPEN E E OPEN
STO TUR STO TUR
TAIL TAIL
P N P N 42 B B 6330 F F 6320
LEFT TAILLIGHT RIGHT TAILLIGHT
HARNESS 6713994 HARNESS 6731239
ADVANCED HAND CONTROL 46 C C 6430 A A 6430
FLOAT HARNESS - 6727328 TO MAINFRAME

41
40
B
A
B
A 2660
6730
OPEN
B
C
B
C
6830
6630
7100 C HARNESS 6713993 2630 D D 2630
2650 F 40 A A 2640 OPEN E E OPEN
C103
G 42 B B 6330 F F 6330
E HARNESS 6713994 HARNESS 6731239
BACK-UP
STROBE OR ALARM 6310 A
6800
2670
6700
2660
BEACON
D
6360
2650
1370
2640
6200 H 2620
2600 B 2630
2 1 SSL 7-PIN 87A 87 86 87A 87 86
CAN CONNECTOR 2640 87A 87 86 87A 87 86
C609 2610 2650
2620
KEY "RUN" D 9800 D
2610
6320
6330
2640
2 1 TO 2660
To Engine Ground 30 85 30 85
STROBE/BEACON UNSW POWER 2 1160 F 2670 30 85 30 85
TO OPTIONS CAN SHIELD C 9700 C 2730
2630 6210 To Mainframe
1 2 2 1 SW POWER 1 1710 E
6350
6340
6700 E
C668 OR C670
1370
6210
6310
Harness
2775
A C604 C605 CAN LOW B 9600 A

TO OPTIONS LEFT WORK RIGHT WORK
1020
1320
1020
1320
1020
1320
(4 WAY FLASHER) C 1 2 2 1 CAN HIGH A 9500 B
2 2785 2780 D GROUND 3 2700 G
C669
7-PIN
1 6440 F Connector
on Loader C666
ATTACHMENT
CONNECTOR C426 A B A B A B
3 6540 B
STANDARD TAILGATE Boom To Starter "B" Terminal
EXTERIOR CAB HARNESS - HARNESS - 7109403 CONTROL HARNESS - 6718426 1010
Left Marker Fuse 10A Right Marker Fuse 10A Signal Fuse 10A
LEFT TAILLIGHT RIGHT TAILLIGHT
6718872 M
FRONT WIPER
BOTTLE AND TANK
HARNESS 6726430
ROAD LIGHTS
FRONT WIPER
MOTOR
SSL 7-PIN
C426 To Mainframe V
Harness M
CAN CONNECTOR D F C E A B G
C622
7200 or YEL
7150 or DGN
2765 or BRN
9800
1160
9700
1710
9500
9600
2710
L X
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN

TO OPTIONS
2745
UNSW POWER 2 1160 RED/WHT 2720 H GROUND (DELUXE ACCESSORY)
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD 3 7310
SW POWER 1 1730 RNG 1720 B SW POWER ACD
PARK
HIGH
2 2735 2755 B B
Machine
C610
C667
CAN LOW B 9620 PUR 9610 E CAN LOW 5 7160 C C
Connector DOOR SENSOR
CAN HIGH A 9520 PUR 9510 D CAN HIGH 1 7210 A A
GROUND 3 2730 BLK C OPEN 6 7180 7180
7-PIN 2 2 2 2
A OPEN
C666 4 4710 1 1 1 1
ATTACHMENT 4720
CONNECTOR G OPEN
J
N
BOOM-MOUNTED
ACD CONNECTORS
WIPER HARNESS DOOR HARNESS
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK
7117322 7104465
E OUTPUT E 5100 5100 C E OUTPUT TO
MAINFRAME
F OUTPUT F 5350 5350 H F OUTPUT
C404
B
G OUTPUT G 5400 5400 J G OUTPUT
ACD 7100 A
H OUTPUT H 5050 5050 B H OUTPUT
Output
C OUTPUT C 5300 5300 G C OUTPUT
Connector BACK-UP ALARM
D OUTPUT D 5150 5150 D D OUTPUT SWITCHES
A OUTPUT A 5250 5250 F A OUTPUT 7110 TO
MAINFRAME
M OUTPUT M 5200 5200 E B OUTPUT
C402
1720 1730 A
ID (K TO L) L 5910 5000 A J OUTPUT
2720 B
ID (K TO P) P 5510 5450 K K OUTPUT
BACK-UP ALARM
C506 14-PIN
C704 ADDITIONAL POWER
ATTACHMENT
CONNECTOR
5900 J ID #1
J3 - 10-PIN GRAY
SWITCHES HARNESS - CONNECTOR
C491
B
5500 A ID #2 7107544 1740 A
B ID #3
ACD
C ID #4 Input
D ID #0 Connector
E OPEN
C433
C433
F OPEN A RNG A
G OPEN C LGN C
H OPEN B BLK B
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K OPEN - +
ADVANCED HAND CONTROL

SSL 7-PIN
C426 To Mainframe
JUMPER HARNESS - 6728742
CAN CONNECTOR Harness
D F C E A B G TO ATTACHMENT
TO ATTACHMENT
B
B
J
9800
1160
1710
9500
9600
2710
9700
J
N
N
P
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN M TO OLDER
P LEFT RIGHT
MODEL ATTACHMENTS M TO OLDER FLASHER FLASHER
UNSW POWER F 1160 RED/WHT 2720 H GROUND A LIGHT LIGHT
C506
MODEL ATTACHMENTS
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD C
C506
D WHT S
SW POWER E 1730 RNG 9 1720 B SW POWER ACD D S
C BRN LT
C623
9 Machine A BRN LT
C623
CAN LOW B 9620 PUR 9610 E CAN LOW E BLK TM

14 Connector to
CAN HIGH A 9520 PUR 9510 D CAN HIGH E BLK TM TO OPTIONS
Engine F DBL CENTER
2790
2795
(EXTERIOR CAB)
GROUND G 2730 BLK 13 C OPEN Compartment F DBL CENTER
G RED GD
Connector 7-PIN A OPEN G RED GD 6440 1
C669
on Loader C666 ATTACHMENT
CONNECTOR G OPEN
H
L
YEL
RNG
RT
H YEL RT 2785 2
Boom L 6540 3
J K RNG
BOOM-MOUNTED K
SW POWER
N
K 1740
ACD CONNECTORS
GRADER HARNESS - 4 WAY FLASHER
GROUND B 2740 C703 J2 - 10-PIN BLACK
GRADER HARNESS - HARNESS - 6718873
E OUTPUT E 5100 5100 C E OUTPUT
6707303 6706391
F OUTPUT F 5350 5350 H F OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
Output
C OUTPUT C 5300 5300 G C OUTPUT TO HORN
Connector to
D OUTPUT D 5150 5150 D D OUTPUT CONNECTOR
Engine
C412
A OUTPUT A 5250 5250 F A OUTPUT Compartment 2750 B

M OUTPUT M 5200 5200 E B OUTPUT HORN RELAY 1730 A
ID (K TO L) L 5910 5000 A J OUTPUT
12 2770
85 86
7200
ID (K TO P) P 5510 5450 K K OUTPUT
87
11 2750 30
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A 2760 ADDITIONAL POWER
CONNECTOR
Connector CONNECTOR
C490
5900 J ID #1 E 85 86 2740 B
on Loader 2780 6415
87
Boom 5500 A ID #2 D 6410 6410 30 1740 A
C411
87A 6020
B ID #3
ACD C
C ID #4 Input B 6000
Connector to TO AWS TO MAINFRAME
C401or
D ID #0 A 6510 B C A
C402
Engine RIGHT BLINKER CONTROLS RED = RED BATTERY FEED 1000-1999 RED, RED/WHT, RNG
C489
DELUXE ATTACHMENT E OPEN

Compartment RELAY C497
2720
1720
B
A TO OPTIONS
DOME LIGHT RNG = ORANGE
BLK = BLACK
WIRES CONNECT BY
LETTER ACROSS
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
F OPEN SWITCH
CONTROL HARNESS - 2790
85 86
6515 LBL = LIGHT BLUE CONNECTORS HYDRAULIC 4000-4999 LGN
C608
G OPEN 87 A RED DBL = DARK BLUE A B ATTACHMENT CONTROLS 5000-5999 YEL

6510 30 LIGHTS 6000-6999 PNK
LGN = LIGHT GREEN
6732730 H
K
OPEN
OPEN
87A 6010 B BLK
DGN = DARK GREEN
B A ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
YEL = YELLOW
593 of 861 Rev. none
AWS HORN/BLINKER HARNESS - 6726662 DOME LIGHT PNK = PINK
WHT = WHITE
SOME CONNECTOR
BODIES NOT SHOWN
COMMUNICATION 9000-9999 PUR
BRN = BROWN FOR DRAWING CLARITY V-1041 (2-6-08)

TAN = TAN
PUR = PURPLE
GRY = GRAY
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

594 of 861
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at

1 SWITCH - Light - Multi position switch a predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

595 of 861
Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown
in the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A SPEED SENSOR - magnetic pickup -

detects RPM.
B

596 of 861
Cab Harness Connectors
C 212
SW9
C670 SW8
SW7 C 483
S3
S4
C 611
C 630
C 635
T5 C 434
T6 *C 129 C 482
408 C 479

S1
C 40
T2 S2
C 209 C 40
T1
T3
SW1
SW2
C 480 SW3
C 435 SW4
C 408 SW5
SW6
S150 - * S/N 529713935 & Above and A8M011011 & Above

S160 - * S/N 529912593 & Above and 530011832 & Above MS2441

597 of 861
Mainframe Harness Connectors
CC426
408
C 405
T1
T6
T8
C 486 T4
T5
C 112 C4
T3
C 108 C 350
408
C 408
C 113
C 135

C 107 C 446
C 407-1
C 407-2
C 103 C 478
C 105 C 489
C 406 C 423
C 606 C 415
J1
C 101 J2
C 413
C 414 C 126
C 416 C 419 C 404
C 417 C 420 C 409 C 410
C 418
C 421 C 411
C 422 C 412
C 425
C 492
MS2179

598 of 861
Description
Figure 60-10-1
P-13849
P-24651
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by

fuses located in the cab on the steering control panel,
and a 100 amp master fuse [Figure 60-10-1] in the
engine compartment on the left side of the engine, under
the air cleaner. The fuses will protect the electrical
system when there is an electrical overload. The reason
for the overload must be found before starting the engine
again.
Figure 60-10-2
P-26323
The electrical system is protected from overload by fuses

and relays under the fuse panel cover (Item 1) [Figure
60-10-2]. A decal is inside the cover to show location and
amp ratings.
Remove the cover to check or replace the fuses.

599 of 861
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

600 of 861
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-4
Fuse And Relay Location / Identification 9 11

1 13 15 17
5
Figure 60-10-3
2 6 18
3 7 19
4 8 14 16 20
10 12
7117407
N-19659
The electrical system is protected from overload by fuses

and relays under the fuse panel cover (Item 1) [Figure

60-10-3]. A decal is inside the cover to show location and
amp ratings. N-19660
Remove the cover to check or replace the fuses.

The location and sizes are shown below and [Figure 60-
10-4].
REF DESCRIPTION AMP REF DESCRIPTION AMP

1 Traction 30 11 Front & Marker R
Lights
2 Fuel Shutoff 30 12 Fuel Shutoff R
3 Power Plug -- 13 Rear Lights R
4 ACS/AWS/SJC -- 14 Traction R
5 Heater 25 15 Switch Power R
6 Front & Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Unswitched 25
Attach.
8 Bobcat Controller 25 18 Switched Attach. 25
9 Heater & Air -- 19 Alternator & 25
Conditioning Accessories
10 Glow Plugs R 20 Accessory Plug 25
R - Relay

601 of 861
Solenoid Testing
Figure 60-10-5
P9175

10-5]. Coil wires do not have polarity. Correct resistance

for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.

602 of 861

603 of 861
BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807 metal parts with the battery terminals.

Connect the negative (-) cable last to prevent sparks.
Open the rear door.
Connect and tighten the battery cables.
Figure 60-20-1
Install and tighten the battery hold down.
Close the rear door before operating the loader.

3
2
WARNING
1
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
P-76740
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
Disconnect the negative (-) battery cable (Item 1) [Figure connecting to a charger. Unplug charger before
60-20-1]. connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Remove the battery hold down clamp (Item 2) [Figure
60-20-1]. Battery gas can explode and cause serious injury.
W-2066-0705
Disconnect the positive (+) battery cable (Item 3) [Figure
60-20-1].
Remove the battery from the loader.

604 of 861
BATTERY (CONT’D) BATTERY (CONT’D)
Servicing Using A Booster Battery (Jump Starting)
Figure 60-20-3 If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF (Key Switch Panel) OR the

STOP Button must be pressed (Keyless Panel). The
booster battery must be 12 volt.
WARNING
P-09589 P-09590 Batteries contain acid which burns eyes and skin on
The battery cables must be clean and tight [Figure 60-
20-3]. Check the electrolyte level in the battery. Add In case of acid contact, wash immediately with water.

distilled water as needed. Remove acid or corrosion from In case of eye contact get prompt medical attention
the battery and cables with a sodium bicarbonate and and wash eye with clean, cool water for at least 15
water solution. minutes.
Put Battery Saver (6664458) or grease on the battery If electrolyte is taken internally drink large quantities
terminals and cable ends to prevent corrosion. of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

rubber gloves to keep acid off body. 2
4
In case of eye contact get prompt medical attention
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807 3 1
P-31860

605 of 861
Connect the end of the first cable (Item 1) [Figure 60-20-
4] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.
Connect the end of the second cable (Item 3) [Figure 60-

20-4] to the negative (-) terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first.
Remove the cable from the positive terminal (Item 2)

[Figure 60-20-4].
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables

disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

606 of 861

607 of 861
ALTERNATOR Belt Replacement
Belt Adjustment Loosen the alternator mounting and adjustment bolts

(Item 1 & 2) [Figure 60-30-2] and loosen the belt all the
Stop the engine. way.
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the belt and install a new belt.
Figure 60-30-1 Adjust the belt as shown above.
P-24543

Loosen the alternator mounting bolt (Item 1) and
adjustment bolt (Item 2) [Figure 60-30-1].
Move the alternator until the belt has 5/16 in. (8,0 mm)
movement at the middle of the belt span with 15 lb. (66
N) of force.
Tighten the adjustment bolt and the mounting bolt.
Lower the operator cab. (See Lowering on Page 10-30-

3.)

608 of 861
ALTERNATOR (CONT’D) Figure 60-30-2
Charging System Inspection
WARNING
1

In case of eye contact get prompt medical attention P-24547
minutes.
If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities Check the condition and tension of the alternator belt.
of water or milk! DO NOT induce vomiting. Get (See Belt Adjustment on Page 60-30-1.) If belt is worn or
prompt medical attention. deteriorated replace.
W-2065-0807
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and

tight.
Check the fuse for the alternator in the fuse panel. If fuse
WARNING is burned, find the cause and repair/replace. If fuse is in
doubt, remove it and check for continuity.
AVOID INJURY OR DEATH Check the electrolyte level in the battery. Add distilled
Keep arcs, sparks flames and lighted tobacco away water as needed. (Does not apply to maintenance free
from batteries. When jumping from booster battery batteries.)
make final connection (negative) at machine frame. Verify the charge of the battery. Make sure battery is fully
charged.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before Disconnect the battery cables (negative first, then
connecting to a charger. Unplug charger before positive). Inspect the cable clamps and battery posts for
connecting or disconnecting cables to battery. Never corrosion. Remove acid or corrosion from the battery
and cables with a sodium bicarbonate and water
lean over battery while boosting, testing or charging.
solution. Put grease on the cable ends and battery
terminals to prevent corrosion. Reconnect the cable to
Battery gas can explode and cause serious injury. the positive terminal.
W-2066-0705
With the key off, connect a test light between the
negative battery post and the disconnected negative
cable clamp.
1. If the test light does not light up, reattach the clamp
IMPORTANT and proceed to alternator voltage test. (See Below.)
2. If the test light lights up, there is a short (drain) in the
Damage to the alternator can occur if: electrical system of the loader. The short must be
• Engine is operated with battery cables repaired before the charging system can be checked.
disconnected.
3. Disconnect the alternator B+ terminal (Item 1) and L
• Battery cables are connected when using a fast & S terminal connector (Item 2) [Figure 60-30-2] and
charger or when welding on the loader. (Remove if the test light goes out, the alternator is faulty. If the
both cables from the battery.) test light stays on, find the short in the system and
• Extra battery cables (booster cables) are repair it.
connected wrong.
I-2023-1285

609 of 861
ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-4
Figure 60-30-3
P-66815
P-34676
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-4] off the alternator.
Open the rear door.
Turn the remote start tool key to the ON position.

Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT -MEL1563 on Page 10-60- Figure 60-30-5
1.)
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-3]. 1
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the

following high voltage test.
If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5 2
volts, proceed with the following low voltage test. P-66816
Check the voltage across the “L” terminal (Item 1) and a

good ground source (Item 2) [Figure 60-30-5]. The
voltage should be what the battery voltage is. If not,
check wire harness, relay and fuses. If the wire harness,
relay and fuses are ok then remove alternator for
replacement or repair. To repair, (See Alternator Voltage
Testing on Page 60-30-3.) for further component testing.

610 of 861
ALTERNATOR (CONT’D)
High Voltage Testing
Figure 60-30-6
P-34679 P-66817
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-4] off the alternator.

Check the continuity between the “S” terminal (Item
1) [Figure 60-30-6] and the positive (+) terminal on
the battery or starter terminal (Item 2) [Figure 60-30-
6]. There should be continuity. If no continuity,
replace wire harness.
If voltage is still above 14.7 volts at 70° F (Alternator

Temperature), then remove alternator for replacement or
repair. To repair, (See Alternator Voltage Testing on Page
60-30-3.) for further component testing.

611 of 861
ALTERNATOR (CONT’D) Raise the lift arms and install an approved lift arm support
Place jackstands under the rear corners of the loader.
Disconnect the negative (-) cable from the battery.
Figure 60-30-7
DANGER
P-90328
AVOID DEATH 1
can cause lift arms to drop. P-66815

unless supported by an approved lift arm Disconnect the red wire (Item 1) [Figure 60-30-7] from
support. Replace if damaged. the alternator which comes from the battery.
D-1009-0409
Disconnect the wiring harness connector (Item 2) [Figure
60-30-7] from the alternator.

W-2059-0598
IMPORTANT 3
P-24543
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected. Remove the adjustment bolt (Item 1) [Figure 60-30-8]
• Battery cables are connected when using a fast from the mounting bracket.
charger or when welding on the loader. (Remove
both cables from the battery.) Remove the alternator belt (Item 2) [Figure 60-30-8]
• Extra battery cables (booster cables) are from the alternator pulley.
connected wrong.
I-2023-1285 Remove the mounting bolt (Item 3) [Figure 60-30-8].

612 of 861
ALTERNATOR (CONT'D)
1. Alternator 11. Bearing

2. Nut 12. Stator
3. Pulley 13. Housing 7
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Housing 16. Rectifier 1
7. Bolt 17. Cover
8. Bearing 18. Spacer 6
9. Retainer 19. Nut
10. Rotor
14
13
4 7
3
2 12 5
11
10

8
19
18
17
15 16 C-3529B

613 of 861
STARTER Figure 60-40-2
Testing
Figure 60-40-1 Bat

S
M
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

A-1992
between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.

The key switch must be in the OFF position.
If the starter does not turn, the starter is defective.

The battery must be at full charge.
The cable connections on the battery must be clean and

tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.

614 of 861
STARTER (CONT’D)
Figure 60-40-3
4
2
1
P-34385

Remove the negative (-) and positive (+) cables from the
battery.
Disconnect the ground wire (Item 1) [Figure 60-40-3]

from the starter.
Disconnect the engine harness power wire and positive

(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-40-3].
Installation: Tighten the nut to 10.8 - 12.3 ft.-lb. (14,7 -

16,7 N•m) torque.
Disconnect the tan wire (Item 3) [Figure 60-40-3] from

the R terminal on the starter solenoid.
Disconnect the brown wire (Item 4) [Figure 60-40-3]

from the S terminal on the starter solenoid.
Remove the mounting bolts (Item 5) [Figure 60-40-3]

from the starter.
Remove the starter from the engine.
Installation: Tighten the three mounting bolts to 25 - 28

Reverse the removal procedure to install the starter.

615 of 861
STARTER (CONT'D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
21
32 7*
15
37
14

16 20
17
19 18
5 8
12
14
6
29
1 4
3
28
2
27
25. Holder
35 26. Bracket
27. Ring
28. Bolt
22 26
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
36. Bracket
24
37. Bearing
* Not serviceable parts B-16488

616 of 861

617 of 861
INSTRUMENT PANELS The left instrument panel is the same for both the Key
Switch and Keyless Instrument Panels [Figure 60-50-1].
Left Panel
The table below shows the DESCRIPTION and
Figure 60-50-1 FUNCTION/OPERATION for each of the components of
the left panel.
2
1
3
4 5 6 7 8
11 12
13 9 10
14
B-15551

REF.
DESCRIPTION FUNCTION / OPERATION
NO
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY / HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES*
ENGINE PREHEAT COUNTDOWN relating to the loader monitoring system. ENGINE PREHEAT COUNTDOWN - Preheat time remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time
to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE CODES (Item 2).
(CODES* show only when there is an error found by loader monitoring system.)
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold two seconds
to view [SHTDN] and Operational Code Number in HOURMETER / CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW Not used.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXIMUM
FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast
movement of auxiliary functions (The farther you move the switch, the faster the movement of auxiliary
functions.) MAXIMUM FLOW allows for only fast movement.]
8 AUXILIARY PRESSURE RELEASE Rear Auxiliary Only - With key ON and engine running, press to shut down engine and relieve rear auxiliary
hydraulic pressure.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
(SEE BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ON PAGE 60-100-1.) for more information)
9 PRESS TO OPERATE LOADER Press to activate BICS when the Seat Bar is down and operator is seated in operating position.
Press and hold three seconds to engage Steering Drift Compensation.
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE button is pressed. The lift and tilt
functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can
be moved forward or backward when the light is ON.
13 TRACTION LOCK OVERRIDE (Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to
use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader
service.(See TRACTION LOCK on Page 60-120-1.). Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or SHUTDOWN condition.
* For further description of SERVICE CODES (See DIAGNOSTICS SERVICE CODES on Page 60-90-1.)

618 of 861
INSTRUMENT PANELS (CONT’D) The right instrument panel shown [Figure 60-50-2] is the
Key Switch Panel.
Right Panel (Key Switch)
The table below shows the icons and other components
Figure 60-50-2 of the Right Key Switch Panel
15 17 19 21 23 25 27
* These functions are monitored and have SERVICE
CODES associated with them. For descriptions, (See
DIAGNOSTICS SERVICE CODES on Page 60-90-1.)
16 18 20 22 24 26 28
29
B-15552G
ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
LIGHT
Advanced Control ON 3 Beeps * Error Error with Advanced Control System (ACS).
15 System (ACS) or Selectable Joystick Control (SJC)

(Opt.)
Attachment Control ON --- - --- Electrical controlled attachment is present.
16 Device (ACD) FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
(Opt.)
General ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
17 Warning ON 3 Beeps * WARNING Engine speed high or in shutdown.
FLASHING Continuous * SHUTDOWN Engine speed extremely high. Engine will stop in 10 seconds.
Two-Speed ON --- - --- High range selected. (Fasten shoulder belt.)
18 (Opt.) FLASHING 3 Beeps * Error Two-speed electrical error.
FLASHING - - - - --- Hydraulic fluid temperature below limit for two-speed operation.
SLOWLY
Fuel ON 3 Beeps * Error Fuel level sender system fault.
19 Level FLASHING 3 Beeps * WARNING Fuel level low.
Engine Preheat ON --- - --- Glow plugs are energized.

20 FLASHING 3 Beeps * Error Error with glow plugs
System Voltage ON 3 Beeps * WARNING Voltage low, high or extremely high.

21
Seat Belt ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine ON 3 Beeps * Error Engine oil pressure sender out of range.
23 Oil Pressure ON 3 Beeps * WARNING Engine oil level low.
FLASHING Continuous * SHUTDOWN Engine oil pressure extremely low. Engine will shutdown in 10 seconds.
Hydrostatic ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure FLASHING Continuous * SHUTDOWN Hydraulic charge pressure extremely low. Engine will stop in 10 seconds.
Engine ON 3 Beeps * Error Engine coolant sender out of range
25 Coolant ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature FLASHING Continuous * SHUTDOWN Engine coolant temperature extremely high. Engine will stop in 10 seconds.
Hydraulic ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature FLASHING Continuous * SHUTDOWN Hydraulic oil temperature extremely high. Engine will stop in 10 seconds.
Engine ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter FLASHING 3 Beeps * WARNING Air filter switch not connected.
Hydraulic ON 3 Beeps * Error Hydraulic filter with high restriction.

Filter FLASHING 3 Beeps * WARNING Hydraulic filter switch not connected.
28
29 Key Switch - - - - Used to start and stop the engine.
* These functions are monitored and have associated SERIVICE CODES. See SYSTEM SETUP AND ANALYSIS for description of SERVICE CODES.

619 of 861
INSTRUMENT PANELS (CONT'D) Figure 60-50-4
Right Panel (Keyless)
Figure 60-50-3
5 6
ENTER PASSWORD
1 3
LANGUAGES
2
B-16165
The first screen you will see on your new loader will be as
shown in [Figure 60-50-4].
When this screen is on the display you can enter the

password and start the engine or change the Display
4 Panel setup features.

NOTE: Your new loader (with Keyless Instrument
Panel) will have a Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
8 7 B-15553H
easily remember to prevent unauthorized use
The right instrument panel shown [Figure 60-50-3] is the of your loader. (See Changing The Owner And
Keyless Panel. User Passwords on Page 60-190-2.) Keep your
password in a safe place for future needs.
1. Display Screen: The Display Screen is where all
system setup, monitoring, troubleshooting, and error Start Engine: Use the Keypad to enter the numbers
conditions are displayed. (letters) of your password and press the RUN / ENTER
key (Item 7) [Figure 60-50-3].
2. Function Icons: The lower left area of the Display
Screen contains the same icons as the Key Switch Press and hold the START button (Item 8) [Figure 60-50-
Panel. These icons are only visible when the 3] until the engine starts.
monitoring system has detected the associated
condition. Change Language: Press the Selection button at the end
3. Selection Buttons: The four Selection Buttons allow of the arrow [Figure 60-50-4] to go to the next screen.
you to select items from the Display Screen and scroll
through screens.
4. Keypad: The numeric keypad has two functions:

- To enter a number code (password) to allow starting
the engine (Keyless Start).
- To enter a number as directed for further use of the
Display Screen.
5. Bobcat Controller / Display Icon: Indicates

communication error between Bobcat controller and
instrument panel. (See DIAGNOSTICS SERVICE
CODES on Page 60-90-1.)
6. BobCARE PMSM Icon: Indicates planned

maintenance is due. (See MAINTENANCE CLOCK
on Page 60-200-1.)

620 of 861
INSTRUMENT PANELS (CONT'D)
Right Panel (Keyless) (Cont’d)
Figure 60-50-5
B-16655
Use the Keypad to select the number of the language

[Figure 60-50-5].

Press EXIT. The screen will return to [Figure 60-50-5].
You can then enter the password and start the engine.
For further description of screens to setup the system for

your use. (See Right Panel Setup (Keyless) on Page 60-
180-1.)
NOTE: Pressing the EXIT key will go to the previous

screen and you can continue pressing until
you get to the initial (home) screen.
SHORTCUT: Press the “0” (zero) key to get to
the home screen immediately.

621 of 861
INSTRUMENT PANELS (CONT'D) Side Panel [Figure 60-50-6].
Side And Front Panels REF.

DESC. FUNCTION/OPERATION
NO.
Figure 60-50-6 1 POWER Provides a 12V receptacle for
PLUG accessories.
SIDE PANEL
2 NOT USED ---
3 FRONT Press the top of the switch to start the
WIPER front wiper (press and hold for washer
fluid). Press the bottom of the switch to
stop the wiper.
4 REAR WIPER Press the bottom of the switch to start
the rear wiper. Press the top of the
switch to provide washer fluid to clean
the rear window.
2 3 4 5 6 7 8 9
1 5 NOT USED ---
6 NOT USED ---
7 FAN MOTOR Turn clockwise to increase fan speed;
counterclockwise to decrease. There
are four positions; OFF-1-2-3.
P16000
8 AIR COND. Press top of switch to start; bottom to
SWITCH stop. Fan Motor (Item 7) must be ON for
A/C to operate.
9 TEMP. Turn clockwise to increase the
CONTROL temperature; counterclockwise to

decrease.
Front Panel [Figure OI-7]

Figure OI-7
FRONT PANEL REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 2 3 4 5 6 7 8 1 ADVANCED Press the top to select Hand
CONTROL Controls; bottom to select Foot
SYSTEM (ACS) Controls.
2 NOT USED ---
3 POWER Press and hold the up arrow to
BOB-TACH disengage the the Bob-Tach
9 OR wedges. Press and hold the down
arrow to engage the wedges into
the mounting frame holes.
4 PARKING BRAKE Press the top to engage the
(Standard on all PARKING BRAKE; bottom to
Loaders) disengage.
B-15993N
5 TURN SIGNAL Indicates left or right TURN
B-15993M
INDICATORS SIGNALS are ON.
6 HAZARD LIGHTS Press the top to turn the HAZARD
NOTE: Parking Brake (Item 4) [Figure OI-7] is LIGHTS ON; bottom to turn OFF.
Standard on all loaders. 7 ROTATING Press the top to turn the
BEACON ROTATING BEACON ON; bottom
to turn OFF.
8 NOT USED ---
9 SELECTABLE Press the top to select ‘ISO’ Control
JOYSTICK Pattern; bottom to select ‘H’ Control
CONTROL (SJC) Pattern.

622 of 861
Removal And Installation (Left And Right)
Figure 60-50-8
1
N-20140
Disconnect the key switch wiring harness (Item 1)

[Figure 60-50-10] from the back of the control panel.
P-28360A
Figure 60-50-11
Remove the three mounting bolts (Item 1) [Figure 60-50-
8].

Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
2
Figure 60-50-9
1
P-28360
Remove the ignition key (Item 1) from the switch.

Remove the ignition switch retaining nut (Item 2) [Figure
60-50-11] from the switch.
N-20158
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-9] from
the panel.
Remove the panel from the loader cab.

623 of 861
Removal And Installation (Left And Right) (Cont’d)
Figure 60-50-12
N-20163
Pull the right instrument panel down and disconnect the

N-20141 the panel.
Remove the ignition switch (Item 1) [Figure 60-50-12] Remove the panel from the loader cab.
from the control panel.
Figure 60-50-15

Figure 60-50-13
1
1
N-20142
N-20103
NOTE: The instrument panel (Item 1) [Figure 60-50-
Remove the three mounting bolts (Item 1) [Figure 60-50- 15] must be replaced as a complete unit.
13].


624 of 861
Removal And Installation (Left And Right) (Cont’d)
Figure 60-50-16
1
1
N-20144
Remove the left side instrument panel.
N-18409 Remove the retaining nut (Item 1) [Figure 60-50-18]

from the loader alarm.
16]. Remove the alarm from the loader instrument panel.

Figure 60-50-17
1
2
N-20165
Pull the left instrument panel down and disconnect the

the loader alarm.

60-50-17] from the loader instrument panel.
NOTE: The wiring harness (Item 3) [Figure 60-50-17]

is an optional accessory harness.
Remove the instrument panel from the loader.

625 of 861
Bulb Removal And Installation (Left Only)
Figure 60-50-19
N-20147
To install the bulbs, place them in the sockets and turn

clockwise [Figure 60-50-21].
N-20145
Remove the two light bulb covers (Item 1) [Figure 60-50-

19] from the back of the instrument panel.
Figure 60-50-20
N-20146
With a flat blade screw driver, turn the light bulb

counterclockwise [Figure 60-50-20] and remove from
the panel.

626 of 861
Key Switch Removal And Installation 1

Figure 60-50-22
N-20141
Remove the ignition switch (Item 1) [Figure 60-50-24]

from the control panel.
N-20140
Disconnect the key switch wiring harness (Item 1)

[Figure 60-50-22] from the back of the control panel.

Figure 60-50-23
P-28360
Remove the ignition key (Item 1) from the switch.

Remove the ignition switch retaining nut (Item 2) [Figure
60-50-23] from the switch.

627 of 861
INSTRUMENT PANELS (CONT'D) Front Accessory Panel Removal And Installation
Alarm Removal And Installation Figure 60-50-26
Figure 60-50-25
1
1
1
P-26255
N-20144 Remove the two mounting bolts (Item 1) [Figure 60-50-

26].
Installation: Be careful to not overtighten the front
Remove the retaining nut (Item 1) [Figure 60-50-25] accessory panel mounting bolts to prevent damage to the

from the loader alarm. plastic panel.
Remove the alarm from the loader instrument panel. Figure 60-50-27
2
1
P-26251
Pull the front accessory panel down and disconnect the

wire harness connector(s) (Items 1 & 2) [Figure 60-50-
27] from the switches.
Remove the panel.
Reverse the procedure to install the front accessory

panel.

628 of 861

629 of 861
LIGHTS Figure 60-60-3
Front Removal And Installation
Figure 60-60-1
1 1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the

N-19348 socket.
Reverse the above procedure to install the bulb.

Open the rear door.

Disconnect the negative(-) cable from the battery. (See
Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.
Figure 60-60-2
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.

630 of 861
LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-6
Figure 60-60-4
1 2 1
1
3
P-66221
P-68264
Remove the screws (Items 1) [Figure 60-60-6] from the
light cover.
Remove the bulb assembly (Items 1 & 2) from the light
housing (Item 3) [Figure 60-60-4] by turning bulb NOTE: The wires for the switch will hold the light

assembly a 1/4 turn. cover. Do not pull the light cover to far away
from the light housing to prevent damage to
Figure 60-60-5 the wires.
Move the light cover to allow access to the bulb.
Figure 60-60-7
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
P-66222
Reverse this procedure for installation.

Remove and replace the bulb (Item 1) [Figure 60-60-7]
from the light housing.

631 of 861
BOBCAT CONTROLLER (MAIN)
Description
The main controller provides information to all other controllers. All loaders have a main controller.
The main controller is located behind the access panel near the operators left foot.

632 of 861
BOBCAT CONTROLLER (MAIN) (CONT’D)
Connector Identification
41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1
9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
Controller

Harness Connector View Harness Connector View
41 50 41 50
31
J1 40 31 J2 40
21 30 21 30
11 20 11 20
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V-171/V-172

633 of 861
BOBCAT CONTROLLER (MAIN) (CONT’D)
Connector Identification (Cont’d)
Harness Connector View
41 50
J1
1400 8000 X 9800 X X 3420 7200 3520 X
31 X 8150 1130 9700 X 8550 3500 2100 6320 8110

40
21 X 4150 3010 9600 4730 4470 X 1120 4450 8210
30
11 X 8250 1110 9500 3400 6510 4200 4460 6210 8800
20
X X 3430 4910 X X X 6410 8510 4110

1 2 3 4 5 6 7 8 9 10
Harness Connector View
41 4410 9410 4640 9340 3920 4500 X 3300 X X

50
31 X 4420 X 9350 3910 J2 4840 X 2110 X 4940
40
21 4340 4430 9400 1900 3900 4830 X 3100 4320 4930
30
11 9110 4440 X 1200 9200 4820 X 3700 4310 4920
20
4360 X 4330 2900 9100 4810 9210 3200 4300 3600
1 2 3 4 5 6 7 8 9 10
V-172

634 of 861
BOBCAT CONTROLLER (MAIN) (CONT’D) Figure 60-70-2
WARNING 1
1

W-2059-0598
P-34842
Figure 60-70-1
Loosen the harness connectors mounting bolts (Item 1)

[Figure 60-70-2] from the Bobcat controller.
1 Remove the connectors.
Installation: Tighten bolts to 30 - 35 in.-lb. (3,39 - 3,96

N•m) torque.
NOTE: The connectors are keyed and will only plug

in one way.
Figure 60-70-3
N-19390
1
Stop the engine. Raise the seat bar. 2

Page 10-10-1.)
Remove the left front side panel (Item 1) [Figure 60-70-

P-34843
1]. (See Removal And Installation (Left) on Page 50-120-
1.)
Remove the top mounting bolt (Item 1) [Figure 60-70-3].
Loosen the two mounting bolts (Item 2) [Figure 60-70-3]

of the system controller.
Installation: Tighten the bolts to 12 - 14 ft.-lb. (16,3 - 19

N•m) torque.
Remove the system controller.
Reverse the above procedure to install the system

controller.

635 of 861
BOBCAT CONTROLLER (ACS) Figure 60-71-2
Description
2
The Bobcat Controller (ACS) is part of the Advanced
Control System (ACS) which is a selectable foot/hand
control system. Electrical actuators shift the spools on
the hydraulic control valve.
The ACS system allows the operator to quickly switch

between foot and hand control modes.
1
The ACS controller is housed in a grey colored plastic
shell with black potting. The ACS controller
communicates with the Main Bobcat Controller by CAN
communication wires. The ACS controller is capable of P-21938 P-21939
receiving upgrades to the software.
Figure 60-71-1 Foot control/sensor assembly (Item 1) [Figure 60-71-2].
Foot sensor (Item 2) [Figure 60-71-2].


11
2 Figure 60-71-3
1
P-16536 P-21879
Control Handle (Item 1) [Figure 60-71-1].
Handle sensor (Item 2) [Figure 60-71-1].
NOTE: The calibration procedure must be followed 1

sensor, actuator or ACS Controller. (See P-68027
Control Valve Actuators (Item 1) [Figure 60-71-3].


636 of 861
BOBCAT CONTROLLER (ACS) (CONT’D)
Description (Cont'd)
Figure 60-71-4
P-21767
ACS Controller (Item 1) [Figure 60-71-4].

Figure 60-71-5
P-21769
ACS error indicator (Item 1) [Figure 60-71-5].
NOTE: The ACS icon will illuminate when an error

occurs. The error is stored as a service code.
(See Service Codes List on Page 60-90-2.)

637 of 861
BOBCAT CONTROLLER (ACS) (CONT’D)
G H
J J1 J3
F K
E A
D J3
B
C G H
F J
K J2
F E
G D A
E H B
A C
B J2
D
J1
C
J3
J1 J2

P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND/FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

638 of 861
BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-8
Figure 60-71-6
P-21840

P-21839 8] from the controller.
Remove the controller from the loader.

Loosen the bottom bolts and remove the top bolt on the
right front panel [Figure 60-71-6]. NOTE: The calibration procedure must be followed

Remove the right front panel (Item 1) [Figure 60-71-6] sensor, actuator or ACS Controller. (See
from the loader. CALIBRATION on Page 60-160-1.)
Figure 60-71-7
P-21843
Disconnect the wiring harness connectors (Item 1)

[Figure 60-71-7] from the controller.

639 of 861
BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The workgroup actuators are the same used on the ACS
drive functions. system.
The drive controller is located behind the right side The hydrostatic drive pump is a Rexroth A22 unit. It has
access panel near the operators right foot. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller monitors the position of the left forward and reverse outputs of the pump to the drive
joystick, pump swash plate angles and the output of the motors. The Rexroth pump is equipped with position
wheel speed sensors. sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
The drive controller works along with the ACS controller uncommanded swash plate movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
P-66836

640 of 861
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
P-64295

641 of 861
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296

642 of 861
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-2
WARNING
W-2059-0598
P-64327
Remove the inside access panel (right side) (Item 1)
Raise the operator cab. (See Raising on Page 10-30-2.) [Figure 60-72-2].

1
P-64300 P-66835
Remove the foot portion of the engine speed control Remove the top controller mounting bolt (Item 1). Loosen
(Item 1) [Figure 60-72-1]. (See Removal And Installation the two bottom controller mounting bolts (Item 2) [Figure
on Page 70-20-1.) 60-72-3] from the right side fender.
Lift and remove the controller from the fender.

(16 - 19 N•m) torque.

643 of 861
BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-6
Removal and Installation (Cont’d)
Figure 60-72-4
P-64325
Remove the drive controller [Figure 60-72-6].

P-64322
Figure 60-72-7
Pull the controller out from the fender and loosen the
connector screw (Item 1) [Figure 60-72-4] to release the

connector.
Installation: Tighten the connector screw to 30 - 35 in.-

lb. (3,39 - 3,96 N•m) torque. DO NOT OVERTIGHTEN! J S
Figure 60-72-5
P-64324
1
The wire location (Item 1) [Figure 60-72-7] is printed on

the connector, in the locations shown.
P-64325
Installation: Note the keyed hole in the controller socket.

(Item 1) [Figure 60-72-5]. The keyed hole matches a tab
on the connector on the wire harness.

644 of 861

645 of 861
WHEEL SPEED SENSORS (SJC) Testing
Figure 60-80-1
1
P-28302
P-64765
procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
80-1] is used by the loader’s controllers to sense if the MEL1609-Wheel Speed Sensor Test Harness

drive motor is rotating. The end of the sensor is magnetic [Figure 60-80-2]
and counts the magnetic pulses as a rotating disc,
attached to the motor carrier shaft, rotates by the sensor MEL1563 or 6689779-Remote Start Tool
end. Multimeter
The speed sensor is sealed with an O-ring (Item 1) Raise the lift arms and install an approved lift arm support
[Figure 60-80-1] to keep hydraulic oil inside the motor device. (See Installing on Page 10-20-1.)
carrier and dirt out.
Connect the remote start tool to the loader. (See

1.)

646 of 861
WHEEL SPEED SENSORS (SJC) (CONT'D) Figure 60-80-4
Testing (Cont’d)
Figure 60-80-3
3
2
1
2
1
P-64976
Connect the speed sensor test harness (Item 1) [Figure

P-64762 60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
Locate the speed sensor (Item 1) [Figure 60-80-3] on the Turn the remote start key to ON position without starting
top of the right or left hydrostatic motor carrier. the loader.

Remove the transmission cover screw (Item 2) [Figure Take a voltage reading, with the multimeter, at the speed
60-80-3], to loosen the connector clamp. sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-80-4].
torque. The voltage should be approximately 5 volts.
Disconnect the speed sensor wire connector (Item 3) Repeat the procedure for the opposite side speed
[Figure 60-80-3] from the loader harness wire connector. sensor. (If needed.)

647 of 861
Figure 60-80-5 1
1 P-64764
Lift the speed sensor (Item 1) [Figure 60-80-7] out from

P-64762 the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.
Raise the lift arms and install an approved lift arm support Figure 60-80-8

Remove the two, speed sensor mount bolts (Item 1)

[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
2
P-64765
1
Remove the speed sensor [Figure 60-80-8].
P-64762
Remove the transmission cover screw (Item 1) [Figure

60-80-6], to loosen the connector clamp.

torque.
Disconnect the speed sensor electrical harness

connector (Item 2) [Figure 60-80-6].

648 of 861
Figure 60-80-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)

P-26293 [Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
The electrical connector can be replaced.

Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
1
2
P-26295
Installation: The alignment pin (Item 1) at the bottom of

the speed sensor must be installed in the hole (Item 2)
P-26294 [Figure 60-80-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue

649 of 861
DIAGNOSTICS SERVICE CODES Viewing Service Codes (Keyless)
Viewing Service Codes (Key Switch) The Service Codes will aid your dealer in diagnosing
conditions which can damage your machine.
Figure 60-80-1
Figure 2
2
Press TOOL / SETUP
3
B-16163
Press OWNER UTILITIES

1 4
B-24288
Enter PASSWORD (owner or master)

on Keypad
then press ENTER
to Continue
B-24290

B-15551
Press and hold the LIGHTS button (Item 1) for two Press SERVICE CODES
seconds to view SERVICE CODES in the HOURMETER/
CODE DISPLAY (Item 2) [Figure 60-80-1]. If more than
B-24291
one SERVICE CODE is present, the codes will scroll on
the HOURMETER/CODE DISPLAY.
NOTE: Corroded or loose grounds can cause Press NEXT to view the next 8
multiple service codes and/or abnormal Service Codes. (A total of 40 Codes
can be stored.)
symptoms. All instrument panel lights
B-24298
flashing, alarm sounding, headlights and
taillights flashing, could indicate a bad
ground. The same symptoms could apply if The Display Panel will list the Code Number, (CODE)
the voltage is low, such as loose or corroded hourmeter reading when the error occurred (HOUR), and
battery cables. If you observe these the User (USER) who was logged in to operate the
symptoms, check grounds and positive leads machine when the error occurred.
first.
A total of 40 Codes can be stored. When more than 40
Service Codes may be either a word (Item 3) or a number codes occur, the oldest code will disappear and the
(Item 4) [Figure 60-80-1]. (See following pages for newest code will be in No. 1 position.
service codes.)
The following word errors may be displayed.
REPLY One or both instrument panel(s) not

communicating with the controller.
INPUT The controller not communicating with the left

instrument panel.
CODE The controller is asking for a password.

(Keyless instrument panel only.)
ERROR The wrong password was entered. (Keyless

instrument panel only.)

650 of 861
DIAGNOSTICS SERVICE CODES (CONT'D)
Service Codes List
CODE CODE
01-16 Air filter not connected 11-05 Seat bar sensor short to battery
01-17 Air filter plugged 11-06 Seat bar sensor short to ground
02-16 Hydraulic/Hydrostatic filter not connected 12-21 Front auxiliary PWM switch out of range high
02-17 Hydraulic/Hydrostatic filter plugged 12-22 Front auxiliary PWM switch out of range low
12-23 Front auxiliary PWM switch not in neutral
03-09 Battery voltage low
03-10 Battery voltage high 13-05 Fuel shut-off hold solenoid short to battery
03-11 Battery voltage extremely high 13-06 Fuel shut-off hold solenoid short to ground
03-14 Battery voltage extremely low 13-07 Fuel shut-off solenoid open circuit
03-22 Battery voltage out of range low
14-02 Fuel shut-off pull solenoid error ON
04-09 Engine oil pressure low 14-03 Fuel shut-off pull solenoid error OFF
04-14 Engine oil pressure extremely low
04-15 Engine oil pressure shutdown level 15-02 Traction lock pull solenoid error ON
04-21 Engine oil pressure out of range high 15-03 Traction lock pull solenoid error OFF
04-22 Engine oil pressure out of range low
16-05 Traction lock hold solenoid short to battery

05-09 Hydraulic charge pressure low 16-06 Traction lock hold solenoid short to ground
05-10 Hydraulic charge pressure high 16-07 Traction lock hold solenoid open circuit
05-11 Hydraulic charge pressure extremely high
05-14 Hydraulic charge pressure extremely low 17-05 Hydraulic lock valve solenoid short to battery
05-15 Hydraulic charge pressure shutdown level 17-06 Hydraulic lock valve solenoid short to ground
05-21 Hydraulic charge pressure out of range high 17-07 Hydraulic lock valve solenoid open circuit
05-22 Hydraulic charge pressure out of range low
18-05 Spool lock solenoid short to battery
06-10 Engine speed high 18-06 Spool lock solenoid short to ground
06-11 Engine speed extremely high 18-07 Spool lock solenoid open circuit
06-13 Engine speed no signal
06-15 Engine speed shutdown level 19-02 Bucket positioning solenoid error ON
06-18 Engine speed out of range 19-03 Bucket positioning solenoid error OFF
07-10 Hydraulic oil temperature high 20-02 Two-speed solenoid error ON

07-11 Hydraulic oil temperature extremely high 20-03 Two-speed solenoid error OFF
07-15 Hydraulic oil temperature shutdown level
07-21 Hydraulic oil temperature out of range high 21-02 Glow plug error ON
07-22 Hydraulic oil temperature out of range low 21-03 Glow plug error OFF
08-10 Engine coolant temperature high 22-02 Starter error ON

08-11 Engine coolant temperature extremely high 22-03 Starter error OFF
08-15 Engine coolant temperature shutdown level
08-21 Engine coolant temperature out of range high 23-02 Rear base solenoid error ON
08-22 Engine coolant temperature out of range low 23-03 Rear base solenoid error OFF
09-09 Fuel level low 24-02 Rear rod solenoid error ON

09-21 Fuel level out of range high 24-03 Rear rod solenoid error OFF
09-22 Fuel level out of range low
25-02 Rear auxiliary relief solenoid error ON
10-17 Hydraulic charge filter plugged 25-03 Rear auxiliary relief solenoid error OFF

651 of 861
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List (Cont’d)
CODE CODE
26-02 Front base solenoid error ON 32-63 ACS Pedal lock short to ground
26-03 Front base solenoid error OFF 32-64 ACS Pedal lock short to battery
32-65 ACS Sensor supply voltage out of range
27-02 Front rod solenoid error ON 32-66 ACS Battery voltage out of range
27-03 Front rod solenoid error OFF 32-67 ACS Switch flipped while operating
32-68 ACS Lift handle information error
28-02 Diverter solenoid error ON 32-70 ACS Right hand drive short to ground
28-03 Diverter solenoid error OFF 32-71 ACS Right hand drive short to battery
32-74 ACS Left joystick X-axis out of range
29-02 High flow solenoid error ON 32-75 ACS Interrupted unswitched power
29-03 High flow solenoid error OFF 32-76 ACS CAN joystick information error
32-77 ACS Remote control information error
30-28 Controller memory failure
33-23 Main Controller (Bobcat Controller) not
programmed
31-28 Interrupted power failure (Also occurs after
software updates)
34-04 Keyless panel no communication to Bobcat

controller
32-04 ACS not communicating with Bobcat Controller
32-23 ACS calibration required 35-02 Hydraulic fan error ON
32-24 ACS calibration performed 35-03 Hydraulic fan error OFF
32-31 ACS Tilt actuator fault
32-32 ACS Tilt actuator wiring fault 36-48 ACD multiple controllers present
32-33 ACS Tilt handle wiring fault
32-34 ACS Tilt actuator not in neutral 37-02 Two-speed secondary error ON
32-35 ACS Tilt handle/pedal not in neutral 37-03 Two-speed secondary error OFF
32-36 ACS Lift actuator fault
32-37 ACS Lift actuator wiring fault 38-01 CAN joystick information error
32-38 ACS Lift handle wiring fault 38-02 Remote control information error
32-39 ACS Lift actuator not in neutral 38-04 No communication from joystick controller
32-40 ACS Lift handle/pedal not in neutral 38-05 Left joystick X axis not in neutral
32-41 ACS No communication 38-06 Right joystick X axis not in neutral
32-49 ACS Lift actuator short to ground 38-07 Left joystick Y axis not in neutral
32-50 ACS Tilt actuator short to ground 38-08 Right joystick Y axis not in neutral
32-51 ACS Lift actuator short to battery 38-09 Control pattern switch - Short to Battery or Ground
32-52 ACS Tilt actuator short to battery 38-10 Actuator calibration performed
32-53 ACS Lift handle/pedal short to ground 38-11 Lift actuator not in neutral
32-54 ACS Tilt handle/pedal short to ground 38-12 Tilt actuator not in neutral
32-55 ACS Lift handle/pedal short to battery 38-13 Lift actuator fault
32-56 ACS Tilt handle/pedal short to battery 38-14 Tilt actuator fault
32-57 ACS Lift actuator reduced performance 38-15 Right wheel speed fault
32-58 ACS Tilt actuator reduced performance 38-16 Left wheel speed fault
32-59 ACS Lift actuator wrong direction 38-17 Tilt actuator reduced performance
32-60 ACS Tilt actuator wrong direction 38-18 Lift actuator reduced performance
32-61 ACS Handle lock short to ground 38-19 Left joystick X axis out of range high
32-62 ACS Handle lock short to battery 38-20 Right joystick X axis out of range high

652 of 861
CODE CODE
38-21 Left joystick Y axis out of range high 38-68 Wheel angles (alignment) not calibrated
38-22 Right joystick Y axis out of range high 38-69 Lift & tilt actuators calibration fault
38-23 Front right steering sensor out of range high 38-70 Recovery mode failure
38-24 Front left steering sensor out of range high 38-71 Battery out of range
38-25 Rear right steering sensor out of range high 38-72 Drive pump not calibrated
38-26 Rear left steering sensor out of range high 38-73 Steering mode switch flipped while operating
38-27 Lift actuator out of range high 38-74 Right wheel speed uncommanded motion
38-28 Tilt actuator out of range high 38-75 Left wheel speed uncommanded motion
38-29 Left joystick X axis out of range low 38-76 Undercurrent steer pressure solenoid
38-30 Right joystick X axis out of range low 38-77 Undercurrent front right extend steer solenoid
38-31 Left joystick Y axis out of range low 38-78 Undercurrent front right retract steer solenoid
38-32 Right joystick Y axis out of range low 38-79 Undercurrent front left extend steer solenoid
38-33 Front right steering sensor out of range low 38-80 Undercurrent front left retract steer solenoid
38-34 Front left steering sensor out of range low 38-81 Undercurrent rear right extend steer solenoid
38-35 Rear right steering sensor out of range low 38-82 Undercurrent rear right retract steer solenoid
38-36 Rear left steering sensor out of range low 38-83 Undercurrent rear left extend steer solenoid
38-37 5 volt sensor supply 1 out of range low 38-84 Undercurrent rear left retract steer solenoid
38-38 5 volt sensor supply 2 out of range low 38-85 5 Volt sensor supply 1 out of range high

38-39 Lift actuator short to ground / out of range low 38-86 5 Volt sensor supply 2 out of range high
38-40 Tilt actuator short to ground / out of range low 38-87 Front right steering error
38-41 Tilt actuator wrong direction 38-88 Front left steering error
38-42 Lift actuator wrong direction 38-89 Rear right steering error
38-43 Left forward drive solenoid error ON 38-90 Rear left steering error
38-44 Left reverse drive solenoid error ON 38-91 Right speed sensor missing pulses
38-45 Right forward drive solenoid error ON 38-92 Left speed sensor missing pulses
38-46 Right reverse drive solenoid error ON 38-93 Unresponsive right speed sensor
38-47 Front right steering solenoid error ON 38-94 Unresponsive left speed sensor
38-48 Front left steering solenoid error ON 38-95 Left speed sensor reverse direction
38-49 Rear right steering solenoid error ON 38-96 Right speed sensor reverse direction
38-50 Rear left steering solenoid error OFF 38-98 Controller in drive calibration mode
38-51 Steering pressure solenoid error ON 38-99 Controller in wheel position calibration mode
38-52 Back-up alarm error ON
38-53 Left forward drive solenoid error OFF 39-04 Left joystick no communication to Bobcat
controller
38-54 Left reverse drive solenoid error OFF 39-05 X-axis not in neutral
38-55 Right forward drive solenoid error OFF 39-07 Y-axis not in neutral
38-56 Right reverse drive solenoid error OFF 39-12 Left joystick thumb switch not in neutral
38-57 Front right extend steering solenoid error OFF 39-13 Left joystick grip not connected
38-58 Front right retract steering solenoid error OFF 39-16 Left joystick not connected
38-59 Front left extend steering solenoid error OFF 39-28 Left joystick internal failure
38-60 Front left retract steering solenoid error OFF 39-48 Left joystick multiple
38-61 Rear right extend steering solenoid error OFF
38-62 Rear right retract steering solenoid error OFF 40-04 Right joystick no communication to Bobcat
controller
38-63 Rear left extend steering solenoid error OFF 40-05 Right joystick X-axis not in neutral
38-64 Rear left retract steering solenoid error OFF 40-07 Right joystick Y-axis not in neutral
38-65 Steering pressure solenoid error OFF 40-12 Right joystick thumb switch not in neutral
38-66 Back-up alarm error OFF 40-13 Right joystick grip not connected
38-67 No communication from Bobcat controller 40-16 Right joystick not connected

653 of 861
CODE CODE
40-28 Right joystick internal failure 75-18 Right swash plate not in neutral
40-48 Right joystick multiple 75-19 Left joystick X-axis out of range high
75-21 Left joystick Y-axis out of range high
41-09 Alternator voltage low 75-22 Right joystick Y-axis out of range high
41-10 Alternator voltage high 75-23 Right front wheel angle sensor out of range high
41-11 Alternator voltage extremely high 75-24 Left front wheel angle sensor out of range high
75-25 Right rear wheel angle sensor out of range high
44-02 Horn error ON 75-26 Left rear wheel angle sensor out of range high
44-03 Horn error OFF 75-27 Left swash plate out of position
75-28 Right swash plate out of position
45-02 Right blinker error ON 75-29 Left joystick X-axis out of range low
45-03 Right blinker error OFF 75-31 Left joystick Y-axis out of range low
75-32 Right joystick Y-axis out of range low
46-02 Left blinker error ON 75-33 Right front wheel angle sensor out of range low
46-03 Left blinker error OFF 75-34 Left front wheel angle sensor out of range low
75-35 Right rear wheel angle sensor out of range low
47-21 8 volt sensor supply out of range high 75-36 Left rear wheel angle sensor out of range low
47-22 8 volt sensor supply out of range low 75-37 5 volt sensor supply 1 out of range low

75-38 Sensor supply 2 out of range low
48-02 Front light relay error ON 75-39 Left swash plate sensor out of range high
48-03 Front light relay error OFF 75-40 Left swash plate sensor out of range low
75-41 Right swash plate sensor out of range high
49-02 Rear light relay error ON 75-42 Right swash plate sensor out of range low
49-03 Rear light relay error OFF 75-43 Left forward drive solenoid error ON
75-44 Left reverse drive solenoid error ON
60-21 Rear auxiliary control out of range high 75-45 Right forward drive solenoid error ON
60-22 Rear auxiliary control out of range low 75-46 Right reverse drive solenoid error ON
60-23 Rear auxiliary control not in neutral 75-47 Right front steer extend short to battery
75-48 Left front steer extend short to battery
64-02 Switched power relay error ON 75-49 Right rear steer extend short to battery
64-03 Switched power relay error OFF 75-50 Left rear steer extend short to battery
75-51 Steer pressure short to battery
73-04 Remote control in error 75-52 Backup alarm error ON
73-13 Remote control no signal 75-53 Left forward drive solenoid error OFF
75-54 Left reverse drive solenoid error OFF
74-72 Bobcat controller in boot code 75-55 Right forward drive solenoid error OFF
75-56 Right reverse drive solenoid error OFF
75-01 CAN joystick information error 75-57 Right front steer extend short to ground
75-04 No communication from drive controller 75-58 Right front steer retract short to ground
75-05 Left joystick X-axis not in neutral 75-59 Left front steer extend short to ground
75-07 Left joystick Y-axis not in neutral 75-60 Left front steer retract short to ground
75-08 Right joystick Y-axis not in neutral 75-61 Right rear steer extend short to ground
75-09 ISO/H pattern switch short to ground or battery 75-62 Right rear steer retract short to ground
75-13 Right front wheel angle sensor stuck 75-63 Left rear steer extend short to ground
75-14 Left front wheel angle sensor stuck 75-64 Left rear steer retract short to ground
75-15 Right rear wheel angle sensor stuck 75-65 Steer pressure short to ground
75-16 Left rear wheel angle sensor stuck 75-66 Backup alarm error OFF
75-17 Left swash plate not in neutral 75-67 No communication from Bobcat controller

654 of 861
CODE CODE
75-68 Angle sensors not calibrated 80-03 ACD output ‘A’ error OFF
75-69 Battery voltage out of range high
75-70 Interrupted power (Also occurs after software 81-02 ACD output ‘B’ error ON
updates)
75-71 Battery voltage out of range low 81-03 ACD output’ B’ error OFF
75-72 Drive pump not calibrated
75-73 ISO/H pattern switch flipped while operating 82-02 ACD output ‘C’ error ON
75-74 Right wheel speed uncommanded motion 82-03 ACD output ‘C’ error OFF
75-75 Left wheel speed uncommanded motion
75-76 No communication from ACS controller 83-02 ACD output ‘D’ error ON
75-77 Left speed sensor out of range high 83-03 ACD output ‘D’ error OFF
75-78 Right speed sensor out of range high
75-79 Left speed sensor out of range low 84-02 ACD output ‘E’ error ON
75-80 Right speed sensor out of range low 84-03 ACD output ‘E’ error OFF
75-81 Right front steer retract short to battery
75-82 Left front steer retract short to battery 85-02 ACD output ‘F’ error ON
75-83 Right rear steer retract short to battery 85-03 ACD output ‘F’ error OFF
75-84 Left rear steer retract short to battery

75-85 5 volt sensor supply 1 out of range high 86-02 ACD output ‘G’ error ON
75-86 Sensor supply 2 out of range high 86-03 ACD output ‘G’ error OFF
75-88 Controller in programming mode
75-91 Left swash plate sensor reversed 87-02 ACD output ‘H’ error ON
75-92 Right swash plate sensor reversed 87-03 ACD output ‘H’ error OFF
75-93 Unresponsive right speed sensor
75-94 Unresponsive left speed sensor 90-02 Service tool output ‘C’ error ON
75-95 Left speed sensor reverse direction 90-03 Service tool output ‘C’ error OFF
75-96 Right speed sensor reverse direction
75-98 Controller in calibration mode 91-02 Service tool output ‘D’ error ON
91-03 Service tool output ‘D’ error OFF
76-73 Left hand panel system RX error
92-02 Service tool output ‘E’ error ON
77-48 Key switch multiple 92-03 Service tool output ‘E’ error OFF
78-74 Door/transport lock open/active 93-02 Service tool output ‘F’ error ON
93-03 Service tool output ‘F’ error OFF
80-02 ACD output ‘A’ error ON

655 of 861
Description
Figure 60-100-1
1 2 3 4
B-15551G
N-18409
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system

consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel [Figure

60-100-1] of the loader cab.
The Press To Operate button activates the system and

allows the operator to function the loader.
If any of these indicator lights do not illuminate the loader

will not function.

656 of 861
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS Controller (Engine Stopped - PRESS TO OPERATE LOADER Button and raise
Key ON) seat bar fully. Slowly operate the machine forward
and backward. The TRACTION lock should be
Figure 60-100-2 engaged. Lower the seat bar. Press the PRESS TO
OPERATE LOADER Button.
7. Engage parking brake and move steering levers

slowly forward and backward. The TRACTION lock
1 2 3 4 should be engaged.
B-15551G NOTE: *The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.
Inspecting The Lift Arm Bypass Control
8. Raise the lift arms 6 feet (2 meters) off the ground.

Stop engine. Turn lift arm bypass control knob
N-18409 clockwise 1/4 turn. Pull up and hold lift arm bypass
control knob until lift arms slowly lower.
1. Sit in operator’s seat. Turn key ON. (Key Switch

Inspecting Deactivation Of Lift And Tilt Functions
Panel), press RUN/ENTER Button (Keyless Panel), (ACS and SJC)
lower seat bar and disengage parking brake. Press
the PRESS TO OPERATE LOADER Button. Three 9. Sit in operator’s seat and fasten seat belt. Lower seat
BICS lights (Items 1, 2 & 3) [PRESS TO OPERATE bar, start engine and press the PRESS TO OPERATE
LOADER, SEAT BAR, AND LIFT & TILT VALVE] on LOADER Button.
left instrument panel should be ON [Figure 60-100-
2]. 10. Raise lift arms about 6 feet (2 meters) off the ground.
2. Raise seat bar fully. All four BICS lights (Items 1, 2, 3, 11. Turn key OFF (Key Switch Panel), press STOP
and 4) [PRESS TO OPERATE LOADER, SEAT BAR, Button (Keyless Panel), and wait for the engine to
LIFT & TILT VALVE AND TRACTION*] on left come to a complete stop.
instrument panel should be OFF [Figure 60-100-2]. 12. Turn key ON (Key Switch Panel), press RUN/ENTER
NOTE: Record what lights are blinking (if any) and the Button (Keyless Panel). Press the PRESS TO
number of light flashes. (See Troubleshooting OPERATE LOADER Button, move hand control or
on Page 60-100-3.) joystick to lower the lift arms. Lift arms should not
lower.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON) 13. Move the control (foot pedal, hand control or joystick)
to tilt the bucket (or attachment) forward. The bucket
3. Sit in operator’s seat, lower seat bar, and press the (or attachment) should not tilt forward.
PRESS TO OPERATE LOADER Button. Press the
auxiliary hydraulics FLOW Button. The auxiliary
FLOW Button light will come ON. Raise the seat bar.
The light should be OFF.
WARNING
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking
The Bobcat Interlock Control System (BICS) must
brake and fasten seat belt.
deactivate the lift, tilt and traction drive functions. If it
5. Start engine and operate at low idle. Press the does not, contact your dealer for service. DO NOT
PRESS TO OPERATE LOADER Button. While modify the system.
W-2151-0394
raising the lift arms, raise the seat bar fully. The lift
arms should stop. Repeat using the tilt function.

657 of 861
(CONT'D)
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS troubleshooting chart.(See Troubleshooting Chart on Page 60-100-4.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into

place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seat bar sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
5. Possible low or high voltage.

658 of 861
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Figure 60-100-3
(CONT'D)
Troubleshooting Chart
The following chart shows the effects which can happen

to the loader, and the probable causes when the BICS 6
Instrument Panel lights are off. See [Figure 60-100-3] for
location of BICS lights and Icons. Have service
procedures performed ONLY BY QUALIFIED BOBCAT
SERVICE PERSONNEL.
5
Press and hold LIGHTS Button (Item 5) [Figure 60-100-
3] for two seconds to view SERVICE CODES in the
HOURMETER / CODE DISPLAY (Item 6) [Figure 60- 2 4
3
100-3]. If more than one SERVICE CODE is present, the 1 B-15551
codes will scroll on the HOURMETER / CODE DISPLAY.
Effect on SERVICE CODES Means System Error
Indicator Operation of (See Your Bobcat Dealer for Service)
Light ON Light OFF
Light Loader When No. of Service
Light is OFF Causes
Flashes Code
PRESS TO PRESS TO ---- ---- ---- ----
OPERATE OPERATE
LOADER button LOADER button

is pressed. is not pressed.
Seat Bar is Seat Bar is up. Lift and tilt 2 11-05 Seat Bar sensor circuit shorted to battery
down. functions will voltage*.
not operate. 3 11-06 Seat Bar sensor circuit shorted to ground.
Continuous 03-09 System voltage low

Flashing 03-10 System voltage high
Control valve Control valve Lift and tilt 1 17-07 Valve output circuit is open.
can be used. cannot be used. functions will 2 17-05 Valve output circuit shorted to battery voltage*.
not operate. 3 17-06 Valve output circuit shorted to ground.
3 17-06 Controller not grounded or intermittent ground.

Loader can be Loader cannot Loader cannot 1 16-07 Traction lock hold solenoid circuit is open.
moved forward be moved be moved 2 16-05 Traction lock hold solenoid circuit shorted to
& backward forward and forward and battery voltage*.
backward. backward. 3 16-06 Traction lock hold solenoid circuit shorted to
ground.
5 15-02 Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be
OFF).
6 15-03 Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
*Normal BICS operating voltage is less than the electrical system voltage.

659 of 861
SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS system
The seat bar sensor is part of the BICS system. The seat problems. It is recommended that these procedures be
bar sensor sends a signal that indicates whether the seat done by authorized Bobcat Service Personnel only.
bar is in the down or up position.
The sensor is located on the left side of seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS

1. Check sensor wire connection.
2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

660 of 861
SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on

N-18463 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adapter (MEL1567) for the following procedure:

Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
P-4699
1
Lower the seat bar. The Sensor Test light (Item 1)

N-19557 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
N-19558 sensor.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. See inset Replace the Seat Bar Sensor. (See Removal And
[Figure 60-110-2]. Installation on Page 60-110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS
ENGINE. circuit test. (See Bobcat Interlock Control System (BICS)
Circuit Test on Page 60-110-5.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

661 of 861
Figure 60-110-5
2
N-19224
Remove the seat bar (Item 1) [Figure 60-110-5] from the

loader. (See Removal And Installation on Page 50-10-1.)

N-19219
Remove the mounting bolt (Item 1) from the seat bar

mount (Item 2) [Figure 60-110-6].
Installation: Tighten the mounting bolt to 50 - 70 in.-lb.

(5,6 - 7,9 N•m) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-

110-6] and nut.

662 of 861
SEAT BAR SENSOR (CONT'D)
Figure 60-110-7
2
1
3
N-19383
Remove the keyed plastic bushing (Item 1) magnetic

bushing assembly (Item 2) and sensor bracket (Item 3)

[Figure 60-110-7].
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [Figure 60-110-7]
of the seat bar.
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar

sensor.

663 of 861
Bobcat Interlock Control System (BICS) Circuit Test
Figure 60-110-8
3
1
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-9] inline

N-18463 to the seat bar sensor connectors.
Turn the key to the ON position. DO NOT START THE

Use Sensor Testers (MEL1428) and seat bar sensor ENGINE.
tester adapter (MEL1567) for the following procedure:

If there is no power light on the sensor tester, check the
Connect the seat bar sensor tester adapter MEL1567 to tester or wiring harness.
the sensor tester.
When the power light is illuminated, move the toggle
Disconnect the seat bar sensor connector (Item 1) switch (Item 2) [Figure 60-110-9] on the sensor tester to
[Figure 60-110-8]. the Present position.
NOTE: The sensor test light (Item 3) [Figure 60-110-9]

is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.

664 of 861
SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit Test

(Cont’d)
Figure 60-110-10
N-18409
The BICS seat bar indicator light (Item 1) [Figure 60-110-

10] should illuminate.
Figure 60-110-11
P-4699
Move the toggle switch (Item 1) [Figure 60-110-11] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-10] should go

off.
If the above test fails, there is a problem with the Bobcat

controller or the wiring harness.

665 of 861
TRACTION LOCK Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS system
The Traction Lock Control System will lock the traction problems. It is recommended that these procedures be
drive system when the engine stops. The Traction Lock done by authorized Bobcat Service Personnel only.
Control System is incorporated into the BICS System.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock. 8, 9, 10, 11

1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it has not released, check the brake 30 amp. fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See
Fuse And Relay Location / Identification on Page 60-10-8.)
5. To test the solenoid, the pull coil should be about 0.3 ohms and the hold coil should be about 10.9 ohms.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check flywheel RPM sensor and wiring.
12. Check the Display Panel for an error code. (See Electrical System Service Manual)
13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.

666 of 861
TRACTION LOCK (CONT'D) Figure 60-120-2
WARNING
1
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat P-68140
Company parts if repair is necessary.
W-2165-0100
Remove the bracket (Item 1) [Figure 60-120-2] from the
chaincase cover.
30-2.)
Installation: Apply polyurethane sealer to the bolt
threads and tighten the mounting bolts to 25 - 28 ft.-lb.
Figure 60-120-1
(34 - 38 N•m) torque.

Be sure the solenoid mounting bracket is installed in the
same position. The solenoid mounting surface has a
2 slight angle which tips the top of the solenoid toward the
rear of the loader when installed correctly. See inset
photo [Figure 60-120-1].
P-4712
Figure 60-120-3
1
P-66958
2
NOTE: The loader control panel and linkage crossbar
have been removed for clarity purpose only.
The traction lock can be removed without
removing the control panel.

120-1] from the electric solenoid mounting bracket. P-68141
Installation: Tighten the mounting screws to 80 - 90 in.-

Remove the traction lock assembly (Item 1) [Figure 60-
120-3] from the chaincase.
Remove the electric solenoid (Item 2) from the chaincase
Inspect gasket (Item 2) [Figure 60-120-3], replace if
cover [Figure 60-120-1].
necessary.

667 of 861

4 5
Figure 60-120-4
3
2
1
4 1
3 2
P-68144
Remove the shaft mounting bolt (Item 1), spring (Item 2),
P-68143 washer (Item 3) and wedge (Item 4) from the assembly
shaft (Item 5) [Figure 60-120-5]. Inspect all parts for
damage or wear. Replace if necessary.
Remove and inspect the compression spring (Item 1) and
spring cap washer (Item 2) [Figure 60-120-4] for wear or Installation: Thoroughly clean and dry the shaft

damage. Replace if necessary. The spring may also stay mounting bolt (Item 1), the shaft (Item 5) and wedge
with the shaft when the electric solenoid and bracket are (Item 4) [Figure 60-120-5]. Use Loctite® #242 when
removed from the chaincase. assembling these parts to the traction lock assembly.
Installation: Install the compression spring (Item 1) Figure 60-120-6

[Figure 60-120-4] on the collar located on the electric
solenoid.
Inspect the shaft (Item 3) and wedge (Item 4) [Figure 60-

120-4] for scoring and deep scratches, replace if
damaged. (Item 3) [Figure 60-120-4] from the
chaincase.
P-68142
Inspect the guides (Item 1) [Figure 60-120-6] for wear or

damage. Replace if necessary.
If replacement is necessary, remove the center

chaincase cover. Remove the screws (Item 2) [Figure
60-120-6] and pry the center cover off.
Installation: Apply polyurethane sealant to the screw

threads and center chaincase cover. Tighten screws to
15 - 20 ft.-lb. (20 - 27 N•m) torque.

668 of 861

1
3
Figure 60-120-7
1
2
2
P11332
Installation: Thoroughly clean the polyurethane from the

P11331 chaincase cover (Item 1), bolts (Item 2) and traction lock
guides (Item 3) [Figure 60-120-9] and dry.
NOTE: Bolt (Item 1) is on the rear of the chaincase Figure 60-120-10

cover, notice the direction of the groove (Item

2) [Figure 60-120-7] in the traction lock
guides.
Figure 60-120-8
P11333
Installation: Apply a bead of polyurethane on the

1
traction lock guides and bolts [Figure 60-120-10].
P11330
To remove the traction lock guides remove the four bolts

(Item 1) [Figure 60-120-8].

669 of 861
Figure 60-120-11
1
INCORRECT CORRECT
2
3
2
P11337
1
Install the traction wedge assembly (Item 1) into the
N-19106 N-19105 solenoid and traction lock guides (Item 2) [Figure 60-
120-12].
Install the traction lock guides (Item 1) to the chaincase After the bolts have been tightened recheck to make sure
cover (Item 2) [Figure 60-120-11] using the four bolts the shaft assembly is moving freely in the guides.

(removed earlier).
Remove the wedge assembly (Item 1) [Figure 60-120-
Do not tighten at this time. 12].
NOTE: The wedge assembly must slide freely in the

grooves of the guides. Tighten the four guide
bolts to 90 - 100 ft.-lb. (123 - 135 N•m) torque.
Lower operator cab. (See Lowering on Page 10-30-3.)
Perform the BICS inspection procedure. (See BOBCAT

INTERLOCK CONTROL SYSTEM (BICS) on Page 60-
100-1.)

670 of 861
Inspecting
Figure 60-120-13
1
P-68145
Check the wire connections at the engine flywheel RPM

N-18409 speed sensor (Item 1) [Figure 60-120-14].
NOTE: When the Traction Lock Override Button is

activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if

the engine stops.
See Adjusting on Page 60-170-1 for Flywheel RPM

sensor adjustment.
1 2 3 4 B-15551G Fasten the seat belt, disengage the parking brake pedal,
press the green PRESS TO OPERATE Button and raise
the Seat Bar fully. Move the control levers slowly forward
Fasten the seat belt, disengage the parking brake button, and backward. The Traction lock should be engaged.
press the PRESS TO OPERATE LOADER Button (Item Lower the Seat Bar. Press the green PRESS TO
1) [Figure 60-120-13] and raise the Seat Bar fully. Move OPERATE Button.
the steering levers slowly forward and backward. The
TRACTION lock (Item 4) [Figure 60-120-13] should be Engage the parking brake pedal and move the control
engaged. Lower the Seat Bar. Press the PRESS TO levers slowly forward and backward. The Traction lock
OPERATE LOADER Button (Item 1) [Figure 60-120-13]. should be engaged.
Engage the parking brake pedal and move the steering

levers slowly forward and backward. The TRACTION
lock should be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.

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CONTROL SYSTEM (ACS)
Description
The (ACS) Actuator Control System system is an option

that allows the operator to quickly switch between foot
and hand control modes.
The ACS control uses the electric actuators on the main

hydraulic control valve to control the lift and tilt spools in
the hydraulic control valve, foot sensors, handle sensors
and a specially designed control handle.
Hand controls contain a locking solenoid which lock

when the switch on the center control panel is switched
to foot mode.
Foot controls also contain solenoids which lock when the

switch on the center control panel is switched to hand
mode.
Both the hand and foot controls contain sensors that

relay information to the ACS controller as to which
function should be activated and how far the spool should

be moved.

672 of 861
CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting Chart
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature

Attachment Two Speed Glow Plugs Seat Belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure
Advanced Control System
Errors-lights solid with 3 beeps 32-54- Tilt handle/pedal short to ground

32-04- ACS in error 32-55- Lift handle/pedal short to battery
32-23- ACS not calibrated 32-56- Tilt handle/pedal short to battery
32-31- Tilt actuator fault 32-57- Lift actuator reduced performance
32-34- Tilt actuator not calibrated 32-58- Tilt actuator reduced performance
32-35- Tilt handle/pedal not calibrated 32-59- Lift actuator wrong direction
32-36- Lift actuator fault 32-60- Tilt actuator wrong direction
32-39- Lift actuator not calibrated 32-61- Handle lock short to ground
32-40- Lift handle/pedal not calibrated 32-62- Handle lock short to battery
32-49- Lift actuator short to ground 32-63- Pedal lock short to ground
32-50- Tilt actuator short to ground 32-64- Pedal lock short to battery
32-51- Lift actuator short to battery 32-65- Sensor supply voltage out of range
32-52- Tilt actuator short to battery 32-66- Battery out of range
32-53- Lift handle/pedal short to ground 32-67- Switch flipped while operating
To see what error occurred. (See DIAGNOSTICS SERVICE CODES on Page 60-90-1.)

673 of 861
CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
2
3
1
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]

and pull the wire from the connector.
P16578
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be

removed from the handle sensor wires, using the 1-Terminal - Red
following procedure.
2-Terminal - Black
Figure 60-130-2
3-Terminal - Green
1
1
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

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Switch Handle Removal
Figure 60-130-4
1
3
2
P13735
1
2
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.

130-4] from the handle sensor connector.

130-4] from the handle lock solenoid connector.
Figure 60-130-5 1
P13725 P13732

harness connector (Black) that connects to the handle
1
lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

675 of 861
Switch Handle Removal (Cont'd)
Figure 60-130-8
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
P13735 3 & 4) [Figure 60-130-10] from the loader wiring harness
connectors.
Using a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.

Figure 60-130-9
2 2
N-22783
2
N-17779 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Items 1 & Using a small screwdriver, lift the handle tabs (Item 2)
2) [Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

676 of 861
CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2 Tape 1/2 of Wires

Tape back 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 6 in. piece of heat shrink

tubing placed over the end of the wires. Remove the heat
Cut the wires (Item 2) [Figure 60-130-12] below the shrink tube from the end of the wires before routing the
switch handle and remove switch handle. harness through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle and harness up through the top through the control lever tube.
of the lever tube.
Figure 60-130-13
P-24234
If the harness has been cut: pull the harness (Item 1)

[Figure 60-130-13] out through the bottom of the control
lever tube.

677 of 861
CONTROL SYSTEM (ACS) (CONT'D) Install the wires into the connectors as listed below:
Switch Handle Installation (Cont'd) Right Switch Handle
Figure 60-130-15 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
1 C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700A C-Terminal - Purple/White
Left Switch Handle

Install the new switch handle and wires from the top of
the control lever. Ten-Pin Connector

A-Terminal - Orange
Route wire (Item 1) [Figure 60-130-15] through the B-Terminal - Dk. Blue
casting, along side the handle sensor and into the control C-Terminal - White
lever tube. D-Terminal - Purple
E-Terminal - Yellow/Red
NOTE: Do not pull the wire harness tight. Allow a F-Terminal - Tan
small amount of slack or slight bend at the G-Terminal - Pink
handle pivot area. Verify the control handle H-Terminal - Orange/Black
returns to neutral position. J-Terminal - Blank
K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
2 B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
1 A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695 E-Terminal - Blank
Remove tape from wires for installation and install the 6

in. of heat shrink tube (Item 1) [Figure 60-130-16]
approximately 3 in. into the control lever. Apply heat to
the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.

678 of 861
Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
P13735
1 Install the wires into the connectors as listed below:

N-17779
Left and Right Control Lever Switch Handle [Figure 60-
130-19]
Figure 60-130-18
1-Terminal - Red/White

2-Terminal - Black/White
3-Terminal - Purple/White
1
Figure 60-130-20
3 1
N-17772
2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] & [Figure 60-130-18] to the loader harness
connectors.
P13735
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

679 of 861
CONTROL SYSTEM (ACS) (CONT'D) Actuator Connector Disassembly And Assembly
Switch Handle Installation (Cont'd) NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
Figure 60-130-21
Figure 60-130-22
P-21804
P-66842
Connect the handle harness connectors to the sensor

and lock solenoid connectors [Figure 60-130-21]. Check the actuator wiring harness connector (Item 1)

[Figure 60-130-22] and replace if broken.
Figure 60-130-23
N-17741
Installation: Install the wires into the connector as listed

below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Lift and Tilt Actuator

1. Terminal-Black/Green-Larger diameter wire (16
gauge)
2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
gauge)
4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)

680 of 861
CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-130-26
Figure 60-130-24
P-21878A
1
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads

and tighten solenoid to 35 - 40 ft.-lb. (47 - 54 N•m) lubed
Disconnect the harness connector (Item 2) [Figure 60- torque.
130-24] from the handle lock solenoid connector.
Figure 60-130-27
Figure 60-130-25
1 P-21789
P-21832
Check the O-ring (Item 1) [Figure 60-130-27] for

Remove the two screws (Item 1) [Figure 60-130-25] damage. Replace as necessary.
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 32 - 38 in.-lb. (3,6 -

4,3 N•m) torque.
Remove handle lock solenoid assembly from handle.

681 of 861
CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Disassembly And Assembly
Figure 60-130-28
1
P-24269
Remove the two bolts (Item 1) [Figure 60-130-28] from

the end of the foot sensor.

Installation: Tighten the bolts to 90 in.-lb. (10,2 N•m)
torque. Apply Loctite® 242 to the threads.
Figure 60-130-29
3
2
1
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-130-29].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-29]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

682 of 861
Foot Lock Solenoid Removal And Installation
Figure 60-130-30
P-21790
Check the O-ring (Item 1) [Figure 60-130-32] for

1
P-21938 damage. Replace as necessary.
Remove the two bolts (Item 1) [Figure 60-130-30] from

the foot sensor shield.

Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2
N•m) torque.
Figure 60-130-31
P-21939
Disconnect the foot lock solenoid connector (Item 1)

[Figure 60-130-31] from the harness.
Remove foot lock solenoid (Item 2) [Figure 60-130-31].
Installation: Apply a drop of oil on the solenoid threads

and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque.

683 of 861
ELECTRICAL/HYDRAULIC CONTROLS
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14

1
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
The ACD (Attachment Control Device), automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab
flashes, check for diagnostic service codes. See the Electrical System Service Manual for the proper
procedure.
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.

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ELECTRICAL/HYDRAULIC CONTROLS (CONT’D)
Identification Chart (Cont’d) Solenoid Hydraulic Wiring

Number Coupler Number
Front
1 Female 4340
S150, S160 (Base)
Front
2 Male 4330
6
(Rod)
4 1 Diverter &
2 3 4450/4480
Bleed
Rear Aux
4 4440
Base
5 Rear Aux Rod 4430
3 High Flow
5 6 4460
(S160 Only)
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.

The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6
on the High Flow valve. (High Flow option is not available on the S150 Loader)

685 of 861
ELECTRICAL/HYDRAULIC CONTROLS (SJC)
RIGHT HAND
17 18
2 1
8
10 1. Front Aux.
2. Front Aux.
3. Auxiliary Detent
11 8. Right Ski (Up) 3
9
9. Right Ski (Down)
16 10. Right Blink
11. Left Blink

16. Float (Yellow in Color)
17. Future Function
P-24802
18. Future Function
P-28316
LEFT HAND
19 20
4 5
4. Rear Aux. (Side Shift
5. Rear Aux. (Side Shift)
12
6. Left Skit (Up)
6 7. Left Ski (Down)
12. Two-Speed (High)
13. Two-Speed (Low)
13 7
14. Horn
15. Inching Control
14
15 (Grey in Color)
19. Future Function
20. Future Function
P-24820
P-28317

686 of 861
ELECTRICAL/HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart (Cont’d)
xxxxxxxxx Attachment Right Side

Left Side
Control Handle Switch Solenoid Number Activated Harness Control Handle
Switches Number Terminal Switches
Activated
STD RH HFH HRH 8
1 1 1 1, 6 1, 6 K
5 2 2 2 2 2 K
4 6
3 1 1 1, 6 1, 6 K 9
1
4 2 3, 5 2 3, 5 K, A, D 2
5 1 3, 4 1 3, 4 K, A, C
7 6 1 3, 4 1 3, 4 K, E
7 1 3, 4 1 3, 4 K, F
8 1 3, 4 1 3, 4 K, G
3
9 1 3, 4 1 3, 4 K, H
Attachment Harness Connector

Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader. 1
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.

HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
HRH - Loaders with High Flow and Rear Hydraulics Option.

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ELECTRICAL/HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart (Cont’d)
Solenoid Hydraulic Wiring

Number Coupler Number
S150, S160 Front

1 Female 4340
(Base)
6 Front
4 2 Male 4330
1 (Rod)
2
Diverter &
3 4450/4480
Bleed
Rear Aux
4 4440
Base
3 5 5 Rear Aux Rod 4430
High Flow
6 4460
(S160 Only)
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary block.

The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6
on the High Flow valve. (High Flow option is not available on the S150 Loader)

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SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2
Figure 60-150-1
1 2
2
3
1
P-76450
P16119
procedure:
procedure: Order from Bobcat Parts P/N: 6689779 - Remote Start

Tool (Service Tool) Kit
MEL1565 - Service Tool Harness Control Kit Includes:
MEL1566 - Service Tool Harness Communicator 6689778 - Remote Start Tool (Service Tool)
(Computer Interface) 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
NOTE: Make all connections with the key in the OFF 6689745 - BOSS® Service Tool Harness
position.
NOTE: Make all connections with the key in the OFF
The Service PC (Item 1) with the Remote Start Tool (Item position.
2) [Figure 60-150-1]. When connected to the loader, the
Service PC is used to monitor, conduct diagnostics, and The Service PC (Item 1) with the Remote Start Tool
upgrade software. (Service Tool) (Item 2) [Figure 60-150-2]. When
connected to the loader, the Service PC is used to
Connect the Service Tool Harness Communicator monitor, conduct diagnostics, and upgrade software.
(MEL1566) (Item 3) [Figure 60-150-1] to the designated
serial port on the Service PC. Connect the Remote Start Tool (Service Tool) Computer
Service Tool Harness (Item 3) [Figure 60-150-2] to the
NOTE: The recommended serial cable length should designated serial port on the Service PC.
not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing NOTE: The recommended serial cable length should
communication errors. not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
Connect the other end to the connector on the Remote communication errors.
Start Tool.
Connect the other end to the connector on the Remote
Connect the remote start tool to the loader. (See Start Tool (Service Tool).
1.) Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL (SERVICE TOOL)
kIT - 6689779 on Page 10-61-1.)

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CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in poor performance
or reduced life of actuator(s).
The Actuator Test is performed with the Service PC.

The Actuator Test should be used if reduced
performance codes are present or when replacing a
controller or actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
The Lift and Tilt Calibration (ACS) provides set points [Figure 60-160-1] Excessive actuator loading can occur
to the ACS controller to actuate the lift and tilt valve. The if the actuator and valve spool components are
Lift and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting

controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
controller or actuator.
If a Service PC is not available, (See Lift And Tilt
The Hydrostatic Pump Calibration (SJC) provides set Calibration (SJC) on Page 60-160-5.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-3.).
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a NOTE: Warm the hydraulic oil to room temperature
desired travel path can not be attained or replacing the 72° F (22° C), stop the engine and clear all
hydrostatic pump, hydrostatic motor, or controller. After active service codes before running the test.
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the Once the test is initiated, an automatic calibration
hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC (Laptop) monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
NOTE: The Actuator Test is the only test that uses a

Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

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CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-160-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns both bolts are tight.
to neutral too slowly.
The pin may be too large. Oversized pins exceeding
• Actuator did not fully extend/retract. During the 0.248 in. (6,30 mm) in diameter should be replaced.
test, the spool was not able to fully stroke in both
directions. If the Actuator Test failed due to a slow return to neutral
after checking the probable causes in Column 1 [Figure
• Actuator out of neutral. The spool did not return to 60-160-2], check the following probable causes in
the neutral window during the test. Column 2 [Figure 60-160-2].

NOTE: A time out will occur if the test cannot be • Contamination in the spool.
completed within 8 seconds. If this happens,
retry the test. • The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
Figure 60-160-2 centering spring, replace if necessary.
Run Actuator Test
• The wire harness or connectors may have an
intermittent short. Check the connections and wire
Pass Fail harnesses.
Retest With Warm Hydraulic Oil • The controller may be defective, replace the
controller.
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

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CALIBRATION (CONT’D) Lift And Tilt Calibration (ACS)
Actuator Testing (Cont’d) The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
If the initial Actuator Test results in the fail mode actuator stroke (full flow) while preventing over stroke (loading) of
did not fully extend / retract, check the following. the actuator and resets the calibration points in the
controller.
• The actuator connectors may be reversed between
the lift and tilt actuator. Reverse the connectors and NOTE: The Actuator Test is the preferred method to
rerun the Actuator Test. calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
• The actuator may be weak, replace the actuator.
NOTE: This calibration procedure must be followed
• The spool end cap may be defective or the centering when replacing a hydraulic control valve,
spring may be broken. Inspect the end cap and the actuator or ACS controller. Failure to calibrate
centering spring, replace if necessary. after component replacement may result in
poor performance or reduced life of
• Contamination in the spool. actuator(s).
If the initial Actuator Test results in the fail mode actuator Figure 60-160-3
out of neutral, check the following.
• The actuator may be defective, replace the actuator.

• The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
1
• Contamination in the spool.
P-24826
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-160-3] in the

hand control mode.

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CALIBRATION (CONT’D) Figure 60-160-6
Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-4 Stroke Both Handles Fully In and Hold Them
Turn the Key On
or
Press RUN/ENTER
B-16628
Fully stroke both control handles in toward the center of

B-16626 the cab and hold the handles [Figure 60-160-6].
Lift the seat bar, high enough for the PRESS TO

Close the cab door. (If loader is equipped.) OPERATE light (Item 2) [Figure 60-160-5] to go OFF.
With the seat bar down, turn the ignition key ON (keyless Lower the seat bar.

panel press RUN/ENTER) [Figure 60-160-4].
Figure 60-160-7
NOTE: Do not start the engine.
Figure 60-160-5
1
2
B-16627
1
Push the PRESS TO OPERATE button (Item 1) [Figure

B-16627
60-160-7] to begin calibration.
Push the PRESS TO OPERATE button (Item 1) [Figure NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
60-160-5] to unlock the hand controls.
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.
NOTE: During the calibration cycle, the system will

beep three times. Once the calibration is
complete code 32-24 (Calibration Performed)
will be generated.
Release the control handles.
Calibration is complete.

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Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
1
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed

when replacing the hydraulic control valve, lift P-45240
or tilt actuator, or drive controller. Failure to
calibrate after component replacement may
result in poor performance or reduced life of With an operator in the seat and the seat bar down.
actuator(s).
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-8] in the ISO position.

Figure 60-160-9
B-19874
P-28063
Move the right joystick to the forward-right corner position

[Figure 60-160-9] and hold in position.

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Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-10
2
1
P-26477A
1
At the left panel, press the PRESS TO OPERATE Button

P-26475 (Item 1) [Figure 60-160-12] while holding the right
joystick in position.
Figure 60-160-11 Release the joystick.

NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
complete code 32-24 (Calibration Performed)
will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P-26480
Turn the key (Item 1) [Figure 60-160-10] to the RUN

position or press the RUN/ENTER button (Item 1)
[Figure 60-160-11] for power, without starting the loader.
The loader Control Pattern Switch (Item 1) [Figure 60-

160-8] will start flashing and will continue to flash until the
calibration procedure is completed.

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CALIBRATION (CONT'D) Figure 60-160-14
Hydrostatic Pump Calibration (SJC)
WARNING
fall or move and cause injury or death. 1
W-2017-0286
Place the loader on jackstands. (See Procedure on Page P-26475

10-10-1.)
Figure 60-160-15
Operator must be in the seat and the seat bar down.
Figure 60-160-13

1
2
1
P-26480
P-45238 Turn the key (Item 1) [Figure 60-160-14] to the RUN

position or press the RUN/ENTER button (Item 1)
Close the cab door. (If loader is so equipped.) [Figure 60-160-15] for power, without starting the loader.
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-13] in the ISO position.
Verify the parking brake (Item 2) [Figure 60-160-13] is

OFF.

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Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-16
P-26477A
Press the PRESS TO OPERATE LOADER Button (Item

P-45238 1) [Figure 60-160-18] while holding the left joystick in
position.
The Control Pattern ISO Switch (Item 1) [Figure 60-160- Three audible beeps will sound.
16] will start flashing.

Figure 60-160-19
Figure 60-160-17
B-19873
B-19873
P-26476
P-26476
Move the left joystick to the reverse-right corner position

Move the left joystick to the forward-left corner position [Figure 60-160-19] and hold in position.
[Figure 60-160-17] and hold in position.

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Figure 60-160-20
2 75-98
P-26477A
1 Press the PRESS TO OPERATE LOADER Button (Item

P-26477A 1) [Figure 60-160-22].
Three audible beeps will sound and the error code (Item
Press the PRESS TO OPERATE LOADER Button (Item 2) (75-98) will be displayed if the operator presses the
1) [Figure 60-160-20] while holding the left joystick in HOLD FOR CODES (LIGHTS) switch (Item 3) [Figure

position. 60-160-22].
Three audible beeps will sound. Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
Figure 60-160-21 the calibration mode and the procedure would have to be
repeated.
Figure 60-160-23
P-26474
Allow the left joystick to go to the neutral position [Figure

P-45238
60-160-21].
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

23] will stop flashing, and will remain ON for the rest of
the calibration procedure.

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Figure 60-160-24
B-19873
P-26482
Move and hold the left joystick to the forward position

P-68134 [Figure 60-160-25] until the forward calibration is
completed.
Move the throttle (Item 1) [Figure 60-160-24] to high idle. Figure 60-160-26

NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the 1
neutral position. 2
The calibration procedure will stop.
To return to calibration mode, the operator

must start the complete procedure from the
beginning.
WARNING P-64321
Put jackstands under the front axles and rear corners The loader speed will “ramp up” quickly (Item 1)
of the frame before running the engine for service. [Figure 60-160-26] and slow down 3 times in a row.
fall or move and cause injury or death. The loader will then “stair step” the speed (Item 2)
W-2017-0286
[Figure 60-160-26] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the forward position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Forward calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.

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CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-27 the calibration procedure from the beginning.
There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
The SEAT BAR and LIFT AND TILT lights will remain on.
The 75-98 error code will clear. There should be no other
codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
B-19873 neutral.
Press the PRESS TO OPERATE LOADER button. Move

P-26483 the left joystick to forward position [Figure 60-160-25]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-160-27] until the reverse calibration is 160-27] and check for normal reverse wheel or track

completed. rotation.
Figure 60-160-28 Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
1 2 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift can not be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-r10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-1.)
or (See Troubleshooting on Page 60-10-7.)
P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-28] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-28] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.

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STEERING DRIFT COMPENSATION Selecting And Adjusting
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
NOTE: Software version 61 or higher is required to pressed to enable the BICS.
support this feature. The loader’s software
version can be displayed in the HOURMETER Perform pre-starting and starting procedures:
/ CODE display. (See Operation and
Maintenance Manual for correct procedure.) 1. Fasten seat belt.
See your Bobcat dealer to update your
machine’s software version if necessary. 2. Lower seat bar.
Description 3. Place joysticks in neutral position.
Steering Drift Compensation can be used to reduce 4. Start the engine.

steering drift to maintain a desired travel path.
5. Press the PRESS TO OPERATE LOADER button.
Examples of applications where this feature can be used:
NOTE: Raising the seat bar or changing drive control
• To compensate for normal variations such as tire patterns (ISO / H) will cause the machine to
inflation pressure, track tension, tire wear and track disengage from steering drift compensation.
wear. The current settings will remain in effect until
the STOP button is pressed (Keyless Panel) or

• Using side shift attachments such as trenchers, the key is turned OFF (Key Switch Panel).
planers and silt fence installers.
• Driving on uneven terrain such as crowned road

surfaces.
Figure 60-161-1
STEERING DRIFT COMPENSATION
[S-L10] [S----] [S-r10]
B-23580B
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
r10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].

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STEERING DRIFT COMPENSATION (CONT’D) NOTE: The display will revert back to hourmeter after
a brief period of time. The machine will remain
Selecting And Adjusting (Cont’d) in steering drift compensation and continue at
the current setting. Pressing the upper left or
Figure 60-161-2 upper right button on the left joystick will
adjust steering drift compensation
accordingly and cause the new setting to
3 appear in the display.
Exiting And Saving

4 Figure 60-161-3
3
5
B-15551
B-15551F2
1 2 B-15551F3 4
B-15551F4
Left Joystick Right Joystick
1 2 B-15551

B-15551F8
B-15551F9
6 7 The current setting can be saved by pressing and holding

the PRESS TO OPERATE LOADER button (Item 1) for
three seconds. [SEt] (Item 3) will appear in the display
P-24820B P-24802B
(item 2) [Figure 60-161-3] and the machine will
disengage from steering drift compensation.
Press and hold the PRESS TO OPERATE LOADER OR

button (Item 1) for three seconds. The current steering
drift compensation setting will appear in the Press the PRESS TO OPERATE LOADER button to
HOURMETER / CODE display (Item 2) [Figure 60-161- disengage from steering drift compensation without
2]. saving the current setting. [donE] (Item 4) will appear in
the display (Item 2) [Figure 60-161-3] and the upper left
Press the upper left button (Item 6) on the left joystick to and upper right buttons on the left joystick will no longer
adjust the machine left. [S-L01] (Item 3) through a make changes to steering drift compensation. The
maximum of [S-L10] will appear in the display (Item 2) current settings will remain in effect until the STOP button
[Figure 60-161-2]. The number will increase by one each is pressed (Keyless Panel) or the key is turned OFF (Key
time you press the button. The higher the number, the Switch Panel). The machine will revert back to the last
greater the amount of steering drift compensation to the saved settings the next time it is started.
left. Adjustments to steering drift compensation will be
effective immediately.
Press the upper right button (Item 7) on the left joystick to

adjust back toward center. The display will decrease
down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-r01] (Item 5)
to appear in the display (Item 2) [Figure 60-161-2]. The
number will increase by one each time you press the
button up to a maximum of [S-r10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.

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FLYWHEEL RPM SENSOR Figure 60-170-2
Description 2
The flywheel RPM sensor has a magnet located on the 1

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
main Bobcat controller which registers the RPM of the
engine.
The flywheel RPM sensor is located just above the

starter on the left side of the engine.
Code 06-13 will occur if the main Bobcat controller loses

the signal for the flywheel RPM sensor.
P-68137
The inability to unlock the traction lock (brake) is a
symptom of losing the flywheel RPM sensor signal. Not
being to read engine speed on the service tool or deluxe Turn the RPM sensor and the jam nut out from the
display panel is also a symptom of losing the flywheel flywheel. Set a clearance of 0.050 in. (1,27 mm) between
RPM sensor signal the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
Adjusting
NOTE: New RPM sensors have a plastic tip which is

Figure 60-170-1 used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 12 - 17

ft.-lb. (16 - 23 N•m) torque, while holding the sensor from
1 turning.
P-68136
When installing the RPM sensor, turn the RPM sensor

(Item 1) [Figure 60-170-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 60-170-1] until it

contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the RPM sensor when the
sensor is turned back out for adjustment.

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CONTROL PANEL SETUP Examples
Right Panel Setup (Keyless) Figure 60-180-2

Icon Identification
Figure 60-180-1
Press
TOOL/SETUP
SELECTION
EXAMPLE
BUTTONS
Press
LOADER FEATURES
B-16162
Make selection by pressing the SELECTION BUTTON

adjacent to the icon [Figure 60-180-1].
ICON DESCRIPTION

Press
LOCK/UNLOCK: Allows machine to be DISPLAY OPTIONS
locked/unlocked. You must lock machine to
activate security system.
When system is unlocked, the user can press
RUN/ENTER then press START to begin
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL/SETUP: Access system options.
Use to set clock, check system warnings, Press
select language, set passwords, etc. ADJUST CONTRAST
? HELP: Access help on current menu item.
EXIT EXIT returns you to previous level menu.

11:23 CLOCK/JOB CLOCK: Press to clear or lock
0.0 job clock; TOOL/SETUP to set time.
UP ARROW: Goes backward one screen.
Press
DOWN ARROW: Goes forward one screen. UP OR DOWN
OUTLINE ARROWS: No screen available Arrow to
(backward/forward). change contrast
SELECTION ARROW: Use to select menu Press EXIT to

item. return to
previous level
NEXT Goes to the NEXT screen in series. menu.
EXAMPLE: the next Active Warning screen.
B-16163/B16164/B-16161/B-16166/B-16167
INFO Goes to more information about attachments.
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.

708 of 861
CONTROL PANEL SETUP (CONT’D) Attachment Control Information (Keyless)
Right Panel Setup (Keyless) (Cont’d) The Keyless Right Panel allows the user to view
information concerning the operation of Bobcat
More Examples attachments.
Clocks Figure 60-180-3
Press . . .
TOOL/SETUP Press
LOADER FEATURES
DISPLAY OPTIONS TOOL/SETUP
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN/ENTER to set clock.
Press EXIT to return to previous level menu.
Press
RESET JOB CLOCK (Password required) LOADER FEATURES
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK/UNLOCK to unlock.
Enter Password and press RUN/ENTER.
Languages

Press . . . Press
TOOL/SETUP ATTACHMENTS
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN/ENTER.
Press EXIT to return to previous level menu.
Vitals (Monitor the engine, hydraulic/hydrostatic, Press

electrical functions when engine is running.) RUN / ENTER BUTTON
on keypad
Press . . .
TOOL/SETUP
LOADER FEATURES.
Press
VITALS UP OR DOWN
Press SELECTION ARROW to select METRIC or Arrow to
ENGLISH (M/E) readouts scroll through
attachments
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature Press
System Voltage the keypad number
Engine Speed
of a switch to view
a description of the
The Keyless Right Panel is easy to use. Continue to set attachment function
your own preferences for running / monitoring your of the switch
Bobcat Loader.
B-16163/B16164/B-16161/B-15753A/B-15754A/B-15755A
Attachments are listed alphabetically. Press the exit

button to return one screen or press the “0” (zero) key to
return to the home screen immediately [Figure 60-180-
3].

709 of 861
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS
START)
Password Description
All new machines with keyless start arrive at Bobcat

dealerships with the keypad in locked mode. This means
that a password must be used to start the engine.
For security purposes, your dealer may change the

password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password:
A permanent, randomly selected password set at the

factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
password.
Owner Password:
Allows for full use of the loader and to setup the

Keyless Right Panel. There is only one owner
password. It must be used to change the owner or
user passwords. Owner should change the password
as soon as possible for security of the loader.
User Password:
Allows starting and operating the loader; cannot

change password or any of the other setup features.

710 of 861
START) (CONT’D)
Changing The Owner And User Passwords
Figure 60-190-1
Changing the Password - Keyless Right Panel Display Screen
Press TOOL / SETUP
B-16163
Press OWNER UTILITIES
B-24288
Enter PASSWORD (owner or master) Keypad

on Keypad
then press ENTER
to Continue ENTER
B-24290

Press PASSWORD UTILITIES
B-24289
B-24291
OWNER PASSWORD USER PASSWORD
Press MODIFY OWNER

Press MODIFY USER
B-16171 B-16171
Enter USER number

Enter new OWNER on Keypad (There can be up to 8
PASSWORD on Keypad different Users, each with their
then press ENTER own password.)
to Continue. then press ENTER to Continue.
B-24292 B-24295
Re-Enter new OWNER

PASSWORD on Keypad Enter USER PASSWORD
then press ENTER on Keypad
to Continue. then press ENTER to Continue.
B-24293
B-24296
OWNER PASSWORD procedure

is now complete. USER PASSWORD procedure
is now complete.
B-24294
B-24297

711 of 861
START) (CONT’D)
Password Lockout Feature
This feature allows the owner to unlock the password

feature so that a password does not need to be used
every time the engine is started.
Figure 60-190-2
Press
LOCK/UNLOCK
Enter OWNER
PASSWORD
on Keypad

then press ENTER
to Continue.
Press
UNLOCK MACHINE
Press
EXIT
Machine is now
UNLOCKED and
can be started
without using a
password.
B-16163/P-76075/P-76076/P-76076A/P-76077

712 of 861

713 of 861
MAINTENANCE CLOCK Figure 60-200-3
Description
The Maintenance Clock alerts the operator when the next

service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.
Figure 60-200-1
1
3
B-16163A
The Keyless Right Panel, if equipped, will display a

1 wrench icon (Item 1) [Figure 60-200-3] alerting the
operator to service the machine. This icon will remain on
the display until the maintenance clock is reset.
2 NOTE: Key Switch machines will not display the

BobCARESM PM message or wrench icon on
the right panel.

B-15551
B-15551-3A
B-15551-3B
During machine operation, a two beep alarm will sound

when there are less than 10 hours until the next planned
maintenance. The hour interval (Item 1) and [SEr] (Item
2) will alternate in the display screen (Item 3) [Figure 60-
200-1] for 10 seconds. The display will then revert back
to the previous display and will appear for 10 seconds
every time the machine is started until the maintenance
clock is reset.
Figure 60-200-2
1
P-76122
The Keyless Right Panel, if equipped, will display a

message (Item 1) [Figure 60-200-2] alerting the operator
to service the machine. This message will remain for 10
seconds before reverting back to the previous screen
and will appear for 10 seconds every time the machine is
started until the maintenance clock is reset.

714 of 861
MAINTENANCE CLOCK (CONT’D) Figure 60-200-5
Setup
Figure 60-200-4
Controller Mounting Bolts
P-64243
The first analyzer screen has an added bar for the

Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-5] to
P-76109 view the next analyzer screen.
Figure 60-200-6
The easiest way to determine if a Bobcat controller is
recent enough to add the maintenance clock is to

measure the controller mounting bolt pattern on the left
side of the loader mainframe. Controllers with a bolt
pattern measuring 5.8 in. are maintenance clock 2
compatible. The previous controller pattern measures 7.0
in. (not maintenance clock compatible) [Figure 60-200-
4].
Using the remote start tool and service PC, connect and
upgrade the Bobcat controller to version 37 or greater
software. (See SERVICE PC (LAPTOP COMPUTER) on 1
Page 60-150-1.)
If the loader is equipped with keyless panel, also update

the keyless panel software. 3
P-76110
Click Options (Item 1) and add your dealer name and

phone number (Item 2). Click Save Options (Item 3)
[Figure 60-200-6] the information is now stored and will
automatically be entered on each machine as the
maintenance clock is activated. This will be displayed on
keyless panel equipped loaders when the maintenance
clock is less than 10 hours until next planned
maintenance.

715 of 861
Setup (Cont’d)
1
Figure 60-200-7
P-76118
Figure 60-200-10
P-76110
Select Install (Item 1) [Figure 60-200-7] to begin

sending the dealer information to the controller.
Figure 60-200-8
2
P-76115
On key switch machines, during the installation process

1 the left panel will display [InPut] (Item 1) [Figure 60-200-
9] and the machine will beep twice confirming the
transfer of data.
P-76113
On keyless machines, during the installation process the
left panel will display [InPut] (Item 1) [Figure 60-200-9],
Click SEND TO MACHINE (Item 1) [Figure 60-200-8] to the right panel will display an icon (Item 2) [Figure 60-
send the dealer information to the machine controller. 200-10] and the machine will beep twice confirming the
transfer of data.

716 of 861
Setup (Cont’d)
Figure 60-200-11
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-13] to scroll
P-76114
through the tabs.
NOTE: The Maintenance tab (Item 1) [Figure 60-200-

A green COMPLETE (Item 1) [Figure 60-200-11] 14] will not appear when servicing loaders

message will be displayed when the dealer information equipped with the older controller.
has been transferred to the machine controller.
Figure 60-200-14
Click Back (Item 2) [Figure 60-200-11] to return to the
Bobcat Service Analyzer screen. 1
Figure 60-200-12
4 2
1
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-14]

to view the maintenance clock screen.
P-76110
Click ON/OFF (Item 2) to turn the maintenance clock on
or off [Figure 60-200-14].
Select Warnings (Item 1) [Figure 60-200-12].
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
new interval. Click SET/RESET (Item 4) [Figure 60-200-
14] to reset and set the maintenance clock.

717 of 861
Setup (Cont’d)
Figure 60-200-15
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-17] to

P-76111 view the maintenance clock.
Figure 60-200-18
The current maintenance clock Length (Interval) and

Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it can not be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-200-15].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.
P-64244
Figure 60-200-16
After the maintenance clock has been activated, the first
analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-18]. If past
the interval, the number will reflect negative hours.
1
P-76111
Select Back (Item 1) [Figure 60-200-16] to return to the

main menu.

718 of 861
MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-19
2
B-15551
Place the key switch in the OFF position (Key Switch) or

press the STOP button (Keyless).
Press the LIGHTS button (Item 1) [Figure 60-200-19] to

turn the panel ON.
Press and hold the HIGH FLOW and AUXILIARY

PRESSURE RELEASE buttons (Item 2) simultaneously,
until [rESEt] appears in the display screen (Item 3)
[Figure 60-200-19].
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-14] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.

719 of 861
BACK-UP ALARM SYSTEM Inspecting
This machine may be equipped with a back-up alarm

system. The back-up alarm will sound when the operator
moves both steering levers or joystick(s) in the reverse 1
position. Slight movement of the steering levers in the
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
P-76108
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER

button. Disengage the parking brake.
Move both steering levers or joystick(s) in the reverse

position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear

door.
Figure 60-210-2
P-69346
Inspect the back-up alarm electrical connections (Item 1)

[Figure 60-210-2], wire harness (Item 2) [Figure 60-210-
2] and back-up alarm switches (if equipped) (Item 2)
[Figure 60-210-3] for tightness and damage. Repair or
replace any damaged components.
If the back-up alarm switches require adjustment, (See

Adjusting Switch Position on Page 60-210-2.)

720 of 861
BACK-UP ALARM SYSTEM (CONT’D)
Adjusting Switch Position
NOTE: Joystick equipped machines do not have

back-up alarm switches and can not be
adjusted.
Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-3
Switch Rollers contacting Bellcranks

2 2
1 1

P-62915
Place the steering levers in the neutral position.
Loosen the screws (Item 1) [Figure 60-210-3] securing

the back-up alarm switches.
Position the back-up alarm switch rollers so that they just

make contact with bellcranks without compressing the
switch springs [Figure 60-210-3]. Torque the screws
(Item 1) [Figure 60-210-3] securing the switches to the
bracket to 14 - 19 in.-lb. (1,6 - 2,1 N•m).
Lower the operator cab (See Lowering on Page 10-30-3.)

and inspect back-up alarm system for proper function.
(See Inspecting on Page 60-210-1.)

721 of 861
Troubleshooting (Standard and ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers in the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The alarm or back-up switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

722 of 861
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) in the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

723 of 861
BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches and can not be
Stop the engine and open the tailgate. adjusted.
Figure 60-210-4 Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-6
1
2 2
1 1
P-69346
Mark the wires for ease of assembly. Disconnect the

wires (Item 1) [Figure 60-210-5] from the alarm.

Installation: Make sure the wire harness ends do not P-62915
touch the mounting bolts during assembly.

Place the steering levers in the neutral position.
Figure 60-210-5
Loosen the screws (Item 1) securing the back-up alarm
switches. Slide the switch assemblies (Item 2) [Figure
60-210-6] off the mounting bracket.
1
1 Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjusting the switches (See
Adjusting Switch Position on Page 60-210-2.) and
inspecting back-up alarm operation (See Inspecting on
Page 60-210-1.) are required.
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-210-5]. Remove the alarm from the
mounting bracket.

724 of 861
Switch Removal And Installation (Cont’d)
Figure 60-210-7
1
3
2
3
P-62917
Mark the wires for ease of assembly.

Disconnect the Orange wire from the common terminal
(Item 1) [Figure 60-210-7].
Disconnect the White wire from the normally open

terminal (Item 2) [Figure 60-210-7].
Disconnect the remaining White wires to the other switch

terminals (Item 3) [Figure 60-210-7].
Remove the switches.

725 of 861
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Idler Gear And Camshaft Removal And Installation . . . . 70-100-4
Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . . 70-100-6
Timing Gearcase Cover Removal And Installation . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . 70-100-3
CRANKSHAFT AND PISTONS. . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Crankshaft And Bearings Removal And Installation . . . . . 70-90-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft Gear Removal And Installation . . . . . . . . . . . . 70-10-6
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Piston And Connecting Rod Removal And Installation . . . 70-90-1
Piston And Connecting Rod - Servicing. . . . . . . . . . . . . . . 70-90-2

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Cylinder Head Disassembly and Assembly . . . . . . . . . . . . 70-80-7
Cylinder Head Removal And Installation . . . . . . . . . . . . . . 70-80-4
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . 70-80-8 ENGINE
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . 70-80-1 SERVICE
Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . 70-80-9
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . 70-80-12
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Blower Housing Removal And Installation . . . . . . . . . . . . . 70-50-4
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 70-50-6
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Disassembly And Assembly . . . . . . . . . . . . 70-50-3
Hydraulic Fan Motor Removal And Installation . . . . . . . . . 70-50-6
Radiator Removal And Installation. . . . . . . . . . . . . . . . . . . 70-50-1
Thermostat Housing Removal And Installation . . . . . . . . . 70-50-8
Water Pump Removal And Installation . . . . . . . . . . . . . . . 70-50-7
Water Pump Disassembly And Assembly . . . . . . . . . . . . . 70-50-7

726 of 861
ENGINE SERVICE (CONT’D)
ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . 70-10-15
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-10-9
Engine Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL (SJC). . . . . . . . . . . . . . . . . . . . . 70-21-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 70-21-3
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . 70-110-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . 70-110-2

Ring Gear Removal And Installation . . . . . . . . . . . . . . . . 70-110-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Governor Disassembly And Assembly. . . . . . . . . . . . . . . . 70-70-7
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-3
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . 70-70-11
Fuel Injector Removal And Installation . . . . . . . . . . . . . . 70-70-10
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid - Removal And Installation . . . . . . . 70-70-1
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Engine Oil Pressure-Testing . . . . . . . . . . . . . . . . . . . . . . . 70-60-3
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . 70-60-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1


ITEMS MAY VARY.

727 of 861
ENGINE INFORMATION Figure 70-10-1
Description
This loader has a Kubota direct injected V2403-M-DI

diesel engine [Figure 70-10-1] with a displacement of
148.5 cu.in. (2,4 L). The engine is rated at an SAE Net 46
HP (34 KW) and has a closed crankcase ventilation
system.
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.
The engine serial number is stamped on the engine and P-66084

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol/water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine

coolant temperature sensor and the hydraulic/hydrostatic
fluid temperature sensor.

728 of 861
ENGINE INFORMATION (CONT’D)
Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles

Opening Pressure 2702 - 2916 PSI (186 - 201 bar)
Fuel Tightness Nozzle Seat Dry Nozzle at 2418 PSI (167 bar) for 10 seconds
Fuel Injection Pump

Injection Timing 6.2 - 8.2 degrees B.T.D.C.
High Idle 2760 - 2900 RPM
Low Idle 1075 - 1225 RPM
Cylinder Head
Cylinder Head Surface Distortion 0.002 (0,05) Max.
Thickness of Gasket (Used) 0.0453 - 0.0492 (1,15 - 1,25)
(New) 0.0512 - 0.0551 (1,3 - 1,4)
Top Clearance (Piston to Head) 0.0236 - 0.0276 (0,60 - 0,70)
Compression 427 - 469 PSI (29,4 - 32,4 bar)

Allowable Limit 341 PSI (23,5 bar)
Difference Between Cylinders 10%
Valves
Valve Seat Width (Intake & Exhaust) 0.0835 (2,12)
O.D. of Valve Stems 0.3134 - 0.3140 (7,96 - 7,98)
I.D. of Valve Guides 0.3156 - 0.3161 (8,015 - 8,03)
Clearance Between Valve Stem & Guide 0.0016 - 0.0028 (0,04 - 0,07)
Allowable Limit 0.0039 (0,1)
Valve Clearance (Cold) 0.007 - 0.0087 (0,18 - 0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.006 (0,15)
Allowable Limit (Recess) 0.0157 (0,4)
Valve Seat Angle (Int.) 45 degrees
Valve Seat Angle (Exh.) 45 degrees
Valve Springs
Free Length 1.642 - 1.661 (41,7 - 42,2)
Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.4 lb. (117,6 N)
Allowable Limit 22.5 lb. (100,0 N)
Inclination Allowable Limit 0.039 (1,0)
Valve Timing
Intake Valve (Open) 9 degrees B.T.D.C.
(Close) 45 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 12 degrees A.T.D.C.

729 of 861
Specifications (Cont’d)
parentheses.
Rocker Arms
O.D. of Rocker Arm Shaft 0.5501 - 0.5506 (13,97 - 13,98)
I.D. of Rocker Arm 0.5512 - 0.5519 (14,0 - 14,02)
Clearance Between Rocker Arm & Shaft 0.0006 - 0.0018 (0,02 - 0,05)
Camshaft
Journal O.D. 1.572 - 1.573 (39,93 - 39,95)
Cylinder Block Bore I.D. 1.575 - 1.576 (40,0 - 40,025)
Oil Clearance 0.002 - 0.0036 (0,05 - 0,091)
Alignment Allowable Limit 0.0004(0,01)
Cam Lobe Height 1.335 (33,9)
End Clearance 0.0028 - 0.0087 (0,07 - 0,22)

Tappet
Clearance Between Tappet & Guide 0.0008 - 0.0024 (0,02 - 0,062)
Tappet O.D. 0.943 - 0.944 (23,96 - 23,98)
Tappet Guide I.D. 0.945 - 0.946 (24,0 - 24,021)
Cylinders
Cylinder Bore I.D. (Standard) 3.425 - 3.426 (87,00 - 87,02)
Allowable Limit (Standard) +0.006 (+0,15)
Cylinder Bore I.D. (Oversize) 3.435 - 3.436 (87,25 - 87,27)
Allowable Limit (Oversize) +0.006 (+0,15)
Piston Rings
Ring Gap (Top) 0.008 - 0.0138 (0,20 - 0,35)
Ring Gap (2nd Ring) 0.0157 - 0.0217 (0,34 - 0,55)
Ring Gap (Oil Ring) 0.0098 - 0.0177 (0,25 - 0,45)
Allowable Limit (All Rings) 0.05 (1,25)
Side Clearance of Ring Groove:
2nd Ring 0.0037 - 0.0050 (0,093 - 0,128)
Oil Ring 0.008 - 0.0021 (0,02 - 0,06)
Pistons
Piston Pin Bore 0.984 - 0.985 (25,0 - 25,013)

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parentheses.
Connecting Rod
Piston Pin O.D. 0.984 - 0.985 (25,0 - 25,011)
Small End Bushing I.D. 0.985 - 0.986 (25,025 - 25,04)
Clearance Between Piston Pin & Small End Bushing 0.0006 - 0.0015 (0,014 - 0,038)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)
Oil Pump
Oil Pressure at Rated RPM 43 - 64 PSI (2,94 - 4,4 bar)
Allowable Limit 36 PSI (2,5 bar)
Idle Speed Allowable Limit 7 PSI (0,48 bar)
Clearance Between Inner Rotor & Outer Rotor 0.0012 - 0.0055 (0,03 - 0,14)
Clearance Between Outer Rotor & Pump Body 0.0043 - 0.0075 (0,11 - 0,19)
End Clearance Between Inner Rotor & Cover 0.0041 - 0.0059 (0,105 - 0,15)

Crankshaft
Crankshaft Alignment 0.0008
Allowable Limit (0,02)
Oil Clearance Between 0.0016 - 0.0047 (0,04 - 0,118)
Journal & Bearing #1
Journal O.D. #1 2.3591 - 2.3598 (59,921 - 59,940)
Bearing I.D. #1 2.3614 - 2.3637 (59,980 - 60,039)
Journal & Bearing #2
Journal O.D. #2 2.3591 - 2.3598 (59,921 - 59,940)
Bearing I.D. #2 2.3614 - 2.3632 (59,980 - 60,025)
Crank Pin & Bearing
Crank Pin O.D. 1.8488 -1.8494 (46,96 - 46,98)
Crank Pin Bearing I.D. 1.850 - 1.852 (47,0 - 47,05)
Crankshaft Side 0.006 - 0.014 (0,15 - 0,35)
Clearance

731 of 861
parentheses.
Timing Gear
Timing Gear Backlash
Crank Gear - Idle Gear 0.0016 - 0.0044 (0,042 - 0,112)
Idle Gear - Cam Gear 0.0016 - 0.0045 (0,042 - 0,115)
Idle Gear - Injection Pump Gear 0.0016 - 0.0045 (0,042 - 0,115)
Crank Gear - Oil Pump Gear 0.0016 - 0.0043 (0,042 - 0,109)
Idle Gear Shaft O.D. 1.494 - 1.495 (37,959 - 37,975)
Idle Gear Bushing I.D. 1.494 - 1.495 (38,000 - 38,025)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.001 - 0.0026 (0,025 - 0,066)
Idler Gear Side Clearance 0.005 - 0.019 (0,12 - 0,48)
Thermostat
Valve Opening Temperature 177° - 182° F (81° - 84° C)

Valve Fully Open 203° F (95° C)

732 of 861
parentheses.
Engine Torque Values
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M12 x 1.25 22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
M14 x 1.5 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)

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Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36

Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

734 of 861
Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.

17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

735 of 861
ENGINE INFORMATION (CONT’D) Figure 70-10-2
Engine Removal And Installation

3
4
2
3
P-68848
WARNING
Remove the nut from the speed control linkage (Item 1)
Never work on a machine with the lift arms up unless and unplug the rear door harness connector (Item 2)
the lift arms are secured by an approved lift arm [Figure 70-10-2].
support device can allow the lift arms or attachment Remove the bracket mounting screws (Item 3) so the belt
to fall and cause injury or death. shield (Item 4) [Figure 70-10-2] can be removed.

W-2059-0598
Installation: Tighten screws and nut to 15 - 20 ft.-lb. (20 -
27 N•m) torque.
Put jackstands under the rear corners of the loader.
Figure 70-10-3
Raise the operator cab. (See Raising on Page 10-30-2.) 1

Disconnect the steering linkage from the hydrostatic

pump. (See Linkage Removal And Installation on Page
2
50-100-7.)
Remove the battery from the loader. (See Removal And

P-66870
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-2.)
Remove the mounting screw (Item 1) to remove the oil
Remove the air cleaner. (See Housing Removal And filter drip shield (Item 2) [Figure 70-10-3].
The drip shield is snapped into place on the filter
Remove the muffler. (See Removal And Installation on housing.
Page 70-30-1.)
torque.

736 of 861
Figure 70-10-4
1
2
1
P-48606
3
Disconnect the engine ground strap (Item 1) [Figure 70-
P-66871 10-6].
Figure 70-10-7
Disconnect the temperature sender connector (Item 1)
[Figure 70-10-4] from the filter housing.

Disconnect the wire connector (Item 2) [Figure 70-10-4]
for the differential pressure switch on the filter housing.

10-4].
Figure 70-10-5
1
1
P-68851
Disconnect fuel line (Item 1) [Figure 70-10-7] for lift

pump.
P-66872
Disconnect radiator hose (Item 1) [Figure 70-10-5].

737 of 861
Figure 70-10-8
1
2
P-66875
3 Disconnect engine coolant hose (Item 1) [Figure 70-10-

P-68849 10].
Cap or plug all hoses and fittings.

Disconnect fuel shutoff solenoid connector (Item 1)
[Figure 70-10-8]. Figure 70-10-11

Disconnect engine oil pressure sender connector (Item 2) 1
[Figure 70-10-8].
Cut tie-strap (Item 3) [Figure 70-10-8].
Figure 70-10-9
P-67069
1
Mark and disconnect the charge pump filter outlet hose
(Item 1) [Figure 70-10-11].
3 Cap or plug all hoses and fittings.

P-68850
Disconnect glow plug wire (Item 1) [Figure 70-10-9].
Disconnect and plug fuel return line (Item 2) [Figure 70-

10-9].
Remove the tie strap (Item 3) [Figure 70-10-9] from

wiring harness clamp and move the wire harness to the
left side of loader to allow clearance for engine removal.

738 of 861
Figure 70-10-12
1
2 P-67078
Disconnect drain hose (Item 1) [Figure 70-10-14] from

P-67082 the hydraulic cooling fan.
Mark and disconnect the hydraulic fan motor inlet hose

Disconnect gear pump inlet hose (Item 1) [Figure 70-10- (Item 1) [Figure 70-10-14].
12].

Disconnect supply hose (Item 2) [Figure 70-10-12] from
Figure 70-10-15
hydraulic fluid reservoir.
Disconnect gear pump outlet hose (Item 3) [Figure 70-

10-12]. 2
Figure 70-10-13
1
2 1
1
2
P-68856
Mark and disconnect the drive motor hoses (Item 1)

1 [Figure 70-10-15].

NOTE: Due to the left drive motor hoses orientation,
P-67077
hoses may not be completely removed from
fittings until the engine and pump are partially
Remove the two bolts (Item 1) and move the hydraulic removed.
reservoir (Item 2) [Figure 70-10-13] out of the way.
Installation: Install the left drive motor hoses prior to
alignment with engine mount bolts.
NOTE: The hydraulic fittings (Item 2) [Figure 70-10-
15] on the hydrostatic pump must be
tightened to 115 - 125 ft.-lb. (156 - 170 N•m)
torque.

739 of 861
Figure 70-10-16
P-68853
Remove the mounting bolt and nut (Item 1) [Figure 70-

P-68858 10-18] from the right rear engine mount.

Remove the mounting bolt and nut (Item 1) [Figure 70- N•m) torque.
10-16] from the right front engine mount.

Figure 70-10-19
N•m) torque.
Figure 70-10-17
2
P-28231
P-68852
1
Remove the mounting bolt and nut (Item 1) [Figure 70-

P-68857 10-19] from the left rear engine mount.

N•m) torque.
and nut from the left front engine mount.
Installation: Slide the engine mount slot (Item 2) [Figure

70-10-17] in between engine mount washer and nut.
Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.

740 of 861
Figure 70-10-20
13”
1
2.5”
1-1/2” I.S. Dia. 1

2-1/2” O.S. Dia.
2.5”
1/4” (4)
1-1/2” Square Tubing
1/4” Wall Thickness Thick Gusset
1” P-48737
16”
Fasten securely one end of the chain to the lifting eye

(Item 1) [Figure 70-10-21].
4” NOTE: You may need to adjust the chain which

fastens to the engine a couple of times to
2”
reach the correct lifting position.

45° 9” Figure 70-10-22
1”
4”
2”
.5” 1”
1
.375”
Use Two 3/8”x 1-1/4” Bolts
for Drilled and Tapped Holes. MC-1799C
A tool needs to be fabricated to use in the removal

procedure. This tool allows the engine/hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
dimensions shown in [Figure 70-10-20] to make the
engine removal tool.
P-48661A
Install the chain hoist on the eyelet [Figure 70-10-22] of

the removal tool.
Fasten a chain to other end of the removal tool with two

bolts as shown in (Item 1) [Figure 70-10-22].

loader.
Reverse the removal procedure to install the engine.

741 of 861
Engine Mount Replacement

Engine
Figure 70-10-23 Mounting
Washer Bracket
1
2
Loader
3 Frame Engine
Mount
4
5 Snubbing Spacer
Washer
MC-1765A
6
7 Install the new engine mount as shown in the cut away

MC-1771A side view [Figure 70-10-24].
Tighten the mounting bolts to 70 ft.-lb. (95 N•m) torque.

Use the following procedure to install new engine
mounts:

Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all four engine mounts two front and two rear.
Use the parts shown to install the new engine mounts

[Figure 70-10-23]:
Square Nut - (Item 1) - Used on left side engine mounts
Hex Nut - (Item 2) - Used on right side engine mounts
Mount Washer - (Item 3)
Engine Mount - (Item 4)
Tube Spacer - (Item 5)
Snubbing Washer - (Item 6)
Mounting Bolt - (Item 7)

742 of 861
Compression - Checking

procedure:
MEL10630 - Engine Compression Kit
MEL1631 - Compression Adapter
The engine must be at operating temperature.
Figure 70-10-25
P-51938
Connect the compression gauge to the adapter [Figure

70-10-27].
Make sure the engine speed control is fully backward
(engine idle).
Disconnect the fuel stop solenoid.
1

Measure compression when cranking engine with the
starter motor.
If the measurement is below the allowable limit, check

P-51932 the cylinder, piston ring, top clearance, valve and cylinder
head.
Disconnect the air cleaner inlet hose (Item 1) [Figure 70- Compression Pressure should be 427-469 PSI (29,4 -
10-25] from the intake manifold. 32,3 bar)
Allowable Limit (minimum) is 341 PSI (23,5 bar)
Remove the glow plugs. (See Glow Plugs Removal And
Installation on Page 70-80-1.) No more than 10% variance among cylinders.
Figure 70-10-28
Figure 70-10-26
P-51936
P-51939
P-51937
Push the button on the compression gauge to release

Install the correct compression adapter (Item 1) [Figure pressure [Figure 70-10-28].
70-10-26] into the cylinder head.
Connect the fuel stop solenoid.

743 of 861
ENGINE SPEED CONTROL Raise the operator cab. (See Raising on Page 10-30-2.)
Removal And Installation Remove the two mounting screws (Item 1) [Figure 70-
20-1] from the speed control mounting bracket.

DANGER N•m) torque.
Installation: Tighten the mounting bolts (Item 2) [Figure
70-20-1] evenly until the speed control lever moves back
and forth at a comfortable tension.
Figure 70-20-2
P-90328
AVOID DEATH

D-1009-0409 1
P-4072
WARNING Pull the speed control away from the loader frame and
disconnect the speed control rod (Item 1) [Figure 70-20-
2] from the control.
the lift arms are secured by an approved lift arm Installation: Be sure to install the speed control rod in
support device. Failure to use an approved lift arm the bottom hole of the speed control lever.
to fall and cause injury or death. Figure 70-20-3
W-2059-0598
Figure 70-20-1
1 1
2
P-34156
Installation: Install the stop bracket (Item 1) [Figure 70-

P-48565 20-3] in the same location. It is necessary for the front
and rear stop on the bracket to be located correctly.
Raise the lift arms and install an approved lift arm device. Reverse the removal procedure to install the engine
(See Installing on Page 10-20-1.) speed control.

744 of 861

745 of 861
ENGINE SPEED CONTROL (SJC) Figure 70-21-2
Removal And Installation 1
Figure 70-21-1
2
P-73687
1 Remove the two screws from the mount (Item 1) [Figure

70-21-2].
Remove the rubber grommet (Item 2) [Figure 70-21-2].

P-73686 N•m) torque.
Figure 70-21-3
1] from the right side foot rest.
Remove the foot rest, from the loader.
P-64313
Disconnect the foot speed control linkage (Item 1)

[Figure 70-21-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.

746 of 861
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-6

1
Figure 70-21-4 2 4 4
1 3 5 3
P-34654A
The parts that go into the pivot arm (Item 1) are the bolt
P-34550 (Item 2), washers (Items 3), fiber washers (Items 4), and
spacer (Item 5) [Figure 70-21-6].
Remove the bolt and nut (Item 1) [Figure 70-21-4] from Figure 70-21-7
the hand speed control pivot arm.

Figure 70-21-5
1
1
P-73685
P-34549 Remove the two screws (Item 1) [Figure 70-21-7] from

the hand speed control lever assembly.
Remove the keeper and pin (Item 1) [Figure 70-21-5] Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
that attaches the pivot arm to the speed control cable. N•m) torque.
Remove the speed control pivot arm from the loader.

747 of 861
ENGINE SPEED CONTROL (SJC) (CONT'D) Disassembly And Assembly
Figure 70-21-8
1
1
P-64305
P-73689
foot speed control assembly.
At the bottom side of the control panel, move the speed
control linkage toward the rear of the loader. Figure 70-21-11

Slide the hand speed control lever (Item 1) [Figure 70-
21-8] forward and lift, and disconnect the assembly from
the speed control rod clevis.
Figure 70-21-9
P-64305A
2
1 Remove the bushing/nut (Item 1) [Figure 70-21-11] from
the pedal lever.
P-73688
Installation: When installing the hand speed control, be

sure the speed control lever and pin (Item 1) fit in the
notch (Item 2) [Figure 70-21-9] of the speed control rod
clevis.

748 of 861
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-14
Figure 70-21-12 1
P-34659
1
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
P-34657 the speed control.
Figure 70-21-15
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing/nut.

Remove the foot pedal lever (Item 2) and linkage rod
(Item 3) [Figure 70-21-12].
Figure 70-21-13
P-64307
1
The pivot assembly shown disassembled [Figure 70-21-

15].
NOTE: No lubrication is necessary or recommended

P-34658 on the engine speed control.
Reverse the disassembly procedure to assemble the

Remove the fiber washer (Item 1) and washer (Item 2) (SJC) speed control.
[Figure 70-21-13] from the pivot bolt.

749 of 861
MUFFLER Figure 70-30-2
Remove the rear grill. (See Removal And Installation on

Page 50-60-1.)
1
Figure 70-30-1
P-54044
3
Remove the right side mounting bolt (Item 1) [Figure 70-
30-2] from the muffler.
2
Installation: Tighten the muffler mounting bolts to 25 - 28
1 ft.-lb. (34 - 38 N•m) torque.

P-54058 Remove the muffler from the loader.
Reverse the removal procedure to install the engine

Remove the exhaust pipe clamp (Item 1) from the muffler muffler.
(Item 2) [Figure 70-30-1].
Disconnect the exhaust pipe from the muffler.
Remove the left side mounting bolt (Item 3) [Figure 70-

30-1] from the muffler.

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751 of 861
AIR CLEANER Figure 70-40-3

1
Figure 70-40-1
1
2
P-54049
Remove the lower mounting bolt (Item 1) and engine

P-54046 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Remove the two upper mounting bolts (Item 3) [Figure
70-40-1] from the air cleaner sensor on the air cleaner. 70-40-2] from the top mount of the air cleaner.

Figure 70-40-2 Installation: Tighten the three mounting bolts to 15 - 20
Remove the air cleaner from the engine compartment.

1
Reverse the removal procedure to install the air cleaner.
P-54054
Loosen the hose clamp (Item 1) [Figure 70-40-2] on the

air cleaner hose.
Loosen the clamp (Item 2) [Figure 70-40-2] from the

hose on the engine manifold.

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753 of 861
ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation
Remove the rear grill. (See Removal And Installation on

Page 50-60-1.)
Remove the oil cooler. (See Removal and Installation on 1

Page 20-100-1.)
WARNING P-68848
AVOID BURNS
Do not remove radiator cap when the engine is hot. Open the drain valve (Item 1) [Figure 70-50-2] on the
You can be seriously burned. engine block and drain the coolant into a container.
W-2070-1203
Figure 70-50-3
Figure 70-50-1

2
1
P-48571
P-54001
Loosen the hose clamp (Item 1) [Figure 70-50-3] from
the left side radiator hose and disconnect the hose from
Loosen the radiator cap (Item 1) [Figure 70-50-1] from the radiator.
the pressurized expansion tank.
Remove the radiator mounting bolt (Item 2) [Figure 70-
50-3].
Installation: Tighten the radiator mounting bolt to 11-13

ft.lb. (15-17 N•m) torque.

754 of 861
ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-6
Radiator Removal And Installation (Cont'd)
Figure 70-50-4 2
1
1
P-54062
Figure 70-50-7
P-54048
Loosen the hose clamp (Item 1) [Figure 70-50-4] from 1 2

the left side radiator hose and disconnect the hose from 1

the radiator.
Figure 70-50-5
P-54311
Remove the two rubber stops (Item 1) [Figure 70-50-6] &

[Figure 70-50-7] from the top of the radiator.
1 2
Disconnect the overflow hose (Item 2) [Figure 70-50-6]
& [Figure 70-50-7].
P-54050
Lift the radiator (Item 3) [Figure 70-50-7] up and remove
from the machine.
Remove the radiator mounting bolt (Item 1) and block off
plate (Item 2) [Figure 70-50-5].
Installation: Tighten the radiator mounting bolt to 11 - 13

ft.-lb. (15 - 17 N•m) torque. Use sealant on the block off
plate and bolt head (Item 2) [Figure 70-50-5].

755 of 861
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Disassembly And Assembly
Hydraulic Fan Description Figure 70-50-8
The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from both the engine 2
and hydraulic temperature sensors.
The hydraulic fan is used to cool the engine and

hydraulic/hydrostatic systems. The hydraulic fan consist
of a fan and hydraulic motor that is controlled by a
proportioning valve.
NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field. The
adjustment screw is sealed with a tamper 1
evident white material, if this screw has been P-68126
adjusted the proportioning valve must be
replaced.
NOTE: The seals, O-rings and coil nut on the
If the flow from the proportioning valve is proportioning valve (Item 1) are available by
determined inaccurate it must be replaced ordering from Bobcat Service Parts. The fan
with a new one from Bobcat Service Parts. motor (Item 2) [Figure 70-50-8] must be

replaced as an assembly if damaged.
The fan speed is determined by the engine coolant
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (RPM’s)
can range from 0 to 4000 RPM’s.
The hydraulic fan speed at cold engine startup will range

from 0 to 500 RPM’s until the engine coolant and the
hydraulic fluid reach basic operating temperatures.
During normal operating temperatures the fan speed may

range from approximately 1900 to 3500 RPM’s.

756 of 861
ENGINE COOLING SYSTEM (CONT’D) Remove the hydraulic fluid reservoir. (See Removing And
Blower Housing Removal And Installation
Figure 70-50-9
DANGER 2 4
P-67080
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 3
tubeline, hose, fitting, component or a part failure P-67076

• Keep out of this area when lift arms are raised Remove cable ties (Item 1) [Figure 70-50-9] attached to
unless supported by an approved lift arm blower housing.

D-1009-0409 Disconnect and plug the heater hoses (Item 2) [Figure
70-50-9].
Disconnect the cab harness connector (Item 3) [Figure

WARNING 70-50-9].
Remove the sealant between the blower housing and the

Never work on a machine with the lift arms up unless loader frame (Item 4) [Figure 70-50-9].
support device. Failure to use an approved lift arm Figure 70-50-10
W-2059-0598
IMPORTANT 1

parts clean. Always use caps and plugs on hoses, 4
damage the system. 3 P-67078
I-2003-0888
Raise the lift arms and install an approved lift arm support Remove the fan motor inlet hose (Item 1) and outlet hose
device. (See Installing on Page 10-20-1.) (Item 2) [Figure 70-50-10].
Raise the operator cab.(See Raising on Page 10-30-2.) Remove the fan motor case drain hose (Item 3) [Figure
70-50-10].
Remove the fan motor/charge pump filter housing. (See
Charge Filter Housing Removal And Installation on Page
20-80-3.)
50-10].

757 of 861
ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-13
Blower Housing Removal And Installation (Cont’d)

Figure 70-50-11 1 2
P-76698
1
2
After the blower housing is installed, apply a bead of
P-76697 polyurethane caulk sealant (P/N 6633583) between the
front edge (Item 1) of the crossmember and blower
NOTE: Remove the two rear mounting bolts first. housing (Item 2) [Figure 70-50-13] directly in front of the
inlet opening only.
Remove the four mounting bolts (Item 1 and Item 2) and

spacer tubes. The only visible spacer tubes are on the
outside of the blower housing using mounting bolts (Item
2) [Figure 70-50-11].
Figure 70-50-12
P-66649
NOTE: The picture shows the blower housing and fan

assembly removed from the loader. Two of
the mounting bolts (Item 1) [Figure 70-50-11]
have clips (Item 1) [Figure 70-50-12] to hold
the bolts from falling out during factory
installation of the blower housing and fan
together. The clips will fall during the removal
of the fan motor assembly bolts.
Remove the blower housing from the loader.
Reverse the removal procedure to install the blower

housing.

758 of 861
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Removal And Installation
Fan Removal And Installation Figure 70-50-16
Figure 70-50-14
1 1
P-54421A
P-54418
Remove bolts (Item 1) [Figure 70-50-16] and discard.
Remove the lock nut and spacer (Item 1) [Figure 70-50- Reverse removal procedure for installation.
14].

Installation: Tighten the nut to 45 - 55 ft.-lb. (61 - 75 Installation: Torque fan motor mounting bolts and nuts
N•m) torque. (Item 1) to 25 - 28 ft.-lb. (34 - 38 N•m).
Figure 70-50-15
1
P-54419
Use the following procedure to remove the fan from the

shaft:
Install the nut (Item 1) [Figure 70-50-15] on the tapered
shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-50-15].
As the center bolt (Item 2) [Figure 70-50-15] is tightened,
periodically strike the bolt head to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [Figure 70-50-
15].

759 of 861
ENGINE COOLING SYSTEM (CONT’D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-18
Drain the cooling system.

2
Remove the alternator belt.
1
Remove the water pump bolts.
3
Figure 70-50-17 4
B-14424
Remove the flange (Item 1) [Figure 70-50-18].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

50-18] out the impeller side of the water pump.

B-5318 Remove the impeller (Item 3) [Figure 70-50-18] from the
shaft.
Remove the water pump [Figure 70-50-17]. Remove the seal (Item 4) [Figure 70-50-18].
Installation: Always use a new gasket when installing Install a new seal (Item 4) [Figure 70-50-18] when
the water pump. assembling the water pump.

760 of 861
ENGINE COOLING SYSTEM (CONT’D)
Thermostat Housing Removal And Installation
Figure 70-50-19
1 2 1
6 4
5 7

9
8
10
9
7 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-19].
Remove clamps (Item 5) and hose (Item 6) [Figure 70-

50-19].
Remove bolts (Item 7), nut (Item 8), top and bottom
housing (Item 9), and gasket (Item 10) from the cylinder
head [Figure 70-50-19].

761 of 861
ENGINE COOLING SYSTEM (CONT’D)
Thermostat - Checking
Figure 70-50-20
P-37172
Push down the thermostat valve and insert a string

between the valve and the valve seat.

Place the thermostat and a thermometer in a container
with water and gradually heat the water [Figure 70-50-
20].
Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 0.315 in. (8 mm).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s valve Factory 74.5° - 78.5° C

opening spec. 166.1° - 173.3° F
temperature
Temperature at Factory 90° C
which thermostat spec. 194° F
completely opens

762 of 861

763 of 861
LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Remove the engine and hydrostatic pump assembly from 100-1.)
the loader. (See Engine Removal And Installation on
Page 70-10-9.) Remove the crankshaft gear.
The engine will have to be on an engine stand or Figure 70-60-3

suspended in the air safely to remove the oil pan.
Figure 70-60-1 1
2
2
B-3658

1
P-66843 Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-60-3].
Remove oil pan bolts securing oil pan (Item 1) [Figure Remove the oil pump mounting bolts. Remove the oil
70-60-2]. Slightly tapping on the oil pan with a soft mallet pump (Item 2) [Figure 70-60-3].
will break loose the oil pan from the engine block.
Installation: Tighten the oil pump mounting bolts to 60 -
Installation: Use a liquid gasket adhesive to the oil pan 72 in.-lb. (6,9 - 8,1 N•m) torque.
side of the oil pan gasket. Tighten oil pan bolts to 29 - 33
Figure 70-60-2
P-66844
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.

764 of 861
LUBRICATION SYSTEM (CONT’D) Figure 70-60-5
Oil Pump Inspection
Figure 70-60-4
A-2732
Measure the clearance between the outer rotor and

B-3616 pump body [Figure 70-60-5].
Clearance 0.0043 - 0.0075 in.

Measure the clearance between the lobes of the inner Between Outer (0,11 - 0,19 mm)
rotor and outer rotor [Figure 70-60-4]. Rotor & Body

Clearance 0.0012 - 0.0055 in. If the clearance exceeds the allowable limit, replace the
Between Inner & (0,03 - 0,14 mm) oil pump.
Outer Rotor
Figure 70-60-6
If the clearance exceeds the allowable limit, replace the
oil pump.
PI-10009
Put a piece of press gauge on the rotor face [Figure 70-

60-6].
Install the cover and tighten the bolts.
Remove the cover carefully. Measure the width of the

press gauge [Figure 70-60-6].
If the clearance exceeds the allowable limit replace the

oil pump.
End Clearance 0.0041 - 0.0059 in. (0,11 - 0,15 mm)

765 of 861
LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure-Testing
Remove the oil pressure sender.
Figure 70-60-7
PI-10010

Install a pressure gauge [Figure 70-60-7].
Start the engine and run until it is at operating

temperature.
If the oil pressure is less than the allowable limit, check

the following items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed 7 PSI

Allowable Limit (0,48 bar)
At Rated Speed 42 - 64 PSI
(2,94 - 4,4 bar)
Allowable Limit 36 PSI
(2,5 bar)

766 of 861

767 of 861
FUEL SYSTEM Fuel Shutoff Solenoid - Removal And Installation
Fuel Shutoff Solenoid - Checking Figure 70-70-3
Figure 70-70-1
1
1
P-48586
P-51940
Stop the engine and open the rear door [Figure 70-70-1]. Disconnect the connector (Item 1) [Figure 70-70-3].

Disconnect the connector (Item 1) [Figure 70-70-1] from Figure 70-70-4
the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Figure 70-70-2
2
P-51943
Remove the mounting nuts (Item 1) [Figure 70-70-4] that

secure the fuel shutoff solenoid.
P-51941
NOTE: There is a ground strap (Item 1) [Figure 70-70-
4] that is needed for the fuel shutoff solenoid
The reading between electrical connector terminal C and to function correctly. A good ground is
terminal A must be between approximately 15.6 ohms essential for correct operation of the fuel
[Figure 70-70-2]. shutoff solenoid.
The reading between electrical connector terminal C and Reverse the above procedure to install the fuel shutoff
terminal B must be between approximately.35-.4 ohms. solenoid.

768 of 861
FUEL SYSTEM (CONT'D) Move the speed control lever to the high engine idle
position.
Fuel Injection Pump - Checking
Turn the flywheel to increase the pressure. If the
The injection pump contains parts which have a very pressure can not reach the allowable limit, replace the
close tolerance and its operation has a direct effect on injection pump assembly.
the performance of the engine.
Fuel Tightness of Pump 2702 - 2916 PSI
Element Allowable Limit (186 - 201 bar)
WARNING With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 2702-
2916 PSI (186-201 bar).
Diesel fuel or hydraulic fluid under pressure can Turn the flywheel back approximately one-half turn. Keep
penetrate skin or eyes, causing serious injury or the flywheel at this position, and measure the time it
death. Fluid leaks under pressure may not be visible. takes the pressure to decrease from 1850 PSI (127.5
Use a piece of cardboard or wood to find leaks. Do bar).
enters skin or eyes, get immediate medical attention Fuel Tightness of Delivery 5 Seconds
from a physician familiar with this injury. Valve Allowable Limit
W-2072-0807

procedure:
MEL 1237 - Adapter Fuel Line

MEL 1173-1 Pressure Gauge
To check the discharge pressure at the fuel injection

pump, use the following procedure:
Disconnect a high pressure fuel line from the injection

pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.
Figure 70-70-5
B-8235
Connect the adapter fuel line (Item 1) to the fitting and

connect the pressure gauge (Item 2) [Figure 70-70-5].

769 of 861
FUEL SYSTEM (CONT'D) Cap the inlets on the injection pump vent where the
hoses were removed [Figure 70-70-7].
Fuel Injection Pump Removal And Installation
Remove the four oil fill tube bolts (Item 3) [Figure 70-70-
Figure 70-70-6 7].
Figure 70-70-8
1 1
1
P-51933
P-76728
Clean the area around the injection pump thoroughly.

Disconnect the high pressure fuel lines (Item 1) [Figure Remove the high pressure fuel lines (Item 1) [Figure 70-
70-70-6] from the fuel injectors. 70-8] from the injection pump.
Note: Do not loosen the clamp screws (Item 2)

[Figure 70-70-8] on the injection pump. This is
to be done only when the entire injection
IMPORTANT pump is sent out to be serviced.
Do not bend the high pressure fuel injection tubes Figure 70-70-9
when removing or installing them.
I-2029-0289
Figure 70-70-7 2
2 1
3
P-48820
Remove the mounting bolts (Item 1) from the intake

manifold (Item 2) [Figure 70-70-9].
3 P-51944
Remove the intake manifold from the engine.
Disconnect the fuel inlet hose (Item 1) and the fuel return Installation: Tighten the mounting bolts to 16 - 20 ft.-lb.
hose (Item 2) from the injection pump vent [Figure 70- (22 - 27 N•m) torque.
70-7].
NOTE: Replace the manifold gasket if it is worn or
damaged.

770 of 861
FUEL SYSTEM (CONT'D) Figure 70-70-12

1
(Cont’d)
Figure 70-70-10
P-51951
1
Remove the cover plate bolts (Item 1) and nuts (Item 2)
[Figure 70-70-12].
P-51942
Remove the cover plate (Item 3) [Figure 70-70-12].
Remove the fuel shutoff solenoid (Item 1) [Figure 70-70- Figure 70-70-13

10]. (See Fuel Shutoff Solenoid - Removal And
Figure 70-70-11
P-51952
P-51953
1
Remove the stop solenoid guide (Item 1) [Figure 70-70-
P-51683 13].
Remove the high-idling body (Item 1) [Figure 70-70-11]

from the engine block.
Installation: Tighten the high idle body to 33 - 36 ft.-lb.

(44 - 49 N•m) torque.

771 of 861
FUEL SYSTEM (CONT'D) NOTE: Make sure the same number of shims with the
same thickness are installed under the
Fuel Injection Pump Removal And Installation injection pump. The shims are used for
(Cont’d) engine timing.
Figure 70-70-14 NOTE: The pin (Item 2) [Figure 70-70-15] located on

the control rack, needs to be installed
correctly during installation. See above for
correct installation.
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1 2
P-4357
Figure 70-70-16
Remove the four mounting bolts (Item 1) and two nuts

(Item 2) [Figure 70-70-14] from the injection pump.
1
(22 - 27 N•m) torque.
Figure 70-70-15
P-4364
2
Install the shim(s) (Item 1) [Figure 70-70-16] on the

injection pump mounting surface. For information on the
number of shims used. (See Fuel Injection Pump -
1 Timing on Page 70-70-8.)
NOTE: Make sure the same number of shims with the

P-4359
same thickness are installed under the
injection pump. The shims are used for
engine timing.
Remove the injection pump (Item 1) [Figure 70-70-15]
and shim(s) from the engine.
Installation: When the injection pump is installed, the

rack pin (Item 1) [Figure 70-70-15] must be aligned with
the slot in the engine block and positioned on the left side
of the fork lever.
If the rack pin is not installed correctly engine damage

can result.

772 of 861
FUEL SYSTEM (CONT'D)

(Cont’d)
Figure 70-70-17
P-64218
Install the injection pump in the engine.

Ensure the control rack pin (Item 1) is to the left side of
the fork lever (Item 2) [Figure 70-70-17].
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

773 of 861
Governor Disassembly And Assembly
The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the
engine according to changes in the engine load.
Figure 70-70-18

1. Start Spring
2. Governor Spring
3. Governor Spring
4. Fork Lever
5. Fork Lever
6. Fork Lever Shaft
7. Fork Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball PI-10008
Disassemble and assemble the governor and fuel

camshaft as shown in figure [Figure 70-70-18].
Check all the parts for wear or damage and replace as

needed.

774 of 861
FUEL SYSTEM (CONT'D) Fuel Injection Pump - Timing
Fuel Camshaft Removal And Installation Timing the injection pump is done by changing the
number of shims between the injection pump and the
Remove the timing gearcase cover.(See Timing injection pump mounting surface.
100-1.) Disconnect the number one (closest to water pump)
cylinder high pressure line from the injection pump.
Remove the idler gear. (See Idler Gear And Camshaft
Removal And Installation on Page 70-100-4.) Figure 70-70-3
Figure 70-70-1

P-54133
1 1
P-47265
Turn the fuel supply lever (Item 1) [Figure 70-70-3] to the
ON position.
Remove the three bolts (Item 1) [Figure 70-70-1].
Figure 70-70-4
Remove the two bolts and fuel camshaft retainer plate
(Item 2) [Figure 70-70-1].
Figure 70-70-2
1
P-4361
Install a short plastic tube (Item 1) [Figure 70-70-4] in the

P-47266 number one cylinder port of the injection pump. The tube
should fit securely in the port and point upward.
Remove the fuel camshaft and fork lever assembly at the

same time [Figure 70-70-2].

775 of 861
FUEL SYSTEM (CONT'D) Figure 70-70-7
Injection Pump - Timing (Cont’d)
Figure 70-70-5
Rotation
Direction
1
P-48779
The correct engine timing is 5 degrees B.T.D.C. (0,087

P-48823 rad) Add or subtract shims (Item 1) [Figure 70-70-7] to
time the engine to 5 degrees B.T.D.C. (0,087 rad) The
engine is correctly timed when the correct mark on the
Rotate the engine in the direction shown [Figure 70-70-
flywheel is aligned with the notch in the timing hole.
5].
The size of shims are identified by a symbol on the

Continue rotation until flywheel timing mark just appears
shims.
in the window (Item 1) [Figure 70-70-5].
(1) Two holes means 0.008 in (0,20 mm) shim.
Rotate slowly until fuel just starts to flow upward into the
plastic tube as shown in [Figure 70-70-4]. (2) One hole means 0.010 in (0,25 mm) shim.
(3) Without hole means 0.012 in (0,30 mm) shim.

Figure 70-70-6
(4) Three holes means 0.014 in (0,35 mm) shim.
P-4364
Add or subtract shim(s) (Item 1) [Figure 70-70-6] as

needed to adjust the fuel delivery timing.
NOTE: Adding or removing one shim will vary the

timing by 0.5 degree. Adding shims retards
timing.

776 of 861
Fuel Injector Removal And Installation
IMPORTANT
Do not bend the high pressure fuel injection tubes
WARNING when removing or installing them.
I-2029-0289

Diesel fuel or hydraulic fluid under pressure can Figure 70-70-9
enters skin or eyes, get immediate medical attention 1
W-2072-0807
Figure 70-70-8
2
1

2
P-48727A
Remove the four retainer bolts from the top of the fuel
injectors (Item 1) [Figure 70-70-9].
1
Remove the fuel return tube (Item 2) [Figure 70-70-9]
from the fuel injectors.
Installation: Tighten retainers and fuel return tubes to

P-51949
7.25 - 8.25 ft-lb. (10 - 11 N•m).
The following are some problems caused by faulty

injectors:
-Engine is hard to start or will not start

-Rough engine operation and idle
-Engine will not have full power
-Excessive exhaust smoke
Disconnect the fuel return hoses (Item 1) [Figure 70-70-

8] from the injectors.
Disconnect the high pressure fuel lines (Item 2) [Figure

70-70-8] from the fuel injectors and from the injection
pump.
Remove the high pressure fuel lines from the engine.

777 of 861
FUEL SYSTEM (CONT'D) Fuel Injector Nozzle Pressure - Checking
Fuel Injector Removal And Installation (Cont’d) The tool listed will be needed to do the following
procedure:
Figure 70-70-10
OEM1064 - Injector Nozzle Tester
Figure 70-70-12
1
P-48728A
Remove the injector nozzle holder bolt (Item 1) [Figure

P-76960
70-70-10] from the cylinder head.

Pull on the injector nozzle to remove the injector nozzle Set the injection nozzle to the nozzle tester [Figure 70-
from the cylinder head. 70-12].
Installation: Tighten the nozzle holder bolt to 19 - 21 ft.- Slowly move the tester handle to measure the pressure
lb. (26 - 29 N•m) torque. at which fuel begins jetting out from the nozzle.
Figure 70-70-11 If the measurement is not within the factory

specifications, replace the injection nozzle assembly.
Fuel Injection Pressure 2702 - 2916 PSI

(186 - 201 bar)
1 NOTE: Injection nozzle gasket must be replaced

2
when the injection nozzle is removed for
checking.
P-37583
[Figure 70-70-11] shows the injector nozzle removed

from the cylinder. Inspect the injector and replace if
necessary.
Check and replace the injector nozzle O-rings (Item 1)

and the nozzle washer (Item 2) [Figure 70-70-11] before
installing new or used injectors.

778 of 861
FUEL SYSTEM (CONT'D) Valve Seat Tightness
Nozzle Spray Condition The tool listed will be needed to do the following
procedure:
procedure: OEM1064 - Injector Nozzle Tester
OEM1064 - Injector Nozzle Tester Figure 70-70-14
Figure 70-70-13
Correct Incorrect
P-76962

P-76961
Set the injection nozzle to a nozzle tester.
Set the injection nozzle to a nozzle tester, and check the Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/
nozzle spraying condition [Figure 70-70-13]. cm², 2418 PSI) for 10 seconds.
If the spraying condition is defective, replace the injection If any fuel leak is found, replace the injection nozzle
nozzle assembly. assembly.
Valve seat Factory No fuel leak at 16.67 MPa

tightness spec. 170 kgf/cm²
2418 PSI

779 of 861
CYLINDER HEAD Glow Plugs Removal And Installation
Glow Plugs - Testing Figure 70-80-2
Figure 70-80-1
2 3
P-51933
P-51934
Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-80-2] from the top of
each glow plug.

Use an ohmmeter to check the glow plugs. Touch one
probe to the end of the glow plug and the other probe to Disconnect the engine harness wire (Item 2) [Figure 70-
the body of glow plug (Item 1) [Figure 70-80-1]. 80-2] from the glow plug.
The resistance should be approximately one ohm. If the Remove the glow plug connecting strap (Item 3) [Figure
resistance is infinite, the coil of the glow plug is broken. 70-80-2].
Repeat the procedure for each glow plug. Figure 70-80-3
P-51935
Loosen and remove the glow plug (Item 1) [Figure 70-

80-3].
Installation: Tighten the glow plug to 14.5 - 18.1 ft.-lb.

(19,6 - 24,5 N•m) torque.

780 of 861
CYLINDER HEAD (CONT'D) Valve Clearance Adjustment
Glow Plugs Removal And Installation (Cont’d) Adjust the valve clearance with the engine stopped and
cold.
Figure 70-80-4
Figure 70-80-5
0.007-0.009 in.
(0,18-0,22 mm)
P-48708
MC-1368
Photo [Figure 70-80-4] shows the glow plug removed The correct valve clearance is 0.007 - 0.009 in. (0,18 -
from the engine. Inspect the glow plugs and replace 0,22 mm) [Figure 70-80-5].

when necessary.
Make sure the piston is at T.D.C. when making the
adjustment for the valves of the particular cylinder.
NOTE: The clearance is measured between the

rocker arm and valve stem tip [Figure 70-80-
5].
Figure 70-80-6
B-11621
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [Figure 70-80-6].
Put the correct size feeler gauge between the rocker arm
and valve stem. Turn the adjustment bolt until the
clearance is correct and tighten lock nut [Figure 70-80-
6].

781 of 861
CYLINDER HEAD (CONT'D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Figure 70-80-9
Figure 70-80-7
4
3
1 2 3 4 5 6 7 8 1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
B-05569
Figure 70-80-8 Remove the engine. (See Engine Removal And


Cylinder Number 1 2 3 4 Remove the timing gearcase cover. (See Timing
100-1.)
Valve Number 1 2 3 4 5 6 7 8
Make sure the timing marks are in correct alignment
[Figure 70-80-9].
Valve
I = Intake I E I E I E I E
E = Exhaust
Adjust the valve clearance as follows:
0.0071 - 0.0087 in. (0,18 - 0,22 mm) Intake &

Exhaust
Use the following sequence to set the valves [Figure 70-

80-7] & [Figure 70-80-8]:
1. With the rocker arm rocking (valves 7 & 8) on No. 4

cylinder set clearance at No. 1 cylinder (valves 1 & 2).




782 of 861
CYLINDER HEAD (CONT'D) Figure 70-80-12
Cylinder Head Removal And Installation
Figure 70-80-10
2 4 1
2
3
P-47243
Remove the glow plugs (Item 1) and fuel injector holder

P-47241 assemblies (Item 2) [Figure 70-80-12].
Installation: Tighten the glow plugs to 11 - 14 ft.-lb. (15 -

Remove the glow plug lead (Item 1), breather hose (Item 20 N•m) torque.
2), and valve cover bolts (Item 3) [Figure 70-80-10].

Tighten the injector holders to 19 - 22 ft.-lb. (26 - 29 N•m)
Remove the valve cover (Item 4) [Figure 70-80-10] and torque.
gasket.
Figure 70-80-13
Installation: Gradually tighten the valve cover bolts to 5 -
8 ft.-lb. (7 - 11 N•m). Tighten center bolts first, then work
your way to the front and back of the valve cover.
1
Figure 70-80-11
2
2
2
2
B-14332
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-80-13].
P-47242
N•m) torque.
Loosen the bolts on the clamps (Item 1) and remove the
injection tubes (Item 2) [Figure 70-80-11]. Remove the pushrods (Item 2) [Figure 70-80-13].
Remove the overflow tube assembly.

783 of 861
Cylinder Head Removal And Installation (Cont'd) 14 6 3 11

18 10 2 7 15
Figure 70-80-14
2
17 9 1 8 16
13 5 4 12
P-47247
Remove the cylinder head bolts in order of #18 to #1

P-47245 [Figure 70-80-16].
NOTE: (A) is the gear case side, (B) is the flywheel

Installation: The push rod (Item 1) must be seated in the side.
tappet (Item 2) [Figure 70-80-14] correctly or the push

rods will be damaged. Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence in order of #1-#18 to 68 - 72 ft.-
After installing the rocker arm assembly and push rods, lb. (93 - 98 N•m).
the valve lash must be adjusted. (See Valve Clearance
Adjustment on Page 70-80-2.) NOTE: Re-tighten the cylinder head bolts in the
correct sequence after the engine has been
NOTE: Remove intake manifold (See Fuel Injection run for 30 minutes.
Pump Removal and Installation on page 70-
70-6) Figure 70-80-17
Figure 70-80-15
2
1
1 2
P-47248
P-47246
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-17].
Remove the clamps (Item 1) and remove the hose (Item
2) [Figure 70-80-15] from the thermostat housing. NOTE: Remove thermostat housing (See Thermostat
Housing Removal and Installation on page 70-
50-8)

784 of 861
Cylinder Head Removal And Installation (Cont'd) Gasket Size

Piston Protrusion
(Number)
Figure 70-80-18 0.475 to 0.525 mm
15
0.0187 to 0.0207 in.
0.525 to 0.575 mm
20
0.0207 to 0.0226 in.
25 0.575 to 0.625 mm
0.0226 to 0.0246 in.
0.625 to 0.067 mm
30
0.0246 to 0.0266 in.
35 0.675 to 0.725 mm
0.0266 to 0.0285 in.
Select the correct gasket size (thickness) from the chart

1 [Figure 70-80-20].
P-47249A
Find the measurement of the highest piston protrusion

and the lowest piston protrusion (recorded earlier) for
When replacing just the gasket, use a new gasket that each piston.
has the same mark (Item 1) [Figure 70-80-18] as the

original gasket. If the highest measurement exceeds the piston
protrusion of the selected gasket, use the gasket which is
one size larger. If the measurement exceeds gasket size
When replacing the gasket after an engine rebuild, the
35, the engine must be disassembled, clearances
piston protrusion must be measured. checked, and reassembled.
(See Cylinder Head Top Clearance on Page 70-80-8.) If the measurement is two sizes smaller than the selected
gasket or smaller than gasket size 15, the engine must
Figure 70-80-19 be disassembled, clearances checked, and
reassembled.
After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
1 interference between the piston, cylinder, and valves.
P-47252
Measure and record the protrusion of each piston in the

four places shown (Item 1) [Figure 70-80-19]. Find the
average of each piston, then find the combined average
of the four pistons.

785 of 861
CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly and Assembly Clean the surface of the cylinder head.
Figure 70-80-21 Figure 70-80-23
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-23] on the
spring [Figure 70-80-21]. cylinder head.

Figure 70-80-22 NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-23] between

the straight edge and the surface of the cylinder head.
Figure 70-80-24
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

(Item 2) [Figure 70-80-21] & [Figure 70-80-22].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 70-80-21] & [Figure 70-80-22].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-21] & [Figure 70-80-22]. and two diagonal as shown in figure [Figure 70-80-24].
The maximum distortion of the head surface is ± 0.002 in.

(± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

786 of 861
CYLINDER HEAD (CONT'D) Valve Guide - Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly and Assembly on Page
Figure 70-80-25 70-80-7.)
Remove the carbon from the valve guide.
2 Figure 70-80-26
1 3
PI9989
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-25] being checked at T.D.C.
B-14335

Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)
[Figure 70-80-25] on the top of the piston. Use grease to Measure the valve stem O.D. [Figure 70-80-26].
hold them in position.
Measure the valve guide I.D. [Figure 70-80-26].
NOTE: Put the solder in position so they do not touch
the valves. Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Turn the piston to bottom dead center.
Valve Guide I.D. 0.3156 - 0.3161 in.
Install the cylinder head and tighten to the correct torque (8,015 - 8,03 mm)
in the correct sequence. (See Cylinder Head Removal
Valve Stem O.D. 0.3134 - 0.3140 in.
And Installation on Page 70-80-4.)
(7,96 - 7,98 mm)
Clearance Between 0.0016 - 0.0028 in.
Turn the crankshaft until the piston exceeds T.D.C.
Valve Stem and Guide (0,04 - 0,07 mm)
Remove the cylinder head.
Allowable Limit 0.004 in.
Remove the solder wire (Item 3) [Figure 70-80-25] and (0,1 mm)
measure it.
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.0236 - 0.0276 in. (0,6 - 0,7 mm)

787 of 861
CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide - Checking (Cont’d) Figure 70-80-29
Figure 70-80-27
8.86” (225 mm)
0.787” 2.76” (70mm) 1.77”

(20 mm) (45 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259”
(6,5-6,6 mm)
0.2” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
0.263-0.275” 0.98” P-51632

0.490-0.50”
(6,7-7 mm) (25,0 mm) (12.5-12.8 mm)
MC-1364
Install the valve into the guide. Measure the valve
recessing or protrusion with a depth gauge [Figure 70-
To remove and replace the valve guide, make the driver 80-29].
tool as shown in figure [Figure 70-80-27].

Figure 70-80-30
Figure 70-80-28
1
1. Cylinder Head
Surface
2 2. Recessing
3. Protrusion
PI-9990
PI-9992
If the measurement exceeds the allowable limit, replace

Press the used valve guide out of the cylinder head using the valve or cylinder head [Figure 70-80-30].
the special driver tool [Figure 70-80-28].
Protrusion 0.002 in. (0,5 mm)
Put oil on the outside diameter of the new valve guide. Recessing 0.006 in. (0,15 mm)
Press the new valve guide into the cylinder head from the Allowable Limit (Recessing) 0.016 in. (0,4 mm)
top side. Use the special driver tools (Items 1 & 2)
[Figure 70-80-28], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

788 of 861
Reconditioning The Valve And Valve Seat (Cont’d) 1 2

15° Exhaust
Figure 70-80-31 30° Intake
PI-9995
Check the seat surface and valve face (Item 1) [Figure

PI-9993 70-80-33].
(a) identical dimensions above and below the valve seat

Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-31]. If the seat surface (b) is too wide, use a 30 degree cutter

(Item 2) on the intake, and a 15 degree cutter on the
Clean the valve seat and combustion chamber. exhaust to get the correct width (Item 3) [Figure 70-80-
33].
Figure 70-80-32
Valve Seat Width
Intake 0.0835 in. (2,12 mm)

Exhaust 0.0835 in. (2,12 mm)
Valve Seat & Face Angle
45° Exhaust Intake 45 degree

15° Exhaust 45° Intake Exhaust 45 degree
30° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-32].

789 of 861
Valve Spring
Figure 70-80-34
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-35].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the
measurement is less than the allowable limit, replace the spring.

spring [Figure 70-80-34].
Setting Length 1.378 in. (35,0 mm)
Free Length 1.6417-1.6614 in. (41,7-42,2 mm) Setting Load 26.4 lb. (117,6 N)
Allowable Limit 1.622 in. (41,2 mm) Allowable Limit 22.5 lb. (100,0 N)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-80-34].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 0.039 in. (1,0 mm)

790 of 861
CYLINDER HEAD (CONT'D) Rocker Arm And Shaft - Checking
Valve Tappets Figure 70-80-38
Figure 70-80-36
1
2
B-3697
P-47267
Measure the rocker arm I.D. (Item 1) [Figure 70-80-38]
with an inside micrometer.
Remove the valve tappets (Item 1) [Figure 70-80-36].
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-

Figure 70-80-37 80-38] with an outside micrometer.

bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Oil Clearance Between 0.0006 - 0.0018 in.

Rocker Arm& Shaft (0,02 - 0,05 mm)
(0,10 mm)
Rocker Arm Shaft O.D. 0.5501 - 0.5506 in.
(13,97 - 13,98 mm)
Rocker Arm I.D. 0.5512 - 0.5519 in.
P-47268 (14,0 - 14,02 mm)
Measure the O.D. of the tappet [Figure 70-80-37].
Measure the ID of the tappet bore [Figure 70-80-37].

tappets.
Tappet OD 0.943 - 0.944 in. (23,96 - 23,98mm)

Tappet Bore ID 0.945 - 0.9457 in. (24 - 24,02 mm)
Clearance
Between Tappet
and Tappet Bore 0.0008 - 0.0024 in. (0,02 - 0,06 mm)
Allowable limit 0.0028 in. (0,07 mm)

791 of 861
CRANKSHAFT AND PISTONS Figure 70-90-40
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

Remove the top edge from the cylinder bore with a ridge
reamer.
1
Remove the oil pan (See Oil Pan Removal and
Installation on page 70-60-1)
Remove the oil pump strainer (See Oil Pan Removal and
Installation on page 70-60-01). A-2903
Figure 70-90-39
Installation: Make sure the marks on the connecting rod
and bearing are aligned when installing the bearing cap
(Item 1) [Figure 70-90-40].
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

Figure 70-90-41
4
1 3
P-51633A
2
1
Turn the flywheel and put a pair of connecting rods at
bottom dead center.
Remove the connecting rod bolts.
Installation: Tighten the connecting rod bolts to 33 - 36 P-47270

Remove the rod cap and bearing [Figure 70-90-39]. Remove the piston rings [Figure 70-90-42].
Use a hammer handle and push the piston/connecting Remove the snap ring (Item 1) and piston pin (Item 2)
rod assembly out of the cylinder bore [Figure 70-90-39]. [Figure 70-90-42].
NOTE: Make sure the pistons are marked so they will Separate the piston (Item 3) from the connecting rod
be returned to the same cylinder bore and (Item 4) [Figure 70-90-42].
direction.
NOTE: Mark the piston (Item 3) [Figure 70-90-42] and
connecting rod (Item 4) [Figure 70-90-42] with
the same number to ensure correct
installation and proper cylinder placement.

792 of 861
CRANKSHAFT AND PISTONS (CONT’D) injection pump side.
Piston And Connecting Rod Removal And Piston And Connecting Rod - Servicing
Figure 70-90-44
Figure 70-90-42
1
3
P-47272
PI-10015
Measure the I.D. of the piston pin bore in both horizontal

Installation: When installing new rings, assemble the and vertical directions [Figure 70-90-44].

ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander If the measurement exceeds the allowable limit, replace
joint (Item 2) on the opposite side of the oil ring gap (Item the piston.
3) [Figure 70-90-42].
Piston Bore I.D. 0.984 - 0.985 in.
Figure 70-90-43 (25,0-25,013 mm)
3 (25,05 mm)
1
2
5
6 4
P-47271
Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in clean engine oil to 176° F (80° C) and tap the
piston pin into position. Place the piston rings so that
there are gaps every 120 degrees (Items 3, 4 & 5)
[Figure 70-90-43] with no gap facing the piston pin in the
cylinder.
NOTE: Assemble the piston to the connecting rod

with the FW mark (Item 6) [Figure 70-90-43] is
facing the flywheel side and the connecting
rod mark (Item 1) [Figure 70-90-43] facing the

793 of 861
CRANKSHAFT AND PISTONS (CONT’D) Figure 70-90-46
Piston And Connecting Rod - Servicing (Cont’d) 1.38” (35 mm)

1.063” (27 mm)
Figure 70-90-45
6.38” (162 mm)
1 1.378”
(35 mm)
1.098-1.1004”
(27,9-27,95 mm)
0.984-0.985”
(25,0-25,01 mm)
MC-1366
To replace the connecting rod small end bushing, make a

P-47273 driver tool as shown in figure [Figure 70-90-46].
Figure 70-90-47
Measure the O.D. of the piston pin (Item 1) [Figure 70-
90-45].

Measure the I.D. of the connecting rod small end (Item 2)
[Figure 70-90-45].
Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.9843 - 0.9847 in.

(25,0 - 25,11 mm)
Bushing I.D. 0.9852 - 0.9858 in.
(25,3 - 25,04 mm)
Oil Clearance Between 0.0006 - 0.0015 in. PI-10016
Piston Pin & Bushing (0,014 - 0,038 mm)
Allowable Limit 0.006 in. Use a press and special driver tool to remove the small
(0,15 mm) end bushing [Figure 70-90-47].
Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until
it is flush [Figure 70-90-47].

794 of 861
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-48
PI-10017
Remove the carbon from the ring grooves. Measure the

B-3622 clearance between the ring and groove with a feeler
gauge [Figure 70-90-49].
Install a piston ring into the lower part of the cylinder If the clearance exceeds the allowable limit, replace the
bore. Measure the ring gap with a feeler gauge [Figure ring. If the clearance still exceeds the allowable limit,

70-90-48]. replace the piston.
If the gap exceeds the allowable limit, replace the ring. Top Ring 0.0020 - 0.0035 in.
(0,05 - 0,09 mm)
Top Ring Gap 0.008 - 0.013 in. Allowable Limit 0.008 in (0,2 mm)
(0,2 - 0,35 mm)
Second ring 0.00307- 0.0043 in.
Oil Ring Gap 0.008 - 0.015 in. (0.080 - 0.110 mm)
(0,20 - 0,40 mm)
Allowable Limit 0.008 in. (0,2 mm)
Oil Ring 0.0012 - 0.0028 in. (0,03
(1,25 mm)
- 0,07 mm)
Second Ring Gap 0.012 - 0.017 in.
(0,30 - 0,45 mm)

795 of 861
CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Alignment
Cylinder Bore - Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-90-50 doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-90-52
B-4066
Use a gauge to check the inside measurement of the

cylinder bore [Figure 70-90-50].

Figure 70-90-51
B-4067
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-52].

the connecting rod.
Rod Alignment 0.002 in. (0,05 mm)
A-2717
Measure the six points as shown in figure [Figure 70-90-

51] to find the maximum wear.
The factory specification is:
3.425 - 3.426 in. (87,0 - 87,022 mm)
The allowable limit is: 3.4319 in. (87,170 mm)

796 of 861
CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings Removal And Installation
Crankshaft Gear Removal And Installation Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
Remove the timing gearcase cover. (See Timing Page 70-90-1.)
100-1.) Figure 70-90-54
Remove the idler gear. (See Idler Gear And Shaft

2 5
Servicing on Page 70-100-6.)
Figure 70-90-53
4
P-47274

Mark and remove the inside screws (Item 1) first, then
remove the outside screws (Item 2) [Figure 70-90-54].
B-3686
NOTE: The inside bolts are different length than the
outside bolts.
Remove the crankshaft gear with a puller [Figure 70-90-
53]. Install two screws in the bearing case cover and remove
the cover (Item 3) [Figure 70-90-54].
Remove the crankshaft key.
Remove the two gaskets (Item 4) and oil seal (Item 5)
[Figure 70-90-54] from the cover.
Figure 70-90-55
P-47275
Installation: Install the gaskets (Item 1) & (Item 2)

[Figure 70-90-55] as shown.

797 of 861
Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 70-90-56
1
1
P-47278
Remove the main bearing case bolt (Item 1) [Figure 70-

90-58].
P-47276
Installation: Align the bearing case hole (Item 2) [Figure
70-90-58] with the hole in the block. Put oil on the bolt
Install the bearing case cover (Item 1) [Figure 70-90-56] threads and tighten to 51 - 54 ft.-lb. (69 - 73 N•m) torque.

with the casting mark (Item 2) [Figure 70-90-56] in the
upward position. Tighten the bolts to 17 - 20 ft.-lb. (24 - Figure 70-90-59
28 N•m) torque.
Figure 70-90-57
P-47279
P-47277 Remove the crankshaft/main bearing assembly from the

engine block [Figure 70-90-59].
Before removing the crankshaft/main bearings, check the NOTE: Turn the crankshaft as needed to allow the
end play. Install a dial indicator. Move the crankshaft crank pin journals to pass through the cut out
[Figure 70-90-57] to the flywheel side, zero the dial
indicator. Measure the end play by pulling the crankshaft (Item 1) [Figure 70-90-59] of the engine block.
toward the gear case side.
Mark the bearing case halves for correct installation.
the thrust washers [Figure 70-90-57].
End Play 0.006 - 0.014 in.

(0,15-0,35 mm)
(0,5 mm)

798 of 861
CRANKSHAFT AND PISTONS (CONT’D) Crankshaft And Bearings - Servicing
Crankshaft And Bearings Removal And Installation Figure 70-90-62

(Cont’d)
Figure 70-90-60
A-2763
B-4092 Put the crankshaft on V-blocks. Install a dial indicator on

the center journal [Figure 70-90-62].
Remove the two bearing case bolts [Figure 70-90-60]. Turn the crankshaft at a slow rate to obtain the

misalignment (one half of the alignment measurement).
Remove the bearing case and bearing.
If the misalignment exceeds the allowable limit, replace
Installation: Tighten the bearing case bolts to 34 - 38 ft.- the crankshaft.
Alignment 0.0008 in. (0,02 mm)
Figure 70-90-61
Tighten the connecting rod bolts to 33 - 36 ft.-lb. (45 - 49
N•m) torque.
Figure 70-90-63
120
PI-10021
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
A-2727
side of the engine block [Figure 70-90-61]. The thrust
washers oil grooves must face outward.
Measure the crankpin bearing I.D. [Figure 70-90-63].

799 of 861
Crankshaft And Bearings - Servicing (Cont’d) 1
Figure 70-90-64
PI-10022
Check the wear on the crankshaft sleeve (Item 1) [Figure

A-2716 70-90-65].
If the wear exceeds the allowable limit or the seal leaks

Measure the crankpin O.D. [Figure 70-90-64]. oil, replace the sleeve.

Calculate the oil clearance. Wear of Sleeve 0.004 in. (0,1 mm)
Crankpin Bearing I.D. 1.850 - 1.852 in. The special tool set will be needed to replace the
(47,0 - 47,05 mm) crankshaft sleeve.
Crankpin O.D. 1.8488 - 1.8494 in.
(46,96 - 46,98 mm) Remove the sleeve.
Oil Clearance 0.0010 - 0.0034 in.
(0,025 - 0,087 mm)
Allowable limit 0.008 in. (0,2 mm)

800 of 861
Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-66
2 2
1 3
B-3618
Measure the O.D. of the crankshaft journal [Figure 70-

PI-10023 90-68].
Calculate the oil clearance.

Install the sleeve guide (Item 1) and stop (Item 2) [Figure
70-90-66]. If the clearance exceeds the allowable limit, replace the

crankshaft bearing.
Heat the sleeve to approximately 302° - 392° F (150° -
200° C). Install the sleeve on the crankshaft using the Bearing 1:
special driver tool (Item 3) [Figure 70-90-66].
Bearing I.D. 2.0362 - 2.0364 in. (59,98 - 60,04
NOTE: The sleeve is installed with the larger mm)
chamfered surface to the front of the
Journal O.D. 2.3591 - 2.3598 in. (59,92 - 59,94
crankshaft (Item 1) [Figure 70-90-65 on Page
mm)
9].
Oil Clearance 0.016 - 0.0046 in. (0,04 - 0,12 mm)
Figure 70-90-67 Allowable Limit 0.008 in. (0,2 mm)
NOTE: Make sure you use the correct size bearing

when installing. Oversize bearings are
generally marked.
B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure

70-90-67].

801 of 861

1. Seam 4
Figure 70-90-69 2. Bearing
3. Engine Block
Removal Tool 4. Bearing Recession
3
5.31” (135 mm)
0.8”
(20 mm)
2.354-2.358”
(59,8-59.9 mm)
2.83”
(72 mm) 2 1 2
P-48778
0.8” (20 mm)
2.551-2.555
1.57” 0.4” (64,8-64,9 mm) Remove the front bearing with the special removal tool
(40 mm) (10 mm) MC-1367 [Figure 70-90-69].
Installation: Clean the new bearing (Item 2) and bore,

To remove the front bearing make the tool as shown in apply oil to the bearing and bore. Install the new bearing
figure [Figure 70-90-69]. with the seam (Item 1) [Figure 70-90-71] towards the

exhaust manifold side, using the installation driver tool.
Figure 70-90-70
Check the depth (Item 4) of the bearing (Item 2) from the
Installation Tool face of the engine block (Item 3) [Figure 70-90-71]. This
5.12” (130 mm) will ensure proper bearing alignment with the crankshaft.
0.8”
(20 mm) Bearing Number 1 0.1654 - 0.1772 in.
0.16”
(4 mm) Recession (4,2 - 4,5 mm)
2.551-2.555”
2.83” (64,8-64.9 mm) Clean the crankshaft journal and bearing. Put a strip of
(72 mm) press gauge on the center journal.
2.68”
(68 mm) Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
0.8” (20 mm)
1.57” 2.354-2.358” NOTE: DO NOT turn the crankshaft with the press
0.4” (59,8-59,9 mm) gauge installed. Incorrect measurements will
(40 mm) (9mm) MC-1365 be obtained.
To install the front bearing make the tool as shown in

figure [Figure 70-90-70].

802 of 861
CRANKSHAFT AND PISTONS (CONT’D)
Figure 70-90-72
PI-10025
Measure the flattened press gauge [Figure 70-90-72].

No. 2 crankshaft bearing.
Crankshaft Journal O.D. 2.3591 - 2.3598 in.

(59,92 - 59,94 mm)
Bearing I.D. 2.3615 - 2.3631 in.
(59,98 - 60,02 mm)
Oil Clearance 0.0016 - 0.0041 in.
(0,04 - 0,12 mm)

803 of 861
CAMSHAFT AND TIMING GEARS Figure 70-100-3
Timing Gearcase Cover Removal And Installation
Figure 70-100-1
7.87” (200 mm)
P-47256
Remove the speed control plate (Item 1) [Figure 70-100-

P-47254 3].
Figure 70-100-4
Bend a hook on the end of a 7.87 in (200 mm) long,
0.050 in (1,2 mm) diameter hard wire [Figure 70-100-1].

Figure 70-100-2
P-47257
Remove the wire (Item 1) [Figure 70-100-4] from the

P-47255 springs.
Installation: Do not drop the governor springs into the

Disconnect the two governor springs (Item 1) [Figure 70- gear case.
100-2].
Remove the crankshaft pulley nut.

N•m) torque.

804 of 861
CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-7
Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 70-100-5
P-47259
Remove the timing gearcase cover [Figure 70-100-7].
P-47258 Figure 70-100-8
Use a puller and remove the crankshaft pulley. [Figure

70-100-5].
3
2
Figure 70-100-6
1
2
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2)

and oil slinger (Item 3) [Figure 70-100-8].
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2)

[Figure 70-100-6].
Remove the bolts from the timing gearcase cover.

N•m) torque.

805 of 861
CAMSHAFT AND TIMING GEARS (CONT’D) Timing Gears Backlash - Checking
Timing Gearcase Cover Removal And Installation When the gears are installed, check the backlash of the
(Cont'd) gears.
Figure 70-100-9 Figure 70-100-10
Oil Seal O-Rings
B-3617B P-47264
Installation: Install new O-rings and oil seal into the Install a dial indicator [Figure 70-100-10].

timing gearcase cover [Figure 70-100-9].
Hold one gear while turning the other gear [Figure 70-
100-10].
If the backlash exceeds the allowable limit, check the oil

clearance of the shaft and gear. If the oil clearance is
correct, replace the gear.
Crank Gear & Idler Gear 0.0016 - 0.0044 in

(0,042 - 0,112 mm)
Allowable Limit 0.006 in (0,15 mm)
Cam Gear & Idler Gear 0.0016 - 0.0045 in
(0,042 - 0,115 mm)
Allowable Limit 0.006 in (0,15mm)
Injection Pump Gear 0.0016 - 0.0045 in
& Idler Gear (0,042 - 0,115 mm)
Oil Pump Gear & Crankgear 0.0016 - 0.0043 in
(0,042 - 0,109 mm)

806 of 861
Idler Gear And Camshaft Removal And Installation
Remove the timing gearcase cover. (See Timing 2

100-1.)
Figure 70-100-11
1
2
1
P-47262
Align the holes (Item 1) on the camshaft gear with the

camshaft retainer plate bolts (Item 2) [Figure 70-100-13].
Remove the bolts.
Installation: Tighten the camshaft retainer bolts to 18 -

P-47260 20 ft.-lb. (24 - 27 N•m) torque.

Remove the camshaft from the engine block.
Remove the snap ring (Item 1) and collar from the idler
gear shaft (Item 2) [Figure 70-100-11].
Figure 70-100-14
Installation: Make sure the timing marks are in correct
alignment when installing the timing gears [Figure 70-
100-11].
Figure 70-100-12
PI-10002
Installation: Check the camshaft end play. If clearance

exceeds the allowable limit, replace the camshaft retainer
B-3699 plate [Figure 70-100-14].
Camshaft End Play 0.003 - 0.009 in

(0,07 - 0,22 mm)
Installation: Check the idler gear end play. If the Allowable Limit 0.0118 in (0,3 mm)
clearance exceeds the allowable limit, replace the gear
collar.
Idler Gear End Play 0.005 - 0.0189 (0,12 - 0,48mm)


807 of 861
Camshaft - Servicing
Figure 70-100-15
B-5001
Measure the cam lobes at their highest point [Figure 70-

P-47263 100-17].
If the measurement is less than the allowable limit,

Measure the cylinder block bore in the engine block replace the camshaft.
[Figure 70-100-15].

Cam Lobe Height 1.3346 in (33,9 mm)
Figure 70-100-16
Figure 70-100-18
A-2761
Measure the camshaft journal [Figure 70-100-16]. A-2760
Calculate the oil clearance. If the clearance exceeds the

Put the camshaft in V-blocks. Install a dial indicator
allowable limit, replace the camshaft.
[Figure 70-100-18].
Cylinder Block Bore I.D. 1.575 - 1.576in Turn the camshaft at a slow rate. If the misalignment
(40,0 - 40,025 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.572 - 1.573 in
(39,93 - 39,95 mm) Camshaft Alignment Allowable Limit 0.0004in
Oil Clearance of 0.002 - 0.0035 in (0,01 mm)
Camshaft Journal (0,05 - 0,091 mm)

808 of 861
Idler Gear And Shaft Servicing

1.49” (38 mm)
Figure 70-100-19
6.89” (175 mm)
1.77” 1.575”
(45 mm) (40 mm)
1.650-1.652”
(41,9-41,95 mm)
1.494-1.495”
(37,95-37,97 mm)
MC-1366
To replace the idler gear bushing, make a driver tool as

PI-10003 shown in figure [Figure 70-100-20].
Figure 70-100-21
Measure the O.D. of the idler gear shaft [Figure 70-100-
19].

Measure the I.D. of the idler gear bushing [Figure 70-
100-19].

bushing.
Idler Gear Shaft O.D. 1.494 - 1.495 in.

(37,96 - 37,98 mm)
Idler Gear Bushing I.D. 1.496 - 1.497 in.
(38,0 - 38,03 mm)
Clearance Between Idler 0.001 - 0.0026 in.
Shaft & Gear Bushing (0,025 - 0,07 mm) PI-10004

Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 70-100-21].

809 of 861
FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-110-2
Remove the drive belt shield. (See Shield Removal And

Remove the drive belt. (See Belt Removal And

Remove the drive belt tension pulley. (See Belt Tensioner

Figure 70-110-1
1
P-48850
The ring gear (Item 1) [Figure 70-110-2] on the flywheel

is an interference fit. Heat the ring gear enough to
1 expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.

Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
2
P-48649 Clean the new ring gear and heat it to a temperature of
450° - 500° F (232° - 260° C)
Remove the six mounting bolts (Item 1) from the engine

Fit the ring on the flywheel and be sure the gear is seated
flywheel (Item 2) [Figure 70-110-1].
correctly.
Installation: Apply engine oil to the threads and seats
before tightening. Tighten to 72 - 80 ft.-lb. (98 - 108 N•m)
torque.
Remove the flywheel from the engine.
Installation: Be sure to align the hole in the flywheel with

the pin located on the crankshaft.
Reverse the removal procedure to install the flywheel.

810 of 861
FLYWHEEL AND HOUSING (CONT’D) Figure 70-110-4
Remove the drive belt shield. (See Shield Removal And

Remove the engine/hydrostatic pump package from the

70-10-9.)
Remove the drive belt. (See Belt Removal And

Remove the drive belt tension pulley. (See Belt Tensioner

Removal And Installation on Page 30-60-4.) P-48651C
Remove the starter. (See Removal And Installation on

Page 60-40-2.) Install a puller in the drive pulley and remove the pulley
from the hydrostatic pump shaft [Figure 70-110-4].
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-110-1.) Installation: Install the pulley key in the shaft before
installing the drive pulley.
Figure 70-110-3

1
P-48651B
Remove the hydrostatic pump drive pulley mounting nut

(Item 1) [Figure 70-110-3] and washer.
Installation: Tighten the mounting nut to 175 - 200 ft.-lb.

(237 - 271 N•m) torque.

811 of 861
FLYWHEEL AND HOUSING (CONT’D) Figure 70-110-7
Housing Removal And Installation (Cont’d)
Figure 70-110-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
P-48650 110-7] which fasten the housing on the engine.

Remove the two mounting bolts (Item 1) [Figure 70-110- (48 - 54 N•m) torque.
5] from the drive belt housing which mount the

hydrostatic pump to the housing. Remove the 2 bolts (Item 2) [Figure 70-110-7] which
fasten the housing on the engine.
(88 - 95 N•m) torque. Installation: Tighten the mounting bolts to 60 - 65 ft.-lb.
(82 - 88 N•m) torque.
Figure 70-110-6
Remove the housing.
Reverse the removal procedure to install the housing.
P-4231A

from engine coolant tubeline mounting bracket which is
attached to the flywheel housing.
Installation: Tighten the mounting bolt to 25 - 28 ft.-lb.

(34 - 38 N•m) torque.

812 of 861

813 of 861
HEATER
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-4
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-2
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operators Normally, But Air Flow Is Insufficient . 80-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . 80-30-6
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . 80-30-7
HEATER

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.

MAY VARY.

814 of 861

815 of 861
HEATER SYSTEM Figure 80-10-3
Description
Figure 80-10-1 1
2 3
N-20876
Control Panel: The panel (Item 1) [Figure 80-10-3] has

P-67081 two separate components.
Fan Switch: This is a four position rotary switch (Item 2)

Heater Unit: The heater (Item 1) [Figure 80-10-1] is [Figure 80-10-3]. When the fan switch is in the off
located behind the loader cab. The unit delivers the warm position the heat valve will operate, as it is controlled by

air for heat into the cab. The unit contains the blower and the ignition power.
heater coil.
Potentiometer: The potentiometer (Item 3) [Figure 80-
Figure 80-10-2 10-3] controls the Heater Valve (Item 1) [Figure 80-10-4]
from fully Off to fully On. This can be used for defrost of
the windows and temperature control.
2
1
N-22092
Heater Coil: The heater coil (Item 1) [Figure 80-10-2]

supplies the warm air into the cab by passing air through
the coil.
Heater Blower: The blower (Item 2) [Figure 80-10-2] is

used to push air through the heater and into the cab.

816 of 861
HEATER SYSTEM (CONT’D)
Description (Cont'd)
Figure 80-10-4
P-66921
Heater Valve: The heater valve (Item 1) [Figure 80-10-4]

is used to control the amount of engine coolant that flows

to the heater coil.

817 of 861
REGULAR MAINTENANCE Heater Coil
Filters Raise the operator cab. (See Raising on Page 10-30-2.)
1
1
P-48012
P-76565
The Fresh Air Filter (Item 1) [Figure 80-20-1] is located
below the rear window outside the cab. Remove the
Remove the cover screws (Item 1) [Figure 80-20-3] and
clamping knobs, filter cover and filter.
remove the cover.
Shake the filter or use low pressure air to remove dirt.
Figure 80-20-4
This can be done several times before replacement is

required. Install the filter, filter cover and clamping knobs.
1
Figure 80-20-2
P-43852A
Use low pressure air or water to remove debris from the

1 heater coil (Item 1) [Figure 80-20-4].
P-48005
Install the cover and lower the operator cab. (See
Lowering on Page 10-30-3.)
The Recirculation Filter (Item 1) [Figure 80-20-2] is
located in front of the rear window inside the cab.
Remove the clamping knobs, filter cover, and filter.
Shake the filter or use a vacuum to clean. This can be

done several times before replacement is required. Install
the filter with the arrows pointing forward (Inset) [Figure
80-20-2], install the filter cover and clamping knobs.

818 of 861

819 of 861
TROUBLESHOOTING
Blower Motor Does Not Operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Motor.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower Motor Operators Normally, But Air Flow Is Insufficient
POSSIBLE CAUSE INSPECTION SOLUTION

1. Air leak. Check to make sure air hoses are properly hooked to Repair or adjust.
Louvers, and air ducts.
2. Plugged cab filters. Check cab filter condition. Clean or replace filters.

820 of 861
TROUBLESHOOTING (CONT’D) Figure 80-30-3
Electrical System
NOTE: The key must be put in the ON position when

checking for power in circuits.
Figure 80-30-1
1 1
P-68444
Check the loader harness (Item 1) [Figure 80-30-3] for

voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the

P-66829 harness for broken wires or blown fuse.

If there is voltage at the wiring harness, check the
Remove the access cover (Item 1) [Figure 80-30-1] from resistance to the blower fan at the blower fan wiring
the operator cab. connector (Item 2) [Figure 80-30-3].
Figure 80-30-2 If there is no resistance value replace the blower fan.

(See Removal And Installation on Page 80-60-1.)
If there is a resistance value check the climate controls at

the control panel inside the loader cab.
P-68118
Disconnect the blower fan wiring connector (Item 1)

[Figure 80-30-2] from the loader wiring harness.

821 of 861
Electrical System (Cont'd)
Figure 80-30-4 1
P-28918
1
Disconnect the loader wiring harness (Item 1) [Figure

N-20876 80-30-6] from the blower switch.
Check the loader harness for voltage. The voltage should

Remove the three mount screws (Item 1) [Figure 80-30- be 12 volts.
4] from the cab control panel.

If there is no voltage at the wiring harness, check the
Figure 80-30-5 harness for broken wires or blown fuse.
P-28920
Remove the control panel and wiring harness from the

cab [Figure 80-30-5].

822 of 861
Figure 80-30-7
C
H
B
M
L P-28920
The potentiometer will affect the operation of the heater.

N-22288
If heater valve does not open, or close, check the
potentiometer.
If there is voltage at the wiring harness, check the blower
switch [Figure 80-30-7] for resistance. At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-8] from the potentiometer.
With the switch in the OFF position, there should be zero
resistance between all terminals. Figure 80-30-9
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal,
between the C terminal and the L terminal and also
between the B terminal and the L terminal frame [Figure
80-30-7].

resistance between C terminal and the B terminal,
between the C terminal and the M terminal and also 1
between the B and the M terminal frame [Figure 80-30-
7].

resistance between C terminal and the B terminal, P-28919
between the C terminal and the H terminal and also
between the B terminal and the H terminal frame [Figure
80-30-7]. Check the loader harness (Item 1) [Figure 80-30-9] for
voltage. The voltage should be 12 volts.
If any of the above resistance tests fail, replace the
blower switch. If there is no voltage at the wiring harness, check the
harness for broken wires or blown fuse.
If the above resistance tests are good, check the
potentiometer.

823 of 861
Figure 80-30-10
A C
1
N-22175
B
To check the resistance of the white wire, turn the

N-22290 potentiometer control (Item 1) [Figure 80-30-12] to the
full A/C position.
If there is voltage at the wiring harness, check the Figure 80-30-13

potentiometer [Figure 80-30-10] for resistance.

The resistance should be 10 K Ohm's between wire
terminal A and wire terminal C frame [Figure 80-30-10].
If no resistance is found replace the potentiometer.

A C
Figure 80-30-11
N-22290
The resistance between the wire terminal A and wire

1 terminal B frame [Figure 80-30-13] should be
approximately 49 K Ohm's.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 80-30-13] should be
approximately 39 K Ohm's.
The white wire B, (Item 1) [Figure 80-30-11], on the

potentiometer, is a resistor wire.

824 of 861
TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Figure 80-30-16
Figure 80-30-14
N-20876
N-22175
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-30-14] to the Turn the fan switch (Item 1) [Figure 80-30-16] to the

full Heater position. High Speed position, with the loader ignition switch OFF.
Figure 80-30-15 Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 80-30-17
A C
N-22290
P-68119
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-30-15] should be
approximately 39 K Ohm's. Connect the remote start tool to the loader. (See
Check the resistance between the wire terminal C and 1.)
wire terminal B frame [Figure 80-30-15] should be
approximately 49 K Ohm's. Start the loader and run at high idle, for ten minutes.
If the resistance is not found replace the potentiometer. Check the heater hose (Item 1) [Figure 80-30-17] for
temperature.
If the hose is hot, the heater valve is leaking by, and


825 of 861
Heater Valve Not Opening Or Closing
Figure 80-30-18
2
1 P-68117
Place the remote start tool on the left fender of the loader,
N-20876 so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-19], as the key of the remote
start tool is turned to the ON position without starting the
Raise the lift arms and install an approved lift arm support loader. The heater valve should rotate. Place a mark on
device. (See Installing on Page 10-20-1.) the heater valve shaft.

Turn the fan switch (Item 1) to position 1. Turn the Turn the key of the remote start tool to the OFF position
temperature control (Item 2) [Figure 80-30-18] to the and remove the remote start tool from fender.
High cold position, with the loader ignition switch OFF.
Lower operator cab.
Turn the temperature control (Item 2) [Figure 80-30-18]
Connect the remote start tool to the loader. (See to the High Heater position, with the loader ignition switch
REMOTE START TOOL KIT -MEL1563 on Page 10-60- OFF.
1.)
Raise the operator cab.
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-19], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-2.)
Replace the heater valve. (See Removal and Installation

on Page 80-70-1.)

826 of 861

827 of 861
HEATER UNIT Figure 80-40-3
Figure 80-40-1
1 P-68840
Remove the two mounting nuts (Item 1) [Figure 80-40-3]

at the right side.
Figure 80-40-4

P-66829
Remove the access cover (Item 2) [Figure 80-40-1] from

the operator cab.
1
Figure 80-40-2
P-68841
1
Remove the two mounting nuts (Item 1) [Figure 80-40-4]
at the left side.
P-68118
Disconnect the blower fan wiring connector (Item 1)

[Figure 80-40-2] from the loader wiring harness.

828 of 861
HEATER UNIT (CONT’D)
Figure 80-40-5
P-66921
Remove the heater hoses (Item 1) [Figure 80-40-5] from

the heater coil.

Remove the heater unit from the loader.
Reverse the removal procedure to install the heater unit.

829 of 861
HEATER COIL Figure 80-50-2
Figure 80-50-1
1
1
2
N-22093
Remove the three mount bolts (Item 1) [Figure 80-50-2]

P-66921 and remove the mount plate from the end of the unit.
Figure 80-50-3

Remove the heater unit from the back of the cab. (See
1
Remove the heater valve (Item 1) [Figure 80-50-1]. (See
Removal and Installation on Page 80-70-1.)
Mark the heater hoses (Item 2) [Figure 80-50-1] for

proper installation.
Cap the hoses and the heater coil with hydraulic caps N-22094
and plugs to prevent oil loss from the system.
Remove the rear cover from the heater unit. (See Heater Remove the two mount bolts (Item 1) [Figure 80-50-3]
Coil on Page 80-20-1.) from the heater coil.
Remove the heater coil from the unit.
Reverse the removal procedure to install the heater coil.

830 of 861

831 of 861
BLOWER FAN Figure 80-60-3
Raise the lift arms and install an approved lift arm support 1
NOTE: The blower fan assembly can be removed

from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is remove here for photo clarity.
Figure 80-60-1
P-39553
1 Remove the two flange mount bolts (Item 1) [Figure 80-

60-3] from the evaporator/heater unit.
Figure 80-60-4

P-39550
1
Remove the cover (Item 1) [Figure 80-60-1] from the
evaporator/heater unit.
Figure 80-60-2
P-39554
1 Remove the flange and attached foam (Item 1) [Figure

80-60-4] from the unit.
P-68120
Remove the two flange mount bolts (Item 1) [Figure 80-

60-2] from the evaporator/heater unit.

832 of 861
BLOWER FAN (CONT'D) Disassembly And Assembly
Figure 80-60-5
1 1
2 N-22102
P-68120A
Remove the eight mount bolts (Item 1) [Figure 80-60-7]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-60-5] from the unit. Remove the blower wheel cover from the housings.

Figure 80-60-6 Remove the four mount bolts (Item 2) [Figure 80-60-7]
from the blower motor mount.
1
Remove the blower motor mount.
Remove the blower motor assembly from the housing.
Figure 80-60-8
P-39556
Remove the three mount bolts (Item 1) [Figure 80-60-6] 1

from the blower fan housing.
2
Remove the blower fan housing from the evaporator/
heater unit.
N-22107
Check the blower housing (Item 1) and blower motor

mount (Item 2) [Figure 80-60-8] for wear and replace as
needed.

833 of 861
BLOWER FAN (CONT'D) Figure 80-60-11
Figure 80-60-9
N-22110
2 Figure 80-60-12
N-22108
Remove the outside rings (Item 1) and blower wheel

covers (Item 2) [Figure 80-60-9] from the blower motor

and blower wheels.
Figure 80-60-10
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-60-11] & [Figure 80-60-12] from the blower wheel.
N-22109
Inspect the end rings and blower wheel covers for wear
and replace as needed [Figure 80-60-10].

834 of 861
BLOWER FAN (CONT'D) Connector Identification
Disassembly And Assembly (Cont'd) Figure 80-60-15
Figure 80-60-13
P-68118
N-22111
The wiring code for the blower fan connector [Figure 80-
60-15] is:
Remove the inside blower wheel clamp (Item 1) [Figure
80-60-13] from the blower wheel. Number on Connector Wire Color

A Orange
Figure 80-60-14
B Red
C Yellow
D Black
1
N-22116
Remove the blower wheel (Item 1) and inside ring (Item

2) [Figure 80-60-14] from the blower motor shaft.
Repeat the procedure for the other blower wheel.

835 of 861
HEATER VALVE Figure 80-70-2
Remove the Heater Unit from under the cab and place it
across the mainframe supported by blocks (See Removal
Remove any tie-straps that hold the heater hoses. 1
Figure 80-70-1 P-66922
Disconnect the loader wiring harness (Item 1) [Figure

80-70-2] from the heater valve.

1 2
3
P-66921
Remove the mount bolts (Item 1) [Figure 80-70-1] from

the heater valve mount.
Remove the heater hose clamps (Item 2) & (Item 3)

[Figure 80-70-1].
Remove the heater hoses from the heater valve.
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.

836 of 861
HEATER VALVE (CONT'D) Figure 80-70-5
Figure 80-70-3 1
P-66925

P-66923 5] from the heater valve mount plate.
Remove the mount plate (Item 2) [Figure 80-70-5] from

Remove the three mount bolts (Item 1) [Figure 80-70-3] the heater valve bracket.
from the heater valve actuator.

Figure 80-70-6
Figure 80-70-4
1
1 1
2
2
P-66926
P-66924

Remove the actuator (Item 1) and the three mounting 6] from the heater valve.
spacers (Item 2) [Figure 80-70-4] from the heater valve
mount plate.

837 of 861
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . SPEC-50-1 SAFETY &
MAINTENANCE
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-30-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-4
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-30-2
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
DRIVE
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS SPEC-40-1 SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
(S150) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3

ELECTRICAL
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 SYSTEM &
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 ANALYSIS
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 ENGINE
SERVICE
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-20-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-20-1
SPECIFICATIONS


ITEMS MAY VARY.
SPEC-01 S150 Service Manual

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SPEC-02 S150 Service Manual

839 of 861
(S150) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and Construction & Industry bucket and may vary with
other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters
enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
68.0 in.
92.3° (1727 mm) 82.4 in.
(2093 mm)
148.0 in.
(3759 mm)
44°
114.5 in.
18.1 in.

(2908 mm)
(461 mm)
76.3 in. 86.5 in.

(1938 mm) (2197 mm)
23° 25°
7.5 in. 40.6 in.

(191 mm) (1030 mm)
55.1 in.
101.8 in.
(2586 mm) (1400 mm)
130.3 in. 66.0 in.
(3310 mm) (1676 mm)
B-22353 B-22354
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
SPEC-10-1 S150 Service Manual

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(S150) LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity (ISO) 1500 lb. (680 kg)
Tipping Load (ISO Rating) 3101 lb. (1407 kg)
Operating Weight 5935 lb. (2692 kg)
SAE Breakout Force - Lift 3200 lbf. (1451 kg)
SAE Breakout Force - Tilt 3050 lbf. (1383 kg)
Push Force 3950 lb. (1792 kg)
Travel Speed
- Single Speed Loader 7.3 mph (11,8 km/hr.)
- Two-Speed Loader (Opt.) Low/High 7.5 mph (12,1 km/hr.) / 11.1 mph (17,9 km/hr.)
Controls
Vehicle Steering Direction and speed controlled by two hand levers or optional joysticks.
Loader Hydraulics
- Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System (ACS)
or optional Selectable Joystick Control (SJC)
- Front Auxiliary (Std.) Controlled by electrical switch on Right Hand steering lever or optional Right
Hand Selectable Joystick Control (SJC)
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or optional Left Hand

Selectable Joystick Control (SJC)
Auxiliary Pressure Release Pressure relieved through front quick couplers. Push couplers in, hold for 5
seconds.
Engine Hand lever speed control; key-type start switch or optional keyless start, and
function error shutdown.
Starting Aid Glow Plugs - Automatically activated by Key Switch or Keyless instrumentation.
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers.
Secondary Brake One of the hydrostatic transmissions.
Engine
Make/Model Kubota V2403-M-DI-E3B

Fuel/Cooling Diesel / Liquid
Horsepower (SAE Net) 46 HP (34,3 kW) @ 2700 RPM
Torque (SAE Net) 109.6 ft.-lb. (148,6 N•m) @ 1650 RPM
Number of Cylinders Four
Displacement 148.5 cu. in. (2,433 L)
Bore/Stroke 3.425 in. / 4.03 in. (87 mm / 102,4 mm)
Lubrication Gear Pump Pressure system with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel Compression
Low Idle 1075 - 1225 RPM
High Idle 2760 - 2900 RPM

841 of 861
Hydraulic System
Pump Type Engine driven gear type

Pump Capacity 16.9 GPM (64 L/min.) @ 3135 Pump RPM @ 91% efficiency
System Relief at Quick Couplers 3250 - 3350 PSI (224 - 231 bar)
Filters Full flow replaceable, 3-micron synthetic media element.
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 2.25 in. (57,1 mm)
Tilt Cylinder (2) 2.75 in. (69,8 mm)
Rod Diameter: Lift Cylinder (2) 1.50 in. (38,1 mm)
Tilt Cylinder (2) 1.375 in. (34,9 mm)
Stroke: Lift Cylinder (2) 23.67 in. (601 mm)
Tilt Cylinder (2) 13.19 in. (335 mm)
Control Valve 3 spool, open center type with float detent on lift
and electrically controlled auxiliary spool.
Fluid Lines SAE standard tubelines, hoses and fittings.
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (2.5 Gal.)
6903118 - (5 Gal.)
6903119 - (55 Gal.)

Hydraulic Function Time:
Raise Lift Arms 3.3 Seconds
Lower Lift Arms 2.2 Seconds
Bucket Dump 2.5 Seconds
Bucket Rollback 1.9 Seconds
Electrical
Alternator Belt driven, 90 amps ventilated

Battery 12 volts, 600 cold cranking amps @ 0° F (-18° C);
115 Minute reserve capacity at 25 amps.
Starter 12 volts; gear reduction type, 3.62 HP (2,7 kW)
Instrumentation Standard Instrumentation:
Gauges:
Hourmeter, Fuel, Engine Temperature.
Warning Lights:
Engine Coolant Temperature, Engine Oil Pressure, Hydraulic Oil Temperature
& Charge Pressure, Hydraulic Filter, Engine Air Filter, Seat Belt, Fuel Level,
General Warning, System Voltage.
Indicators:
Attachment Control Device (ACD), Advanced Control System (ACS), BICS
Functions, Engine Preheat, Headlights, Bucket Positioning, Attachment
Auxiliary Hydraulics modes.
Optional Instrumentation:
Same gauges and warning lights as standard Instrumentation.
- Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
- Additional Features Include: Keyless Start with password capability, Digital
Clock, Attachment Information, Digital Tachometer, High-Flow & Two-Speed
Lockouts, Multi-Language Display, Help Screens, Diagnostic Capability &
Engine / Hydraulic Systems Shutdown Function.

842 of 861
Drive System
Main Drive Hydrostatic 4 wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final Drive Pre-stressed #80 HSOC endless roller chain (no master link) and sprockets in
sealed chaincase with oil lubrication (Chains do not require periodic
adjustments) Two chains per side with no idler sprocket
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 in. (50,8 mm), Heat treated
Wheel Bolts Eight 9/16 inch wheel bolts fixed to axle hubs
Capacities
Fuel 24 Gal. (90,8 L)

Engine Lubrication & Filter 9.2 qt. (8,7 L)
Engine Cooling System w/o Heater 10.8 qt. (10,2 L)
Engine Cooling System w/ Heater 12 qt. (11,3 L)
Hydraulic/Hydrostatic Reservoir 4.8 Gal. (18,2 L)

Hydraulic/Hydrostatic System 9 Gal. (34,1 L)
Chaincase Reservoir 8.0 Gal. (30,3 L)
Tires
Bobcat Standard Duty 10-16.5 8 PR Bobcat Standard Duty

Bobcat Severe Duty Bobcat Severe Duty 10 - 16.5 10 Ply Rating
Bulky Hulk Bobcat Super Float 31.5 x 13 - 16.5
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.

843 of 861
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
Thread
SAE Grade 5 SAE Grade 8
Size
in.-lb. 0.250 80 - 90 110 - 120
(N•m) (9,0 - 10,2) (12,4 - 13,6)
0.3125 180 - 200 215 - 240
(20,3 - 22,6) (24,2 - 27-1)
ft.-lb. 0.375 25 - 28 35 - 40
(N•m) (34 - 38) (47 - 54)
0.4375 40 - 45 60 - 65
(54 - 61) (81 - 88)
0.500 65 - 70 90 - 100
(88 - 95) (122 - 136)
0.5625 90 - 100 125 - 140
(122 - 136) (170 - 190)
0.625 125 - 140 175 - 190
(170 - 190) (240 - 260)

0.750 220 - 245 300 - 330
(300 - 330) (410 - 450)
0.875 330 - 360 475 - 525
(450 - 490) (645 - 710)
1.000 475 - 525 725 - 800
(645 - 710) (985 - 1085)
1.125 650 - 720 1050 - 1175
(880 - 975) (1425 - 1600)
1.250 900 - 1000 1475 - 1625
(1200 - 1360) (2000 - 2200)
1.375 1200 - 1350 2000 - 2200
(1630 - 1830) (2720 - 2980)
1.500 1500 - 1650 2600 - 2850
(2040 - 2240) (3530 - 3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680 - 5150)
1.750 2500 - 2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150 - 3500 5500 - 6100
(4270 - 4750) (7450 - 8300)
2.000 3800 - 4200 6500 - 7200
(5150 - 5700) (8800 - 9800)

844 of 861
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M 6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M 8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M 10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M 12 x 1.25 22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
M 14 x 1.25 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)

845 of 861
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (N•m)
IMPORTANT 1/4” 9/16” - 18 13 (18)
3/8” 11/16” - 16 22 (30)
1/2” 13/16” - 16 40 (54)
parts clean. Always use caps and plugs on hoses, 5/8” 1” - 14 60 (81)
tubelines and ports to keep dirt out. Dirt can quickly 3/4” 1-3/16” - 12 84 (114)
damage the system.
I-2003-0888
7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-30-1 1-1/4” 1-11/16” - 12 154 (209)
1-1/2” 2” - 12 163 (221)

B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].

846 of 861
HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Straight Thread O-ring Fitting restrict flow, which will slow hydraulic action and cause
heat.
Figure SPEC-30-3
Replace hoses which show signs of wear, damage or
weather cracked rubber.
Always use two wrenches when loosening and tightening

Nut Nut hose or tubeline fittings.
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until

the washer is tight against the surface [Figure SPEC-30-
3].

847 of 861
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)
Flare Fitting
Figure SPEC-30-4
TS-1619
Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-30-4]
Figure SPEC-30-5
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (N•m)
1/4” 7/16” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)
Use the chart [Figure SPEC-30-5] to find the correct

tightness needed (Item 2) [Figure SPEC-30-4]. If the
fitting leaks after tightening, disconnect it and inspect the
seat area for damage.

848 of 861
HYDRAULIC CONNECTION SPECIFICATIONS Port seal and nut, washer and O-ring (O-ring Boss)
(CONT'D) fittings use the same tightening torque valve chart.
Port Seal Fitting If a torque wrench cannot be used, use the following
method.
Figure SPEC-30-6
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Nut Seals NOTE: If a torque wrench cannot be used, use the

To Fitting hex flat tightening method as an approximate
guideline.
Nut Seals NOTE: Port seal fittings are not recommended in all
To Port applications. Use O-ring boss fittings in these
applications.

Secondary O-ring Seal P-13008
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-30-6].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Figure SPEC-30-7
Port Seal and O-ring Boss

Tightening Torque
x TORQUE
x ft.-lb.
Thread Size (N•m)
7/16” - 20 13 (18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
1-5/8” - 12 163 (221)
Use the following procedure to tighten the port seal

fitting:

849 of 861
HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
Use Bobcat hydraulic/hydrostatic transmission fluid
(P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.), During cold weather (32°F [0°C] and below), do not
(P/N 6903119 - 55 Gal.). operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285

DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below zero degree F (-18° C) are

common, the loader must be kept in a warm building.
Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
not flow easily and it makes action of the hydraulic
function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can
cause transmission damage in less than 60 seconds.

850 of 861

851 of 861
CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion Chart

852 of 861

853 of 861
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: S150 - 1

Date: 4 March 2008
Product: Bobcat Loader
Model: S150
Manual No: 6986566 (3-08)
The following Sections are a revision to the above Service Manual.

COVER
10-110
Printed in U.S.A.
854 of 861
855 of 861
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 11 May 2008
Model: S150
Manual No: 6986566 (5-08)

COVER
30-22 REMOVED
30-41 REMOVED
50-112
SECTION 80
Printed in U.S.A.
856 of 861
857 of 861
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 3 March 2009
Model: S150
Manual No: 6986566 (3-09)

COVER
FOREWORD
10-01
20-01
30-01
30-51
40-01
50-01
60-01
70-01
80-01
SPEC-01
Printed in U.S.A.
858 of 861
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ROUTE TO
ATTENTION
PARTS MANAGER

Date: 1 July 2009
Model: S150
Manual No: 6986566 (7-09)

COVER
MAINTENANCE SAFETY
70-70
Printed in U.S.A.
860 of 861
861 of 861

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Service Manual

S150 Skid-Steer Loader

S/N A3L111001 - A3L119999

Dealer Copy -- Not for Resale

© Bobcat Company 2009

CORRECT CORRECT CORRECT

P-90216 B-15590 B-15591

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

B-15600 B-15601 B-6589

ACCESS PANEL (INSIDE) ..................................... 50-01 ENGINE COOLING SYSTEM .................................70-01

Dealer Copy -- Not for Resale

DIAGNOSTICS SERVICE CODES......................... 60-01

ELECTRICAL/HYD. CONTROLS ........................... 60-01

S150 Service Manual

LIFT ARMS ..............................................................50-01 WHEEL SPEED SENSOR (SJC) ............................ 60-01

MAIN RELIEF VALVE ..............................................20-01

PASSWORD SETUP (IF EQUIPPED WITH

Dealer Copy -- Not for Resale

SEAT BAR ...............................................................50-01

S150 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

Dealer Copy -- Not for Resale

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER

I S150 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

4. The seat bar must be 12. Safety treads must be in good

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

II S150 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

III S150 Service Manual

IV S150 Service Manual

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

V S150 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

VI S150 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use