Service Manual: S/N 525011001 & Above S/N 525111001 & Above S/N 525211001 & Above S/N 525311001 & Above

Service
Manual
S/N 525011001 & Above

S/N 525111001 & Above
S/N 525211001 & Above
S/N 525311001 & Above
INCLUDES HIGH FLOW
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6902732 (2-06) Printed in U.S.A. Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators 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-2003-0903
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
B-10731a B-15535 B-15524
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-15734 B-15732 B-15525

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 approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15733 B-15523 B-6589

B-16102 B-16102
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.
MSW07-0805
ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM (ACS) FAN GEARBOX.......................................................10-01

SELECTABLE HAND/FOOT CONTROL .............. 60-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01
AIR CLEANER .................................................... 70-01 FLYWHEEL AND HOUSING ............................... 70-01
AIR CLEANER SERVICE ....................................... 10-01 FLYWHEEL RPM SENSOR ....................................60-01
AIR CONDITIONING SERVICE.............................. 80-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FUEL SYSTEM........................................................10-01
ALTERNATOR ........................................................ 60-01 FUEL TANK .............................................................50-01
GENERAL AIR CONDITIONING SERVICE
BATTERY ............................................................... 60-01 GUIDELINES .........................................................80-01
BASIC TROUBLESHOOTING ................................80-01
BICS SYSTEM .................................................... 60-01 HEATER COIL.........................................................80-01
BOBCAT CONTROLLER ....................................60-01 HEATER/AC FAN ....................................................80-01
BOB-TACH .............................................. 10-01, 50-01 HEATER VALVE .....................................................80-01
BRAKE .................................................................... 40-01 HIGH FLOW VALVE................................................20-01
BUCKET POSITION VALVE ............................... 20-01 HYDRAULIC CONNECTION SPECS. .............. SPEC-01
HYDRAULIC CONTROL VALVE.............................20-01
CALIBRATION ........................................................ 60-01 HYDRAULIC FILTER HOUSING.............................20-01
CHAINCASE ........................................................... 40-01 HYDRAULIC FLUID SPECIFICATIONS ........... SPEC-01
CHARGE PRESSURE ............................................ 30-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
COMPONENTS ...................................................... 80-01 HYDRAULIC/HYDROSTATIC SYSTEM .................10-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC PUMP ................................................20-01
CONDENSER ......................................................... 80-01 HYDRAULIC PUMP (HIGH FLOW).........................20-01
CONTROL HANDLE ............................................... 50-01 HYDRAULIC PUMP (HIGH FLOW) (SJC)...............20-01
CONTROL HANDLE (SJC)..................................... 50-01 HYDARULIC PUMP (SJC) ......................................20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDRAULIC SYSTEM INFORMATION ..................20-01
(ACS) SELECTABLE HAND/FOOT CONTROL ... 50-01 HYDROSTATIC MOTOR .................................... 30-01
CONTROL PANEL.................................................. 50-01 HYDROSTATIC MOTOR CARRIER .......................30-01
CONTROL PANEL (SJC) ....................................... 50-01 HYDROSTATIC MOTOR CARRIER (SJC) .............30-01
CONTROL PEDALS ............................................... 50-01 HYDROSTATIC PUMP ....................................... 30-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDROSTATIC SYSTEM INFORMATION .........30-01
CONTROLLER (SELECTABLE JOYSTICK CONTROL)
(SJC) ..................................................................... 50-01 INSTRUMENT PANEL ............................................60-01
CONVERSIONS ............................................SPEC-01
COOLING FAN ....................................................... 70-01 LIFT ARMS ..............................................................50-01
CYLINDER (LIFT) ................................................... 20-01 LIFT ARM BY-PASS CONTROL VALVE ............ 20-01
CYLINDER (POWER BOB-TACH) ......................... 20-01 LIFT ARM SUPPORT DEVICE ........................... 10-01
CYLINDER (TILT) ................................................ 20-01 LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS ................................................................60-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 LOADER SPECIFICATIONS ............................. SPEC-01
DRIVE BELT ........................................................... 30-01 LUBRICATING THE LOADER ................................10-01
DRIVE COMPONENTS .......................................... 40-01
MAIN RELIEF VALVE .............................................20-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 MUFFLER................................................................70-01
ELECTRICAL/HYRAULIC CONTROLS REF.......... 60-01
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE OIL COOLER...........................................................30-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01 OPERATOR CAB .........................................10-01, 50-01
ENGINE ................................................................. 70-01 OPERATOR SEAT ..................................................50-01
ENGINE COMPONENTS AND TESTING .............. 70-01 OPERATOR SEAT (SUSPENSION) .......................50-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM ......................... 10-01 POWER BOB-TACH ................................10-01, 50-01
ENGINE SPECIFICATIONS ..........................SPEC-01 POWER BOB-TACH BLOCK ..................................20-01
ENGINE SPEED CONTROL .................................. 70-01 PRESSURE RELIEF VALVE...................................80-01
EVAPORATOR ....................................................... 80-01 PRESSURE SWITCH..............................................80-01
EVAPORATOR/HEATER UNIT .............................. 80-01
EXPANSION VALVE .............................................. 80-01
ALPHABETICAL INDEX (CONTD)
RADIATOR ............................................................. 70-01

REAR AUXILIARY DIVERTER VALVE ...................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ...........................................................50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE-V2203-M-DI AND
V2003-M-DI-T (TURBO) ....................................... 70-01
REGULAR MAINTENANCE ................................... 80-01
REMOTE START ................................................ 10-01
RPM SENSOR ....................................................70-01
SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR...............................................60-01
SERVICE PC (LAPTOP COMPUTER)....................60-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER............................. 10-01
SPEED SENSOR ................................................... 60-01
STARTER ................................................................60-01
SYSTEM CHARGING AND RECLAMATION ......... 80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE/PRESSURE................................ 80-01
THERMOSTAT ....................................................... 80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS ... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER ............10-01
TROUBLESHOOTING.............................................70-01
TURBOCHARGER ..................................................70-01
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X HYDROSTATIC

SYSTEM
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . XI
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SERVICE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
S175, S185 Bobcat Loader

I Service Manual
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 lift arm support device, 9. The parking brake must
replace if damaged. (Stored function correctly.
Position)
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 (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers and foot 15. Inspect for fuel, oil or

pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct function of 16. Lubricate the loader.

the work lights

II Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to
service.
21. Inspect for loose or broken

parts or connections.
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.

III Service Manual
IV Service Manual
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, Operators 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 Operators Handbook fastened to the operator
can cause injury or death. cab. Its 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.
WARNING The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
The Skid-Steer Loader Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
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.
The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI SSL-0206 SM

V Service Manual
SAFETY INSTRUCTIONS (CONTD)
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.
Call Before You Dig

1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM

VI Service Manual
SAFETY INSTRUCTIONS (CONTD) Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
The operator cab, engine compartment, and engine

Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
Always clean the machine, disconnect the battery,

and disconnect the wiring from the 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 a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI SSL-0206 SM

VII Service Manual
VIII Service Manual
SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 3

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.
Loader Serial Number
Figure 2
P-48387
The engine serial number is in the location shown

[Figure 3].
P-31846
The loader serial number plate is located on the outside

of the loader frame [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
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.

IX Service Manual
DELIVERY REPORT
Figure 4
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
4].

X Service Manual
BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS OPERATOR SEAT

WITH SEAT BELT
SEAT BAR
REAR AUXILIARY
GRAB HANDLES QUICK COUPLERS
STEERING
LEVER
TILT CYLINDER
STABILIZER ROD
BUCKET
FRONT AUXILIARY
QUICK COUPLERS
BUCKET STEPS SAFETY TREAD
zOPERATOR CAB
REAR WINDOW (ROPS & FOPS)
LIFT ARM LINK
REAR GRILL
LIFT ARM
TAIL LIGHT LIFT CYLINDER

LIFT ARM
SUPPORT DEVICE
REAR
LIGHT
REAR DOOR
* TIRES
B-16604
B-16605
OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)
* TIRES - The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section and your
Bobcat dealer for available tires.
BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective
Structure per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a
standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

XI Service Manual
XII Service Manual
SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 SAFETY &
MAINTENANCE
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 DRIVE
SYSTEM
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 ELECTRICAL
SYSTEM &
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 ANALYSIS
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing Oil From The Chaincase. . . . . . . . . . . . . . . . . 10-130-1
ENGINE
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2 SPECIFICATIONS
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . 10-120-1
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1
Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . 10-160-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Continued On Next Page

10-01 Service Manual
SAFETY AND MAINTENANCE (CONTD)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . 10-151-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Figure 10-10-1
N-18877
B-7023A
Put the floor jack under the front of the loader [Figure 10-
10-2].
Lift the front of the loader and put jackstands under the
WARNING axle tubes [Figure 10-10-2].
NOTE: Make sure the jackstands do not touch the

Instructions are necessary before operating or
tires. Make sure tires clear floor or any
servicing machine. Read and understand the
obstacles.
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
Figure 10-10-3
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-2003-0199
Procedure
Always park the loader on a level surface.
WARNING P-31849
Put jackstands under the front axles and rear corners

of the frame before running the engine for service.
Put the floor jack under the rear of the loader [Figure 10-
Failure to use jackstands can allow the machine to
10-3].
fall or move and cause injury or death.
W-2017-0286
Lift the rear of the loader and install jackstands [Figure
10-10-3].

10-10-1 Service Manual
LIFT ARM SUPPORT DEVICE Figure 10-20-2
Installing Lift Arm Support Device
1
WARNING P-34556
Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-31857
WARNING The operator must be in the operator's seat, with the seat
belt fastened and seat bar lowered, until the lift arm
support device is installed.
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or Start the engine, and raise the lift arms all the way up.
with missing parts can cause lift arms to drop
causing injury or death. Have a second person install the lift arm support device
W-2271-1197 (Item 1) [Figure 10-20-2] over the rod of one of the lift
cylinders.
Figure 10-20-1
The lift arm support device must be tight against the
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].
P-31849
1
P-31842
Put jackstands under the rear corners of the loader frame

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

20-1] from storage position.

LIFT ARM SUPPORT DEVICE (CONTD)
Installing Lift Arm Support Device (Contd)
Figure 10-20-3
P-31856
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-
20-3].
Removing Lift Arm Support Device
The operator must be in the operator's seat, with the seat

belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.
Start the engine, raise the lift arms all the way up.
Have a second person remove the lift arm support

device.
Lower the lift arms all the way and stop the engine.
Return the lift arm support device to storage position and

secure with clamping knobs.
Remove the jackstands.

OPERATOR CAB Raising The Operator Cab
Description Figure 10-30-1
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 roll over protection.
ROPS/FOPS - Roll Over Protective Structure per SAE

J1040 and 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 P-31849
construction site services.
Level II - Protection from falling trees, rocks; for Always stop the engine before raising or lowering the
machines involved in site clearing, overhead demolition cab.
or forestry.
Stop the loader on a level surface. Lower the lift arms. If
the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
P10564 P10563
Remove the nut and plate (both sides) at the front

corners of the operator cab [Figure 10-30-2].

OPERATOR CAB (CONT'D) Lowering The Operator Cab
Raising The Operator Cab (Contd) Figure 10-30-4
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover N-20120
and falling objects, and result in injury or death.
W-2069-1299
Figure 10-30-3
P-31859
Always stop the engine before raising or lowering the

cab.
NOTE: Make sure seat bar is fully raised or lowered

when lowering the cab. Always use the grab
handles to lower the cab.
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
P-31858 Release the latching mechanism (Inset) [Figure 10-30-4]

and pull the cab all the way down.
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching Figure 10-30-5
mechanism engages [Figure 10-30-3].
Advanced Hand Controls (AHC) and Advanced Control

System (ACS)
P10563
P10564 P10563
Install the plates and nuts [Figure 10-30-5] (both sides).
Tighten the nuts to 40-50 ft.-lb. (54-68 Nm) torque.

OPERATOR CAB (CONTD) Figure 10-30-8
Emergency Exit
Figure 10-30-6
N-20171
Front Door (If Equipped)

P0660
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
The front opening on the operator cab and rear window used as an emergency exit. [Figure 10-30-8].
provide exits.
NOTE: If the loader has a Special Application Door
Rear Window (If Equipped) Kit installed, the window of the front door is
NOT an emergency exit.
Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-30-6]. Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].
Figure 10-30-7
Figure 10-30-9
x
N-18495
P-24472
Push the rear window out of the rear of the operator cab.
Push the window out with your foot [Figure 10-30-9] at
Exit through the rear of the operator cab [Figure 10-30- any corner of the window.
7].
Exit through the front door.

TRANSPORTING THE BOBCAT LOADER Figure 10-40-2
Procedure
WARNING
P-24480 P-24785
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
Figure 10-40-1
P-31829
1
P-31912
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
Lower the bucket or attachment to the floor.
Be sure the transport and towing vehicles are of
adequate size and capacity (See LOADER Stop the engine.
SPECIFICATIONS on Page SPEC-10-1.), for weight of
loader.) Engage the parking brake.
The rear of the trailer must be blocked or supported (Item Install chains at the front and rear loader tie down
1)[Figure 10-40-1] when loading or unloading the loader positions (Inset) [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
Fasten each end of the chain to the transport vehicle.

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 LOADER
SPECIFICATIONS on Page SPEC-10-1.)

REMOTE START Figure 10-60-2
Procedure
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
1
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
P-24651
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-3
Figure 10-60-1
1
1
P-24653
P16115
Lift and block the loader. (See Procedure on Page 10-10-
1.)
The tool listed will be need to do the following procedure:
Raise the lift arms (if required by the procedure) and
MEL1563 - Remote Start Tool Kit install an approved lift arm support device. (See Installing
Lift Arm Support Device on Page 10-20-1.)
The remote start (Item 1) [Figure 10-60-1] is required
when the operator cab is in the raised position for service Raise the operator cab (if required by the procedure).
and the service technician needs to turn the key switch (See Raising The Operator Cab on Page 10-30-1.)
on or start the engine. Example: Control Handle: linkage
neutral adjustment. Open the rear door of the loader.
Remove the plug (Item 1) [Figure 10-60-2] or disconnect

the attachment control harness (Item 1) [Figure 10-60-3]
if connected.

REMOTE START (CONT'D)
Procedure (Cont'd)
Figure 10-60-4
1 Figure 10-60-6
P-24652
Connect the remote start tool to the engine harness

connector (Item 1) [Figure 10-60-4].
NOTE: The key switch on the right-hand side 2

3 1
operator panel must be in the off position or
the Remote Start Kit will not operate.
Figure 10-60-5
P16118
The traction lock switch (Item 1) [Figure 10-60-6] 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
1 able to turn.
The maximum flow/variable flow switch (Item 2) [Figure

10-60-6] 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
P16116 OFF. The switch is used when checking pressures and
flow rate.
The remote start tool (Item 1) [Figure 10-60-5] has three The auxiliary pressure release (Item 3) [Figure 10-60-6]
rocker switches. is used to release hydraulic pressure to the right hand
auxiliary and/or rear auxiliary couplers ONLY.
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

REMOTE START (CONT'D)
Procedure (Cont'd)
Figure 10-60-7
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 10-60-7].

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, Operators
Handbook and signs (decals) on machine. Follow warnings and
WARNING 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-2003-0903
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED

8-10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
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 & grill. Check coolant level COLDand add
premixed coolant as needed.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure
shown on sidewall of tire.
Seat Belt, Seat Bar, Control Check the condition of seat belt. Check the seat bar and control interlocks for
Interlocks and Seat Belt correct operation. Clean dirt and debris from moving parts. Clean or replace seat
Retractors belt retractors as needed.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
Indicators & Lights Check for correct operation of all indicators and lights.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Fuel Filter Remove the trapped water.
Heater Filters Clean or replace filters as needed during heating/cooling season.
Bobcat Interlock Control System Check the four (4) BICS indicator lights and functions are activated. See details
(BICS) in this Manual.
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 oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls Check for correct operation. Repair or adjust as needed.
and Steering Levers
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE
MAINTENANCE on Page 10-170-1.)
Parking Brake Check operation.
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease two fittings.
Engine/Hydrostatic Drive Belt Check for wear or damage. Adjust as needed. *
Fan Drive Gearbox Check gear lube level. Add as needed.
Alternator Belt Check belt tension and adjust as needed.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^
Fuel Filter Replace the filter element.
Bobcat Interlock Control System Check the function of the lift arm by-pass control
(BICS)
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter Replace the filter element.
Hydraulic Reservoir Replace the fluid
Final Drive Trans. (Chaincase) Replace the fluid
Case Drain Filters Replace the filters
Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
Or every 12 months.

AIR CLEANER SERVICE Replacing Filter Element(s)
Checking OUTER FILTER
Figure 10-80-1 Figure 10-80-3
1
1
P-21769 P-31836
It is important to change the air filter element only when Remove the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated on Contents Page 70-01.
Figure 10-80-2
2 P-31837
1
Remove the wing nut (Item 1) [Figure 10-80-4] from the

outer filter element and the outer filter element.
N-18409
Press and hold the LIGHT Button (Item 1) [Figure 10-80-

2] for two seconds.
If the filter element needs replacement, the CODE [01-

17] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2].

AIR CLEANER SERVICE (CONTD) INNER FILTER
Replacing Filter Element(s) (Contd) Figure 10-80-6
Figure 10-80-5
P-31838
P-31837
Only replace the inner filter element under the following
conditions:
NOTE: Be sure all sealing surfaces are clean.
Replace the inner filter element every third time the
Install the new filter element and washer. Tighten the outer filter is replaced.
wing nut.
After the outer element has been replaced, start the
NOTE: Be sure sealing washer is in place on each engine and run at full RPM. If the HOURMETER /
wing nut [Figure 10-80-4]. CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
Install the dust cover and tighten the wing nut.
Remove the inner filter wing nut [Figure 10-80-6].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight. Remove the inner filter (Item 1) [Figure 10-80-6].
Install a new filter and tighten the wing nut.

ENGINE COOLING SYSTEM
Cleaning The Cooling System

IMPORTANT
AVOID ENGINE DAMAGE
WARNING Always use the correct ratio of water to antifreeze.
To much antifreeze reduces cooling system

Wear safety glasses to prevent eye injury when any efficiency and may cause serious premature engine
of the following conditions exist: damage.
When fluids are under pressure.
Flying debris or loose material is present. Too little antifreeze reduces the additives which
Engine is running. protect the internal engine components; reduces the
Tools are being used. boiling point and freeze protection of the system.
W-2019-1285
Always add a premixed solution. Adding full strength

Figure 10-90-1 concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Figure 10-90-2
P-45101
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
P-45103
Open the rear door and remove the rear grill. (See
Removal And Installation on Page 50-60-1.) Raise the air conditioning condenser (If equipped) and
the oil cooler and clean the top of the radiator [Figure 10-
Use air pressure or water pressure to clean the top of the 90-2].
oil cooler [Figure 10-90-1].
Lower the oil cooler on the loader frame.
WARNING
Check cooling system for leaks.
Lower the rear grill and close the rear door.

Do not use your bare hands to remove debris from
the oil cooler. Cooling fins are sharp and may cause
injury.
W-2460-0303

ENGINE COOLING SYSTEM (CONT'D) Replacing the Coolant
Checking The Coolant Level
Figure 10-90-3
WARNING
MAX Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
MIN P-45106 Figure 10-90-4
P-45102
Open the rear door and raise the rear grill.
Check the coolant level [Figure 10-90-3]. The level

markers are on the outside of the tank. Coolant must be
between the bottom marker and the top marker when the
P-45102
engine is cold.
Close the rear door before operating the loader. Open the rear door and remove the rear grill.
Remove the radiator cap (Item 1) [Figure 10-90-4].
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
To much antifreeze reduces cooling system

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

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

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

ENGINE COOLING SYSTEM (CONT'D)
Replacing the Coolant (Contd)
Figure 10-90-5
P-48075
Turn the valve (Item 1) [Figure 10-90-5] 90 degrees

and drain the coolant into a container.
Recycle or dispose of used coolant in an environmentally

safe manner. Close the drain valve and remove the hose.
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
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 -34F (-37C) freeze protection.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Fill the radiator with the premixed coolant. Install the

radiator cap.
Remove the cover from the coolant recovery tank. Fill the
tank until it is at the lower marker (inside the tank).
Run the engine until it is at operating temperature.
Stop the engine.
Check the coolant level in the recovery tank when cool.
Add coolant as needed.
Lower the rear grill and close the rear door.

FUEL SYSTEM Figure 10-100-1
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
The following is one suggested blending guideline which

should prevent fuel gelling during cold temperatures:
TEMP. F (C) NO. 2 NO. 1
+15 (9) 100% 0% 1
Down to -20 (-29) 50% 50%
Below -20 (29) 0% 100% P-48074
Contact your fuel supplier for local recommendations. Open the rear door.
Filling The Fuel Tank Remove the fuel fill cap (Item 1) [Figure 10-100-1]
Figure 10-100-2
WARNING WRONG
Stop and cool the engine before adding fuel. NO

SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. B-15650
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].

FUEL SYSTEM (CONTD) Removing Air From The Fuel System
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
Figure 10-100-3 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.
2 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
1
from a physician familiar with this injury.
W-2072-0496
Figure 10-100-4
P-48077
(See SERVICE SCHEDULE on Page 10-70-1), for the

service interval for removing water from, or replacing the 3
fuel filter.
Removing Water
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter. 1
Replacing Element 2
Remove the filter element (Item 2) [Figure 10-100-3].

P-48076
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and Open the vent (Item 1) [Figure 10-100-1] on the fuel filter
hand tighten.
housing.
Remove the air from the fuel system. (See Removing Air
Squeeze the hand pump (priming bulb) (Item 2) [Figure
From The Fuel System on Page 10-100-2)
10-100-1] until fuel flows from the vent with no air
bubbles.
Close the vent (Item 1) [Figure 10-100-1] on the fuel

filter housing.
Open the vent (Item 3) [Figure 10-100-1] on the fuel

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

10-100-1] until the pump feels solid.
Tighten the vent plug (Item 3) [Figure 10-100-1].
Start the engine.
It may be necessary to open the vent plug (Item 3)

[Figure 10-100-1] briefly while the engine is running.
Close the vent when the engine runs smoothly.

ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-110-1
P-48079
Park the loader on level ground.
Open the rear door and remove the dipstick (Item 1)

[Figure 10-110-1].
Keep the oil level between the marks on the dipstick. DO

NOT OVERFILL.
Use a good quality motor oil that meets API Service

Classification of CD or better. (See Oil Chart.)
Install the dipstick and close the rear door.

ENGINE LUBRICATION SYSTEM (CONTD)
Replacing Oil And Filter

WARNING
service interval for replacing the engine oil and filter. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Run the engine until it is at operating temperature. Park Failure to use care around combustibles can cause
the loader on level ground and stop the engine. explosion or fire which can result in injury or death.
W-2103-1285
Open the rear door.
Figure 10-110-3
Figure 10-110-2
1
3
1 P-1575
P-48078
Put oil in the engine. (See Capacities on Page SPEC-10-

Remove the drain plug (Item 1) [Figure 10-110-2]. 4.)[Figure 10-110-3] (See Oil Chart on Page 10-110-1.)
Drain the oil into a container and dispose of used oil in an Start the engine and let it run for several minutes.
environmentally safe manner.
Stop the engine and check for leaks at the oil filter.
Remove the oil filter (Item 2) [Figure 10-110-2].
Remove the dipstick and check the oil level.
Clean the filter housing surface.
Add oil until it reaches the top mark (Item 1) [Figure 10-
Put clean oil on the new oil filter gasket. 110-3] on the dipstick. DO NOT OVERFILL.
Install the filter and hand tighten. Install the dipstick and the fill plug.
Install and tighten the drain plug. Close the rear door.
Remove the fill cap (Item 3) [Figure 10-110-2].

HYDRAULIC/HYDROSTATIC SYSTEM Replacing Hydraulic/Hydrostatic Filter
Checking And Adding Fluid (See SERVICE SCHEDULE on Page 10-70-1) for the
correct service intervals.
Figure 10-120-1
Open the rear door.
Remove the filter element (Item 2) [Figure 10-120-2].
Clean the surface of the filter housing where the seal

contacts the housing.
Put clean oil on the seal of the new filter element.
Install and hand tighten the filter element.
Close the rear door before operating the loader.
Replacing Hydraulic Fluid

N-18445
service interval.
Use only recommended fluid in the hydraulic system.
(See HYDRAULIC/HYDROSTATIC FLUID
The fluid must be replaced if it becomes contaminated or
SPECIFICATIONS on Page SPEC-50-1.)
after major repairs. If the fluid is replaced, the hydrostatic
Stop the loader on a level surface. filter and both case drain filters must be replaced.
Lower the lift arms and tilt the Bob-Tach fully back. Use only recommended fluid in the hydraulic system.
(See HYDRAULIC/HYDROSTATIC FLUID
Stop the engine. SPECIFICATIONS on Page SPEC-50-1.)
Check fluid level in the sight gauge [Figure 10-120-1]. Stop the loader on a level surface.
Open the rear door and remove the rear grill. Lower the lift arms and tilt the Bob-Tach fully back.
Figure 10-120-2 Stop the engine.
Check fluid level in the sight gauge [Figure 10-120-1].
Open the rear door and remove the rear grill.
Figure 10-120-3
2
1
P-45243
P-45243 P-48866
1
Remove the fill cap (Item 1) [Figure 10-120-2].
Add the fluid as needed to bring the level to the center of

the sight gauge [Figure 10-120-1].
P-45245
Install the fill cap. Replace the rear grill and close the rear
door. Remove the reservoir fill cap (Item 1) [Figure 10-120-3].
HYDRAULIC/HYDROSTATIC SYSTEM (CONTD) Figure 10-120-5
Replacing Hydraulic Fluid (Contd)
WARNING
1
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons 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 2
immediately.
W-2145-0290
P-45493
Disconnect the hose (Item 1) [Figure 10-120-5] from the

WARNING case drain filter located on the right drive motor. Use a
plug and cap on the filter and case drain hose to prevent
leakage.
Remove the case drain filters (Item 2) [Figure 10-120-4]
& [Figure 10-120-5] and drain the fluid into a container.
W-2103-1285
Replace the hydraulic/hydrostatic filter element. (See
Replacing Hydraulic/Hydrostatic Filter on Page 10-120-
Figure 10-120-4 1.)
Replace both hydrostatic motor case drain filters (Item 2)

[Figure 10-120-4] & [Figure 10-120-5].
Connect the hoses to the case drain filters.

2
P-45499
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
Drain the hydraulic fluid reservoir. (See Replacing

Hydraulic Fluid on Page 10-120-1.)
Disconnect the hoses (Item 1) [Figure 10-120-4] from

the case drain filter located on the reservoir. Use a plug
and cap on the filter hose and case drain hose to prevent
leakage.

HYDRAULIC/HYDROSTATIC SYSTEM (CONTD) Breather Cap
Replacing Hydraulic Fluid (Contd) Figure 10-120-7
Figure 10-120-6
P-34227
P-64317
correct replacement interval.
On SJC equipped loaders, the hydrostatic charge
pressure filter (Item 1) [Figure 10-120-6] is located on a Raise the operator cab. (See Raising The Operator Cab
bracket mounted to the transmission. on Page 10-30-1.)
Remove and replace the hydrostatic charge pressure Remove the breather cap (Item 1) [Figure 10-120-7] and
filter. discard.
Add the correct fluid to the reservoir until the fluid level is Install new cap.
at the center of the sight gauge (Do not overfill).
Lower the operator cab. (See Lowering The Operator
Lower the operator cab. (See Raising The Operator Cab Cab on Page 10-30-2.)
on Page 10-30-1.)
Start the engine and operate the loader hydraulic

controls.
Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing Oil From The Chaincase
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
P-64141
P-45496
Remove the chaincase cover (Item 1) [Figure 10-130-
2](See CHAINCASE on Page 40-30-1.)
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the hydraulic/ Use a vacuum pump to extract the fluid from the chain
hydrostatic system. (See LOADER SPECIFICATIONS on case.
Page SPEC-10-1.)
To check the chaincase oil level, use the following

procedure:
Stop the loader on a level surface.
Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the

front of the chaincase housing.
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole.
Install and tighten the plug.

FAN GEARBOX
Checking And Maintaining
Figure 10-140-1
N-18460

correct service interval.

on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the

lubricant level.
If the level is low, add SAE 90W gear lubricant through

the check plug hole until lubricant flows from the hole.

Cab on Page 10-30-2.)

BOB-TACH Figure 10-150-3
Inspection And Maintenance

Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1
In The Attachment B-15177
The spring-loaded wedge (Item 1) [Figure 10-150-1]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
1
If the wedge does not contact the lower edge of the hole
[Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4
N-17027
Move the Bob-Tach levers to engage the wedges

[Figure 10-150-1]. The levers and wedges must move
freely.
Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
1
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
N-16044A Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1) and (See LUBRICATION OF THE
BOBCAT LOADER on Page 10-160-1.)
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-150-2].

POWER BOB-TACH (OPTION) Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
FRONT ACCESSORY PANEL

1
B-15177
Wedge Must Contact Lower Edge

Of Hole In The Attachment P-24487
If the wedge does not contact the lower edge of the hole
B-15891 [Figure 10-151-3], the attachment will be loose and can
come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
B-17460
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
1
P-24487 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds.
and must contact the lower edge of the hole in the
attachment [Figure 10-151-2] and (Item 1) [Figure 10- Lubricate the wedges. (See SERVICE SCHEDULE on
151-3]. Page 10-70-1) and (See LUBRICATION OF THE
BOBCAT LOADER on Page 10-160-1.)

LUBRICATION OF THE BOBCAT LOADER Figure 10-160-2
Procedure 3
Figure 10-160-1
2
1
N-18506
P-18506
N-18505
Access
Lubricate the loader as specified in the SERVICE Hole
SCHEDULE, Contents Page 10-01, for the best
performance of the loader.
Record the operating hours each time you lubricate the

P-31841
Bobcat loader.
Always use a good quality lithium based multi-purpose 2. Stabilizer Rod - Rear (Both Sides) [Figure 10-160-2]
grease when you lubricate the loader. Apply lubricant
until extra grease shows. 3. Lift Cylinder Rod End (Both Sides) [Figure 10-160-2].
Lubricate the following locations on the loader: 4. Lift Cylinder Base End (Both Sides) [Figure 10-160-
2].
1. Stabilizer Rod - Front (Both Sides) [Figure 10-160-1].
Figure 10-160-3
N-18510
5. Tilt Cylinder Base End (Both Sides) [Figure 10-160-

3]

LUBRICATION OF THE BOBCAT LOADER (CONTD) Figure 10-160-6
Procedure (Contd)
Figure 10-160-4
10
6 7
N-18508
10. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-6].

P-48104
Figure 10-160-7
6. Tilt Cylinder Rod End. [Figure 10-160-4].
7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-4].
Figure 10-160-5
8 11
N-18511
P-31839
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-160-
9 7].
P16045
8. Bob-Tach Wedge (Both Sides) [Figure 10-160-5].
9. Power Bob-Tach Cylinder (Both Sides) [Figure 10-

160-5].

LUBRICATION OF THE BOBCAT LOADER (CONTD)
Procedure (Contd)
Figure 10-160-8
12
P1533
12. 250 Hours: Steering Lever Shaft (2) [Figure 10-160-

8].

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 10-170-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Mounting
Tires are to be repaired only by an authorized person

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

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

N-18514
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
service interval to check the wheel nuts [Figure 10-170- Avoid excessive pressure which can rupture the tire and
1]. cause serious injury or death.
When installing wheel nuts, tighten to 160 ft.-lb. (217 During inflation of the tire, check the tire pressure
Nm) torque. frequently to avoid over inflation.
When checking wheel nut torque, set the torque wrench
to 140 ft.-lb. (190 Nm) torque to prevent over-tightening.
Rotating IMPORTANT
Figure 10-170-2 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
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
B-9976
Check the tires regularly for wear, damage and pressure.

(See Tires on Page SPEC-10-4), for the correct tire
pressure.
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 10-170-2].

SPARK ARRESTOR MUFFLER
Cleaning Procedure
WARNING
Figure 10-180-1
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
Start the engine and run for about ten seconds while a
second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
1 This will force contaminants out through the cleanout

hole.
Stop the engine.

P-45498
(See SERVICE SCHEDULE on Page 10-70-1), for Lower the rear grill and close the rear door.
service interval for cleaning the spark arrestor muffler.
Do not operate the loader with a defective exhaust

system.
WARNING
When an engine is running in an enclosed area, fresh
IMPORTANT air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
This loader is factory equipped with a U.S.D.A. gases which can kill without warning.
Forestry Service approved spark arrestor muffler. It W-2050-1285
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation.
WARNING
If this machine is operated on flammable forest,
brush or grass covered land, it must be equipped Stop engine and allow the muffler to cool before
with a spark arrestor attached to the exhaust system cleaning the spark chamber. Wear safety goggles.
and maintained in working order. Failure to do so will Failure to obey can cause serious injury.
be in violation of California State Law, Section 4442 W-2011-1285
PRC.
Make reference to local laws and regulations for

spark arrestor requirements.
I-2022-0595 WARNING
Stop the engine. Open the rear door and rear grill. Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-180-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285

HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-90-5 HYDRAULIC
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3 SAFETY
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . 20-90-1 SYSTEM &
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
DRIVE
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . 20-22-1 SYSTEM
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7 ELECTRICAL
Base End Pivot Pin Replacement . . . . . . . . . . . . . . . . . . . 20-21-3 SYSTEM &
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ANALYSIS
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2 ENGINE
Rod End Pivot Pin Bushing And Seal Replacement . . . . . 20-21-4
SERVICE
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . 20-130-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
SPECIFICATIONS
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Checking The High Flow Relief Valve . . . . . . . . . . . . . . . 20-100-1
High Flow Relief Valve Adjustment Procedure . . . . . . . . 20-100-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8

HYDRAULIC SYSTEM (CONTD)
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . . . . 20-43-6
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 20-43-24
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-43-23
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-43-28
BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-43-29
BICS Valve, Lift Load Check Valve Removal And Installation . . . . . . 20-43-10
BICS Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . 20-43-26
BICS Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-43-25
End Cap Block Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 20-43-16
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Lift Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . 20-43-11
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-29
Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-15
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-43-13
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-43-13
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-43-14
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-21
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) 20-42-1

Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-9
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 20-42-28
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-42-32
BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-42-33
BICS Valve, Lift Load Check Valve Removal And Installation . . . . . . . 20-42-7
BICS Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . 20-42-30
BICS Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-42-29
End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . . 20-42-14
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Lift Spool and Detent Removal and Installation . . . . . . . . . . . . . . . . . . . 20-42-15
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . 20-42-8
Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-42-10
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-42-11
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-42-10
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-12
Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-13
Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-24

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . 20-41-8
BICS Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . 20-41-7
BICS Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . 20-41-9
BICS Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
BICS Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 20-41-10
BICS Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-41-20
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) 20-40-1

Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . 20-40-7
BICS Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . 20-40-6
BICS Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . 20-40-8
BICS Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . 20-40-9
BICS Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Lift And Tilt Lock Block Removal And Installation . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26

HYDRAULIC/HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . . . . . . 20-70-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . 20-60-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . 20-60-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . 20-61-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . 20-61-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . 20-62-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . 20-62-2
HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . 20-63-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . 20-63-2
Test The Output Of The Hydraulic Pump (High Flow) . . . . . . . . . . . . . . . 20-63-4
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1


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

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

REAR AUXILIARY DIVERTER VALVE. . . . . . . . . . . . . . . . . 20-110-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS OTHERWISE
SPECIFIED.

HYDRAULIC/HYDROSTATIC SCHEMATIC
S175 (S/N 525211001 - 525214999)
(S/N 525311001 - 525314999)
S185 (S/N 525011001 - 525014999)
(S/N 525111001 - 525114999)
(PRINTED APRIL 2005) Printable Version Click Here
V-0444legend
LEGEND
1 RESERVOIR: 14 LOAD CHECK VALVE 27 PILOT ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 Qts. (18,2 L) CONTROL VALVE - REAR AUXILIARY CONTROL VALVE - BUCKET POSITION
SPRING LOADED FILTER BY-PASS 15 LIFT CYLINDER SPOOL - MADE TO VALVE (ON/OFF)
2 28 RESTRICTOR - 0.140 inch (3,6 mm)
VALVE: 45-55 PSI (3,1-3,8 Bar) RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 41 CHECK VALVE - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 29 RESTRICTOR - 0.031 inch (0,8 mm)
36-44 PSI (2,5-3,0 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 42 RELIEF VALVE - PORT:
Normally Closed CONTROL VALVE - BICS CONTROL 30 RELIEF VALVE: 3300 PSI (228 Bar) 3500 PSI (241,3 Bar)
4 DRIVE MOTOR SHUTTLE VALVE 17 PILOTED ACTIVATED DIRECTIONAL 43 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - TILT CONTROL 31 FILTER - HYDRAULIC (CANISTER) PORT (TILT BASE END)
5 RELIEF/REPLENISHING VALVE - HIGH 3500 PSI (241,3 Bar)
PRESSURE: 5000 PSI (345 Bar) 18 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 32 FILTER - CASE DRAIN (SINTERED 44 PILOT ACTIVATED DIRECTIONAL
6 RELIEF VALVE - CHARGE INLET: BRONZE) CONTROL VALVE - HYDRAULIC
19 PULL BUTTON ACTIVATED
220-270 PSI (15,1-18,6 Bar) POWERED BOB-TACH
DIRECTIONAL CONTROL VALVE - LIFT 33 FILTER - BICS CONTROL VALVE
at High Engine Idle
ARM BY-PASS (SCREEN) 45 RESTRICTION - 0.089 inch (2,26 mm)
With 140 degrees F. (60 degrees C.) Fluid
20 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION 46 RESTRICTION - 0.025 inch (0,6 mm)
7 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - UNLOADING VALVE
BLEED-OFF VALVE SPOOL 47 RELIEF VALVE - 2000 PSI (137 Bar)
21 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION
8 HYDRAULIC PUMP . . . . . . . Gear Type
16.9 GPM (64 L/min.) at High Engine Idle CONTROL VALVE - FLOW CONTROL 48 RELIEF VALVE - 1200 PSI (83 Bar)
SPOOL 36 VARIABLE CAPACITY DISPLACEMENT
9 RELIEF VALVE - MAIN: BIDIRECTIONAL HYDROSTATIC PUMP 49 SOLENOID ACTIVATED DIRECTIONAL
22 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE (TWO COIL)
3250 - 3350 PSI (224-231 Bar) 37 SHUTTLE RELIEF VALVE
at Front Quick Couplers (Not Adjustable - Factory Set) 50 CHECK VALVE - With 300 PSI (20,7 Bar)
23 SOLENOID ACTIVATED DIRECTIONAL
65 PSI (4,5 Bar) Spring And With 0.016 inch (0,40 mm) Orifice
10 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - BASE
3500 PSI (241,3 Bar)
24 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT
11 ANTICAVITATION VALVE CONTROL VALVE - ROD BIDIRECTIONAL HYDROSTATIC
MOTOR
12 SOLENOID ACTIVATED DIRECTIONAL 25 LOAD SHUTTLE VALVE - BLEED OFF 39 CHECK VALVE - With 80 PSI (5,5 Bar)
CONTROL VALVE - AUXILIARY Spring
13 RELIEF VALVE - PORT: . . . . . (Optional)
CONTROL VALVE - TWO COIL
3500 PSI (241,3 Bar)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-0444legend (4-11-05)

(REAR QUICK
FEMALE COUPLERS) MALE
S175 (S/N 525211001 - 525214999)
(S/N 525311001 - 525314999)
BASE ROD REAR AUX VALVE (OPTIONAL)
S185 (S/N 525011001 - 525014999)
(S/N 525111001 - 525114999)
INTEGRATED QUICK
(PRINTED APRIL 2005) Printable Version Click Here 23 24 COUPLER BLOCK
V-0444 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
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20
12 12
13 B
CHARGE
INLET B A
BOB-TACH
CYLINDER
(OPTIONAL)
AUXILIARY
SPOOL
HYDRAULIC 14
36 POWERED
43 TILT CYLINDERS
BOB-TACH BICS CONTROL VALVE
(OPTIONAL)
5 5
D C
39
DR
8
INLET OUTLET
50
48 46 B A 17
47 TILT
42
CYLINDER
49 45 SPOOL
PP 11
DRIVE MOTOR 14
P1 P2
10 LIFT CYLINDERS
44
38
18
B A
LIFT
CYLINDER
SPOOL 35
15
14
4 37
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE

32
19
Printed in U.S.A. V-0444 (4-11-05)

WITH HIGH FLOW OPTION
S175 (S/N 525211001 AND ABOVE)
(S/N 525311001 AND ABOVE)
S185 (S/N 525011001 AND ABOVE)
(PRINTED APRIL 2005) Printable Version Click Here
V-0445legend
LEGEND
36-44 PSI (2,5-3,0 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 42 RELIEF VALVE - PORT:
Normally Closed CONTROL VALVE - BICS CONTROL 30 RELIEF VALVE: 3300 PSI (228 Bar) 3500 PSI (241,3 Bar)
4 DRIVE MOTOR SHUTTLE VALVE 17 PILOTED ACTIVATED DIRECTIONAL 43 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - TILT CONTROL 31 FILTER - HYDRAULIC (CANISTER) PORT (TILT BASE END)
5 RELIEF/REPLENISHING VALVE - HIGH 3500 PSI (241,3 Bar)
at High Engine Idle
7 FRONT AUXILIARY MANUAL CONTROL VALVE - UNLOADING VALVE
PRESSURE SPOOL 47 RELIEF VALVE - 2000 PSI (137 Bar)
BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION
3250-3350 PSI (224-231 Bar) 37 SHUTTLE RELIEF VALVE
at Front Quick Couplers (Not Adjustable - Factory Set) 50 RELIEF VALVE - 3300 PSI (228 Bar)
10 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - BASE 65 PSI (4,5 Bar)
51 DUMP VALVE - (ON/OFF)
3500 PSI (241,3 Bar)
BIDIRECTIONAL HYDROSTATIC 52 CHECK VALVE
11 ANTICAVITATION VALVE CONTROL VALVE - ROD
MOTOR
25 53 AUXILIARY HYDRAULIC PUMP -
12 SOLENOID ACTIVATED DIRECTIONAL LOAD SHUTTLE VALVE - BLEED OFF 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 9.5 GPM (36 L/min) at High Engine Idle
CONTROL VALVE - AUXILIARY
26 SOLENOID ACTIVATED DIRECTIONAL 54 CHECK VALVE - With 300 PSI (20,7 Bar)
13 RELIEF VALVE - PORT: . . . . . (Optional) Spring And With 0.016 inch (0,40 mm) Orifice
CONTROL VALVE - TWO COIL
3500 PSI (241,3 Bar)

pressure value.

(REAR QUICK
HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE COUPLERS) MALE

S175 (S/N 525211001 - 525214999)
(S/N 525311001 - 525314999) BASE ROD REAR AUX VALVE (OPTIONAL)
S185 (S/N 525011001 - 525014999)

(S/N 525111001 - 525114999) INTEGRATED QUICK
23 24 COUPLER BLOCK
(PRINTED APRIL 2005) Printable Version Click Here 25 MALE
V-0445 26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
5 36
5
A
6 3 40 C
20
12 12
13 B
CHARGE
INLET B A
AUXILIARY
SPOOL
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
B A 17
42 TILT
53 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
BOB-TACH LIFT CYLINDERS
10
38 (OPTIONAL)
18
39
DR B A
LIFT
CYLINDER
54 SPOOL 35
48 46 15
47
14
37 49 45
4
PP
P1 P2 33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
44
COMPONENTS

32
19
Printed in U.S.A. V-0445 (4-11-05)

S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED JULY 2005) Printable Version Click Here
V-0565legend
LEGEND
36-44 PSI (2,5-3,0 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 42 SOLENOID ACTIVATED DIRECTIONAL
Normally Closed CONTROL VALVE - BICS CONTROL 30 RELIEF VALVE: 3300 PSI (228 Bar) CONTROL VALVE (TWO COIL)
4 DRIVE MOTOR SHUTTLE VALVE 17 PILOTED ACTIVATED DIRECTIONAL 43 CHECK VALVE - With 300 PSI (20,7 Bar)
CONTROL VALVE - TILT CONTROL 31 FILTER - HYDRAULIC (CANISTER) Spring And With 0.016 inch (0,40 mm) Orifice
5 RELIEF/REPLENISHING VALVE - HIGH
at High Engine Idle
9 RELIEF VALVE - MAIN: BIDIRECTIONAL HYDROSTATIC PUMP 49 FILTER - BOB-TACH VALVE
22 FLOW DIVIDER ADJUSTMENT VALVE
3250 - 3350 PSI (224-231 Bar) 37 (S/N 525217391 & Above)
SHUTTLE RELIEF VALVE
at Front Quick Couplers (S/N 525315822 & Above)
23 SOLENOID ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set)
(S/N 525019833 & Above)
10 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - BASE 65 PSI (4,5 Bar)
(S/N 525115274 & Above)
PORT 3500 PSI (241,3 Bar)
CONTROL VALVE - ROD BIDIRECTIONAL HYDROSTATIC
11 ANTICAVITATION VALVE MOTOR
25 LOAD SHUTTLE VALVE - BLEED OFF
12 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 Bar)
CONTROL VALVE - AUXILIARY Spring
13 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - TWO COIL
PORT (OPTIONAL) 3500 PSI (241,3 Bar)

pressure value.

(REAR QUICK
FEMALE COUPLERS) MALE
S175 (S/N 525215000 AND ABOVE)
BASE ROD REAR AUX VALVE (OPTIONAL)
S185 (S/N 525015000 AND ABOVE)
INTEGRATED QUICK
(PRINTED JULY 2005) Printable Version Click Here 23 24 COUPLER BLOCK
V-0565 25 MALE
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
5 36
5
A
6 3 40 C
13
20
12 12
CHARGE 13 B
INLET B A
BOB-TACH
CYLINDER
(OPTIONAL)
AUXILIARY
SPOOL
HYDRAULIC 14
36 POWERED
10 TILT CYLINDERS
BOB-TACH BICS CONTROL VALVE
(OPTIONAL)
5 5
D C
39
DR
10
INLET OUTLET
43
48 46 B A 17
47 TILT
13 CYLINDER
8 42 SPOOL
45
PP 11
DRIVE MOTOR 49 14
LIFT CYLINDERS
38 P2 10
P1
18
44
B A
13 LIFT
CYLINDER
SPOOL 35
15
4 37
14
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS

32
19
Printed in U.S.A. V-0565 (7-12-05)

S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
V-0566legend
LEGEND
36-44 PSI (2,5-3,0 Bar) 16 SOLENOID ACTIVATED DIRECTIONAL 42 AUXILIARY HYDRAULIC PUMP -
Normally Closed CONTROL VALVE - BICS CONTROL 30 RELIEF VALVE: 3300 PSI (228 Bar) 9.5 GPM (36 L/min) at High Engine Idle
4 DRIVE MOTOR SHUTTLE VALVE 17 PILOTED ACTIVATED DIRECTIONAL 43 CHECK VALVE - With 300 PSI (20,7 Bar)
CONTROL VALVE - TILT CONTROL 31 FILTER - HYDRAULIC (CANISTER) Spring And With 0.016 inch (0,40 mm) Orifice
5 RELIEF/REPLENISHING VALVE - HIGH
at High Engine Idle
3250-3350 PSI (224-231 Bar) 37 SHUTTLE RELIEF VALVE
at Front Quick Couplers (Not Adjustable - Factory Set) 50 RELIEF VALVE - 3300 PSI (228 Bar)
10 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - BASE 65 PSI (4,5 Bar)
51 DUMP VALVE - (ON/OFF)
PORT 3500 PSI (241,3 Bar)
BIDIRECTIONAL HYDROSTATIC 52 CHECK VALVE
11 ANTICAVITATION VALVE CONTROL VALVE - ROD
MOTOR 53 FILTER - BOB-TACH VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 25 LOAD SHUTTLE VALVE - BLEED OFF (S/N 525217391 & Above)
39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
CONTROL VALVE - AUXILIARY (S/N 525315822 & Above)
26 SOLENOID ACTIVATED DIRECTIONAL (S/N 525019833 & Above)
13 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - TWO COIL (S/N 525115274 & Above)
PORT (OPTIONAL) 3500 PSI (241,3 Bar)

pressure value.

(REAR QUICK
HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE COUPLERS) MALE
S175 (S/N 525215000 AND ABOVE)
(S/N 525315000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)
S185 (S/N 525015000 AND ABOVE)

(S/N 525115000 AND ABOVE) INTEGRATED QUICK
23 24 COUPLER BLOCK
(PRINTED JULY 2005) Printable Version Click Here MALE
25
V-0566 26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
5 36
5
A
6 3 40 C
13
20
12 12
CHARGE 13 B
INLET B A
AUXILIARY
SPOOL
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
38
18
39
DR B A
13 LIFT
CYLINDER
43 SPOOL 35
48 46 15
47
37 49 45
4
PP
14
53 41
33 33 PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
44
32
19
Printed in U.S.A. V-0566 (7-12-05)

With SJC Option
S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
V-0715legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 FILTER - Bob-Tach Valve
RESTRICT FLOW DURING BOOM
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 bar)
VALVE: 45-55 PSI (3,1-3,8 bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 33 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5250 PSI (362 bar) (SCREEN) 47 RELIEF VALVE - 2000 PSI (137 bar)
6 RELIEF VALVE - CHARGE INLET: DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
360 PSI (24,8 bar) ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
VALVE
at High Engine Idle
20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
With 140 degrees F. (60 degrees C.) Fluid RESTRICTION
CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 bar) Spring
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
CONTROL VALVE - FLOW CONTROL
8 HYDRAULIC PUMP . . . . . . . Gear Type SPOOL 37 SHUTTLE RELIEF VALVE 51 CHARGE PRESSURE SENSOR
16.9 GPM (64 L/min.) at High Engine Idle (Not Adjustable - Factory Set)
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 bar) 52 POSITION SENSOR - Swash Plate
9 RELIEF VALVE - MAIN:
53 SERVO PISTON - Swash Plate
3250-3350 PSI (224-231 bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC SOLENOID ACTIVATED CONTROL
54
MOTOR VALVE - FORWARD/REVERSE
10 PORT RELIEF/ANTICAVITATION VALVE 24 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,3 bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 55 CHARGE PUMP . . . . . . . Gear Type
11 ANTICAVITATION VALVE 12.8 GPM (48,5 L/min.) at High Engine Idle
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
13 41 CHECK VALVE - BICS CONTROL VALVE
PORT RELIEF/ANTICAVITATION VALVE: 27 PILOT ACTIVATED DIRECTIONAL
. . . . . (Optional) CONTROL VALVE - REAR AUXILIARY 42 RESTRICTION - 0.343 inch (8,7 mm)
3500 PSI (241,3 bar)
28 RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE
NOTE: Unless otherwise specified, springs have
NO significant pressure value.

HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE
(REAR QUICK
COUPLERS) MALE
WITH SJC OPTION
S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)

(PRINTED JULY 2005) 23 24 COUPLER BLOCK
Printable Version Click Here
(V-0715) 25 MALE
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
34
38 HYDRAULIC FILTER
31
B HYDROSTATIC PUMPS A OIL

COOLER 22
2
54
53 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
52
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
51
52 14
2 31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 53 5
54
3
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
LIFT CYLINDERS
55 10
18
OUTLET HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
50
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-0715 (7-12-05)
WITH SJC AND HIGH FLOW OPTION
S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
V-0716legend
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 RELIEF VALVE - 3300 PSI (228 bar)
4 DRIVE MOTOR SHUTTLE VALVE 19 PULL BUTTON ACTIVATED 51

35 RESTRICTION DUMP VALVE - (ON/OFF)
DIRECTIONAL CONTROL VALVE -
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 52 CHECK VALVE
36 VARIABLE CAPACITY DISPLACEMENT
PRESSURE: 5250 PSI (362 bar) 20 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 53 AUXILIARY HYDRAULIC PUMP -
6 RELIEF VALVE - CHARGE INLET: SPOOL 37 SHUTTLE RELIEF VALVE 9.5 GPM (36 L/min) at High Engine Idle
360 PSI (24,8 bar) (Not Adjustable - Factory Set) 54
21 PILOTED ACTIVATED DIRECTIONAL CHECK VALVE - With 300 PSI (20,7 bar) Spring
at High Engine Idle 65 PSI (4,5 bar)
CONTROL VALVE - FLOW CONTROL with 0.016 inch (0,40 mm) orifice
SPOOL 55 SOLENOID ACTIVATED CONTROL
38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL BI-DIRECTIONAL HYDROSTATIC VALVE - FORWARD/REVERSE
22 FLOW DIVIDER ADJUSTMENT VALVE
PRESSURE BLEED-OFF VALVE MOTOR 56 SERVO PISTON -Swash Plate
8 HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 57 POSITION SENSOR -Swash Plate
16.9 GPM (64 L/min.) at High Engine Idle
CONTROL VALVE - BASE
40 SOLENOID ACTIVATED DIRECTIONAL 58 CHARGE PRESSURE SENSOR
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 bar) 59 CHARGE PUMP -
VALVE (ON/OFF)
at Front Quick Couplers 12.8 GPM (48,5 L/min) at High Engine Idle
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE
10 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 26 SOLENOID ACTIVATED DIRECTIONAL
42 RESTRICTION - 0.343 inch (8,7 mm)
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
27 PILOT ACTIVATED DIRECTIONAL
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-0716legend (7-12-05)
Printed in U.S.A.
HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE
(REAR QUICK
COUPLERS) MALE
S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)

(PRINTED JULY 2005) 23 24 COUPLER BLOCK
Printable Version Click Here
(V-0716) 25 MALE
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
D
34
38 HYDRAULIC FILTER
31
B HYDROSTATIC PUMPS A OIL

COOLER 22
2
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
2 31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 56 5
55 51
50
3 52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
LIFT CYLINDERS
59 10
18
HYDRAULIC
OUTLET
53 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-0716 (7-12-05)
HYDRAULIC SYSTEM INFORMATION

HYDRAULIC SYSTEM INFORMATION (CONTD)

HYDRAULIC SYSTEM INFORMATION (CONTD)

HYDRAULIC SYSTEM INFORMATION (CONT'D)
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 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
By-pass valve stuck 12
By-pass 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 LOADER SPECIFICATIONS on Page SPEC-10-1.)
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.

CYLINDER (LIFT) Figure 20-20-2
Checking
WARNING
2
Diesel fuel or hydraulic fluid under pressure can 1
Use a piece of cardboard or wood to find leaks. Do
W-2072-0496 N-18786
Figure 20-20-1 Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the
engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
Repeat the procedure to check the other lift cylinder.
N-18785
Lower the lift arms. Stop the engine. Pull up on the lift WARNING
arm by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar. Always clean up spilled fuel or oil. Keep heat, flames,
Check only one cylinder at a time. Open the rear door. Failure to use care around combustibles can cause
Disconnect the negative ground cable to the battery. W-2103-1285

lift cylinder base end port.

CYLINDER (LIFT) (CONTD) Figure 20-20-4
Removal And Installation

1
Figure 20-20-3
2
N-18806
Remove the retainer bolt (Item 1) [Figure 20-20-4] and

N-18785 nut from the lift arm pin (both sides).
Installation: Tighten the bolt and nut to standard torque.

Stop the engine. Pull up on the lift arm by-pass control to
release the hydraulic pressure. Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-4] (both sides).
Open the rear door.
Roll the lift arm link back.
Disconnect the negative ground cable to the battery.
Figure 20-20-5
lift cylinder base end port.
Install a plug in the hose and tighten.
P-34048

nut from the lift cylinder rod end pivot pin (both sides).

Removal And Installation (Contd)
Figure 20-20-6
1
1 2
N-18782

P-34049 nut from the lift cylinder pivot pin.

Use a slide hammer, remove the lift cylinder rod end
pivot pin (Item 1) [Figure 20-20-6]. Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-8].
Figure 20-20-7
P-34047
Install a smaller pin (Item 1) [Figure 20-20-7] to hold the

cylinder in place.
Disconnect the hose (item 2) [Figure 20-20-7] from the

lift cylinder rod end port.
Install a plug in the hose and tighten.

CYLINDER (LIFT) (CONTD)
Figure 20-20-9
P-34050
Remove the smaller pin (Item 1) [Figure 20-20-7] and lift

the lift cylinder (Item 1) [Figure 20-20-9] out from the
loader.

CYLINDER (LIFT) (CONTD)
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
1 6
15
2
5
4
14
1 13
2 12
3
11
10
B-13593

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

Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise. 3
Figure 20-20-10 P-48038
1 Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

20-12] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-12] on

the piston head, becomes damaged, the
complete piston head must be replaced.
Figure 20-20-13
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-10] from the cylinder case.
2
Figure 20-20-11
4
3 P-48039
2
1 Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-13] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-11].

CYLINDER (LIFT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-20-14 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
1 Figure 20-20-16
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-14] from

the cylinder head.
P7424
Figure 20-20-15
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

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

1
Lubricate all O-rings and seals with hydraulic oil during
installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-16].
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-20-15] from the
cylinder head.

CYLINDER (LIFT) (CONT'D) Figure 20-20-19
Assembly (Cont'd)
Figure 20-20-17
1
2
P7425
Install the rod seal in the head [Figure 20-20-19].

P-48038
Figure 20-20-20
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

20-17] on the cylinder piston.
2
Figure 20-20-18
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-
P-48043A P7427 20].
Install the rod seal on the rod seal tool [Figure 20-20-18].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-18] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-18].

CYLINDER (LIFT) (CONT'D)
Assembly (Cont'd)
Figure 20-20-21
1
2 3
P-48036
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.
Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-21].
Tighten the nut (Item 4) [Figure 20-20-21] to 600 ft.-lb.

(814 Nm) torque.
Figure 20-20-22
P-48035
Put the base end of the hydraulic cylinder in a vise.
Tighten the head (Item 1) [Figure 20-20-22] using a

spanner wrench.

CYLINDER (TILT) Figure 20-21-2
Checking
WARNING 1

and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
N-18802
Figure 20-21-1
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the base end of the tilt cylinder.
Install a cap (Item 1) [Figure 20-21-2] on the fitting and

tighten.
Engage the parking brake. Lower the seat bar.
1 Start the engine and push the Press to Operate button.

Push the bottom (heel) of the tilt pedal.
N-18801 If there is leakage from the open port, remove the tilt
cylinder for repair.

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

W-2103-1285
Figure 20-21-3 N-18545
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.

nut from the rod end pin. P-34137

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 Nm) torque.
Remove the step (Item 2) [Figure 20-21-5].

cylinders.

CYLINDER (TILT) (CONT'D) Base End Pivot Pin Replacement
Removal And Installation (Contd) Figure 20-21-7
Figure 20-21-6
2
P-24709
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.
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.

Rod End Pivot Pin Bushing And Seal Replacement
Figure 20-21-8
1
1
N-18554
Reverse the removal procedure to install the pivot pin

N-18556 bushing and seal.
Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Rod End Pivot Pin Bushing And Seal
Replacement, Page 20-21-4.)
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].

CYLINDER (TILT) (CONT'D)
Parts Identification
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
4
10
7
12
6 13
5 11
MC-01688D
14
15
MC-01688C 16
15
PE-1056A

Disassembly
2
MEL1074 - O-ring Seal Hook 1

Spanner Wrench

cylinder.
Put the base end of the cylinder in a vise.
Figure 20-21-11 P-48073
Remove the seal (Item 1), and O-ring (Item 2) [Figure

1 20-21-13] from the piston.
Figure 20-21-14
2
P-48034
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-11] from the cylinder case.
Figure 20-21-12 P-48039
3 Remove the two O-rings (Item 1) and the back-up washer

2 (Item 2) [Figure 20-21-14] from the cylinder head.
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].

CYLINDER (TILT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-21-15 MEL1396 - Seal Installation Tool

Spanner Wrench
1 Figure 20-21-17
P-48040
Remove the wiper seal (Item 1) [Figure 20-21-15] from

the cylinder head.
P7424
Figure 20-21-16


1
Lubricate all O-rings and seals with hydraulic oil during
installation.
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-21-16] from the
cylinder head.

Assembly (Cont'd)
Figure 20-21-18
P7425

P-48073
Figure 20-21-21
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-18] on the cylinder piston.
2
Figure 20-21-19
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
P-48043 P7427 21].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-21-19] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

21-19].

Assembly (Cont'd)
Figure 20-21-22
1
1
2
P-48070

P-48071
Tighten the head (Item 1) [Figure 20-21-24] using a
spanner wrench.
nut. Install the new nut from the kit.
Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-22].
Tighten the nut (Item 3) [Figure 20-21-22] to 100 ft.-lb.

(136 Nm) torque.
Figure 20-21-23
P-48088 P-48089
Mark the end of the shaft and nut. Tighten the nut an
additional 135 degrees or 2-1/4 flats [Figure 20-21-23].

CYLINDER (POWER BOB-TACH) Figure 20-22-2
Checking
WARNING
W-2103-1285
1
P16330
WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the

power Bob-Tach cylinder base end port.
Figure 20-22-3
W-2072-0496
2
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.
N-21401
Push and hold the BOB-TACH "WEDGES UP" Switch
(Front Accessory Panel).
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1]. If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the Power Bob-Tach
cylinder for repair.

CYLINDER (POWER BOB-TACH) (CONTD)
Figure 20-22-4
1 1
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 end (Item 1)

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

torque.
Remove the washers and cylinder from the lever pivots.

Identification
1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
2
3
4
5
6
7
8 9
10
11
12
13
B-16276

CYLINDER (POWER BOB-TACH) (CONTD) Figure 20-22-8
Disassembly
3
2
1
MEL1074 - O-ring Seal Hook
Spanner Wrench

cylinder.
Figure 20-22-6
P16295
Piston: Remove the O-ring (Item 1) [Figure 20-22-8],

and seal (Item 2) [Figure 20-22-8] from the piston (Item
3) [Figure 20-22-8].
Figure 20-22-9
3 5
4
P16293
Put the base end of the cylinder in a vise. 2

1
Use a spanner wrench to loosen the head [Figure 20-22-
6].
Figure 20-22-7
N-20611
3 2
1 Remove the wiper seal (Item 1) [Figure 20-22-9], and
rod seal (Item 2) [Figure 20-22-9], the back up washer
(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9]
from the head.
P16294
Remove the head and rod assembly from the cylinder

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

[Figure 20-22-7] and head (Item 3) [Figure 20-22-7]
from the rod.
Assembly
3
Use the following tools to assembly the cylinder: 2 1
MEL1396 - Seal Installation Tool

Spanner Wrench
4

P16295
Lubricate all O-rings and seals with hydraulic oil during Piston: Install the O-ring (Item 1) [Figure 20-22-11] and
installation. seal (Item 2) [Figure 20-22-11] on the piston (Item 3)
[Figure 20-22-11].
Figure 20-22-10
NOTE: The piston center hole (Item 4) [Figure 20-22-
11] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
P7424
N-20612
Allow the seal to stretch for 30 seconds before installing it
on the piston.
NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

Assembly (Contd)
Figure 20-22-13
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) [Figure 20-22-15]
and thick O-ring (Item 3) [Figure 20-22-15] into the
Rotate the handles to collapse the rod seal [Figure 20- groove on the head.
22-13].
Figure 20-22-14 nut. Install the new nut from the seal kit.
Figure 20-22-16
1 3
2 4
P7425
P16294
Install the wiper seal with the wiper toward the outside of Install the head (Item 1) [Figure 20-22-16], and spacer
the head. (Item 2) [Figure 20-22-16].
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 90 ft.-lb. (122 Nm) torque.

Assembly (Contd)
Figure 20-22-17
P16293
Tighten the head using a spanner wrench [Figure 20-22-

17].

MAIN RELIEF VALVE Figure 20-30-1
Checking
IMPORTANT
2
The hydraulic tester must be in the fully open
1
position before you start the engine.
I-2024-0284
WARNING P-34480
When the engine is running during service, the Connect the IN port (Item 1) [Figure 20-30-1] of the
steering levers must be in neutral and the parking hydraulic tester to the bottom (female) quick coupler on
brake engaged. Failure to do so can cause injury or the loader.
death.
W-2006-0284
Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.
WARNING Figure 20-30-2

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

procedure:
1
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position. To release the N-18409
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds. Press the AUXILIARY HYDRAULICS Button (Item 1)
[Figure 20-30-2] Maximum Flow.
Lift and block the loader. (See Procedure on Page 10-
100-1.)

MAIN RELIEF VALVE (CONTD) Adjustment
Checking (Contd) Figure 20-30-4
Figure 20-30-3
Right
Steering
Lever O-ring
Control
Back-up
B-6764
1
P-31833
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [Figure 20-30-4].
Push the front switch (Item 1) [Figure 20-30-3] to give
the front quick couplers a constant flow of fluid. Turn the adjusting screw in or out until the pressure is
correct.
To release from continuous operation, press the front
switch (Item 1) [Figure 20-30-3] a second time. NOTE: If the correct pressure can not be reached,
replace the main relief valve. Check the
Watch the flow meter on the hydraulic tester to make pressure setting of the new relief valve.
sure the flow is correct. Increase the engine speed to full
RPM.
Refer to Specifications, (Contents Page SPEC-01) for

both flow and pressure specifications of the hydraulic
system.
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

relief valve opens. Check the relief pressure.
If the relief pressure is not correct, stop the engine and

adjust the main relief valve.

MAIN RELIEF VALVE (CONTD) Figure 20-30-6
Removal and Installation
Figure 20-30-5
1
1
P-48874
1
Clean the area around the control valve. Loosen and

P-48872 remove the main relief valve (Item 1) [Figure 20-30-6].
Remove the O-rings and back-up washers [Figure 20-

Remove the four motor cover mounting bolts (Item 1) 30-4].
[Figure 20-30-5].
Clean the main relief valve in clean solvent. Use air
Installation: Tighten the mounting bolts to 25-28 ft.-lb. pressure to dry the valve.
(34-38 Nm) torque.
Install new O-rings and back-up washers. Install the main
relief valve (Item 1) [Figure 20-30-6] and tighten. Check
the pressure again. (See Checking on Page 20-30-1.)
Installation: Tighten the main relief valve to 35-40 ft.-lb.

(47-54 Nm) 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

HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL)
Identification IMPORTANT
Figure 20-40-1 When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888

1.)
Raise the lift arms and install an approved lift arm

support device (See Installing Lift Arm Support Device on
Page 10-20-1.)
1
N-18695
on Page 10-30-1.)
The hydraulic control valve (2 piece casting) (foot control) Clean the area around the control valve.
has a removable BICS section (Item 1) [Figure 20-40-
1]. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-1.)
The BICS section and main control valve are in two
seperate castings. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (1 piece
casting) (foot control), (See Identification Chart on Page Remove the control pedal crossbar linkage and tilt
20-42-6.). linkage. (See Crossbar Linkage Removal and Installation
on Page 50-90-2.)
Figure 20-40-2
WARNING
Never work on a machine with the lift arms up unless P-34004
Remove the right rear tire.
W-2059-0598
Locate and remove the access covers (Item 1)
[Figure 20-40-2] on the right side of the machine.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-5
(FOOT CONTROL) (CONTD)
Removal and Installation (Contd)
Figure 20-40-3
3
1
1
P-34387
Disconnect the tubeline (Item 1) [Figure 20-40-5] from

the lift arm by pass valve.
P-31998
Remove the drain tubeline (Item 2) [Figure 20-40-5] from
the lift arm by-pass valve and the control valve.
Mark all tubelines and hoses for correct installation.
Remove the bolts (Item 3) [Figure 20-40-5] from the lift
The fixed end main valve hose assembly (Item 1) arm by-pass control valve.
[Figure 20-40-3] is connected to a fixed end fitting on the
control valve. The hose is routed to the back upright Installation: Tighten the bolts to 180-200 in.-lb. (21-23
where the hose is connected to a tee fitting that feeds Nm) torque.
the base end of both lift cylinders. The hose must be
removed at the back tee fitting, located in the right side Figure 20-40-6
upright.
NOTE: Remember the hose routing for ease of

control valve installation. 1
Figure 20-40-4
2
1
1
P-34388
Label and disconnect the four electrical connectors

(Item 1) [Figure 20-40-6].
P-31999 Disconnect the outlet tubeline (Item 2) [Figure 20-40-6]

from the control valve.
Remove the tie - strap (Item 1) [Figure 20-40-4] from the

fixed end main valve hose.

Figure 20-40-7
5 1
4 3
1
P-31997
2
Disconnect the BICS valve electrical connector (Item 1)

[Figure 20-40-9].
P-34389
Figure 20-40-10
Disconnect the drive motor case drain hose (Item 1)

[Figure 20-40-7].
Disconnect the Power Bob-Tach drain hose (Item 2)

[Figure 20-40-7] if so equipped.
Disconnect the drain to reservoir hose (Item 3) [Figure 1

20-40-7].
Disconnect the auxiliary tubeline (Item 4) and (Item 5)

[Figure 20-40-7].
Figure 20-40-8
P-34005
Disconnect the inlet hose (Item 1) [Figure 20-40-10]

1 from the bottom of the control valve.
2
4
P-34390
Disconnect the tilt tubeline (Item 1) [Figure 20-40-8].
Disconnect the drain hose (Item 3) [Figure 20-40-8].
Disconnect the lift tubeline (Item 4) [Figure 20-40-8].

Figure 20-40-11
P-34391
Remove the control valve from the loader

[Figure 20-40-13].
P-34391
Connect a hoist (Item 1) [Figure 20-40-11] to the control

valve.
Figure 20-40-12
P-34006
Locate and remove the two control valve mounting bolts

(Item 1) [Figure 20-40-12] through the right side access
panels.
Installation: Tighten the bolts to 25-28 ft.-lb. (34-

38 Nm) torque.

BICS Valve Removal And Installation
Figure 20-40-14
1 1
1 1
2
1 1
N-18697
1
1
Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-40-16] from the top of the control
valve.
N-18679
Installation: Install the four large O-rings (Item 1) and

Remove the control valve. (See Removal And Installation the small O-ring (Item 2) [Figure 20-40-16] on the top of
the control valve.
on Page 20-40-1.)
Figure 20-40-17
To remove the BICS from the control valve loosen and
remove the six mounting bolts (Item 1)
[Figure 20-40-14].
Figure 20-40-15
6
3
1
2
5
4
N-18679
Install the six mounting bolts [Figure 20-40-17].
N-18695
The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS
valve assembly to the control valve. Thoroughly clean
Remove the BICS valve assembly from the top of the and dry bolts and threads in valve. Use liquid adhesive
control valve [Figure 20-40-15]. LOCTITE #242 or equivalent.
STEP TORQUE SEQUENCE
1 110-130 in.-lb.
(12,5-23,7Nm)
2 190-210 in.-lb.
1,2,3,4,5 & 6
(21,5-23,7Nm)
3 190-210 in.-lb.
(21,5-23,7 Nm)
*Torque must be 190-210 in.-lb. (21,5-23,7 Nm) for
every bolt or repeat step 3.

BICS Valve, Lift Arm By-Pass Orifice Removal And

Installation
Figure 20-40-18
N-18687
1
Figure 20-40-20
N-18686
Remove the fitting (Item 1) [Figure 20-40-18] from the

valve.
1
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-19] & [Figure 20-40-
20].
Orifice size is 0.078 inch.
Reverse the removal procedure to install the lift arm by-

pass orifice.

BICS Valve, Check Valve Removal And Installation
Figure 20-40-21 1
P-8956
1
Clean and inspect the screen (Item 1) [Figure 20-40-23]

on the end of the valve.
N-18683
Reverse the removal procedure to install the BICS
check valve.
Remove the check valve (Item 1) [Figure 20-40-21].
Installation: Tighten the valve to 20 ft.-lb. (27 Nm)

torque.
Figure 20-40-22
2
1
N-18684
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-40-22].
Install new O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-40-22] on the check valve.
Check valve (Item 3) [Figure 20-40-22] has a rating of

5-10 PSI.

BICS Valve Lock Valve Removal And Installation
Figure 20-40-24
1
1
1
N-18689
Remove the lock valves (Item 1) [Figure 20-40-24],

[Figure 20-40-25] & [Figure 20-40-26] from the BICS
N-18682 valve.
Installation: Tighten the lock valves to 25 ft.-lb. (34 Nm)

Figure 20-40-25 torque.
Figure 20-40-27
1
1
N-18688 2
2
2 N-18690
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-27] from both the tilt and lift lock valves.
Install new O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-27] on the tilt and lift lock valves.
Reverse the removal procedure to install the lock valve.

BICS Valve Solenoid Removal And Installation

1
Figure 20-40-28
N-18692
Remove the solenoid cartridge (Item 1)

[Figure 20-40-30].
N-18691
Installation: Tighten the cartridge to 20 ft.-lb. (27 Nm)
torque.
Remove the mounting nut (Item 1) [Figure 20-40-28]
from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lb. (6

Nm) torque.
Figure 20-40-29
N-18693
Remove the O-rings (Item 1) [Figure 20-40-29] from

both ends of the solenoid.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS Valve Solenoid Testing
Figure 20-40-32
(Contd)
Figure 20-40-31
3
2
P9175
1
Use an Ohm meter to measure coil resistance

N-18694 [Figure 20-40-32].
Coil wires do not have polarity.

[Figure 20-40-31] from the cartridge. Correct resistance for the BICS is 9.7 1 Ohm @
20C.
Clean all parts in solvent and dry with compressed air.
Correct resistance for the tilt and lift lock coils is 7.7 1
Inspect all parts for wear and replace any showing Ohm @ 20C.
excessive wear.
NOTE: The screen (Item 3) [Figure 20-40-31] 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 20-40-29] & [Figure

20-40-31] and new back-up rings (Item 2) [Figure 20-40-
31] on the solenoid cartridge.

H1
H3 H2
Identification Chart
ITEM S175, S185 LOADER C4

A1 Lift Cylinder Base End/Restrictor G3
B3 A3 D3
A2 Tilt Cylinder Base End C3
A3 Auxiliary Hydraulics G2 B2 A2 E2 D2
F2 C2
B1 Lift Cylinder Rod End
G1 B1 A1 E1 D1
B2 Tilt Cylinder Rod End F1 C1
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function MR
TS-1918
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring/Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve-3500PSI
E2 Anti-Cavitation/Port Relief Valve-3500PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve-3500PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional)-3100PSI
MR Main Relief Valve-3300PSI

Load Check Valve
IMPORTANT 1
damage the system.
I-2003-0888
N-18698
Figure 20-40-34
Mark each valve section, spool and related parts so that
they will be returned to its original valve section during
assembly.
1 1
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
1 1 Loosen the load check valve plugs (Item 1)
[Figure 20-40-35].
2 Installation: Always use new O-ring. tighten the plug to

35-40 ft.-lb. (47-54 Nm) torque.
Figure 20-40-36
N-18697
Remove the BICS valve assembly from the control

valve. (See BICS Valve Removal And Installation on
Page 20-40-5.)
Remove the four large O-rings (Item 1) and small O-ring

(Item 2) [Figure 20-40-34]. Always replace these O-rings
before installing the BICS valve assembly. 1
3
2 N-18699
Remove the load check plugs (Item 1) [Figure 20-40-36].
Remove the spring (Item 2) and poppet (Item 3)

[Figure 20-40-36].

Load Check Valve (Contd)
Figure 20-40-37
1
N-19031
Remove the main relief valve (Item 1) [Figure 20-40-39].

2
N-18700 Figure 20-40-40
2 3 4
The auxiliary section (Item 1) uses an orifice load check l l l 5
poppet (Item 2) [Figure 20-40-37]. l l
1
NOTE: For correct port locations and valve
B-06764
component values (See Identification Chart
on Page 20-40-11.)
1. Relief Valve
2. O-ring
Main Relief Valve
3. Sleeve
4. Glide Ring
Figure 20-40-38
5. O-ring
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-40].
Installation: Always use new O-rings. sleeve, and glide

ring. Tighten to 35-40 ft.-lb. (47-54 Nm) torque.
N-18923
Loosen the main relief valve (Item 1) [Figure 20-40-38].

Port Relief Valve
Figure 20-40-41
N-18977
Remove the port relief valve (Item 1) [Figure 20-40-43].
N-18976 Figure 20-40-44
Figure 20-40-42 4
3
1 1
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844
N-18923 Remove the O-rings and back-up washer from the port
Loosen the port relief valve (Item 1) [Figure 20-40-41] &

[Figure 20-40-42] (Port E1 or F2).
Installation: Always use new O-rings and back-up

washers. Tighten to 35-40 ft.-lb. (47-54 Nm) torque.

Anti-Cavitation Valve/Port Relief Valve
Figure 20-40-45
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-47] from the

anti-cavitation/port relief valve.
N-18976
Anti-Cavitation Valve
Loosen the anti-cavitation valve (Item 1) [Figure 20-40- Figure 20-40-48

45].

washers. Tighten to 35-40 ft.-lb. (47-54 Nm) torque. 2
Figure 20-40-46
1
1
N-18923
Remove the lift lock solenoid (Item 1) [Figure 20-40-48]

& [Figure 20-40-49].
N-18978 Installation: Always use new O-rings and back-up

Remove the anti-cavitation/port relief valve (Item 1)

[Figure 20-40-46] from the control valve for the tilt
section.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Rubber Boot
Figure 20-40-51
Anti-Cavitation Valve (Contd)
Figure 20-40-49
1 N-18923
N-19032 Remove the two screws (Item 1) [Figure 20-40-51] on

the rubber boot retainer.
Remove the anti-cavitation valve (Item 2) Installation: Tighten the screws to 90-100 in.-lb. (10,2-
[Figure 20-40-48] & [Figure 20-40-49] from the control 11,3 Nm) torque.
valve for the lift section.
Figure 20-40-52
Figure 20-40-50
1 2 3 2
4
E-01509
1. Anti-Cavitation Valve
2. O-ring 2
1
3. Backup Washer
4. O-ring
N-18924
N-18839
Remove the rubber boot (Item 1) and retainer (Item 2)

Remove the O-rings and back-up washer from the [Figure 20-40-52].
anti-cavitation valve [Figure 20-40-50].

Lift And Tilt Lock Block Removal And Installation
Figure 20-40-53
N-18926
2
1
Remove the block [Figure 20-40-55].
N-18923 NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Figure 20-40-54
Lift Spool and Detent
The tool listed will be needed to do the following

1
procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Figure 20-40-56
2
2 1
N-18925
1
Remove the lock solenoids (Item 1) [Figure 20-40-53] &
[Figure 20-40-54] from the lock block.
Remove the rubber boot (Item 2) [Figure 20-40-53] & 2

[Figure 20-40-54]. (See Identification Chart on Page 20- 1
40-11.)
N-18923
Remove the lift and tilt lock solenoids (Item 1) [Figure

20-40-56].
Remove the lift and tilt lock block (Item 2)

[Figure 20-40-56] from the control valve. (See Lift And
Tilt Lock Block Removal And Installation on Page 20-40-
17.)

Lift Spool and Detent (Contd)
Figure 20-40-57
1 2 2
N-18971
Use safety glasses and a screwdriver to remove the snap

ring (Item 1) [Figure 20-40-59].
N-18927
Remove the washer (Item 2) [Figure 20-40-59].
Remove the spacer (Item 1) and O-ring (Item 2) Figure 20-40-60

[Figure 20-40-57] from the lift spool.
Figure 20-40-58
2
1
1
N-18972
N-18976 Remove the screws (Item 1) [Figure 20-40-60] from the

detent bonnet.
Remove the end cap (Item 1) [Figure 20-40-58]. Remove the detent bonnet (Item 2) [Figure 20-40-60].
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284

Figure 20-40-61
N-18975
1 Remove the spool assembly and seal (Item 1)

[Figure 20-40-63] from the control valve.
N-18973
Figure 20-40-64
Put a rag around the detent assembly (Item 1)

[Figure 20-40-61]. This will prevent the detent balls and
spring from being lost when the detent sleeve is
removed.
Figure 20-40-62
2
3 N-18930
1
Remove the spool seal (Item 1) [Figure 20-40-64] from

the linkage end of the valve.
2
N-18974
Remove the detent sleeve (Item 1), detent balls (Item 2)

and spring (Item 3) [Figure 20-40-62].

Figure 20-40-65
1
2
N-18916
Put a rag around the detent assembly [Figure 20-40-67].

This will prevent the detent balls and spring from being
P-8988 lost when the detent adapter is removed.
Remove the detent adapter with an allen wrench.

Clamp the linkage end of the spool in a vise
[Figure 20-40-65]. Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-67].
Figure 20-40-66
Figure 20-40-68
2
1
1
N-18915
N-19004
Install the spring tool (Item 1) [Figure 20-40-66] over the

centering spring. Remove the detent adapter (Item 1) [Figure 20-40-68]
from the spring assembly.
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-66] from the centering
spring, as it is under spring pressure.

Figure 20-40-69
N-18918
Remove the stud from the end of the spool

[Figure 20-40-71].
N-19009
Figure 20-40-72
Remove spring tool (Item 1) [Figure 20-40-69] from the

spring assembly.
Figure 20-40-70
1
2
3 1
N-18920
Removal of the plastic plug:
N-18919A Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
Inspect the adapter (Item 1), collar (Item 2), spring tap drill.
(Item 3), and washer (Item 4) [Figure 20-40-70].
Turn a 6-32 tap (Item 1) [Figure 20-40-72] 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.

Lift Spool and Detent (Contd) O-ring
Figure 20-40-73
2
Plastic
1 Plug
.60 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.60 inch (15,2 mm) from the spool
N-18961 [Figure 20-40-75].
Figure 20-40-76
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-73].
Figure 20-40-74
N-18967
Clamp the collar (Item 1) [Figure 20-40-76] in a vice.

N-18963
Install the plastic plug and O-ring in the spool

[Figure 20-40-74].

Figure 20-40-77
1 N-19004
3
2
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-80
Apply grease on all the detent component surfaces

before assembly [Figure 20-40-77].
Install the spring (Item 1) and detent balls (Item 2) into 2

the adapter (Item 3) [Figure 20-40-77] and compress
with the detent pliers [Figure 20-40-78].
Figure 20-40-78
N-18917
Install the spool seal (Item 1) and back-up washer

(Item 2) [Figure 20-40-80].
N-18968
Install the detent adapter to the collar [Figure 20-40-78].
NOTE: The collar and the detent adapter are held

together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

Figure 20-40-81
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-40-83].
N-19005
Figure 20-40-84
Install the spring assembly to the lift spool hand tight

[Figure 20-40-81].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
1
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 Nm).
NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-40-81].
Figure 20-40-82
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-84] to the

detent adapter.
CD-15051
Install the detent balls and spring [Figure 20-40-82].

Figure 20-40-85
N-18976
1
Install the end cap (Item 1) [Figure 20-40-87].
2
N-18972 Figure 20-40-88
Install the lift spool assembly in the spool bore

[Figure 20-40-85].
Install the detent bonnet (Item 1) [Figure 20-40-85].
Install the mounting screws (Item 2) [Figure 20-40-85].
Installation: Tighten the screws to 90-100 in.-lb. (10,2-

11,3 Nm) torque. 1
Figure 20-40-86
N-18930
Install the spool seal (Item 1) [Figure 20-40-88] on the

linkage end of the valve.
N-18971
Install the washer (Item 1) and snap ring (Item 2) [Figure

20-40-86].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Tilt Spool Removal And Installation
Figure 20-40-91
Figure 20-40-89
1 2
1
N-18923
N-18927 Remove the lift and tilt lock block (Item 1)

[Figure 20-40-91] from the control valve. (See Lift And
Tilt Lock Block Removal And Installation on Page 20-40-
Install the spacer (Item 1) and O-ring (Item 2) 17.)
[Figure 20-40-89] on the linkage end of the lift spool.
Figure 20-40-92
Figure 20-40-90
2
1
N-18928
N-18923
Remove the spacer (Item 1) and O-ring (Item 2)

Install the lift and tilt lock block (Item 1) [Figure 20-40-92] from the tilt spool.
[Figure 20-40-90]. (See Lift And Tilt Lock Block Removal
And Installation on Page 20-40-17.)

Tilt Spool Removal And Installation (Contd)

1
Figure 20-40-93
N-18942
N-18942
Put the linkage end of the spool in the vice

[Figure 20-40-95].
N-18686
Install the spool tool (Item 1) [Figure 20-40-95] over the
centering spring.
Remove the screws (Item 1) [Figure 20-40-93] from the
end cap. Figure 20-40-96
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3

Nm) torque.
Figure 20-40-94 1
N-19014
Remove the bolt (Item 1) [Figure 20-40-96] holding the

centering spring to the spool.
N-18816
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-
11,3 Nm) torque.
Remove the spool, centering spring, back-up washer and
spool seal [Figure 20-40-94]. Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal.

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Auxiliary Spool Removal And Installation
Figure 20-40-99
Figure 20-40-97
2 1
3
4
1
N-18976
N-18944A Remove the screws (Item 1) [Figure 20-40-99] from the

end cap (both sides).
Inspect the adapter (Item 1), collar (Item 2), spring Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
(Item 3), and washer (Item 4) [Figure 20-40-97]. Nm) torque.
Figure 20-40-98 Figure 20-40-100
2
1
N-18930 N-18943
N-18990
Remove the spool seal(s) (Item 1) and the back-up Remove the end cap, O-ring, springs and washer (both
washer (Item 2) [Figure 20-40-98]. sides).
Assembly: Always use a new spool seal. Assembly: Put grease on all the centering spring
component parts.

Auxiliary Spool Removal And Installation (Contd)
Figure 20-40-101
1
2
N-18823
Remove the end plate (Item 1) and housing (Item 2)

[Figure 20-40-103].
N-18989
Figure 20-40-104
Remove the spool (Item 1) [Figure 20-40-101].
Auxiliary Electric Solenoid
Figure 20-40-102 3 2
1
N-18992
1 Remove the coil (Item 1) and end plate (Item 2)

[Figure 20-40-104].
1 Remove the solenoid valve (Item 3) [Figure 20-40-104].
N-18822 Installation: Tighten valve to 96-144 in.-lb. (11-16 Nm)

torque.
Remove the nut (Item 1) [Figure 20-40-102] from both

solenoids.
Installation: Tighten the nut to 96-144 in.-lb. (11-

16 Nm) torque.

Plug
Auxiliary Electric Solenoid (Contd)
Figure 20-40-105
2
1
1
N-18800
Figure 20-40-108
N-18795 Port Relief (Optional)

the solenoid valves.
2
1
Port-Auxiliary Section
Figure 20-40-106
N-18843
Remove the O-rings (Item 1) [Figure 20-40-107] &

[Figure 20-40-108] and back-up ring (Item 2)
[Figure 20-40-107] & [Figure 20-40-108] from the plug
1 or port relief.
N-18993
Remove the plug (Item 1) [Figure 20-40-106] or optional

port relief valve from the control valve.

Cleaning And Inspection
Clean all components with clean solvent and dry with

compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.
Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before

installation.

(ADVANCED CONTROL SYSTEM) (ACS)
damage the system.
I-2003-0888
Lift and block the loader. (See Procedure Page 10-10-1.)

support device (See Installing Lift Arm Support Device
Page 10-20-1.)
1
Raise the operator cab. ((See Raising The Operator Cab
Page 10-30-1.)
N-18695
Clean the area around the control valve.

The hydraulic control valve (2 piece casting) (Advance
Control System) (ACS) has a removable BICS section Drain the hydraulic reservoir. (See Replacing Hydraulic
(Item 1) [Figure 20-41-1]. Fluid Page 10-120-1.)
The BICS section and main control valve are in two Remove the control panel. ((See Removal and
seperate castings. Installation Page 50-100-1.)
For identification of the hydraulic control valve (1 piece Figure 20-41-2

casting) (Advanced Control System) (ACS), (See
Identification Chart (ACS) Page 20-43-9.)
Removal and Installation 1
P-48872
WARNING Remove the right rear tire.
Locate and remove the access covers (Item 1) [Figure

20-41-2] on the right side of the machine.
W-2059-0598

(ADVANCED CONTROL SYSTEM) (ACS) (CONTD)
Figure 20-41-3
1
1
P-48881
Remove the tubeline clamp (Item 1) [Figure 20-41-5].

This will allow room to move the auxiliary tubelines away
P-31998 from the control valve.
Figure 20-41-6
The fixed end main valve hose assembly (Item 1) [Figure

20-41-3] is connected to a fixed end fitting on the control 4
valve. The hose is routed to the back upright where the
hose is connected to a tee fitting that feeds the base end
of both lift cylinders. The hose must be removed at the 1
back tee fitting, located in the right side upright.

control valve installation.
2
3
Figure 20-41-4
P-48878

the lift arm by-pass valve.
Disconnect the drain hose (Item 2) [Figure 20-41-6] from

1 the control valve.
Disconnect the motor case drain hose (Item 3) [Figure

20-41-6] from the lift arm by-pass valve.
Remove the bolts (Item 4) [Figure 20-41-6] from the lift

P-31999 arm by-pass control valve. After removing the lift arm by-
pass valve mounting bolts move the wire harness and by-
pass valve towards the engine to give more room for
Remove the tie - strap (Item 1) [Figure 20-41-4] from the control valve removal.


1 2
Figure 20-41-7
1
1 3
P-48884
Remove the drain tubeline (Item 1) [Figure 20-41-9] from

the control valve and BICS valve.
P-48879
Disconnect the auxiliary tubelines (Item 2) [Figure 20-41-
9].
Label and disconnect the electrical connectors (Item 1)
[Figure 20-41-7]. Disconnect the drain hose (Item 3) [Figure 20-41-9] from
the control valve.
Disconnect the outlet tubeline (Item 2) [Figure 20-41-7]
from the control valve. Figure 20-41-10
Figure 20-41-8
3
2
2 5
1 4
P-48883
P-48880
Remove the tilt tubeline (Item 1) [Figure 20-41-10] from
the bucket positioning valve (if so equipped) and the
Label and disconnect the actuator electrical connectors control valve.
(Item 1) [Figure 20-41-8].
Disconnect the lift tubeline (Item 2) [Figure 20-41-10].
Remove the bolt (Item 2) [Figure 20-41-8] from the wire
harness clamp. Disconnect the tilt tubeline (Item 3) [Figure 20-41-10].
Installation: Tighten the bolt to 25-28 ft.-lb. (34-38 Nm) Remove the tilt tubeline (Item 4) [Figure 20-41-10] from
torque. the bucket positioning valve and the control valve (if so
equipped).

Figure 20-41-11
1
1
2
P-48873
Locate and remove the two control valve mounting bolts

(Item 1) [Figure 20-41-13] through the right side access
P-48876 panels.

Disconnect the BICS valve electrical connector (Item 1) torque.
[Figure 20-41-11].
Remove the control valve from the loader.
Disconnect the inlet hose (Item 2) [Figure 20-41-11]
from the bottom of the control valve.
Figure 20-41-12
P-48884
Connect a hoist (Item 1) [Figure 20-41-12] to the control

valve.

BICS Valve Removal And Installation
Figure 20-41-14
1 1
1
1
2
1 1
N-18697
1
1 Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-41-16] from the top of the control
N-18679 valve.
Install the four large O-rings (Item 1) and the small O-ring
Remove the control valve. (See Removal and Installation (Item 2) [Figure 20-41-16] on the top of the control valve.
Page 20-41-1.)
To remove the BICS from the control valve loosen and

remove the six mounting bolts (Item 1) [Figure 20-41-
14].
Figure 20-41-15
N-18695
Remove the BICS valve assembly from the top of the

control valve [Figure 20-41-15].

BICS Valve Removal And Installation (Contd)
Figure 20-41-17
3 6
1 2
5 4
N-18679
Install the six mounting bolts [Figure 20-41-17].
The chart below lists the correct torque specifications

and tightening sequence when reinstalling the BICS
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.
STEP TORQUE SEQUENCE

1 110-130 in.-lb.
(12,4-14,7 Nm)
2 190-210 in.-lb. 1,2,3,4,5 & 6
(21,5-23,7 Nm)
3 190-210 in.-lb.
(21,5-23,7 Nm)
*Torque must be 190-210 in.-lb. (21,5-23,7 Nm) for

every bolt or repeat step 3.

BICS Valve, Lift Arm By-Pass Orifice Removal And

Installation
Figure 20-41-18
N-18687
1
Figure 20-41-20
N-18686

valve.
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-41-19] & [Figure 20-41-
20].
Orifice size is 0.078 inch.
Reverse the removal procedure to install the lift arm by-

pass orifice.

BICS Valve, Check Valve Removal And Installation
Figure 20-41-21 1
1 P-8956
Clean and inspect the screen (Item 1) [Figure 20-41-23]

on the end of the valve.
N-18683
Reverse the removal procedure to install the BICS
check valve.
Remove the check valve (Item 1) [Figure 20-41-21].
Installation: Tighten the valve to 20 ft.-lb. (27 Nm)

torque.
Figure 20-41-22
2
1
N-18684
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-22].
Install new O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-22] on the check valve.
Check valve (Item 3) [Figure 20-41-22] has a rating of 5-

10 PSI.

Figure 20-41-24
1
1
1
N-18689
Remove the lock valves (Item 1) [Figure 20-41-24],

[Figure 20-41-25] & [Figure 20-41-26] from the BICS
N-18682 valve.
Installation: Tighten the lock valves to 25 ft.-lb. (34 Nm)

N-18688


(Contd) 1
Figure 20-41-27 1
N-18693
2 Remove the O-rings (Item 1) [Figure 20-41-29] from

2 both ends of the solenoid.
2
N-18690 Figure 20-41-30

[Figure 20-41-27] from both the tilt and lift lock valves. 1
Install new O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-41-27] on the tilt and lift lock valves.
Reverse the removal procedure to install the lock valve.
Figure 20-41-28
1 N-18692
Remove the solenoid cartridge (Item 1) [Figure 20-41-

30].
2 Installation: Tighten the cartridge to 20 ft.-lb. (27 Nm)

torque.
N-18691

from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lb. (6

Nm) torque.
Remove the solenoid (Item 2) [Figure 20-41-28].

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS Valve Solenoid Testing
Figure 20-41-32
(Contd)
Figure 20-41-31
3
2
P9175
1
Use an Ohm meter to measure coil resistance [Figure
N-18694 20-41-32].
Coil wires do not have polarity.

[Figure 20-41-31] from the cartridge. Correct resistance for the BICS is 9.7 1 Ohm at
20C.
Correct resistance for the tilt and lift lock coils is 7.7 1
Inspect all parts for wear and replace any showing Ohm at 20C.
excessive wear.

back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-29] & [Figure

20-41-31] and new back-up rings (Item 2) [Figure 20-41-
31] on the solenoid cartridge.

Actuator Removal And Installation
NOTE: Actuators can be removed with the control

valve in the loader. Remove the lift arm by-
pass valve to allow room for actuator removal
in the loader.
4
Figure 20-41-33
3
2
1 1 N-19114
Remove the actuator (Item 1) [Figure 20-41-35].
Remove the O-ring (Item 2) [Figure 20-41-35].
Remove the spacer block (Item 3) [Figure 20-41-35].

1
2 N-19112
Figure 20-41-36
Remove the two screws (Item 1) [Figure 20-41-33] on

the actuator retainer.
Installation: Tighten the bolt and nut to 90-100 in.-lb.

(10,2-11,3 Nm) torque.
Pull the actuator (Item 2) [Figure 20-41-33] away from

the control valve.
Figure 20-41-34
N-18940
Repeat removal for the other actuator [Figure 20-41-36].
NOTE: The calibration procedure must be followed

1 when replacing handle sensor, actuator or
ACS controller. (See Calibration Procedure
Page 60-120-16.)
N-19113
Use a drift pin and hammer to remove the actuator pin

(Item 1) [Figure 20-41-34] from the actuator and the lift
or tilt spool.

H1
H3 H2
Identification Chart (ACS)
ITEM S175, S185 ACS LOADER

C4
A1 Lift Cylinder Base End/Restrictor B3
G3 A3 D3
A2 Tilt Cylinder Base End
C3
G2 D2
A3 Auxiliary Hydraulics B2 A2 E2
C2
B1 Lift Cylinder Rod End F2 G1 D1
B1 A1 E1
B2 Tilt Cylinder Rod End C1
F1
MR
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
PE1339
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve-3500PSI
E2 Anti-Cavitation/Port Relief Valve-3500PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve-3500PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H2 Plug/Port Relief (Optional)-3100PSI
MR Main Relief Valve-3300PSI

Lift Base End Restrictor IMPORTANT

damage the system.
I-2003-0888
1
Figure 20-41-40
N-21159
1

valve. (See Removal and Installation Page 20-41-1.)
Remove the restrictor (Item 1) [Figure 20-41-38] from

the lift section base end port.
N-19100
Load Check Valve

Mark each valve section, spool and related parts so that
Figure 20-41-39
they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.
1 1
Loosen the load check valve plugs (Item 1) [Figure 20-
41-40].
1
1
Installation: Always use new O-ring. tighten the plug to
35-40 ft.-lb. (47-54 Nm) torque.
N-19099

valve. (See Removal and Installation Page 20-41-1.)
Remove the four large O-rings (Item 1) and small O-ring

(Item 2) [Figure 20-41-39]. Always replace these O-rings
before installing the BICS valve assembly

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Main Relief Valve
Figure 20-41-43
Load Check Valve (Contd)
Figure 20-41-41
1 1
N-19034
3
2 N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-43].
Figure 20-41-44
Remove the load check plugs (Item 1) [Figure 20-41-41].
Remove the spring (Item 2) and poppet (Item 3) [Figure

20-41-41].
Figure 20-41-42
1
1
N-19035
Remove the main relief valve (Item 1) [Figure 20-41-44].
2 N-19102
The auxiliary section (Item 1) uses an orifice load check

poppet (Item 2) [Figure 20-41-42].

Main Relief Valve (Contd)
Figure 20-41-45
1
2
3 4 5
B-06764
1. Relief Valve N-19034

2. O-ring
3. Sleeve
4. Glide Ring Loosen the port relief valve (Item 1) [Figure 20-41-46] &
5. O-ring [Figure 20-41-47] (Port E1 or F2). (See Identification
CD-15092 Chart (ACS) Page 20-41-13.)

Remove the O-rings, sleeve, and glide ring from the main washers. Tighten to 35-40 ft.-lb. (47-54 Nm) torque.
Figure 20-41-48
Installation: Always use new O-rings, sleeve, and glide
ring. TIghten to 35-40 ft.-lb. (47-54 Nm) torque.
Port Relief Valve
Figure 20-41-46
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-48].
N-19000

Port Relief Valve (Contd)
Figure 20-41-49
4 1
2
1
1. O-ring N-18980
2. Backup Washer
3. O-ring
Remove the anti-cavitation/port relief valve (Item 1) from
4. Relief Valve
the control valve for the tilt section [Figure 20-41-51].
N-18844
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-41-49]. Figure 20-41-52
Anti-Cavitation Valve/Port Relief Valve
Figure 20-41-50
N-18843

N-19003 anti-cavitation/port relief valve.
Loosen the anti-cavitation valve (Item 1) [Figure 20-41-

50].

1 2 4
Anti-Cavitation Valve 3
Figure 20-41-53
E-1509A
1
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
N-18839
Remove the O-rings and back-up washer from the anti-

cavitation valve [Figure 20-41-55].
N-19034
Tilt Spool Removal And Installation
Figure 20-41-54 Figure 20-41-56
N-19036
N-19112
Remove the anti-cavitation valve (Item 1) [Figure 20-41- Remove the actuator (Item 1) [Figure 20-41-56] from the
53] & [Figure 20-41-54] from the control valve. control valve. (See Actuator Removal And Installation
Page 20-41-12.)

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Lift Spool Removal And Installation
Figure 20-41-59
Figure 20-41-57
1 1
N-19112
N-19003 Remove the actuator (Item 1) [Figure 20-41-59] from the

control valve. (See Actuator Removal And Installation
Page 20-41-12.)
cap. Figure 20-41-60

Nm) torque.
Figure 20-41-58
1
1
1 N-19003

end cap.
N-18983
Nm) torque.
Remove the spool assembly (Item 1) [Figure 20-41-58]
and seal from the control valve.

Lift Spool Removal And Installation (Contd)
Figure 20-41-61 1
N-19014

N-18985
Nm) torque.
Remove the spool assembly (Item 1) [Figure 20-41-61]
and seal from the control valve. Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal. Figure 20-41-64
Lift and Tilt Spool Disassembly And Assembly

2 1
Figure 20-41-62 3
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
N-18942 3), and washer (Item 4) [Figure 20-41-64].
Put the linkage end of the spool in the vice [Figure 20-
41-62].

centering spring.

Lift and Tilt Spool Disassembly And Assembly

(Contd)
4
3
Figure 20-41-65
2
1
2
1
N-18987
1
Remove the end cap (Item 1), O-ring (Item 2) springs

(Item 3) and washer (Item 4) [Figure 20-41-67] (both
sides).
N-18930 N-18943
Remove the spool seal(s) (Item 1) and the back-up Figure 20-41-68
Auxiliary Spool Removal And Installation 1
Figure 20-41-66
1 N-18988
Assembly: Put grease on all the centering spring

component parts.
N-19003

end cap (both sides).

Nm) torque.

Auxiliary Electric Solenoid
Figure 20-41-69
3
2
1 N-18992
Remove the coil (Item 1) and end plate (Item 2) [Figure

1 20-41-71].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-41-71].
Remove the nut (Item 1) [Figure 20-41-69] from both Installation: Tighten valve to 96-144 in.-lb. (11-16 Nm)
solenoids. torque.
Installation: Tighten the nut to 96-144 in.-lb. (11-16 Nm) Figure 20-41-72
torque.4
Figure 20-41-70
2
1
1
N-18795
N-18823 Remove the O-rings (Item 1) [Figure 20-41-72] from the

solenoid valves.
Remove the end plate (Item 1) and housing (Item 2) Installation: Always use new O-rings and apply oil to the
[Figure 20-41-70]. O-rings prior to installation.

Port-Auxiliary Section
Figure 20-41-73
2 1
N-18843
1
Remove the O-rings (Item 1) [Figure 20-41-74] &

[Figure 20-41-75] and back-up ring (Item 2) [Figure 20-
N-18996 41-74] & [Figure 20-41-75] from the plug.
Cleaning And Inspection

Remove the plug (Item 1) [Figure 20-41-73] or optional
port relief valve from the control valve. Clean all components with clean solvent and dry with
compressed air.
Figure 20-41-74
Check the spools for wear or scratches.
Plug
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.

2
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
1 Check the rubber boots and retainers.
1 Replace the parts as needed.
N-18800 Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before

installation.

(FOOT CONTROL)
damage the system.
I-2003-0888
1
Lift and block the loader. ((See Procedure on Page 10-
10-1.)

Page 10-20-1.)

P-51436
on Page 10-30-1.)
The hydraulic control valve (1 piece casting) (foot control) Clean the area around the control valve.
(Item 1) [Figure 20-42-1] does not have a removable
BICS section. Drain the hydraulic reservoir. (See Replacing Hydraulic
The BICS section and main control valve are in one
casting. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
casting) (foot control), (See Identification on Page 20-40- Figure 20-42-2
1.)
P-34004

W-2059-0598

4
Figure 20-42-3 2 1
3
1
1
P-51714
Mark and disconnect the four electric solenoid

connectors for correct installation (Item 1) [Figure 20-42-
5].
P-51710
Remove the outlet tubeline (Item 2) [Figure 20-42-5]
from the control valve to the hydraulic oil cooler.
Disconnect and cap the supply hose (Item 3) and the
The fixed end main valve hose (Item 1) [Figure 20-42-3]
supply hose clamp (Item 4) [Figure 20-42-5].
is connected to a fixed end fitting on the control valve.
The hose is routed to the back upright where the hose is
Figure 20-42-6
connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright. 1

Figure 20-42-4
P-51715
1
Disconnect and cap the tubeline (Item 1) [Figure 20-42-

6] from the lift arm by-pass valve to the control valve.
Disconnect and cap the hose (Item 2) [Figure 20-42-6]

from the lift arm by-pass valve to the drive motor case
P-31999 drain.
Remove the tie-strap (Item 1) [Figure 20-42-4] from the


Removal And Installation (Cont'd)
Figure 20-42-7
1
1 1
P-48287
Remove the connector pins (Item 1) [Figure 20-42-9].
P-51719 Figure 20-42-10

main valve mounting bracket.
1
Figure 20-42-8
P-51723
1
Remove the wire harness clamp bolt (Item 1) [Figure 20-

42-10].
P-51724 Remove the control pedal crossbar linkage and tilt

linkage. (See Crossbar Linkage Removal and Installation
on Page 50-90-2.)
Disconnect the wire harness tie-strap mounts (Item 1)
[Figure 20-42-8] from the lift arm by-pass bracket.
Remove the lift arm by-pass tubeline (Item 2) [Figure

20-42-8] from the control valve drain.

Figure 20-42-11
2
1 1
P-51714
Remove and cap both tubelines (Item 1) [Figure 20-42-

13] from the auxiliary section of the control valve.
P-51721
Disconnect and cap the drain hose (Item 2) [Figure 20-
42-13] from the control valve.
Remove the two lift arm by-pass valve mounting bolts
(Item 1) [Figure 20-42-11]. Figure 20-42-14
Remove the lift arm by-pass valve and mounting bracket.
Figure 20-42-12
P-51729
Disconnect and cap the tubelines (Item 1) and (Item 2)

P-51727 [Figure 20-42-14] from the tilt section of the control
valve.
Remove tubeline clamp bolt (Item 1) [Figure 20-42-12] Disconnect and cap the tubeline (Item 3) [Figure 20-42-
from the auxiliary tubelines in the left rear upright. 14] from the lift section of the control valve.
Installation: Tighten bolt to 15-20 ft.-lb. (20-27 Nm)

torque.

(FOOT CONTROL) (CONT'D)
Figure 20-42-15 1
1
P-51726
1
Connect a hoist to the lifting brackets (Item 1) [Figure
20-42-17] on the control valve.
P-51728
Figure 20-42-18
Remove the fixed-end main valve hose (Item 1) [Figure

20-42-15] from the main control valve fitting.
Figure 20-42-16 1
1
P-34004P-
P-51713
51713
Remove the two mounting bolts (Item 1) [Figure 20-42-

18] fastening the control valve and bracket to the side of
P-51722 the loader.

Mark and disconnect the BICS electric solenoid
connector (Item 1) [Figure 20-42-16]. Reverse procedure for installation.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-19
C2 J2 C3
J4
D5 B3
E3
E3
G1 G2
F2 A3 D3
B2
D4 F4 E2
A2
D1
D2
A1
E1
F1 H2 B1
F3 H3
MR C1
H1 J3
J1
MS1926
ITEM S175/S185 LOADER ITEM S175/S185 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 Load Check/BICS Valve F4 Tilt Spool Lock Solenoid
Lift G1 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function G2 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function 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 By-Pass Orifice
D4 Port Relief/Anti-Cavitation Valve 3500 PSI
J4 Drain (Case)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) MR Main Relief Valve 3300 PSI
3500 PSI (Optional)

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve, Lift Load Check Valve Removal And
(FOOT CONTROL) (CONT'D) Installation
Mount Bracket Removal and Installation Figure 20-42-22
Figure 20-42-20
1 P-51438
P-51690
Remove the lift load check valve (Item 1) [Figure 20-42-
22].
Remove the control valve and mount bracket (Item 1)
[Figure 20-42-20] from the loader. Installation: Lubricate the o-ring and tighten the valve to
55-65 ft.-lb. (75-88 Nm) torque.
Figure 20-42-21
Figure 20-42-23
2 1
2
2
P-51435
P-51439

the inlet fitting on the control valve. Remove and install new O-rings (Item 1) and back-up
Remove the two mount bolts (Item 2) [Figure 20-42-21]
from the control valve mount plate. Remove the mount
plate and tubeline.

BICS Valve, Lift Load Check Valve Removal And

Installation (Contd)
4
Figure 20-42-24
1 1
3
2
P-51453

20-42-26].
P-51440 Check the orifice (Item 3) [Figure 20-42-26] in the

poppet to be sure it is not plugged.
Check for free movement of the load check valve (Item 1) Installation: Install a new O-ring (Item 4) [Figure 20-42-
[Figure 20-42-24]. 26] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lb. (52-61 Nm)
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)
Figure 20-42-25
P-51691
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-42-25].
At the front side of the control valve locate the auxiliary

section load check valve (Item 2) [Figure 20-42-25].
NOTE: The tilt and auxiliary load check valves are

interchangeable.

Anti-Cavitation Valve (Lift, Rod End)

4
Figure 20-42-27
1
3
2
1 P-51453

20-42-29].
P-51692
Check the orifice (Item 3) [Figure 20-42-29] in the
At the back side of the control valve, remove the lift
Installation: Install a new O-ring (Item 4) [Figure 20-42-
section anti-cavitation valve (Item 1) [Figure 20-42-27]. 29] on the plug and lightly lubricate with oil before
torque.
WARNING
damage the system.
I-2003-0888
Figure 20-42-28
P-51693
Installation: Always use new O-ring (Item 1) [Figure 20-

42-28] on the anti-cavitation valve plug. Tighten the plug
to 35-40 ft.-lb. (47-54 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Figure 20-42-32
Port Relief/Anti-Cavitation Valve (Lift, Base End)
Figure 20-42-30
P-51692
P-51692 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-42-32] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-42-33
1) [Figure 20-42-30].
Figure 20-42-31
P-51454
1
Replace the O-ring (Item 1) [Figure 20-42-33] before
P-51451
installation.
Replace the O-ring (Item 1) [Figure 20-42-31] before Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.
installation.
Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief Valve
Figure 20-42-36
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Figure 20-42-34
P-51692
P-51692 Remove the port relief plug (Item 1) [Figure 20-42-36]

from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-42-37
[Figure 20-42-34] from the rod end of the tilt section.
Figure 20-42-35
1 P-51695
P-51694 Installation: Always use new O-rings (Item 1) [Figure

20-42-37]. Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

installation.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Plug Removal
Figure 20-42-40
Figure 20-42-38
1 1
P-51459
P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-42-40].
The control valve may be equipped with an optional Figure 20-42-41

auxiliary port relief valve (Item 1) [Figure 20-42-38].
Remove the auxiliary port relief valve.
Figure 20-42-39
1
P-51460
Installation: Always use new O-rings (Item 1) [Figure

20-42-41]. Tighten to 40 ft.-lb. (54 Nm) torque.
P-51640

20-42-39]. Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Rubber Boot Removal and Installation
Figure 20-42-44
Plug Removal (Contd)
1
Figure 20-42-42
P-51506
1
P-51461 Remove the three screws (Item 1) [Figure 20-42-44] 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 20-42-42]. 11,3 Nm) torque.
Figure 20-42-43 Figure 20-42-45
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
20-42-43]. Tighten to 40 ft.-lb. (54 Nm) torque. (Item 2) [Figure 20-42-45].

End Cap/Spool Lock Block Removal and Installation
Figure 20-42-46
1 1
P-51699
1
Remove the four end cap/spool lock block mount screws

(Item 1) [Figure 20-42-48].
P-51697
Installation: Tighten the screws to 90 in.-lb. (10-11,3
Nm) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-42-46] from the Remove the rubber boots and retainer plate from the lift
end cap/spool lock block. and tilt spools.
Figure 20-42-47 Figure 20-42-49
1
P-51698
P-51700
Disconnect the tube line (Item 1) [Figure 20-42-47] from Remove the end cap/spool lock block (Item 1) [Figure
the end cap/spool lock block. 20-42-49] from the control valve.

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 20-42-50
P-51513
Remove the end cap (Item 1) [Figure 20-42-52].
Figure 20-42-53
1
P-51511
1
Remove the O-ring (Item 1) [Figure 20-42-50]. 2
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap/spool lock block.
P-51514
Figure 20-42-51
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-42-53].
Remove the washer (Item 2) [Figure 20-42-53].
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-42-51] from the lift spool.


(Cont'd)
Figure 20-42-54
2 1
3
1
2 P-51517
Remove the detent sleeve (Item 1), detent balls (Item 2)

and spring (Item 3) [Figure 20-42-56].
1 2
P-51515
Figure 20-42-57

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-42-54].
Installation: Lubricate the screws and tighten to 90-100
in.-lb. (10-11,3 Nm) torque.
IMPORTANT
The detent assembly has small springs and balls. Do 1
not lose these parts during disassembly and
assembly. P-51518
I-2012-0284
Figure 20-42-55 Remove the lift spool assembly and seal (Item 1) [Figure
20-42-57] from the control valve.
P-51516
Put a rag around the detent assembly [Figure 20-42-55].

lost when the detent sleeve is removed.

2
(Cont'd)
Figure 20-42-58 1
3
N-18915
1 Install the spring tool (Item 1) [Figure 20-42-60] over the

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

(Item 2) [Figure 20-42-60] from the centering
spring, as it is under spring pressure.
Remove the lift spool seal (Item 1) [Figure 20-42-58]
from the linkage end of the valve. NOTE: The centering spring (Item 3) [Figure 20-42-60]
is white on all 700 series loaders.
Figure 20-42-59
Figure 20-42-61
1
P-8988 2
N-18916
Clamp the linkage end of the spool in a vise [Figure 20-

42-59]. Put a rag around the detent assembly [Figure 20-42-61].
NOTE: Protect spool before clamping in vise. lost when the detent adapter is removed.
Remove the detent adapter with an Alan wrench.
Remove the back-up washer (Item 1) and spool seal

(Item 2) [Figure 20-42-61].

Lift Spool and Detent Removal and Installation 1

2
(Cont'd)
3
Figure 20-42-62
1 4
N-18919A
3) and washer (Item 4) [Figure 20-42-64].
N-19004 Figure 20-42-65
Remove the detent adapter (Item 1) [Figure 20-42-62]

from the spring assembly.
Figure 20-42-63
N-18918
Remove the stud from the end of the spool [Figure 20-
42-65].
N-19009
Remove spring tool (Item 1) [Figure 20-42-63] from the

spring assembly.


(Cont'd)
Figure 20-42-66
N-18963
1
Install the plastic plug and O-ring in the spool [Figure 20-
42-68].
N-18920 Figure 20-42-69
Removal of the plastic plug: O-Ring
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-42-66] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
Plastic
break the tap.
Plug
0.60 inch
Clean all the debris from inside the spool bore. (15,2 mm)
NOTE: DO NOT USE LOCTITE ON THE STUD

B-14712
THREADS.
Figure 20-42-67
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-42-69].
2
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-42-67].


(Cont'd)
Figure 20-42-70
1
1
N-18968
Install the detent adapter to the collar [Figure 20-42-72].
NOTE: The collar and the detent adapter are held

N-18967 together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
Clamp the collar (Item 1) [Figure 20-42-70] in a vice. the detent balls and spring from falling out.
Figure 20-42-71 Figure 20-42-73
1 3
2
N-18958
N-19004
Apply grease on all the detent component surfaces Install the spring tool (Item 1) [Figure 20-42-73] over the
before assembly [Figure 20-42-71]. washer, spring, collar and detent adapter.
Install the spring (Item 1) and detent balls (Item 2) into

the adapter (Item 3) [Figure 20-42-71] and compress
with the detent pliers (Item 1) [Figure 20-42-72].


(Cont'd)
Figure 20-42-74
CD-15051
1
Install the detent balls and spring [Figure 20-42-76].
Figure 20-42-77
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-42-74].
Figure 20-42-75
1
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-42-77].
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-42-75].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 Nm).
NOTE: The adapter must fit in the center of the



(Cont'd)
Figure 20-42-78
1
P-51514
Install the washer (Item 1) and snap ring (Item 2) [Figure

20-42-80].
N-19008 Figure 20-42-81
Install the detent sleeve (Item 1) [Figure 20-42-78] to the

detent adapter.
Figure 20-42-79
2
P-51513
1
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-42-79].
Install the detent bonnet (Item 1) [Figure 20-42-79].
Install the mounting screws (Item 2) [Figure 20-42-79].



(Cont'd)
Figure 20-42-82 1
P-51511
Install the O-ring (Item 1) [Figure 20-42-84] on the

control valve.
P-51520 Figure 20-42-85

linkage end of the valve. 2
Figure 20-42-83
1 4
P-51701
2 Install the end cap/spool lock block (Item 1) and the

mount bolt (Item 2) [Figure 20-42-85].
P-51512 Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-42-85].
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-42-83] on the lift spool. Installation: Tighten the screws to 90-100 in.-lb. (10-
11,3 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Tilt Spool Removal and Installation
Remove the lift and tilt end cap/spool lock block. (See
Lift Spool and Detent Removal and Installation End Cap/Spool Lock Block Removal and Installation on
(Cont'd) Page 20-40-14.)
Figure 20-42-86 Figure 20-42-88
1 2
P-51698
P-51521
Connect the tubeline (Item 1) [Figure 20-42-86]. Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-42-88] from the tilt spool.
Figure 20-42-87
Figure 20-42-89
1
P-51697
P-51522
Use an Ohm meter to measure the lock solenoid coils

resistance. Remove the three screws (Item 1) [Figure 20-42-89]
from the spool centering block.
The correct resistance for the coil is 5.5 .28 Ohms.
Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3
Installation: Install the lift spool (Item 1) and tilt spool Nm) torque.
(Item 2) [Figure 20-42-87] lock solenoids and tighten to
35-45 ft.-lb. (52-61 Nm) torque.

Tilt Spool Removal And Installation (Cont'd)

1
Figure 20-42-90
N-18942
1 Put the linkage end of the spool in the vice [Figure 20-
42-92].
P-51543
centering spring.
Remove the spool centering block (Item 1) [Figure 20-
42-90] from the control valve. Figure 20-42-93
Check and replace the O-ring (Item 2) [Figure 20-42-90]

before replacing the spool centering block.
1
Figure 20-42-91
N-19014

P-51544
Nm) torque.
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-42-91]. Remove spring tool from the spring assembly.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Auxiliary Spool Removal And Installation
Figure 20-42-96
Figure 20-42-94
2 1
3 1
P-51522
N-18944A Remove the three screws (Item 1) [Figure 20-42-96]

Inspect the adapter (Item 1), collar (Item 2), spring (Item Installation: Tighten the bolt to 90-100 in.-lb. (10-11,3
3) and washer (Item 4) [Figure 20-42-94]. Nm) torque.
Figure 20-42-95 Remove the spool centering block (Item 2) [Figure 20-
2
1 Figure 20-42-97
1 2
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-42-95] and

P-51546
the back-up washer (Item 2) [Figure 20-42-95].
Assembly: Always use a new spool seal. Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-42-97] from the auxiliary spool.
Note: If the centering spring retainer (Item 2) [Figure

20-42-97] must be replaced, replace the
retainer on the opposite end also.

Figure 20-42-98
1 2
1
2 P-51550

20-42-100] from the auxiliary spool.
P-51547
Figure 20-42-101

Figure 20-42-99
2 1
P-51551
P-51549
Remove the spring (Item 1) and center spring retainer

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


Auxiliary Solenoid Disassembly and Assembly
Figure 20-42-102
1
P-51703
Remove the solenoid stem (Item 1) [Figure 20-42-104].
P-51702 Installation: Tighten the stem to 10-14 ft.-lb. (14-19

Nm) torque.
Remove the nut (Item 1) [Figure 20-42-102] from both Figure 20-42-105
solenoids.
Installation: Tighten the nut to 48-72 in.-lb. (5-8 Nm)

torque.
Figure 20-42-103
1
2
2
P-51555

the solenoid stem.
P-51553 Check and clean the screen (Item 2) [Figure 20-42-105].
Remove the nut (Item 1) and solenoid coil (Item 2)

[Figure 20-42-103].
Use an Ohm meter to measure the solenoid coil

resistance.

BICS Valve Solenoid Disassembly And Assembly
Figure 20-42-106
2
P-51445
P-51444 Installation: Lubricate the O-rings and tighten the stem

Remove the nut (Item 1) [Figure 20-42-106] from the Figure 20-42-109
solenoid stem.
Installation: Tighten the nut to 53 in.-lb. (6 Nm) torque.
Remove the solenoid coil (Item 2) [Figure 20-42-106]. 3

2
Figure 20-42-107
N-18694

[Figure 20-42-109] from the cartridge.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-42-109] may be
Use an Ohm meter to measure the solenoid coil needs to be replaced.
resistance.
The correct resistance for the coil is 9.79 .29 Ohms. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-42-107] &

[Figure 20-42-109] and new back-up rings (Item 2)
[Figure 20-42-109] on the solenoid stem.

BICS Valve, Lock Valve Removal And Installation
Figure 20-42-110 1
1
1
1 2
1
2
2
2
P-51564

[Figure 20-42-112] from the lift lock valve, and replace
P-51704 with new.
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-42-110] is for the lift
circuit.
Figure 20-42-111
P-51443
Remove the lift lock valve (Item 1) [Figure 20-42-111]

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

tighten to 20-24 ft.-lb. (27-33 Nm) torque.


(Contd)
Figure 20-42-113
1
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-42-115]

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 20-42- Figure 20-42-116
113].
Figure 20-42-114
1
1
2 1
1
2
1
2
2
P-51564
P-51697P-
51504
[Figure 20-42-116] from the tilt lock valve, and replace
with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-
42-114].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

42-114].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 38-45 ft.-lb. (52-61 Nm) torque.

BICS Valve, Check Valve Removal And Installation 1
Figure 20-42-117
1
4
P-51447
Check that there is no blockage in the orifice (Item 1)

[Figure 20-42-119].
P-51438
Inspect the check valve (Item 2) and spring (Item 3)
[Figure 20-42-119].
Remove the BICS valve (Item 1) [Figure 20-42-117].
Replace the O-ring (Item 4) [Figure 20-42-119] on the
Installation: Lubricate the o-ring and tighten the valve to plug before installation.
55-65 ft.-lb. (75-88 Nm) torque.
Figure 20-42-118
P-51446

top of the BICS valve.

Figure 20-42-122
BICS Valve, Lift Arm By-Pass Orifice Disassembly
And Assembly
Figure 20-42-120
1 P-51707
Remove the main relief valve (Item 1) [Figure 20-42-

P-51436 122].
Figure 20-42-123
valve.
Figure 20-42-121
1
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-42-123].
Installation: Always use new O-rings. Tighten to 38-45

Check the lift arm by-pass orifice (Item 1) [Figure 20-42- ft.-lb. (52-61 Nm) torque.
121].
NOTE: This orifice is not removable from the valve

casting.

(ADVANCED CONTROL SYSTEM) (ACS)
damage the system.
I-2003-0888
1 Lift and block the loader. ((See Procedure on Page 10-

10-1.)

Page 10-20-1.)

P-51730
on Page 10-30-1.)
The hydraulic control valve (1 piece casting) (ACS) (Item Clean the area around the control valve.
1) [Figure 20-43-1] does not have a removable BICS
section. Drain the hydraulic reservoir. (See Replacing Hydraulic
The BICS section and main control valve are in one
casting. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
casting) (ACS), (See Identification on Page 20-41-1.) Figure 20-43-2
P-34004

W-2059-0598

Removal and Installation (Contd) 4
Figure 20-43-3 1
2
1 3
1
P-51975
Mark and disconnect the two auxilliary electric solenoid

connectors (Item 1) [Figure 20-43-5] for correct
P-51710 installation.
Remove the outlet tubeline (Item 2) [Figure 20-43-5]

Mark all tubelines and hoses for correct installation. from the control valve to the hydraulic oil cooler.
The fixed end main valve hose (Item 1) [Figure 20-43-3] Disconnect and cap the supply hose (Item 3) and the
is connected to a fixed end fitting on the control valve. supply hose clamp (Item 4) [Figure 20-43-5].
The hose is routed to the back upright where the hose is
connected to a tee fitting that feeds the base end of both Figure 20-43-6
lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.
1
Figure 20-43-4
3
P-51976
1
Disconnect and cap the tubeline (Item 1) [Figure 20-43-
6] from the lift arm by-pass valve to the control valve.
Disconnect and cap the hose (Item 2) [Figure 20-43-6]

P-31999 from the lift arm by-pass valve to the drive motor case
drain.
Remove the tie-strap (Item 1) [Figure 20-43-4] from the Remove the lift arm by-pass tubeline (Item 3) [Figure
fixed end main valve hose. 20-43-6] from the control valve drain.

Figure 20-43-7
P-51983
Disconnect the connectors (Item 1) [Figure 20-43-9]

from the lift and tilt actuators.
P-51719

main valve mounting bracket.
Figure 20-43-8
P-51977
Disconnect the wire harness tie-strap mounts (Item 1)

[Figure 20-43-8] from the lift arm by-pass bracket.

Figure 20-43-10
2 1
1
P-51980
Remove and cap both tubelines (Item 1) [Figure 20-43-

12] from the auxiliary section of the control valve.
P-51721
Disconnect and cap the drain hose (Item 2) [Figure 20-
Remove the two lift arm by-pass valve mounting bolts
(Item 1) [Figure 20-43-10]. Figure 20-43-13
Remove the lift arm by-pass valve and mounting bracket.
Figure 20-43-11
2
1
1
P-51982
Disconnect and cap the tubelines (Item 1) and (Item 2)

P-51727 [Figure 20-43-13] from the tilt section of the control
valve.
Remove tubeline clamp bolt (Item 1) [Figure 20-43-11] Disconnect and cap the tubeline (Item 3) [Figure 20-43-
from the auxiliary tubelines in the left rear upright. 13] from the lift section of the control valve.
Installation: Tighten bolt to 15-20 ft.-lb. (20-27 Nm)

torque.

Figure 20-43-14 1
1
P-51726
1
Connect a hoist to the lifting brackets (Item 1) [Figure
20-43-16] on the control valve.
P-51728
Figure 20-43-17
Remove the fixed-end main valve hose (Item 1) [Figure

20-43-14] from the main control valve fitting.
Figure 20-43-15
1
1 P-31999
P-34004P-
51713

17] fastening the control valve and bracket to the side of
P-51722 the loader.

Mark and disconnect the BICS electric solenoid
connector (Item 1) [Figure 20-43-15]. Reverse procedure for installation.

Actuator Removal And Installation (Out of Loader)
Figure 20-43-18
1
1
P-51734
1
Using a drift pin and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-43-20] from the actuator
and the tilt spool.
P-51732 Remove the actuator and linkage pin from the valve.
Figure 20-43-21
from the tilt actuator.
Installation: Tighten the mounting bolts to 90-100 in.-lb.

(10,2-11,3 Nm) torque.
Figure 20-43-19 1
1 P-51736
Inspect the O-ring (Item 1) [Figure 20-43-21] on the face

of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-43-21] and

P-51733 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-43-

19] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
43-19].


(Contd)
Figure 20-43-22
P-51800
Using a drift pin and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-43-24] from the actuator
and the tilt spool.
P-51737
Remove the actuator and linkage pin from the valve.
Remove the two mount bolts (Item 1) [Figure 20-43-22] Figure 20-43-25
from the lift actuator.

(10,2-11,3 Nm) torque.
Figure 20-43-23
1
1
2
P-51736
Inspect the O-ring (Item 1) [Figure 20-43-25] on the face

of the actuator, and replace as needed.
P-51799 Check the linkage pin (Item 2) [Figure 20-43-25] and

replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-43-

23] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
43-23].


(Contd)
Figure 20-43-26
1 2
3
P-51738
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-43-26] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-43-26].

(10,2-11,3 Nm) torque (Item 1) [Figure 20-43-26]

Identification Chart (ACS)
Figure 20-43-27
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3 D3
B2
D4 E2
A2
D1
D2
A1
E1
F1 H2 B1
H3
MR C1
H1 J3
J1
MS1929
ITEM S175/S185 LOADER ITEM S175/S185 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 Load Check/BICS Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS Valve Solenoid
C2 Load Check Valve Tilt Function
H2 BICS Lock Valve (Tilt)
C3 Load Check Valve Auxiliary Function
D1 Anti-Cavitation Valve H3 BICS Lock Valve (Lift)
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 By-Pass Orifice
D3 Port Relief/Anti-Cavitation Valve 3500 PSI J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve 3300 PSI
D4 Port Relief/Anti-Cavitation Valve 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve, Lift Load Check Valve Removal And
(ADVANCED CONTROL SYSTEM) (ACS) (CONTD) Installation
Mount Bracket Removal and Installation Figure 20-43-30
Figure 20-43-28
1 P-51740
P-51730
Remove the lift load check valve (Item 1) [Figure 20-43-
30].
Remove the control valve and mount bracket (Item 1)
[Figure 20-43-28] from the loader. Installation: Lubricate the O-ring and tighten the valve to
55-65 ft.-lb. (75-88 Nm) torque.
Figure 20-43-29
Figure 20-43-31
P-51731
P-51439

the inlet fitting on the control valve. Remove and install new O-rings (Item 1) and back-up
from the control valve mount plate. Remove the mount
plate and tubeline.

BICS Valve, Lift Load Check Valve Removal And

4
Figure 20-43-32
1 1
3
2
P-51453

20-43-34].
P-51440 Check the orifice (Item 3) [Figure 20-43-34] in the

Check for free movement of the load check valve (Item 1) Installation: Install a new O-ring (Item 4) [Figure 20-43-
[Figure 20-43-32]. 34] on the plug and lightly lubricate with oil before
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)
Figure 20-43-33
P-51741
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-43-33].
At the front side of the control valve locate the auxiliary

section load check valve (Item 2) [Figure 20-43-33].
NOTE: The tilt and auxiliary load check valves are

interchangeable.

Anti-Cavitation Valve (Lift, Rod End)

4
Figure 20-43-35
1
3
2
P-51453
1

20-43-37].
P-51742
Check the orifice (Item 3) [Figure 20-43-37] in the
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-43-35]. Installation: Install a new O-ring (Item 4) [Figure 20-43-
37] on the plug and lightly lubricate with oil before
torque.
WARNING
damage the system.
I-2003-0888
Figure 20-43-36
P-51452
Always use new O-ring (Item 1) [Figure 20-43-36] on the

anti-cavitation valve plug.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Figure 20-43-40
Port Relief/Anti-Cavitation Valve (Lift, Base End)
Figure 20-43-38
1
P-51742
P-51742 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-43-40] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-43-41
1) [Figure 20-43-38].
Figure 20-43-39
1 P-51454
P-51451 Replace the O-ring (Item 1) [Figure 20-43-41] before

installation.
Replace the O-ring (Item 1) [Figure 20-43-39] before Installation: Lightly lubricate with oil and tighten to 38-45
installation. ft.-lb. (52-61 Nm) torque.
Installation: Lightly lubricate with oil and tighten to 38-45

ft.-lb. (52-61 Nm) torque.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief Valve
Figure 20-43-44
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Figure 20-43-42
P-51742
P-51742 Remove the port relief plug (Item 1) [Figure 20-43-44]

from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-43-45
[Figure 20-43-42] from the rod end of the tilt section.
Figure 20-43-43
1 P-51801
P-51455 Installation: Always use new O-rings (Item 1) [Figure

20-43-45]. Lightly lubricate with oil and tighten to 38-45
installation.
Installation: Lightly lubricate with oil and tighten to 38-45


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Plug Removal
Figure 20-43-48
Figure 20-43-46
1
1
P-51459
P-51743 At the top side of the control valve, remove the plug (Item
1) [Figure 20-43-48].
The control valve may be equipped with an optional Figure 20-43-49

auxiliary port relief valve (Item 1) [Figure 20-43-46].
Remove the auxiliary port relief valve.
Figure 20-43-47
1
P-51460

P-51640

20-43-47]. Lightly lubricate with oil and tighten to 38-45

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) End Cap Block Removal and Installation
Remove the lift and tilt actuators from the control valve.
Plug Removal (Contd) (See Actuator Removal And Installation (Out of Loader)
on Page 20-43-6.)
Figure 20-43-50
Figure 20-43-52
1
P-51461 2
P-51744
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-43-50]. Disconnect the tube line (Item 1) [Figure 20-43-52] from
the end cap block.
Figure 20-43-51
Remove the two end cap block mount screws (Item 2)
[Figure 20-43-52].
Installation: Tighten the screws to 90-100 in.-lb. (10-

11,3 Nm) torque.
Figure 20-43-53
1
P-51462 1

P-51745
Remove the end cap block (Item 1) [Figure 20-43-53]

from the control valve.

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

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-43-54
1
P-51748
Remove the two screws (Item 1) [Figure 20-43-56] from

the lift spool end cap.
1
Figure 20-43-57
P-51746
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
Figure 20-43-55 1
P-51749
Remove the lift spool end cap (Item 1) [Figure 20-43-57]

2 from the control valve.
1
P-51747

20-43-55] from the lift spool.

Lift Spool Removal and Installation (Cont'd)
Figure 20-43-58
P-51772
1 Clamp the linkage end of the spool in a vise [Figure 20-

43-60].
P-51770
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-43-61
20-43-58] from the control valve.
Figure 20-43-59
1
P-51773
P-51771 Install the spring tool (Item 1) [Figure 20-43-61] over the
centering spring.
Remove the lift spool seal (Item 1) [Figure 20-43-59]

from the linkage end of the valve.


2
1
Figure 20-43-62
P-51771 P-51775
Remove the spool seal(s) (Item 1) and the back-up

N-190146
Remove the bolt (Item 1) [Figure 20-43-62] holding the Figure 20-43-65

Nm) torque. 1
Remove spring tool from the spring assembly.
Figure 20-43-63
2
3
3 3
4 1 P-51749
Install the lift spool assembly (Item 1) [Figure 20-43-65]

in the spool bore.
P-51776 Install the mounting screws (Item 3) [Figure 20-43-65].

Inspect the adapter (Item 1), collar (Item 2), spring (Item in.-lb. (10-11,3 Nm) torque.

Figure 20-43-66
P-51746
Install the O-ring (Item 1) [Figure 20-43-68] on the

control valve.
P-51777
Figure 20-43-69

linkage end of the valve.
Figure 20-43-67
3
2
1 1
2
P-51744
2
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-43-69].
P-51747
Installation: Tighten the screws to 90-100 in.-lb. (10-
11,3 Nm) torque.
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-43-67] on the lift spool. Connect the tube line (Item 3) [Figure 20-43-69] to the
end cap block.
Install the lift and tilt actuators to the control valve.

Tilt Spool Removal and Installation
Remove the end cap block. (See End Cap Block

Removal and Installation on Page 20-43-16.)
Figure 20-43-70 2
P-51780
Remove the spool centering block (Item 1) [Figure 20-

2 43-72] from the control valve.
1
Check and replace the O-ring (Item 2) [Figure 20-43-72]
before replacing the spool centering block.
P-51778
Figure 20-43-73

20-43-70] from the tilt spool.
Figure 20-43-71
2
P-51781
Remove the tilt spool, centering spring, back-up washer

2 and spool seal (Item 1) [Figure 20-43-73].
P-51779
Disconnect the tubeline (Item 1) [Figure 20-43-71].
Remove the three screws (Item 2) [Figure 20-43-71]


Nm) torque.


2 1
Figure 20-43-74
3
4
1
N-18944A
N-18942
Figure 20-43-77
Put the linkage end of the spool in the vice [Figure 20-
43-74]. 2
1
centering spring.
Figure 20-43-75
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

N-19014


Nm) torque.
Remove spring tool from the spring assembly.

Auxiliary Spool Removal And Installation
Figure 20-43-78
1 1
2
P-51783

2 P-51779
Figure 20-43-81

the spool centering block.
Remove the three screws (Item 2) [Figure 20-43-78]


Nm) torque.
1
Remove the spool centering block from the control valve.
Figure 20-43-79 2
P-51784

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

2
1
P-51782

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


HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Auxiliary Solenoid Disassembly and Assembly
Figure 20-43-84
Figure 20-43-82
1
2
P-51552
P-51785 Remove the nut (Item 1) [Figure 20-43-84] 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 Nm)
20-43-82] from the auxiliary spool. torque.
Figure 20-43-83 Figure 20-43-85
P-51786
P-51553
Remove the auxiliary spool (Item 1) [Figure 20-43-83]. Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-43-85].
Use an Ohm meter to measure the solenoid coil

resistance.

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve Solenoid Disassembly And Assembly
Figure 20-43-88
Auxiliary Solenoid Disassembly and Assembly
(Contd)
Figure 20-43-86
1
1
2
P-51788
Remove the nut (Item 1) [Figure 20-43-88] from the

P-51787 solenoid stem.
Installation: Tighten the nut to 53 in.-lb. (6 Nm) torque.

Remove the solenoid coil (Item 2) [Figure 20-43-88].
Installation: Tighten the stem to 10-14 ft.-lb. (14-19
Nm) torque. Figure 20-43-89
Figure 20-43-87
1
2
N-18693A
P-51555
both ends of the solenoid coil.
solenoid stem. Use an Ohm meter to measure the solenoid coil
resistance.
Check and clean the screen (Item 2) [Figure 20-43-87].

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Use only new O-rings and apply oil to all O-rings and
(ADVANCED CONTROL SYSTEM) (ACS) (CONTD) back-up rings before installation.
BICS Valve Solenoid Disassembly And Assembly Install new O-rings (Item 1) [Figure 20-43-89] & [Figure
(Contd) 20-43-91] and new back-up rings (Item 2) [Figure 20-43-
91] on the solenoid stem.
Figure 20-43-90
Figure 20-43-92
1
2
1
P-51789
Remove the solenoid stem (Item 1) [Figure 20-43-90]. P-51790
Installation: Lubricate the O-rings and tighten the stem

to 20-24 ft.-lb. (27-33 Nm) torque. Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-43-92] is for the lift circuit.
Figure 20-43-91
Figure 20-43-93
3
2
1
1
N-18694
P-51791

[Figure 20-43-91] from the stem. Remove the lift lock valve (Item 1) [Figure 20-43-93]
Inspect all parts for wear and replace any showing tighten to 20-24 ft.-lb. (27-33 Nm) torque.
excessive wear.



(Contd)
1
Figure 20-43-94
1
1
1 1
1 2
1 2
2
P-51564
1
2
2 [Figure 20-43-96] from the tilt lock valve, and replace
2 with new.
P-51564

[Figure 20-43-94] from the lift lock valve, and replace
with new.
Figure 20-43-95
P-51792
Remove the tilt lock valve (Item 1) [Figure 20-43-95]



BICS Valve, Check Valve Removal And Installation 1
Figure 20-43-97
4
P-51447
1
Check that there is no blockage in the orifice (Item 1)

[Figure 20-43-99].
P-51788
Inspect the check valve (Item 2) and spring (Item 3)
[Figure 20-43-99].
Remove the BICS valve (Item 1) [Figure 20-43-97].
Replace the O-ring (Item 4) [Figure 20-43-99] on the
Installation: Lubricate the o-ring and tighten the valve to plug before installation.
55-65 ft.-lb. (75-88 Nm) torque.
Figure 20-43-98
P-51446
Remove the plug (Item 1) [Figure 20-43-98] from the top

of the BICS valve.

Figure 20-43-102
BICS Valve, Lift Arm By-Pass Orifice Disassembly
And Assembly
Figure 20-43-100
1
P-51794
Remove the main relief valve (Item 1) [Figure 20-43-

P-51793 102].
Figure 20-43-103
valve.
Figure 20-43-101
1
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-43-103].
Installation: Always use new O-rings. Tighten to 38-45

Check the lift arm by-pass orifice (Item 1) [Figure 20-43- ft.-lb. (52-61 Nm) torque.
101].
NOTE: This orifice is not removable from the valve

casting.

LIFT ARM BY-PASS CONTROL VALVE Figure 20-50-1
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull the Lift Arm By-Pass 1
Control Knob until the lift arms slowly lower.
Removal and Installation 4

3
1
P-31990A
The Lift Arm By-Pass valve (Item 1) [Figure 20-50-1] is

located under the right side of the control panel.
WARNING Hold the Lift Arm By-Pass Control knob (Item 2) and
loosen the jam nut (Item 3) on the Lift Arm By-Pass valve
Never work on a machine with the lift arms up unless shaft [Figure 20-50-1].
support device. Failure to use an approved lift arm Remove the Lift Arm By-Pass Control knob (Item 2) and
support device can allow the lift arms or attachment the jam nut (Item 3) from the Lift Arm By-Pass valve shaft
to fall and cause injury or death. [Figure 20-50-1].
W-2059-0598
Remove the rubber washer (Item 4) [Figure 20-50-1].
Install jack stands under the rear corners of the loader.
Start the engine. Raise the lift arms and install an

approved lift arm support device. (See Installing Lift Arm
Raise the operator cab.(See Raising The Operator Cab

on Page 10-30-1.)

LIFT ARM BY-PASS CONTROL VALVE (CONT'D) Disassembly And Assembly
Figure 20-50-2
1
1
4
2
3
P-26065
P-48431
Remove the by-pass valve (Item 1) [Figure 20-50-3]
from the valve block. Inspect the by-pass valve for
Disconnect the base end lift tubeline (Item 1) [Figure 20- damage and replace if necessary.
50-2] from the Lift Arm By-Pass valve.
Installation: Tighten the valve to 33-37 ft.-lb. (45-50
Disconnect the drain hose (Item 2) [Figure 20-50-2] from Nm) torque.
the Lift Arm By-Pass valve.
Inspect the hydraulic fittings on the valve block for
Disconnect the motor case drain hose (Item 3) [Figure damage and replace if necessary.
20-50-2].
Remove the two mounting bolt/nuts (Item 4) [Figure 20-

50-2].
Installation: Tighten the mounting bolts to 180-200 in. lb.

(21-23 Nm) torque.
Remove the lift arm by-pass control valve.

HYDRAULIC PUMP Figure 20-60-1
Check The Output Of The Hydraulic Pump Without

Power Bob-Tach
WARNING
W-2017-0286
1
P-26071
WARNING Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]

from the pump.
Figure 20-60-2
W-2059-0598

2 1
procedure:
MEL1563 - Remote Start Tool


1.) P-24594

support device. (See Installing Lift Arm Support Device Connect the INLET hose (Item 1) [Figure 20-60-2] from
on Page 10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-60-1]
of the pump. Connect the OUTLET hose (Item 2)
Raise the operator cab. (See Raising The Operator Cab [Figure 20-60-2] from the tester to the hose (Item 1)
on Page 10-30-1.) [Figure 20-60-1] which was disconnected from the
pump.
Open the rear door of the loader.
Connect the remote start tool. (See Procedure on Page

10-60-1.)
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT'D)

Power Bob-Tach (Cont'd)
Figure 20-60-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
Sample tester connection shown [Figure 20-60-3].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor

control (Item 1) [Figure 20-60-3] 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) X100

FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*Refer to SPECIFICATIONS Section SPEC-01 for

system relief pressure and full RPM.

HYDRAULIC PUMP (CONT'D) Figure 20-60-4
Check The Output Of The Hydraulic Pump With

Power Bob-Tach.
1 2
WARNING
W-2017-0286
P-26682

from the top of the Power Bob-Tach block.
Figure 20-60-5
W-2059-0598

2 1
procedure:


1.) P-24594

on the top of the Power Bob-Tach block. Connect the
Raise the operator cab. (See Raising The Operator Cab OUTLET hose (Item 2) [Figure 20-60-5] from the tester
on Page 10-30-1.) to the hose (Item 1) [Figure 20-60-4] which was
disconnected from the Power Bob-Tach block.

10-60-1.)
IMPORTANT
I-2024-0284


Power Bob-Tach. (Cont'd)
Figure 20-60-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
RPM*.


start tool) to engage the front auxiliary hydraulics. The
80% of free flow.

FREE FLOW (GPM)


HYDRAULIC PUMP (CONT'D) Remove the Power Bob-Tach block if equipped. (See
Removal And Installation on Page 20-120-1.)
Disconnect and cap the outlet hose (Item 1)
[Figure 20-60-7] from the back of the hydraulic pump.
Figure 20-60-8
WARNING
support device. Failure to use an approved lift arm 1
P-26068
W-2059-0598
Disconnect and cap the inlet hose (Item 1)
[Figure 20-60-8] from the front of the hydraulic pump.
Figure 20-60-7
Figure 20-60-9
2
1
P-26071
P-26069

support device. (See Procedure on Page 10-10-1.)
Remove the two mounting bolts (Item 1)
[Figure 20-60-9] from the hydraulic pump.
Lift and block the rear of the loader. (See Installing Lift Installation: Tighten the mounting bolts to 27-37 in.-lb.
Arm Support Device on Page 10-20-1.) (37-50 Nm) torque.
Raise the operator cab. (See Raising The Operator Cab Remove the hydraulic pump (Item 2) [Figure 20-60-9]
on Page 10-30-1.) from the hydrostatic pump.
Drain the hydraulic fluid from the reservoir. (See

Replacing Hydraulic Fluid on Page 10-120-1.)

Figure 20-60-10
P-26347
1 2
P-26347
Remove the coupler (Item 2) [Figure 20-60-10] from the

hydraulic pump shaft.
Reverse the removal procedure to install the hydraulic

pump.
Installation: Use a new O-ring (Item 1) [Figure 20-60-10]

when installing the hydraulic pump. (See Disassembly
And Assembly on Page 20-60-8.)

Identification
15
8
7
6
14
13
12
11
7 9
1 5 10
4
3
B-16050A
REF. DESCRIPTION REF. DESCRIPTION
1 RETAINING RING 9 IDLER GEAR

2 PUMP END SECTION 10 PUMP CENTER SECTION
3 PRE-LOAD SEAL 11 WEAR PLATE
4 LOAD SEAL 12 SECTION SEAL
5 SECTION SEAL 13 PUMP END SECTION
6 WEAR PLATE 14 BOLTS (4)
7 PINS 15 BOLTS (4)
8 DRIVE GEAR

Disassembly And Assembly

1
Figure 20-60-11
P-26352
2
2
P-26353
1
Remove the pump end section (Item 1)

P-26351 [Figure 20-60-12].
Mark the pump sections for correct assembly

[Figure 20-60-11].
Remove the four smaller pump housing bolts (Item 1)

[Figure 20-60-11].
Remove the four larger pump housing bolts (Item 2)

[Figure 20-60-11].
Installation: Tighten the four smaller bolts (Item 1) to 30

ft.-lb. (40,7 Nm) torque. Tighten the four larger bolts
(Item 2) [Figure 20-60-11] to 54 ft.-lb. (73,2 Nm) torque.
IMPORTANT
damage the system.
I-2003-0888

Disassembly And Assembly (Cont'd)
Figure 20-60-13 1
P-26358
2
Figure 20-60-16
P-26354
1
Figure 20-60-14
4
3
1
P-26359
2 Remove the pump center section (Item 1)

P-26355 [Figure 20-60-15] & [Figure 20-60-16] from the pump
end section.
Remove the wear plate (Item 1) [Figure 20-60-13] & NOTE: Inspect the pump center section (Item 1)
[Figure 20-60-14] and section seal (Item 2) [Figure 20-60-16]. If excessive wear or
[Figure 20-60-13] & [Figure 20-60-14] from the pump damage is visible, the pump must be
end section. replaced.
NOTE: Position wear plate (Item 1) [Figure 20-60-14]

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

bushings (Item 4) [Figure 20-60-14]. If
excessive wear or damage is visible, the
pump must be replaced.

Figure 20-60-17
1
P-26391
Figure 20-60-20
P-26389
Figure 20-60-18
P-26362
1
1
P-26362
To remove the drive gear (Item 1) [Figure 20-60-19] from

P-26390 the pump end section, locate and remove the retaining
ring (Item 2) (Inset) [Figure 20-60-20] from the spline
end of the drive gear.
Remove the idler gear (Item 1) [Figure 20-60-17] &
[Figure 20-60-18].
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

18]. If excessive wear or damage is visible, the

Figure 20-60-21
P-26394

P-26392 inlets and traps as shown with bronze side
toward gears.
Remove the drive gear (Item 1) [Figure 20-60-21] from Figure 20-60-24
the pump end section.
NOTE: Inspect the drive gear (Item 1) 1

[Figure 20-60-21]. If excessive wear or
damage is visible, the pump must be
replaced.
P-26396
Figure 20-60-22
1
P-26395
1
Remove the load seal (Item 1) [Figure 20-60-24].
P-26393
Remove the wear plate (Item 1) [Figure 20-60-22] &

[Figure 20-60-23] and section seal (Item 2)
[Figure 20-60-22] & [Figure 20-60-23] from the pump
end section.


1
Figure 20-60-25
2
P-26398
P-26374

P-26397 bushings (Item 2) [Figure 20-60-26]. If
Remove the pre-load seal (Item 1) [Figure 20-60-25].

HYDRAULIC PUMP (HIGH FLOW) Figure 20-61-1

Power Bob-Tach
WARNING
W-2017-0286
1
P-26753

from the pump.
Figure 20-61-2
W-2059-0598

2 1
procedure:


1.) P-24594

of the pump. Connect the OUTLET hose (Item 2)
Raise the operator cab. (See Raising The Operator Cab [Figure 20-61-2] from the tester to the hose (Item 1)
on Page 10-30-1.) [Figure 20-61-1] which was disconnected from the
pump.

10-60-1.)
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (HI FLOW) (CONT'D)

Power Bob-Tach (Cont'd)
Figure 20-61-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
RPM*.


start tool) to engage the front auxiliary hydraulics, the
80% of free flow.

FREE FLOW (GPM)


HYDRAULIC PUMP (HI FLOW) (CONT'D) Figure 20-61-4

Power Bob-Tach. 1
WARNING
W-2017-0286
P-26754

from the top of the Power Bob-Tach block.
Figure 20-61-5
W-2059-0598
The tools listed will be needed to do the following 2

1
procedure:


1.) P-24594

on the top of the Power Bob-Tach block. Connect the
Raise the operator cab. (See Raising The Operator Cab OUTLET hose (Item 2) [Figure 20-61-5] from the tester
on Page 10-30-1.) to the hose (Item 1) [Figure 20-61-4] which was
disconnected from the Power Bob-Tach block.

10-60-1.)
IMPORTANT
I-2024-0284


Power Bob-Tach. (Cont'd)
Figure 20-61-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
RPM*.


start tool) to engage the front auxiliary hydraulics, the
80% of free flow.

FREE FLOW (GPM)


HYDRAULIC PUMP (HI FLOW) (CONT'D) Remove the Power Bob-Tach block if equipped. (See
Disconnect and cap the outlet hoses (Item 1)
[Figure 20-61-7] from the back of the hydraulic pump.
Figure 20-61-8
WARNING
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm P-26739
W-2059-0598
Disconnect and cap the inlet hoses (Item 1)
[Figure 20-61-8] from the front of the hydraulic pump.
Figure 20-61-7
Figure 20-61-9
1
2
1
P-26741
P-26740

support device. (See Installing Lift Arm Support Device Remove the two mounting bolts (Item 1)
on Page 10-20-1.) [Figure 20-61-9] from the hydraulic pump.
Stop the engine. Raise the seat bar. Installation: Tighten the mounting bolts to 27-37 ft.-lb.
Lift and block the rear of the loader. (See Procedure on (37-50 Nm) torque.
Page 10-10-1.)
Remove the hydraulic pump (Item 2) [Figure 20-61-9]
Raise the operator cab. (See Raising The Operator Cab from the hydrostatic pump.
on Page 10-30-1.)


Figure 20-61-10
P-26684
1 2
P-26684
Remove the coupler (Item 2) [Figure 20-61-10] from the

hydraulic pump shaft.

pump.
Installation: Use a new O-ring (Item 1)

[Figure 20-61-10] when installing the hydraulic pump.
(See Disassembly And Assembly on Page 20-61-8.)

Identification
26
22 23
19
27
24 25
23
20
21
17 18
15 16 7 8
14
2
13
12
1 11
10
6 7 9
3 4 5
B-16051a
REF. DESCRIPTION REF. DESCRIPTION
1 RETAINING RING 14 PUMP CENTER SECTION

2 PUMP END SECTION 15 PRE-LOAD SEAL
3 PRE-LOAD SEAL 16 LOAD SEAL
4 LOAD SEAL 17 SECTION SEAL
5 SECTION SEAL 18 WEAR PLATE
6 WEAR PLATE 19 DRIVE GEAR
7 PINS 20 IDLER GEAR
8 DRIVE GEAR 21 PUMP SECTION
9 IDLER GEAR 22 WEAR PLATE
10 PUMP SECTION 23 PINS
11 WEAR PLATE 24 SECTION SEAL
12 SECTION SEAL 25 PUMP END SECTION
13 SPLINE SHAFT 26 BOLT (4)
27 BOLT (4)


IMPORTANT
Figure 20-61-11
damage the system.
1 I-2003-0888
P-26622
Figure 20-61-12
2
1
2
1 P-26622
Mark the pump sections for correct assembly

[Figure 20-61-11].
Remove the four smaller pump housing bolts (Item 1)

[Figure 20-61-11].
P-26624
Remove the four larger pump housing bolts (Item 2)
[Figure 20-61-11].
Remove the pump end section (Item 1)
Installation: Tighten the four smaller bolts (Item 1) to [Figure 20-61-12].
30 ft.-lb. (40,7 Nm) torque. Tighten the four larger bolts
(Item 2) [Figure 20-61-11] to 54 ft.-lb. (73,2 Nm) torque.

Figure 20-61-13
1 1
P-26627
2 Figure 20-61-16
P-26625
Figure 20-61-14
1
3
1 P-26628
Remove the pump section (Item 1) [Figure 20-61-15] &

2
P-26626 [Figure 20-61-16] from the pump center section.
NOTE: Inspect the pumps center section (Item 1)

Remove the wear plate (Item 1) [Figure 20-61-13] & [Figure 20-61-16]. If excessive wear or
[Figure 20-61-14] and section seal (Item 2) damage is visible, the pump must be
[Figure 20-61-13] & [Figure 20-61-14] from the pump replaced.
end section.

toward gears.


Figure 20-61-17
P-26631
Figure 20-61-20
P-26629

[Figure 20-61-18].
Figure 20-61-18
P-26632
1
Remove the drive gear (Item 1) [Figure 20-61-19] &
[Figure 20-61-20].
NOTE: Inspect the drive gear (Item 1)

P-26630 [Figure 20-61-20]. If excessive wear or
replaced.
NOTE: Inspect the idler gear (Item 1)
replaced.


1
Figure 20-61-21
P-26636A
1
1
P-26635
2
P-26633
Figure 20-61-24
Figure 20-61-22
1
P-26638A
P-26637
P-26634

center section.

toward gears.

Disassembly And Assembly (Cont'd) 3
Figure 20-61-25
2
P-26657

toward gears.
Remove the pump center section (Item 1) NOTE: Inspect the pump center section (Item 3) and
[Figure 20-61-25] from the pump sections. bushings (Item 4) [Figure 20-61-27]. If
Figure 20-61-26 pump must be replaced.
Figure 20-61-28
1
2
P-26655
P-26659
[Figure 20-61-26] & [Figure 20-61-27] from the pump Remove the pump section (Item 1) [Figure 20-61-28]
section. from the pump end section.

Figure 20-61-29
P-26662
NOTE: Inspect the idler gear (Item 1)

P-26660 [Figure 20-61-31]. If excessive wear or
replaced.
NOTE: Inspect the pump section (Item 1)
replaced.
Figure 20-61-30
P-26661

[Figure 20-61-31].

Figure 20-61-32
P-26666
Remove the drive gear (Item 1) [Figure 20-61-34] from

P-26663 the pump end section.
NOTE: Inspect the drive gear (Item 1)

Figure 20-61-33 [Figure 20-61-34]. If excessive wear or
replaced.
Figure 20-61-35
1
P-26665
1
1
P-26664
To remove the drive gear (Item 1) [Figure 20-61-32] from

the pump end section, locate and remove the retaining
P-26674
ring (Item 1) [Figure 20-61-33] from the spline end of the
drive gear.
Remove the spline shaft (Item 1) [Figure 20-61-35] from
the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1)

replaced.


1
Figure 20-61-36
P-26670A
P-26669
2
P-26667
Figure 20-61-39
Figure 20-61-37
1
P-26672A
1
1
P-26671
P-26668

end section.

toward gears.

Figure 20-61-40
P-26673


HYDRAULIC PUMP (SJC) Figure 20-62-2
Test The Output Of The Hydraulic Auxiliary Pump
WARNING
2 1
W-2017-0286
Figure 20-62-1 P-48256
Connect the INLET hose (Item 1) [Figure 20-62-2] from

the tester, to the OUTLET hose (Item 1) [Figure 20-62-1]
coming from the gear pump. Connect the OUTLET hose
1 (Item 2) [Figure 20-62-2] from the tester, to the INLET
tubeline (Item 2) [Figure 20-62-1] leading to the control
valve.
IMPORTANT
P-64570 The hydraulic tester must be in the fully open
I-2024-0284
procedure:


1.)

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

on Page 10-30-1.)

10-60-1.)
Disconnect the OUTLET hose (Item 1) [Figure 20-62-1].

HYDRAULIC PUMP (SJC) (CONT'D) Test The Output Of The Hydraulic Charge Pump

(Cont'd)
Figure 20-62-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
W-2017-0286
Figure 20-62-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277
2
P-64315
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-62-3] on the tester to about procedure:
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm
and flow (GPM). The high pressure flow must be at least support device. (See Installing Lift Arm Support Device
80% of free flow. on Page 10-20-1.)
HIGH PRESSURE FLOW (GPM) Raise the operator cab. (See Raising The Operator Cab
%= X100 on Page 10-30-1.)
FREE FLOW (GPM)

*Refer to SPECIFICATIONS Section, Contents Page
10-60-1.)
SPEC-01 for system relief pressure and full RPM.
Disconnect the charge pump OUTLET hose (Item 1)
from the INLET fitting (Item 2) [Figure 20-62-4] at the
charge filter housing.

HYDRAULIC PUMP (SJC) (CONT'D) Turn the restrictor down to 2000 PSI. DO NOT EXCEED
2000 PSI. The high pressure flow must be at least 80% of
Test The Output Of The Hydraulic Charge Pump free flow.
(Contd)
HIGH PRESSURE FLOW (GPM)
Figure 20-62-5 %= X100
FREE FLOW (GPM)
*Refer to Hydraulic Schematics for pump flow and full

RPM.
2 1
P-48256

the tester, to the charge pump OUTLET hose (Item 1)
[Figure 20-62-4] coming from the gear pump. Connect
the OUTLET hose (Item 2) [Figure 20-62-5] from the
tester, to the INLET fitting (Item 2) [Figure 20-62-4] at
the charge filter housing.
IMPORTANT
I-2024-0284
RPM*.

1000 PSI (6895 kPa). DO NOT exceed 2000 PSI.
Open the restrictor control and record the free flow

(GPM) at full RPM.

HYDRAULIC PUMP (SJC) (CONT'D)

WARNING
W-2059-0598
Figure 20-62-7
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
1
Figure 20-62-6
P-64547
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

62-7] from the front of the hydraulic pump.
1 Figure 20-62-8
2
P-64546 1
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)
on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab P-64549
on Page 10-30-1.)
Replacing Hydraulic Fluid on Page 10-120-1.) Remove the two mounting bolts (Item 1) [Figure 20-62-
8] from the hydraulic pump.
Disconnect and cap the outlet hose (Item 1) [Figure 20- Installation: Tighten the mounting bolts to 55-60 ft.-lb.
62-6] from the back of the hydraulic pump. (75-85 Nm) torque.
Remove the Power Bob-Tach block (Item 2) [Figure 20-
62-6] if equipped. (See Removal And Installation on
Page 20-120-1.)

HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-10
Figure 20-62-9 1
3
1
P-64446
2
Replace the O-ring (Item 1) [Figure 20-62-10] in the
P-64343 hydrostatic pump.

Remove the bracket mounting bolt (Item 1) from the pump.
pump mounting bracket (Item 2) [Figure 20-62-9].
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 Nm)
torque.
Remove the mounting bracket (Item 2) [Figure 20-62-9].

from the hydrostatic pump.

HYDRAULIC PUMP (SJC) (CONT'D)
Identification
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

Disassembly And Assembly 1
Figure 20-62-11
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-62-
P-64508 12].
Mark the pump sections for correct assembly [Figure 20-

62-11].
Remove the eight pump housing bolts (Item 1) [Figure

20-62-11].
Installation: Tighten the bolts (Item 2) [Figure 20-62-11]

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

Figure 20-62-13 1
P-64511
2
Figure 20-62-16
P-64509
1
Figure 20-62-14
3
4
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 62-15] & [Figure 20-62-16] 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 20-62-13] & [Figure 20-62-14] from the pump 62-16]. 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

20-62-14] and bushings (Item 4) [Figure 20-62-

Figure 20-62-17
P-64515
Figure 20-62-20
P-64513
Figure 20-62-18
P-64516

P-64514 [Figure 20-62-20] from the pump center section.

Remove the drive gear (Item 1) [Figure 20-62-17] & 20]. If excessive wear or damage is visible, the
[Figure 20-62-18]. pump must be replaced.
NOTE: Inspect the drive gear (Item 1) [Figure 20-62-


Figure 20-62-21
1
P-64519
1
2 Figure 20-62-24
P-64517
2
Figure 20-62-22
2 1
P-64520
Remove the load seal (Item 1) [Figure 20-62-23] &

P-64518 [Figure 20-62-24]. 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 20-62-24].
center section. Inspect for damage and replace as
needed.

toward gears.

Figure 20-62-25
2
1
1
P-64526
Figure 20-62-28
P-64521
3
Inspect the pre-load seal (Item 1) [Figure 20-62-25] for

damage and replace as needed. 4
NOTE: Inspect the pump center section (Item 2) and
pump must be replaced. 1
Figure 20-62-26
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 20-62- pump must be replaced.
26].

Figure 20-62-29
1
P-64530
1
P-64528 the pump flange section.
Figure 20-62-32
Figure 20-62-30
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 32]. If excessive wear or damage is visible, the
62-29] & [Figure 20-62-30] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

62-30]. If excessive wear or damage is visible,
the pump must be replaced.

Figure 20-62-33
2
P-64535
Figure 20-62-36
P-64532

the end of the drive gear.
Remove the idler gear (Item 2) [Figure 20-62-33].
Figure 20-62-34
2
P-64536

1 [Figure 20-62-35] & [Figure 20-62-36] from the pump
flange section. Inspect for damage and replace as
needed.

toward gears.


Figure 20-62-37
3
2
1
P-64540

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

Figure 20-62-38 bushings (Item 3) [Figure 20-62-39]. If
Figure 20-62-40
1
2
2
1 P-30188A
P-64538

[Figure 20-62-38]. Inspect for damage and replace as
P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-62-38]. Remove the shaft seal (Item 1) [Figure 20-62-40] from
the pump flange section.
Installation: The shaft seal flush surface (Item 2)

[Figure 20-62-40] must be facing out away from the
pump.

HYDRAULIC PUMP (HIGH FLOW) (SJC) Figure 20-63-2
WARNING
2 1
W-2017-0286
Figure 20-63-1 P-48256

the tester, to the OUTLET hose (Item 1) [Figure 20-63-1]
coming from the gear pump. Connect the OUTLET hose
1 (Item 2) [Figure 20-63-2] from the tester, to the INLET
tubeline (Item 2) [Figure 20-63-1] leading to the
hydraulic control valve.
IMPORTANT
P-64570 The hydraulic tester must be in the fully open
I-2024-0284
procedure:


1.)

on Page 10-20-1.)

on Page 10-30-1.)

10-60-1.)
Disconnect the OUTLET hose (Item 1) [Figure 20-63-1].

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Charge Pump

(Cont'd)
Figure 20-63-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
W-2017-0286
Figure 20-63-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277
2
P-64315
RPM*.
Warm the fluid to 140F. (60C.) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-63-3] on the tester to about procedure:
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm
and flow (GPM). The high pressure flow must be at least support device. (See Installing Lift Arm Support Device
80% of free flow. on Page 10-20-1.)
%= HIGH PRESSURE FLOW (GPM) X100 Raise the operator cab. (See Raising The Operator Cab
FREE FLOW (GPM) on Page 10-30-1.)

*Refer to SPECIFICATIONS Section, Contents Page
10-60-1.)
SPEC-01 for system relief pressure and full RPM.
Disconnect the charge pump OUTLET hose (Item 1)
from the INLET fitting (Item 2) [Figure 20-63-4] at the
charge filter housing.

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Turn the restrictor down to 2000 PSI. DO NOT EXCEED
2000 PSI. The high pressure flow must be at least 80% of
Test The Output Of The Hydraulic Charge Pump free flow.
(Contd)
Figure 20-63-5 FREE FLOW (GPM)
*Refer to Hydraulic Schematics for pump flow and full

RPM.
2 1
P-48256

the tester, to the charge pump OUTLET hose (Item 1)
[Figure 20-63-4] coming from the gear pump. Connect
the OUTLET hose (Item 2) [Figure 20-63-5] from the
tester, to the INLET fitting (Item 2) [Figure 20-63-4] at
the charge filter housing.
IMPORTANT
I-2024-0284
RPM*.

1000 PSI (6895 kPa). DO NOT exceed 2000 PSI.
Open the restrictor control and record the free flow

(GPM) at full RPM.

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-6
Test The Output Of The Hydraulic Pump (High Flow)
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-63-6] onto the

front auxiliary quick couplers.
on Page 10-20-1.)
W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)

on Page 10-30-1.)

10-60-1.)

Test The Output Of The Hydraulic Pump (High Flow) EXAMPLE: TESTER
(Cont'd) CONNECTION
Reservoir
Figure 20-63-7
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
63-7]. wrong. With the hoses connected correctly, increase the
engine speed to full RPM*.
Figure 20-63-8
1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
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 High Flow
Relief Valve Adjustment Procedure on Page 20-100-3.)
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 20-63-7]. Connect the OUTLET hose (Item 2) FREE FLOW (GPM)
[Figure 20-63-8] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-63-7] 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.

2
P-64546
on Page 10-20-1.)
Lift and block the rear of the loader. (See Procedure on Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Page 10-10-1.) 63-10] and [Figure 20-63-11] from the back of the
hydraulic pump.
on Page 10-30-1.) Remove the Power Bob-Tach block (Item 2) [Figure 20-
63-11] if equipped. (See Removal And Installation on
Drain the hydraulic fluid from the reservoir. (See Page 20-120-1.)
Figure 20-63-12
WARNING
to fall and cause injury or death. 1
W-2059-0598
Figure 20-63-10
P-64544
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

63-12] from the front of the hydraulic pump.
P-64545

Figure 20-63-13
3
1
1
2
P-64343
Remove the bracket mounting bolt (Item 1) from the

P-64549 pump mounting bracket (Item 2) [Figure 20-63-14].
NOTE: The mounting bolt is a special purpose bolt.

Remove the two mounting bolts (Item 1) [Figure 20-63- Only replace with original Bobcat Parts.
13] from the hydraulic pump.
Installation: Apply a medium strength threadlocker to
Installation: Tighten the mounting bolts to 55-60 ft.-lb. mounting bolt and tighten to 90-100 ft.-lb. (122-136 Nm)
(75-85 Nm) torque. torque.
Remove the mounting bracket (Item 2) [Figure 20-63-

14].

from the hydrostatic pump.
Figure 20-62-15
P-64446
Replace the O-ring (Item 1) [Figure 20-62-15] in the

hydrostatic pump.

pump.

HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)
Identification
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
10. Auxiliary Pump Section
11. Auxiliary Center Section
12. Splined Shaft
13. Charge Pump Section
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

Disassembly And Assembly 1
Figure 20-63-16
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 63-17].
Mark the pump sections for correct assembly [Figure 20-

63-16].
Remove the eight pump housing bolts (Item 1) [Figure

20-63-16].
Installation: Tighten the bolts (Item 2) [Figure 20-63-16]

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

Figure 20-63-18 1
P-64556
2
Figure 20-63-21
P-64554
1
Figure 20-63-19
3
4
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 63-20] & [Figure 20-63-21] 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 20-63-18] & [Figure 20-63-19] from the high flow [Figure 20-63-21]. 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


Figure 20-63-22
P-64560
Figure 20-63-25
P-64558
Figure 20-63-23
P-64561

P-64559 [Figure 20-63-25] from the charge center section.

Remove the drive gear (Item 1) [Figure 20-63-22] & 25]. If excessive wear or damage is visible, the
[Figure 20-63-23]. pump must be replaced.


Figure 20-63-26
P-64564
2
Figure 20-63-29
P-64562
2
Figure 20-63-27
2
1
P-64565

needed.
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-29].
[Figure 20-63-26] & [Figure 20-63-27] from the charge
needed.

toward gears.

Figure 20-63-30 2
3
1
1
P-64569
Figure 20-63-33
P-64567
3

damage and replace as needed. 4
NOTE: Inspect the charge center section (Item 2) and
1
Figure 20-63-31
2
1 P-64571

[Figure 20-63-32] & [Figure 20-63-33] from the charge
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.
63-31].

Figure 20-63-34
1 1
P-64574

P-64572 the auxiliary center section.
Figure 20-63-37
Figure 20-63-35
P-64575
P-64573

Remove the charge pump section (Item 1) [Figure 20- 37]. If excessive wear or damage is visible, the
63-34] & [Figure 20-63-35] from the auxiliary pump pump must be replaced.
center section.
NOTE: Inspect the charge pump section (Item 1)

replaced.

Figure 20-63-38
1 2
2
P-64578
Figure 20-63-41
P-64576

the end of the drive gear. Inspect for damage and replace
as needed.
Remove the idler gear (Item 2) [Figure 20-63-38]. 1
Figure 20-63-39 2
P-64579
1
[Figure 20-63-40] & [Figure 20-63-41] from the auxiliary
needed.

P-64577 toward gears.


Disassembly And Assembly (Cont'd) 2
Figure 20-63-42
1
1
P-64521

P-64519 damage and replace as needed.
NOTE: Inspect the auxiliary center section (Item 2)

Figure 20-63-43 and bushings (Item 3) [Figure 20-63-44]. If
2
Figure 20-63-45
1
P-64520

[Figure 20-63-43]. Inspect for damage and replace as
P-64525
needed.
Remove the pre-load seal (Item 2) [Figure 20-63-43]. Remove the auxiliary center section (Item 1) [Figure 20-
63-45].

Figure 20-63-46
P-64528
1
Figure 20-63-49
P-64526
Figure 20-63-47
4
1
1
P-64529
2 Remove the auxiliary pump section (Item 1) [Figure 20-

P-64527 63-48] & [Figure 20-63-49] 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 20-63-46] & [Figure 20-63-47] from the auxiliary [Figure 20-63-49]. If excessive wear or
center section. Inspect for damage and replace as damage is visible, the pump must be
needed. replaced.

toward gears.
NOTE: Inspect the auxiliary center section (Item 3)

and bushings (Item 4) [Figure 20-63-47]. If

Figure 20-63-50
1
1
P-64532

P-64530 the end of the drive gear.
Remove the idler gear (Item 2) [Figure 20-63-52].

the pump flange section. Figure 20-63-53
Figure 20-63-51
1
1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-63-53] from
the pump flange section.
51]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-63-
pump must be replaced. 53]. If excessive wear or damage is visible, the

Figure 20-63-54
P-64537
Figure 20-63-57
P-64535
Figure 20-63-55
1 P-64538

2
needed.
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-57].
flange section. Inspect for damage and replace as
needed.

toward gears.

Figure 20-63-58
1
2
P-30188A
3
2
P-64541
Remove the shaft seal (Item 1) [Figure 20-63-59] from

1
P-64540 the pump flange section.
Installation: The shaft seal flush surface (Item 2)

Inspect the pre-load seal (Item 1) [Figure 20-63-58] for [Figure 20-63-59] must be facing out away from the
damage and replace as needed. pump.
NOTE: Inspect the pump flange section (Item 2) and


HYDRAULIC/HYDROSTATIC FILTER HOUSING Figure 20-70-2
IMPORTANT 1

2
damage the system.
3
P-48260
Implement Filter Housing
Figure 20-70-1 Disconnect the wires from the charge pressure sender
(Item 1) [Figure 20-70-2] from the filter housing.
Disconnect the temperature sender connector (Item 2)

[Figure 20-70-2] from the filter housing.
Disconnect the wire connector (Item 3) [Figure 20-70-2]

from the differential pressure switch on the filter housing.
1
Figure 20-70-3
P-48259
1
Stop the engine and open the rear door.
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid

on Page 10-120-1.)
Remove the two mounting bolts (Item 1) and remove the

hydraulic filter drip pan (Item 2) [Figure 20-70-1]. P-48257

the filter housing. Using MEL 1558 tool disconnect the oil cooler tubeline

HYDRAULIC/HYDROSTATIC FILTER HOUSING Charge Filter Housing
(CONTD)
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid
Figure 20-70-4 on Page 10-120-1.)
Figure 20-70-5
1
P-48258
P-64317
Remove the two mounting screws (Item 1) [Figure 20-
70-4] from the filter housing mounting bracket.
Disconnect the hoses (Item 1) [Figure 20-70-5] from the
Installation: Tighten the mounting screws to 15-20 ft.-lb. filter housing.
(20-27 Nm) torque.
Remove the hydraulic filter housing and filter. filter housing.
Reverse the removal procedure to install the filter Figure 20-70-6

housing and filter.
1
2
P-64317

Remove the four mounting bolts (Item 2) [Figure 20-70-

6] from the filter housing.
Remove the hydraulic filter housing and filter.
Reverse the removal procedure to install the filter

housing and filter.
HYDRAULIC FLUID RESERVOIR
Fluid Removal
IMPORTANT
Figure 20-80-1
1 damage the system.
I-2003-0888
Stop the engine.

on Page 10-30-1.)
Remove the fluid from the hydraulic reservoir.
P-34037 Remove the control panel.(See Removal and Installation

on Page 50-100-1.)
Remove Bucket position valve if so equipped. (See
hydraulic reservoir.
Remove the fluid from the tank with pump.
Remove the crossbar linkage. (See Crossbar Linkage
Figure 20-80-2
1.)

2
1
P-34113
Remove the left rear tire assembly (Item 1) [Figure 20-

WARNING 80-2].
Remove the two access panels (Item 2) [Figure 20-80-

2].
W-2059-0598

HYDRAULIC FLUID RESERVOIR (CONTD) Figure 20-80-5
Figure 20-80-3
1
1
2
3
2
P-34040
Remove the drive motor drain hose (Item 1) [Figure 20-

P-34037 80-5] at the drain filter
Remove the auxiliary pressure relief drain hose (Item 2)

Remove the two mounting bolts (Item 1) [Figure 20-80- [Figure 20-80-5] at the drain filter.
3] and remove the plate (Item 2) [Figure 20-80-3] from
the loader. Remove the drive motor supply hose (Item 3) [Figure 20-
80-5].
Figure 20-80-4
Figure 20-80-6
2
1
1
2
P-34038N-
19059
P-34039
Remove the tie-straps (Item 1) [Figure 20-80-4] from the

breather hose. Remove the two control valve drain hoses (Item 1)
[Figure 20-80-6].
Remove the hose clamp (Item 2) [Figure 20-80-4].
Remove the hydraulic fill hose (Item 3) [Figure 20-80-4] reservoir.
from the hydraulic reservoir.

HYDRAULIC FLUID RESERVOIR (CONTD) Figure 20-80-9
Figure 20-80-7
2
P-34044
Remove the hose clamp (Item 1) [Figure 20-80-9] from

P-34042 the fitting.
Remove the breather hose (Item 2) [Figure 20-80-9]

Remove the hose clamp (Item 1) [Figure 20-80-7] from from the hydraulic reservoir.
the tank outlet.
Figure 20-80-10
Remove the hydrostatic supply hose (Item 2) [Figure 20-
80-7] from the bottom of the reservoir.
Figure 20-80-8
1
2
P-34053
If the loader is equipped with rear auxiliaries remove the

P-34043 auxiliary tubeline (Item 1) [Figure 20-80-10] to allow the
hydraulic reservoir to roll out from under the fender.
Remove the bolt and nut (Item 1) [Figure 20-80-8]. NOTE: Standard loaders without rear auxiliaries and
all high flow loaders will have a one-piece
Loosen the bolt and nut (Item 2) [Figure 20-80-8] to auxiliary tubeline from the control valve to the
allow the hydraulic reservoir mount to drop down. rear upright hoses. Disconnect the tubeline
(Item 1) [Figure 20-80-10] from the control
valve and loosen the fitting in the left rear
upright to allow movement of the tubeline for
the hydraulic reservoir removal.

HYDRAULIC FLUID RESERVOIR (CONTD)
Figure 20-80-11
P-34052
Remove the hydraulic reservoir (Item 1) [Figure 20-80-

11] from the loader.

BUCKET POSITION VALVE Figure 20-90-3
Solenoid Removal And Installation
Figure 20-90-1
1 2
1
P-26312A
Remove the solenoid stem (Item 1) [Figure 20-90-3]

P-26310A from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

Disconnect the wire harness connector (Item 1) [Figure tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 Nm)
20-90-1] from the bucket position shut-off solenoid. torque.
NOTE: Loosening the two mounting bolts (Item 2) Figure 20-90-4

[Figure 20-90-1] on the Bucket Positioning
Valve Bracket may aid in the solenoid
removal.
Figure 20-90-2
1
2
N-18191
1 Inspect the solenoid stem and replace the O-rings (Item

1) [Figure 20-90-4] and the back-up washer (Item 2)
P-26311A [Figure 20-90-4].
Remove the solenoid nut (Item 1) [Figure 20-90-2].
Installation: Tighten the solenoid nut to 4-6 ft.-lb. max.

(5-8 Nm max.) torque. Overtightening may cause valve
failure.
Remove the solenoid coil (Item 2) [Figure 20-90-2].

BUCKET POSITION VALVE (CONT'D)
Solenoid Testing
Figure 20-90-5
P9175
Use a test meter to measure coil resistance [Figure 20-

90-5]. Coil wires do not have polarity. Correct resistance
for the coil is 9.8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

BUCKET POSITION VALVE (CONT'D)
WARNING
W-2059-0598
Figure 20-90-6
P-26310A

Stop the engine.

on Page 10-30-1.)
Disconnect the electric solenoid connector (Item 1)

[Figure 20-90-6].

BUCKET POSITION VALVE (CONT'D) Figure 20-90-9
Figure 20-90-7
1
P-26313A
1
Disconnect the two tubelines (Item 1) [Figure 20-90-9]
P-26311A from the tee fitting.
Figure 20-90-10
Figure 20-90-8
4
1 2
3
P-26314
P-26312A
Remove the tubeline (Item 1) [Figure 20-90-10] from the

Remove the solenoid nut (Item 1) [Figure 20-90-7]. B port to the control valve.
Installation: Tighten the nut to 4-6 ft.-lb. max. (5-8 Nm Disconnect the tubeline (Item 2) [Figure 20-90-10] from
max.) torque. Overtightening may cause valve failure. the C port (tilt rod end) on the BPV.
Remove the solenoid (Item 2) [Figure 20-90-7] and the Disconnect the tubeline (Item 3) [Figure 20-90-10] from
solenoid stem (Item 1) [Figure 20-90-8]. the D port (tilt base end) on the BPV.
Installation: Put oil on the O-rings and back-up washers Remove the mounting screws (Item 4) [Figure 20-90-
and tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 10].
Nm) torque.
Installation: Tighten the mounting screws to 15 ft.-lb. (20
Nm) torque.
Remove the bucket position valve and bracket from the

loader.

Figure 20-90-11
1
N-19072
Remove the flow adjustment valve and O-ring (Item 1)

N-19069 [Figure 20-90-13]
NOTE: Always install new O-rings before any parts

Remove the solenoid nut (Item 1) [Figure 20-90-11]. are installed into the valve. Check the parts
for wear or damage and replace as needed.
Installation: Tighten the nut to 4-6 ft.-lb. max. (5-8 Nm
max.) torque. Overtighten may cause valve failure. Figure 20-90-14
Figure 20-90-12
1 1
N-19041
N-19070
Remove the plug (Item 1) [Figure 20-90-14].
Remove the solenoid (Item 1) and the solenoid stem

(Item 2) [Figure 20-90-12].
Installation: Tighen the solenoid stem to 30-35 ft.-lb.

(40,8-47,6 Nm) torque.

Figure 20-90-15
1
N-19045
Remove the plug [Figure 20-90-17].

N-18339
Figure 20-90-18
Remove the plug (Item 1), and flow control spool (Item 2)
[Figure 20-90-15].
Check the flow control spool for wear, check the O-ring
on the plug and replace as needed.
Figure 20-90-16 3
N-19046
1
Remove the plug (Item 1), spring (Item 2) and unloading
2 spool (Item 3) [Figure 20-90-18].
Check all parts and replace as needed. Install a new O-

3 ring on the plug before installing.
N-19042
Remove the tilt cylinder check valve (item 1) spring (Item

2) and plug (Item 3) [Figure 20-90-16]. Check for wear,
check the O-ring and replace as needed.

HIGH FLOW VALVE
Checking The High Flow Relief Valve

WARNING
Figure 20-100-1
1
2 fall or move and cause injury or death.
W-2017-0286
Figure 20-100-2
3
1
P-34480
2

procedure:

N-18409

1.) Start the engine and run at low idle RPM. Push the flow
switch (Item 1) once (on the instrument panel) to engage
NOTE: Check the Main Relief Valve (See Removal the front auxiliary hydraulics variable flow, the light (Item
and Installation on Page 20-30-3.) for proper 2) will come ON [Figure 20-100-2].
flow and pressure before checking the High
Flow Relief Valve. Push the high flow switch (Item 3) [Figure 20-100-2] and
the High Flow light will come ON.
Connect the IN port of the hydraulic tester to the female
quick coupler (Item 1) [Figure 20-100-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-100-1] on the loader.
IMPORTANT
I-2024-0284

HIGH FLOW VALVE (CONT'D)
Checking The High Flow Relief Valve (Contd)
Figure 20-100-3
Right
Steering
Lever
Control
1
P-31833
Push the front switch (Item 1) [Figure 20-100-3] to

give the front quick couplers a constant flow of fluid.
To release from continuous operation, press the front

switch (Item 1) [Figure 20-100-3] 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.

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure.
NOTE: DO NOT EXCEED 3300 PSI.
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
front auxiliary hydraulics off.
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 Procedure on Page 20-
100-3.)

HIGH FLOW VALVE (CONT'D) Figure 20-100-5
High Flow Relief Valve Adjustment Procedure
NOTE: The high flow relief valve is located between

the control valve and the hydraulic reservoir.
Figure 20-100-4
1 P-45469
To increase the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-100-5] clockwise a 1/4 turn and
recheck the high flow relief valve. (1/4 turn equals
approximately 200 PSI.)
P-48231
To decrease the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-100-5] counterclockwise a 1/4 turn
If the relief pressure is not correct, stop the engine and and recheck the high flow relief valve. (1/4 turn equals
raise the operator cab.(See Raising The Operator Cab approximately 200 PSI.)
on Page 10-30-1.)
NOTE: If the relief screw (Item 1) [Figure 20-100-5]
Remove the high flow relief valve adjustment plug (Item has been turned in 1/4 turn and the pressure
1) [Figure 20-100-4]. remains the same, remove and inspect the
high flow relief valve, replace as needed.
Install the plug into the high flow relief valve.

Figure 20-100-6
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
P-48235 100-7] from the solenoid.
Figure 20-100-8
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 20-100-6] which are connected to the
steering shaft on the control panel.
Remove the four steering linkage mounting bolts (Item 2)

[Figure 20-100-6].
2
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 25-
28 ft.-lb. (34-38 Nm) 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.
When repairing hydrostatic and hydraulic systems, Disconnect and cap the hose (Item 1) [Figure 20-100-8]
clean the work area before disassembly and keep all from the pump outlet to the high flow valve.
tubelines and ports to keep dirt out. Dirt can quickly Disconnect and cap the hose (Item 2) [Figure 20-100-8]
damage the system. from the high flow valve to the pump inlet.
I-2003-0888

Figure 20-100-9
1
2
P-48232
Disconnect and cap the tubelines (Item 1) [Figure 20-

100-9] to the tilt cylinders.

9].
Installation: Tighten the mounting bolts to 25-28 ft.-lb.

(34-38 Nm) torque.

Figure 20-100-10
2 1
1
P-48110
Inspect O-rings (Item 1) and back-up washer (Item 2) on

P-48108 the solenoid stem [Figure 20-100-12].
Installation: Put oil on O-rings and back-up washer.

Remove the solenoid nut (Item 1) and solenoid (Item 2) Install and tighten to 25 ft.-lb. (39,9 Nm) torque.
from the solenoid valve [Figure 20-100-10].
Figure 20-100-13
Figure 20-100-11
1
P-48111
P-48109 Remove the relief valve (Item 1) [Figure 20-100-13].
Installation: Apply to oil to the O-rings and back-up

Remove the solenoid valve (Item 1) [Figure 20-100-11] washers. Tighten to 30-35 ft.-lb. (41-47 Nm) torque.
from the valve.

Figure 20-100-14
1
P-48113
2
Remove the check valve (Item 1) [Figure 20-100-16]
P-48112 from the high flow valve.
Figure 20-100-17
Inspect the relief valve and replace the two o-rings (Item
Figure 20-100-15
1
P-48114
Inspect the check valve, O-rings & back-up washers for

P-45469 wear and replace as needed [Figure 20-100-17].
Installation: Apply oil to the O-rings (Item 1) and back-

Inspect the O-ring (Item 1) [Figure 20-100-15] on the up washers (Item 2) [Figure 20-100-17]. Tighten to 30-
relief valve adjustment plug for damage and replace as 35 ft.-lb. (41-47 Nm) torque.
needed.
Installation: Tighten to 20 ft.-lb. (27,1 Nm) torque.

Solenoid Testing
Figure 20-100-18
P9175

100-18]. Coil terminals do not have polarity. Correct
resistance for the pressure relief coil is 7.5 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

REAR AUXILIARY DIVERTER VALVE Figure 20-110-1
P-48301
WARNING
The rear auxiliary valve (Item 1) [Figure 20-110-1] is
Never work on a machine with the lift arms up unless located between the control valve and the gear pump on
the lift arms are secured by an approved lift arm the right side of the loader.
W-2059-0598
IMPORTANT
WARNING clean the work area before disassembly and keep all
Always clean up spilled fuel or oil. Keep heat, flames, damage the system.
sparks or lighted tobacco away from fuel and oil. I-2003-0888
explosion or fire which can result in injury or death. Figure 20-110-2
W-2103-1285

1.)

on Page 10-20-1.) 1

on Page 10-30-1.)
Disconnect the negative battery cable. (See Removal

And Installation on Page 60-20-1.) 2
P-48302
Remove the speed control lever. (See Control Lever
Disconnect the base and rod end tubelines (Item 1)
Remove the control panel. (See Removal and Installation [Figure 20-110-2].
on Page 50-100-1.)
Remove the fittings (Item 2) [Figure 20-110-2] from the
Remove the right rear tire. (See TIRE MAINTENANCE valve.
on Page 10-170-1.)

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-5
Figure 20-110-3
1 1
P-48304
Disconnect the drain tubeline (Item 1) [Figure 20-110-5]

P-48872 from the lift arm by pass valve.
Figure 20-110-6
Remove the three access covers (Item 1) [Figure 20-
110-3] on the right side of the machine.
Figure 20-110-4
1
P-48303
Disconnect and remove the drain tubeline (Item 1)

P-48300 [Figure 20-110-6] from the rear auxiliary valve.
Disconnect the four solenoid connectors (Item 1) [Figure

20-110-4] from the rear auxiliary valve.

Figure 20-110-7
2
P-48870
1
Remove the rear auxiliary valve (Item 1) [Figure 20-110-
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-
110-7] from the rear auxiliary valve. The valve needs to be tilted as shown in [Figure 20-110-
9] for it to be removed through the hole.
the bottom of the control valve and the rear auxiliary
vavle.
Figure 20-110-8
P-48869
Loosen and remove the two bolts and nuts (Item 1)

[Figure 20-110-8] that hold the rear auxiliary valve.

REAR AUXILIARY DIVERTER VALVE (CONT'D)

IMPORTANT
Figure 20-110-10
damage the system.
I-2003-0888
Figure 20-110-12
1
1
1
P-48751
Figure 20-110-11
1 P-48755
Figure 20-110-13
2 2 2
P-48752
1
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-110-10] & [Figure 20-

110-11] are located all over the diverter valve and can be
P-48756
removed for cleanout purposes.
Installation: Put oil on O-rings and back-up Remove the shuttle valve (Item 1) [Figure 20-110-12] &
washers.Tighten to 10 ft.-lb. (13,6 Nm) torque. [Figure 20-110-13] from diverter valve and inspect the
O-rings and back-up washers (Item 2) [Figure 20-110-
13] for damage.
Installation: Put oil on the O-rings and back-up washers.

Tighten to 10-12 ft.-lb. (14-16 Nm) torque.

Figure 20-110-14
P-48753
1
Figure 20-110-17
P-48755
Figure 20-110-15 1
2
2
2
1
P-48754
Remove the relief valve (Item 1) [Figure 20-110-16] &

P-48757 [Figure 20-110-17] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20-
110-17] for damage.
Remove the differential sensing valve (Item 1) [Figure
20-110-14] & [Figure 20-110-15] from diverter valve and Installation: Put oil on O-ring and back-up washers.
inspect the O-rings and back-up washers (Item 2) Tighten to 20-25 ft.-lb. (27-34 Nm) torque.
[Figure 20-110-15] for damage.
Installation: Put oil on O-ring and back-up washers.


Figure 20-110-18
1
P-48761
NOTE: Before removing the solenoid coils mark the

P-48759 coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-110-20] from the

Figure 20-110-19 solenoid valve stems.
Installation: Tighten the nut to 4-6 ft.-lb. (5-8 Nm)

torque.
1
2
P-48760
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-18] & [Figure

20-110-19] from the solenoid valve stem.

torque.
Remove the spacer (Item 2) and solenoid valve coils

(Item 3) [Figure 20-110-19].

Figure 20-110-21 1
P-48763A
Figure 20-110-24
P-48762
Figure 20-110-22
1 2
2 2
1 1 P-48764
Remove the solenoid valve stem (Item 1) [Figure 20-

P-48763 110-23] & [Figure 20-110-24] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-24] for
damage.
Remove the solenoid valve stems (Item 1) [Figure 20-
110-21] & [Figure 20-110-22] and inspect the O-rings Installation: Put oil on O-rings and back-up washers.
and back-up washers (Item 2) [Figure 20-110-22] for Tighten to 30-35 ft.-lb. (41-47 Nm) torque.
damage.
Installation: Put oil on O-rings and back-up washers.


Figure 20-110-25
P-48765

P-48765
Installation: Tighten the plug to 10 ft.-lb. (13,6 Nm)
torque.
Figure 20-110-28
Installation: Tighten the plug to 38 ft.-lb. (51,5 Nm)
torque.
Figure 20-110-26
P-48786
1 Remove the orifice (Item 1) [Figure 20-110-28].

P-48766
Installation: Tighten the orifice to 3.3 ft.-lb. (4,5 Nm)
torque.
Remove and inspect the orifice (Item 1) [Figure 20-110-
26] for dirt and debris.
Installation: Tighten the orifice to 22 ft.-lb. (29,8 Nm)

torque.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Solenoid Testing
Disassembly And Assembly (Cont'd) Figure 20-110-30
Figure 20-110-29
P9137
P-48758
110-30]. Coil wires do not have polarity. Correct
Remove the plugs (Item 1) [Figure 20-110-29]. resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.
Installation: Tighten the plug to 14 ft.-lb. (19 Nm) Replace the test meter with 12 volt power. You can see
torque. and hear the spool shift.
Inspection
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.

POWER BOB-TACH BLOCK Figure 20-120-1

3
WARNING
2
W-2059-0598 3
P-48229

1.)

on Page 10-20-1.)

on Page 10-30-1.)
Open the rear door.

IMPORTANT Drain the hydraulic reservoir. (See Replacing Hydraulic
Remove the nut from the speed control linkage (Item 1)
and unplug the rear lights electrical connector (Item 2)
[Figure 20-120-1].
damage the system.
I-2003-0888
Remove the fuel fill bracket mounting bolts (Item 3)
[Figure 20-120-1].

POWER BOB-TACH BLOCK (CONT'D) Figure 20-120-4
Figure 20-120-2
P-48227

P-48230 4].

Installation: The harness connectors are marked with (34-38 Nm) 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 20-120-2] by the Tach block and the hydraulic pump. Inspect
hydraulic pump. and replace as needed.
Figure 20-120-3
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 20-120-3]

from the fitting on top of the block.

Figure 20-120-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-6].
Check the O-ring (Item 4) [Figure 20-120-6] on the plug

Clean the block (Item 1) [Figure 20-120-5] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct
assembly. Figure 20-120-7
Installation: Tighten the plug to 25-30 ft.-lb. (34-40,6

Nm) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-7].
Installation: Tighten the plug to 12-14 ft.-lb. (16,3-19

Nm) torque.

Figure 20-120-8
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-120-10].

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 20-120-8]. will be altered.
Installation: Oil the check valve and O-rings and tighten Figure 20-120-11
the check valve to to 20-25 ft.-lb. (27,1-34 Nm) torque.
Figure 20-120-9
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-120-11], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-
(Item 2) [Figure 20-120-9]. 11] to 12-14 ft.-lb. (16,3-19 Nm) torque.
Check the O-rings and back up washers (Item 3) [Figure

20-120-9] on the check valve and piston assembly and
replace as needed.

Figure 20-120-12 3
2
1
P-48106
Remove the first solenoid coil (Item 1), spacer (Item 2)

P-48664 and the second solenoid coil (Item 3) [Figure 20-120-
14].
Remove the orifice screw (Item 2) located behind the NOTE: Remember the solenoid coil orientation for
plug (Item 1) [Figure 20-120-11]. ease of installation.
Installation: Tighten the orifice screw (Item 2) [Figure Figure 20-120-15

20-120-11] to 6-8 ft.-lb. (8,1-10,8 Nm) torque.
Figure 20-120-13
1 1
P-48386
P-48127 Remove the the solenoid stem (Item 1) [Figure 20-120-

15].
NOTE: This plug is a zero leak plug and should not be Installation: Tighten the solenoid stem to to 20-25 ft.-lb.
removed. If removed damage may occur and (27,1-34 Nm) torque.
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-13].
Remove the solenoid nut (Item 2) [Figure 20-120-13].
Installation: Tighten the solenoid valve stem nut to 15-

45 in.-lb. (1,7-5,1 Nm) torque.

Figure 20-120-16
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-18].
Installation: Tighten the screened orifice plug to to 11-

Remove the armature rod assembly (Item 1) [Figure 20- 12 ft.-lb. (14,9-16,3 Nm) torque.
120-16].
Figure 20-120-19
Figure 20-120-17
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 120-19] 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.
120-17].
Check the O-ring (Item 2) [Figure 20-120-19] 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 20-120-
17].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Removal and Installation Figure 20-130-2
IMPORTANT 1

clean the work area before disassembly and keep all 2
tubelines and ports to keep dirt out. Dirt can quickly 4
damage the system.
3
I-2003-0888
Figure 20-130-1
P-34661
Figure 20-130-3
2
1 1
3
6 2
4
5 3
P-48464
Disconnect the auxiliary tubelines (Item 1) and drain

tubeline (Item 2) from the coupler block [Figure 20-130- P-34760
1].
Remove the male coupler (Item 1) [Figure 20-130-2] &
Remove the two mounting bolts (Item 3) [Figure 20-130- [Figure 20-130-3].
1].
Installation: Tighten the male coupler (Item 1) [Figure
20-130-2] & [Figure 20-130-3] to 59 ft.lb. (80 Nm)
Remove the drain coupler (Item 2) [Figure 20-130-2] &

[Figure 20-130-3].
Installation: Tighten the drain coupler (Item 2) [Figure

20-130-2] & [Figure 20-130-3] to 37 ft.lb. (50 Nm)
Remove the female coupler (Item 3) [Figure 20-130-2] &

[Figure 20-130-3].
Installation: Tighten the female coupler (Item 3) [Figure

20-130-2] & [Figure 20-130-3] to 59 ft.lb. (80 Nm)
Remove the fittings (Item 4) [Figure 20-130-2] & [Figure

20-130-3] check the O-rings (Item 5) [Figure 20-130-3]
and replace as needed.
Remove the springs (Item 6) [Figure 20-130-3].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-6
(CONTD)
Disassembly And Assembly (Contd)

1
Figure 20-130-4
1
2
P-34665
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-130-6].
P-34663
Figure 20-130-7
Check the O-ring (Item 1) [Figure 20-130-4] for damage

and replace as needed. 1
Figure 20-130-5
P-34664
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-130-7].
P-34701
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-130-5] for damage and replace as
needed.

HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Adjusting (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . 30-30-2
Adjusting (SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4 SAFETY &
Sender Removal And Installation (Non SJC Machines) . . 30-30-1 MAINTENANCE
Sender Removal And Installation (SJC Machines) . . . . . . 30-30-3
Testing (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing (SJC Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3 HYDROSTATIC
SYSTEM
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3 DRIVE
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1 SYSTEM
Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Tensioner Pulley Disassembly. . . . . . . . . . . . . . . . . . . . . . 30-50-6
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . 30-50-5
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Assembly (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9 ELECTRICAL
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 SYSTEM &
Disassembly and Assembly (Dry Bolt). . . . . . . . . . . . . . . 30-20-16 ANALYSIS
Disassembly (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Parts Identification (Dry Bolt) . . . . . . . . . . . . . . . . . . . . . . 30-20-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 ENGINE
SERVICE
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-21-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-3 SPECIFICATIONS
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
HYDROSTATIC MOTOR CARRIER (SJC). . . . . . . . . . . . . . . 30-22-1

Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Hydraulic Pump Removal And Installation. . . . . . . . . . . . . 30-40-8
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-4
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-40-1
CONTINUED ON NEXT PAGE

HYDROSTATIC SYSTEM (CONTD)
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1

Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
High Pressure Relief and By-Pass Valve. . . . . . . . . . . . . . 30-41-7
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . 30-41-28
Hydraulic Controller Removal And Installation. . . . . . . . . . 30-41-2
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . 30-41-25
HYDROSTATIC SYSTEM INFORMATION. . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

HYDROSTATIC SYSTEM INFORMATION
WARNING
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
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
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump 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.

HYDROSTATIC SYSTEM INFORMATION
IMPORTANT
damage the system.
I-2003-0888
Replenishing Valve Function
Figure 30-10-1
CHARGE OIL
Valve Moves for Charge

FUNCTION 1 Oil Replacement
FUNCTION 2 Valve Stays on Seat to

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

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
2. To keep high pressure fluid out of the low pressure

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

HYDROSTATIC MOTOR Removal And Installation
Description
Two types of hydrostatic drive motors have been used on

this model loader. Both designs remove and install the
same.
Figure 30-20-1
WARNING
1
W-2059-0598
N-00621
The early design is identified by the tie bolts (Item 1)

[Figure 30-20-1] mounting from the inside of the
WARNING
hydrostatic drive motor with the heads of the tie bolts
immersed in the hydraulic oil. The tie bolts are not visible Always clean up spilled fuel or oil. Keep heat, flames,
when the hydrostatic drive motor is installed on the sparks or lighted tobacco away from fuel and oil.
loader. This type is called the wet bolt design. Failure to use care around combustibles can cause
W-2103-1285
Figure 30-20-2

on Page 10-30-1.)
Remove the front and rear wheel/tire assemblies. (See

TIRE MAINTENANCE on Page 10-170-1.)
Remove the control panel. (See Removal and Installation

on Page 50-100-1.)
1
on Page 10-20-1.)
P-39894 Lift and block the loader. (See Procedure on Page 10-10-
1.)
The later design has the tie bolts (Item 1) [Figure 30-20-
2] mounting from the outside of the hydrostatic drive
motor. The tie bolt heads are not immersed in hydraulic
oil and are visible when the hydrostatic drive motor is
installed on the loader. This type is called the dry bolt
design.

HYDROSTATIC MOTOR (CONTD) Figure 30-20-5
Figure 30-20-3
1
1
1
1 N-19240
Remove the four drive motor mounting bolts (Item 1)

P-34004 [Figure 30-20-5].
Installation: Tighten the drive motor mounting bolts to

Remove the four motor cover mounting bolts (Item 1) 90-100 ft.-lb. (122-136 Nm) torque.
[Figure 30-20-3] .
Figure 30-20-6
Figure 30-20-4
1 1
2 P-4141
N-19238
Remove the drive motor from the access hole in the

Mark the two hoses (Item 1) [Figure 30-20-4] before loader frame [Figure 30-20-6].
disconnecting them from the HYDROSTATIC MOTOR
for correct installation. Inspect drive motor o-ring (Item 1) and carrier shaft seal
(Item 2) [Figure 30-20-6].
Remove the two hoses (Item 1) [Figure 30-20-4] from
the drive motor. Reverse the removal procedure to install the
HYDROSTATIC MOTOR.
Remove the drain hose (Item 2) [Figure 30-20-4] from
the drive motor.

HYDROSTATIC MOTOR (CONTD)
Parts Identification (Wet Bolt)
3
10
11
9
8
13
16
3
5
11 14
6
15 3
21 7
6
22
20
17
19
18
19
17
20 1
26
24
12 25 2
23
D-3431B
Ref. Description Ref. Description

1. HOUSING 15. SHAFT, drive
2. O-RING 16. BOLT
3. SEAL, square 17. SPRING
4. VALVE, plate 18. PISTON
5. GEROLER 19. POPPET
6. BALL 20. SLEEVE
7. PLATE, balance 21. PLUG
8. RING, back-up 22. O-RING
9. SEAL 23. O-RING
10. RING, back-up 24. SPRING
11. O-RING 25. SHIM
12. PLUG 26. POPPET
13. FLANGE, mounting
14. SEAL, face

Disassembly (Wet Bolt)

1
IMPORTANT
damage the system.
I-2003-0888
N-00623
Figure 30-20-7
Lift and remove the mounting flange (Item 1) [Figure 30-

20-9] from the motor.
NOTE: Do not scratch or damage the surfaces of the

motor sections. Always put them on a soft
surface.
Figure 30-20-10
1
2
N-00621
Drain the oil from the motor.
Seal all open ports and clean the motor with solvent.
Put a mark across the sections of the motor for correct

assembly [Figure 30-20-7].
Figure 30-20-8
N-00624
1 Turn the mounting flange over and remove the O-ring

(Item 1) and back-up ring (Item 2) [Figure 30-20-10].
N-00622
Remove the nine bolts (Item 1) [Figure 30-20-8] from the

motor.
Disassembly (Wet Bolt) (Contd)

1
Figure 30-20-11
N-00627
Remove the main drive (Item 1) [Figure 30-20-13] from

N-00625 the gerolor assembly.
Figure 30-20-14
Turn the mounting flange backover and remove the seal
(Item 1) [Figure 30-20-11] from the mounting flange.
Figure 30-20-12
N-00628
Remove the two check balls (Item 1) [Figure 30-20-14]

N-00626 from the gerolor.
Remove the balance plate (Item 1) [Figure 30-20-12]

from the gerolor assembly.

Figure 30-20-15
N-00631
1 Carefully turn the gerolor assembly over and remove the

N-00629 square cut seal (Item 1) [Figure 30-20-17].
Figure 30-20-18
Remove the square cut seal (Item 1) [Figure 30-20-15]
from the gerolor.
1
Figure 30-20-16
N-00632
Remove the valve plate (Item 1) [Figure 30-20-18] from

N-00630 the end cap.
Remove the gerolor assembly (Item 1) [Figure 30-20-

16].
NOTE: Care should be taken to keep the gerolor

assembly together.
NOTE: If rollers are removed, put them back in their

original bore.

HYDROSTATIC MOTOR (Wet Bolt) (CONTD) Figure 30-20-21

1
Figure 30-20-19
N-00635
Remove the poppet and shuttle valve (Item 1) [Figure

N-00633 30-20-21].
Figure 30-20-22
Remove the square cut seal (Item 1) and small O-ring
(Item 2) [Figure 30-20-19] from the end cap.
Figure 30-20-20
N-00636
Turn the end cover over and remove the shuttle valve
N-00634 plug from the end cover [Figure 30-20-22].
Remove the spring seat (Item 1) and spring (Item 2)

[Figure 30-20-20].


3
Figure 30-20-23
2
1
1
2
3
N-00640
Remove the spring (Item 1) and poppet (Item 2) from the

N-00637 end cover (Item 3) [Figure 30-20-25].
NOTE: The relief pressure is factory set and must not

Remove the spring seat (Item 1), spring (Item 2) and be changed. Shims may or may not have been
poppet (Item 3) [Figure 30-20-23]. used at the factory for setting the pressure. If
shims are present, make sure they are
Figure 30-20-24 reinstalled during assembly.
Figure 30-20-26
2
1
N-00639
N-00641
Remove the low pressure relief valve plug from the side
of the end cover [Figure 30-20-24].
The low pressure relief valve is made up of the poppet
(Item 1), the spring (Item 2) and the plug assembly
(Item 3) [Figure 30-20-26].

Assembly (Wet Bolt)
IMPORTANT
damage the system.
I-2003-0888
N-00643
Prior to assembly:
Clean all parts with solvent and dry with compressed air. Install the new O-ring on the plug and tighten to 300 in.-
lb. (34 Nm) torque [Figure 30-20-28].
Put grease on O-rings.
Figure 30-20-29
Lubricate parts with oil.
Figure 30-20-27
3 2
1
1
N-00644
Install the poppet (Item 1), the spring (Item 2) and the
N-00642
spring seat (Item 3) [Figure 30-20-29] in the end cover.
Install the poppet (Item 1) and spring (Item 2) [Figure 30- NOTE: The tapered end of the poppet must face
20-27] in the low pressure relief port in the end cover. towards the shuttle valve.

Assembly (Wet Bolt) (Contd)
Figure 30-20-30 1
N-00648
Install the square cut seal (Item 1) and small O-ring (Item
N-00646 2) [Figure 30-20-32] in the end cover.
Figure 30-20-33
Install a new O-ring on the plug [Figure 30-20-30] and
tighten to 260 in.-lb. (41 Nm) torque.
NOTE: Always use new O-rings and seals when

assembling the motor. Put a small amount of
grease on all the O-rings and seals for easier
installation.
Figure 30-20-31
4
2
3 1 N-00649
Mark the case drain port location on the outside of the

end cover for ease of assembly [Figure 30-20-33].
N-00647
Install the shuttle valve (Item 1), poppet (Item 2), spring
(Item 3) and spring seat (Item 4) [Figure 30-20-31] in the
port hole in the end cap.
NOTE: The tapered end of the poppet must face

towards the shuttle valve.

Figure 30-20-34
N-00652
Mark the case drain port location on the outside edge of

N-00650 the valve plate as shown [Figure 30-20-36].
Figure 30-20-37
Align the case drain ports in the valve plate with the case
drain port in the end cover [Figure 30-20-34].
1
Figure 30-20-35
N-00653
Install the gerolor assembly (Item 1) [Figure 30-20-37]

N-00651 by aligning the case drain hole with the case drain hole in
the valve plate.
Install the large square cut seal (Item 1) [Figure 30-20-

35] in gerolor assembly.

Assembly (Wet Bolt) (Contd) 1
Figure 30-20-38
N-00656
Install the main drive (Item 1) [Figure 30-20-40] in the

N-00654 gerolor (as shown).
NOTE: Whenever the main drive is not symmetrical,

Install the square cut seal (Item 1) [Figure 30-20-38] in the smallest end of the main drive must be
the gerolor outer ring. installed into the gerolors.
Figure 30-20-39 Figure 30-20-41
N-00655 N-00657
Install the two check balls (Item 1) [Figure 30-20-39] in Mark the case drain hole on the outer ring of the gerolor
their bores in the gerolor. (as shown) [Figure 30-20-41].


1
Figure 30-20-42
2
3
4
5
N-00660
1 Install the square cut seal (Item 1), seal (Item 2), back-up
N-00658 seal (Item 3), seal (Item 4) and back-up ring (Item 5)
[Figure 30-20-44] in the mounting flange.
Align the case drain holes and install the balance plate Figure 30-20-45
(Item 1) [Figure 30-20-42] on the gerolor assembly.
Figure 30-20-43
N-00661
N-00659 Mark the case drain holes on the side of the balance
plate [Figure 30-20-45].
Install the seal (Item 1) [Figure 30-20-43] (as shown).

Figure 30-20-46
N-00664
Install the nine bolts into the motor. Make sure all the
N-00662 parts are in correct alignment [Figure 30-20-48].
Figure 30-20-49
Align the case drain port (Item 1) [Figure 30-20-46] in
the mounting flange with the case drain port in the
balance plate (as shown).
Figure 30-20-47
MC-2230
1. Tighten the bolts to 45-55 ft.-lb. (61-75 Nm) torque as

shown in figure [Figure 30-20-49].
N-00663
2. Tighten the bolts to 55-65 ft.-lb. (75 -88 Nm) torque
as shown in figure [Figure 30-20-49].
Align the two case drain port (Item 1) [Figure 30-20-47]
and install the mounting flange on the balance plate. NOTE: To prevent damage to the balance plate, never
lift or support the motor by the center shaft.
Be careful not to displace the seals and back-up rings.

HYDROSTATIC MOTOR (CONTD)
Parts Identification (Dry Bolt)
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

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

Disassembly and Assembly (Dry Bolt)

1
IMPORTANT
damage the system.
I-2003-0888
P-39894
Figure 30-20-50
Remove the nine tie bolts (Item 1) [Figure 30-20-51]

from the motor.
Figure 30-20-52
9 1
6
4
3
7
P-64267
Drain the oil from the motor. 8 2

Seal all open ports and clean the motor with solvent. 5
P-39894
Put a mark across the sections of the motor for correct
assembly [Figure 30-20-50].
Assembly:
1. Tighten the bolts to 45-55 ft.-lb. (61-75 Nm) torque in

the order shown in figure [Figure 30-20-52].
2. Tighten the bolts to 55-65 ft.-lb. (75 -88 Nm) torque

in the order shown in figure [Figure 30-20-52].
NOTE: To prevent damage to the balance plate, never

lift or support the motor by the drive shaft.

Disassembly and Assembly (Dry Bolt) (Contd)
Figure 30-20-53
3
1
2
1
P-63785
Remove the plug (Item 1) spring (Item 2) and poppet

P-64267 (Item 3) [Figure 30-20-55] 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 can be removed. (Item Installation: Lubricate relief valve assembly with
1) [Figure 30-20-53]. hydraulic oil and tighten plug to 260 in.-lb. (41 Nm)
torque.
Assembly: Install drive shaft before tightening tie bolts.
Figure 30-20-56
Figure 30-20-54
2
1
P-39896
P-39895
Remove the plug (Item 1) and shuttle valve assembly

Lift and remove the end cap (Item 1) [Figure 30-20-54] (Item 2) [Figure 30-20-56]. Inspect for scoring on shuttle
from the motor. valve. Ensure it can operate freely in the bore.
NOTE: Do not scratch or damage the surfaces of the Installation: Lubricate shuttle valve assembly with
motor sections. Always put them on a soft hydraulic oil and tighten plug to 260 in.-lb. (41 Nm)
surface. torque.


3
Figure 30-20-57
2
P-64274
Remove and inspect/replace seal (Item 1) [Figure 30-

P-39897 20-59].
Remove the gerolor section as an assembly (Item 2)

Remove the remaining pieces to the shuttle valve [Figure 30-20-59].
assembly (Item 1) [Figure 30-20-57] 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 carefull not to lose
these check balls. See [Figure 30-20-60]. Note
Assembly: Apply grease to shuttle valve parts to help location of case drain hole (Item 3) [Figure 30-
hold in place during assembly. 20-59]. Align hole with other sections on drive
motor.
Figure 30-20-58
2 3
P-39898
Remove and inspect/replace seals (Item 1) [Figure 30-

20-58].
Remove the valve plate (Item 2) [Figure 30-20-58].
Assembly: Apply grease to seals. Note location of case

drain hole (Item 3) [Figure 30-20-58]. Align hole with
other sections on drive motor.


1
4
Figure 30-20-60 2
3
1
P-64268
Remove the center piece of the balance plate (Item 1)

P-39901 [Figure 30-20-61].
Remove and inspect/replace the seal (Item 2) [Figure

Remove the two check balls (Item 1) [Figure 30-20-60] 30-20-61].
from the gerolor.
Remove the balance plate (Item 3) [Figure 30-20-61].
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 30-20-61]. Align hole with
other sections on drive motor.
NOTE: Care should be taken to keep the gerolor
assembly together.
NOTE: If rollers are removed, put them back in their

original bore.


1
Figure 30-20-62
1
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-64].

P-64270
Assembly: If the belleville spring is no longer cone
shaped, replace with new.
Remove the back up ring (Item 1) [Figure 30-20-62].
Figure 30-20-65
Assembly: Apply grease to back up ring. One side of the
back up ring is grooved to fit against the o-ring
underneath.
Figure 30-20-63
1
1
P-64273
1
Carefully turn the mounting flange over and remove the

1 seal (Item 1) [Figure 30-20-65].
P-64271
Assembly: Replace the seal.
Remove and inspect/replace the seals (Item 1) [Figure

30-20-63] from the gerolor.
Assembly: Apply grease to seals.

HYDROSTATIC MOTOR CARRIER Figure 30-21-2
Shaft Seal Replacement
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. (See Removal And

Installation on Page 30-21-3.)
WARNING
P-4456
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure. Drill a .125 inch (3 mm) hole in the motor carrier seal
Flying debris or loose material is present. [Figure 30-21-2].
Engine is running.
Tools are being used. Figure 30-21-3
W-2019-1285
Figure 30-21-1
1
P-4455
P-4153
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-21-3].
The motor carrier seal (Item 1) [Figure 30-21-1] is

located on the outside of the motor carrier shaft.

HYDROSTATIC MOTOR CARRIER (CONTD) Figure 30-21-6
Shaft Seal Replacement (Contd)
Figure 30-21-4
P-4149
Photo [Figure 30-21-6] shows the motor carrier seal

P-4454 correctly installed.
NOTE: Before reinstalling the hydrostatic motor,

Installation: Install a new seal over the motor carrier check the plug (Item 1) [Figure 30-21-6]
shaft [Figure 30-21-4]. located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
Figure 30-21-5 drain lubrication oil from the hydrostatic
motor can leak into the chaincase.
P-4150
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-21-5].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-21-5].


2
WARNING
W-2059-0598
P-4152
Raise the loader lift arms and install an approved lift arm
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-21-
7]. (See Disk Removal And Installation on Page 40-10-
Lift and block the loader. (See Procedure on Page 10-10- 1.)
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising The [Figure 30-21-7] from the inside of the chaincase.
Operator Cab on Page 10-30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing The 125-140 ft.-lb. (170-190 Nm) torque.
Oil on Page 40-30-1.)
Figure 30-21-8
Remove the engine speed control. (See Removal And
Remove the control panel. (See Removal and Installation 1

on Page 50-100-1.)
Remove the lift arm by-pass control valve. (See Removal

and Installation on Page 20-50-1.)
2
Remove the traction lock assembly. (See TRACTION
LOCK on Page 60-110-1.)
Remove the center chaincase cover. (See Center Cover

P-4167
Remove the front chaincase cover. (See Front Cover
For ease of removal, fasten the front drive chain
Remove the front axle and sprocket. (See Axle Sprocket (previously removed) to the chaincase as shown (Item 1)
And Bearings Removal And Installation on Page 40-20- [Figure 30-21-8].
3.)
Tip the end of the sprocket toward the rear of the loader
Remove the hydrostatic motor. (See Removal And and remove the rear drive chain (Item 2) [Figure 30-21-
Installation on Page 30-21-3) 8] from the sprocket.

HYDROSTATIC MOTOR CARRIER (CONTD)
Figure 30-21-9
P-4165
Slide the motor carrier out of the chaincase [Figure 30-

21-9].
Installation: Check the motor carrier gasket (Item 1)

[Figure 30-21-9] for wear or damage and replace if
necessary.
Figure 30-21-10
P-4168
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-21-10] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

remove the carrier from the loader.
Reverse the removal procedure to install the motor

carrier.

2 8
3 4
5
4
3
6 7
MC-1937A
1. MOUNT ASSY. 5. HOUSING
2. SHAFT 6. SNAP RING
3. BEARING 7. SEAL
4. RACE 8. PLUG

Disassembly and Assembly
Figure 30-21-11
3.000 O.D. Diameter

(76,2 mm)
2.530 I.D. Diameter

(64,26 mm)
7.000
Length
(177,8 mm) P-4176
Put the motor carrier in the hydraulic press as shown

MC-2102 [Figure 30-21-13].
Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-21-13].
procedure. Refer to photo [Figure 30-21-11] for the
correct dimensions of the tool needed. NOTE: The outer bearing will now be free from the
sprocket shaft.
Figure 30-21-12
Figure 30-21-14
2
1
1
P-4372
P-4365
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-21-14] on the sprocket shaft.
Remove the motor carrier shaft seal. (See Disassembly
and Assembly on Page 30-21-6). Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-21-12] from 21-14] from the shaft.
the motor carrier shaft using the snap ring pliers.

Disassembly and Assembly (Contd)
Figure 30-21-15
P-4369
Put the motor carrier housing in the press as shown

P-4373 [Figure 30-21-17].
Use 4-5/16 inch driver tool and press the new inner
Fasten the carrier motor housing to the work surface bearing race into the motor carrier housing [Figure 30-
securely with the inner bearing race (Item 1) [Figure 30- 21-17].
21-15] facing up.
Press the bearing race in until it is fully seated in the
Install the slide hammer with puller end (Item 2) [Figure carrier housing.
30-21-15] on the bottom side of the bearing race.
Figure 30-21-18
Remove the bearing race from the carrier housing
[Figure 30-21-15].
Figure 30-21-16
P-4368
Turn the motor carrier housing over as shown [Figure

P-4370 30-21-18].
Use 4-5/16 inch driver tool and press the new outer
Put the motor carrier housing in the hydraulic press as bearing race into the motor carrier housing [Figure 30-
shown [Figure 30-21-16]. 21-18].
Use a 3-7/8 inch driver tool and press the outer bearing Press the bearing race in until it is fully seated in the
race from the housing. carrier housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

Figure 30-21-19
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-21-20]
over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 inch driver
tool, install the new inner bearing (Item 2) [Figure 30-21- Put the outer bearing over the end of the sprocket shaft
19] on the sprocket shaft as shown. and press the bearing on with the press tool and driver
tool [Figure 30-21-20].
Remove the press and drive tools from the sprocket
shaft. Remove the press and driver tools from the sprocket
shaft.

Figure 30-21-21
1
1
P-4374
Put the snap ring (Item 1) [Figure 30-21-21] over the end
P-4375
of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-21-
ring so it will fit over the sprocket shaft. 23] and install the shaft seal.
Using the press and driver tools, press the snap ring Hit the tool with a hammer until the seal is fully seated on
(Item 1) [Figure 30-21-21] over the sprocket. the carrier shaft [Figure 30-21-23].
Press the snap ring on until it snaps into the groove on Figure 30-21-24
the shaft.
Figure 30-21-22
N-15088
P-4376 Check the end play of the motor carrier as follows:
Use a rubber mallet [Figure 30-21-24], tap down on the

Put a new shaft seal (Item 1) [Figure 30-21-22] on the cluster shaft.
sprocket shaft.

Figure 30-21-25
N-15087
Install a dial indicator as shown in Photo [Figure 30-21-

25].
Use a pry bar (Item 1) [Figure 30-21-25] 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 inch (0,17 mm).

HYDROSTATIC MOTOR CARRIER (SJC) Figure 30-22-2
Shaft Seal Replacement
The tool listed is necessary for the following procedure:
MEL1420 - Carrier Seal Tool
Remove the hydrostatic motor. ((See Removal And

WARNING
P-39783
of the following conditions exist:
When fluids are under pressure. Drill a .125 inch (3 mm) hole in the motor carrier seal
Flying debris or loose material is present. [Figure 30-22-2].
Engine is running.
Tools are being used. Figure 30-22-3
W-2019-1285
Figure 30-22-1
1
P-39784
P-39780
Use a slide hammer to remove the seal from the motor
carrier shaft [Figure 30-22-3].
The motor carrier seal (Item 1) [Figure 30-22-1] is

located on the outside of the motor carrier shaft.

HYDROSTATIC MOTOR CARRIER (SJC) (CONTD) Figure 30-22-6
Shaft Seal Replacement (Contd)
Figure 30-22-4
P-39780
Photo [Figure 30-22-6] shows the motor carrier seal

P-4454A correctly installed.
NOTE: Before reinstalling the hydrostatic motor,

Installation: Install a new seal over the motor carrier check the plug (Item 1) [Figure 30-22-6]
shaft [Figure 30-22-4]. located in the center of the carrier shaft for
tightness. If the plug becomes loosened, case
Figure 30-22-5 drain lubrication oil from the hydrostatic
motor can leak into the chaincase.
P-39786
Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-22-5].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-22-5].

WARNING
2
to fall and cause injury or death. 1
W-2059-0598
P-39781
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-22-
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the loader operator cab. (See Raising The [Figure 30-22-7] from the inside of the chaincase.
Figure 30-22-8
Installation on Page 70-20-1.) 1

on Page 50-100-1.)
Remove the lift arm by-pass control valve. (See Removal

2

P-4167A
Remove the front chaincase cover. (See Front Cover
For ease of removal, fasten the front drive chain
Remove the front axle and sprocket. (See Axle Sprocket (previously removed) to the chaincase as shown (Item 1)
And Bearings Removal And Installation on Page 40-20- [Figure 30-22-8].
3.)
Tip the end of the sprocket toward the rear of the loader
Remove the hydrostatic motor. (See Removal And and remove the rear drive chain (Item 2) [Figure 30-22-
Installation on Page 30-20-1.) 8] from the sprocket.

HYDROSTATIC MOTOR CARRIER (SJC) (CONTD)
Figure 30-22-9
P-39812
Slide the motor carrier out of the chaincase [Figure 30-

22-9].
Installation: Check the motor carrier gasket (Item 1)

[Figure 30-22-9] for wear or damage and replace if
necessary.
Figure 30-22-10
P-39813
Use one of the motor carrier mounting bolts (Item 1)

[Figure 30-22-10] and install partially into one mounting
hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and

remove the carrier from the loader.
Reverse the removal procedure to install the motor

carrier.

2
3
4
5
4
3
6
7
P-64693
1. SHAFT 5. HOUSING
2. SENSOR DISC 6. SNAP RING
3. BEARING 7. SEAL
4. RACE

Figure 30-22-11
3.000 O.D. Diameter

(76,2 mm)
2.530 I.D. Diameter

(64,26 mm)
7.000
Length
(177,8 mm) P-39816
Put the motor carrier in the hydraulic press as shown

MC-2102 [Figure 30-22-13].
Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-22-13].
procedure. Refer to photo [Figure 30-22-11] for the
correct dimensions of the tool needed. NOTE: The outer bearing will now be free from the
sprocket shaft.
Figure 30-22-12
Figure 30-22-14
2
1
1
P-39815
P-4365
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. Remove the housing from the press and install a bearing
puller (Item 1) [Figure 30-22-14] on the sprocket shaft.
Remove the motor carrier shaft seal. (See Shaft Seal
Replacement on Page 30-22-1.) Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-22-12] from 22-14] from the shaft.
the motor carrier shaft using the snap ring pliers.

Figure 30-22-15
P-39820
Put the motor carrier housing in the press as shown

P-39817 [Figure 30-22-17].
Use a 4-5/16 inch driver tool and press the new inner
Fasten the carrier motor housing to the work surface bearing race into the motor carrier housing [Figure 30-
securely with the inner bearing race (Item 1) [Figure 30- 22-17].
22-15] facing up.
Press the bearing race in until it is fully seated in the
Install the slide hammer with puller end (Item 2) [Figure carrier housing.
30-22-15] on the bottom side of the bearing race.
Figure 30-22-18
Remove the bearing race from the carrier housing
[Figure 30-22-15].
Figure 30-22-16
P-39819
Turn the motor carrier housing over as shown [Figure

P-39818 30-22-18].
Use 4-5/16 inch driver tool and press the new outer
Put the motor carrier housing in the hydraulic press as bearing race into the motor carrier housing [Figure 30-
shown [Figure 30-22-16]. 22-18].
Use a 3-7/8 inch driver tool and press the outer bearing Press the bearing race in until it is fully seated in the
race from the housing. carrier housing.
Check all parts for wear and damage. Replace the

bearing race when new bearings are to be installed.

Figure 30-22-19
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-22-20]
over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 inch driver
tool, install the new inner bearing (Item 2) [Figure 30-22- Put the outer bearing over the end of the sprocket shaft
19] on the sprocket shaft as shown. and press the bearing on with the press tool and driver
tool [Figure 30-22-20].
Remove the press and drive tools from the sprocket
shaft. Remove the press and driver tools from the sprocket
shaft.

Figure 30-22-21
1
1
P-39814
Put the snap ring (Item 1) [Figure 30-22-21] over the end
P-4375
of the sprocket shaft.
NOTE: Use the snap ring pliers to spread the snap Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-22-
ring so it will fit over the sprocket shaft. 23] and install the shaft seal.
Using the press and driver tools, press the snap ring Hit the tool with a hammer until the seal is fully seated on
(Item 1) [Figure 30-22-21] over the sprocket. the carrier shaft [Figure 30-22-23].
Press the snap ring on until it snaps into the groove on Figure 30-22-24
the shaft.
Figure 30-22-22
P-39821
P-4376 Check the end play of the motor carrier as follows:
Use a rubber mallet [Figure 30-22-24], tap down on the

Put a new shaft seal (Item 1) [Figure 30-22-22] on the cluster shaft.
sprocket shaft.

Figure 30-22-25
N-15087
Install a dial indicator as shown in Photo [Figure 30-22-

25].
Use a pry bar (Item 1) [Figure 30-22-25] 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 inch (0,17 mm).

CHARGE PRESSURE Figure 30-30-2
Sender Removal And Installation (Non SJC

Machines)
2
WARNING
1
W-2017-0286
P-28590
Figure 30-30-1
Disconnect the wires (Item 1) [Figure 30-30-2] from the

charge pressure sender.
Remove the charge pressure sender (Item 2) [Figure 30-

30-2] from the fitting.
1
Installation: Tighten the sender to 7.4-8.1 ft.-lb. (10-11
Nm) torque.
2 Testing (Non SJC Machines)

1.)
P-48580
Remove the two mounting bolts (Item 1) to remove the oil
filter drip shield (Item 2) [Figure 30-30-1].
Open the rear door.
Remove the two mounting bolts (Item 1) to remove the oil charge pressure sender.
Installation: Tighten the mounting bolts and nuts to 15 30-2] from the fitting.
ft.-lb. (20 Nm) torque.
Nm) torque.
Install a tee fitting into the charge pressure sender fitting.
Install a hose with a pressure gauge of at least 500 PSI

on one end of the tee fitting and the charge pressure
sender into the other end.
Reconnect the wires to the charge pressure sender.
Start the engine.
The gauge must read as follows:
220-270 PSI (15,1-18,6 bar) with approximately 140F

(60C) fluid @ High Idle.

CHARGE PRESSURE (CONT'D) Figure 30-30-4
Adjusting (Non SJC Machines)
IMPORTANT
damage the system.
I-2003-0888
N-17231
Figure 30-30-3
Remove the plug, spring and poppet [Figure 30-30-4].
Check the poppet and spring for wear or damage.

1
Figure 30-30-5
N-19567
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-3].
Assemble: Always use a new O-ring. Tighten the plug to N-19568

30-50 ft.-lb. (41-68 Nm) torque.
There are several different thickness of the shims (Item

1) [Figure 30-30-5] and are used to adjust the charge
pressure.
NOTE: 0.010 inch (0,254 mm) is 8 PSI (55.16 kPa)

increase in pressure.
The charge pressure should be set at 220-270 PSI (15,1-

18,6 bar).

CHARGE PRESSURE (CONT'D) Testing (SJC Machines)
Sender Removal And Installation (SJC Machines) Lift and block the loader. (See Procedure on Page 10-10-
1.)

WARNING support device (See Installing Lift Arm Support Device on
Page 10-20-1.)
on Page 10-30-1.)
W-2017-0286
Figure 30-30-6 Remove the charge pressure sender (Item 2) [Figure 30-

Nm) torque.
1
2 Install a tee fitting into the charge pressure sender fitting.
Install a hose with a pressure gauge of at least 500 PSI

on one end of the tee fitting and the charge pressure
sender into the other end.
Reconnect the wires to the charge pressure sender.
Start the engine.

P-64580
The gauge must read as follows:
360 PSI (24,8 bar) with approximately 140F (60C) fluid
Page 10-20-1.) @ High Idle.

on Page 10-30-1.)



Nm) torque.

CHARGE PRESSURE (CONT'D) Figure 30-30-8
Adjusting (SJC Machines)
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888
P-64435
Figure 30-30-7
Check the poppet and spring for wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-30-8] used to adjust the charge pressure.
NOTE: 1.0 mm shim (Item 1) [Figure 30-30-8] = 43.5

1 PSI (3 bar) in pressure change. Adding shims
increses charge pressure. Removing shims
decreases charge pressure.
The charge pressure should be set at 360 PSI (24,8 bar).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-7].
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.
Assemble: Always use a new O-ring. Tighten the plug to

30-50 ft.-lb. (41-68 Nm) torque.

HYDROSTATIC PUMP Figure 30-40-2
Replenishing/High Pressure Relief Valve
Figure 30-40-1 1
2
1
3
N-19566
Remove the high pressure relief valve (Items 1) [Figure

N-19565 30-40-2] from the pump.
Assemble: Tighten the plug to 30-50 ft.-lb. (41-68 Nm)

There are four replenishing/high pressure relief valves torque.
(Item 1) [Figure 30-40-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and Check for damage and replace as needed.
two at the bottom of the pumps.
Check the O-rings (Items 2 & 3) [Figure 30-40-2] for
(See Replenishing Valve Function on Page 30-10-2.), for damage and replace as needed.
valve function.
If the high pressure relief valve must be replaced, it must
NOTE: The two top valves are for the reverse drive be replaced as a complete unit.
loop and the two bottom valves are for the
forward drive loop. The pressure setting for a new high pressure relief valve
is 5000 PSI (34475 kPa).

HYDROSTATIC PUMP (CONTD) Figure 30-40-4

1
IMPORTANT
2
damage the system.
I-2003-0888
P-34567
Remove the engine/hydrostatic pump assembly from the
loader. (See Removal And Installation on Page 70-80-1.)
Loosen the drive belt tensioner (Item 1) [Figure 30-40-4]
Remove the control handle linkage from the hydrostatic and remove the drive belt.
pump. (See Control Lever Removal And Installation on
Page 50-110-1.) Remove the hydrostatic pump drive pulley mounting nut
(Item 2) [Figure 30-40-4] and washer.
Remove the hydraulic pump from the hydrostatic pump.
(See Removal And Installation on Page 20-60-5.) Installation: Tighten the pump pulley mounting nut to
175-200 ft.-lb. (237-271 Nm) torque.
Figure 30-40-3
Figure 30-40-5
1
P-34568
P-4235
Remove the hydrostatic pump mounting bolt (Item 1)

[Figure 30-40-3] and washer(s). Install a puller on the hydrostatic pump drive pulley and
remove the pulley from the pump shaft [Figure 30-40-5].
Installation: Tighten the mounting bolt to 65-70 ft.-lb.
(88-95 Nm) torque.

HYDROSTATIC PUMP (CONTD)

WARNING
Figure 30-40-6
1 W-2103-1285
Reverse the removal procedure to install the hydrostatic

pump assembly.
P-48650
Installation: Install the key in the hydrostatic pump shaft

(Item 1) [Figure 30-40-6] before installing the pump drive
pulley.
Figure 30-40-7
P-28850
Hold the nut (Item 1) [Figure 30-40-7] on the two

hydrostatic pump mounting bolts (Item 2) [Figure 30-40-
6].
Remove the two hydrostatic pump mounting bolts from

the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 65-70


HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
5
4
8
3
7
6
2
9 1
13 14
10 15
11 12
17
19
16
21
18
23 20
25
27
22
24
29
26
28
30 38
33
36
34 32
31
37
35
49 46
47 48
40 45
42
39 44
49
41
43
D-2427

Parts Identification (Right Half) (Cont'd)

1. Bolt 26. Retainer
2. End Cap 27. Retainer
3. Plug 28. Piston Assembly
4. O-ring 29. Plate
5. Plug 30. Swashplate
6. O-ring 31. Pin
7. O-ring 32. Housing
8. Relief Valve 33. Plug
9. Bolt 34. Bearing
10. Gasket 35. Seal
11. Bearing 36. O-ring
12. Plug 37. Cover
13. O-ring 38. Boltg
14. O-ring 39. Shaft
15. Relief Valve 40. Snap Ring
16. Pin 41. Bearing
17. Valve Plate 42. Snap Ring
18. Retainer 43. Snap Ring
19. Washer 44. Plug
20. Spring 45. O-ring
21. Washer 46. Bearing
22. Block 47. O-ring
23. Retainer 48. Plate
24. Pin 49. Bolt
25. Washer

Parts Identification (Left Half)
17 6
16 1
8 2
11 3
14 13 10 5
12 7
15 9
22
23
18 19 21
20
24
26
28
30 25
32 27
29
34 31
36
38
33
35
37 47
39 46
45
44
48 43
49 40
42
50
51
41 58
52
53
57
53 52
59
55
54 56
D-2428

Parts Identification (Left Half) (Cont'd)

1. Snap Ring 31. Pin
2. Washer 32. Retainer
3. Seal 33. Block
4. Snap Ring 34. Washer
5. Snap Ring 35. Spring
6. Bearing 36. Washer
7. Snap Ring 37. Washer
8. Key 38. Valve Plate
9. Shaft 39. Pin
10. Housing 40. Gasket
11. Plug 41. Bearing
12. O-ring 42. Plug
13. Bearing 43. Poppet
14. Seal 44. Spring
15. O-ring 45. Shim
16. Cover 46. O-ring
17. Bolt 47. Plug
18. Pin 48. Relief Valve
19. O-ring 49. O-ring
20. Plug 50. O-ring
21. Bearing 51. Plug
22. O-ring 52. Pin
23. Plate 53. O-ring
24. Bolt 54. Coupler
25. Swash Plate 55. O-ring
26. Wear Plate 56. Bolt
27. Piston Assembly 57. O-ring
28. Piston Retainer 58. O-ring
29. Retainer 59. Relief Valve
30. Washer

HYDROSTATIC PUMP (CONT'D) Pump Separation
Hydraulic Pump Removal And Installation Figure 30-40-10
Figure 30-40-8
1
2
1 1
N-19569
N-21967
10].
Remove the pump mounting bolts (Item 1) [Figure 30-
40-8] (both sides). Figure 30-40-11

(34-37 Nm) torque.

from the hydrostatic pumps.
Figure 30-40-9
1
2 N-19570
Separate the two hydrostatic pumps [Figure 30-40-11].
N-21969
Remove the O-ring (Item 1) [Figure 30-40-9] and coupler

(Item 2) [Figure 30-40-9] with the hydraulic pump.

HYDROSTATIC PUMP (CONT'D) Figure 30-40-14
Pump Separation (Contd)
Figure 30-40-12
1
3
1
N-19551
2 3
Remove the pump housing end cap (Item 1) [Figure 30-
N-19571 40-14].
Remove the gasket (Item 2) [Figure 30-40-14].

Remove the pump coupler (Item 1) [Figure 30-40-12].
Figure 30-40-15
Remove the large O-ring (Item 2) [Figure 30-40-12].
Remove the two small O-rings (Item 3) [Figure 30-40- 1

12].
Disassembly
Figure 30-40-13
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-40-15].
Check the valve plate for wear. (Both Sides.)
N-19550
Remove the four bolts (Item 1) [Figure 30-40-13] from

the pump housing end cap.

Disassembly (Cont'd)
1
Figure 30-40-16
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-40-18] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-40-18] for wear

Check the valve plate locating pin (Item 1) [Figure 30-40- and replace the rotating group as needed.
16] for wear and replace if needed.
Figure 30-40-19
Check the needle bearing (Item 2) [Figure 30-40-16] for
wear and replace if needed. 1
Figure 30-40-17
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-40-

N-17197 19] from the cylinder block.
Remove the rotating group (Item 1) [Figure 30-40-17]

from the pump.

Figure 30-40-20
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 30-40-22].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-23
2) for wear and replace as needed [Figure 30-40-20].
Remove the four pins (Item 3) [Figure 30-40-20] from the

cylinder block. 1
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-40-20] to see if they are

all the same length.
Figure 30-40-21
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-40-23] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-21] from

the pump housing.

Figure 30-40-24 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-40-26] for

N-17240 wear and replace if needed.
Figure 30-40-27
Remove the snap ring (Item 1) [Figure 30-40-24] from
the pump housing and remove the driveshaft and bearing
from the housing.
Figure 30-40-25
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-40-27]
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.

Figure 30-40-28
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
30-40-30].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-31
from the pump housing [Figure 30-40-28].
Figure 30-40-29
1
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-40-

31].
Check the bearing race (Item 1) and O-ring (Item 2) for

wear and replace as needed [Figure 30-40-29].

Figure 30-40-32
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-40-34] and replace as needed.
Figure 30-40-35
Inspect the seal (Item 1) [Figure 30-40-32] in the upper
trunnion cover and replace if needed.
Figure 30-40-33
1 N-17251
2
Slide the swashplate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-40-35] from
the swashplate shaft.
Remove the O-ring (Item 1) [Figure 30-40-33] and

bearing race (Item 2) [Figure 30-40-33] from the pump
housing.

Assembly
Figure 30-40-36
N-17252
Install the swashplate and bearing into the pump housing

N-17252 [Figure 30-40-38].
Figure 30-40-39
Tilt the swashplate (Item 1) [Figure 30-40-36] and
remove the swashplate and lower bearing from the pump
housing.
Figure 30-40-37
1
1
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-39] on

the swashplate shaft.
N-17253
Install the lower bearing (Item 1) [Figure 30-40-37] on

the swashplate.

Assembly (Cont'd)
Figure 30-40-40
2
N-17246
1
Install the linkage bracket (Item 1) [Figure 30-40-42] and
N-17248 the four mounting bolts and tighten to 18-22 ft.-lb. (24-30
Nm) torque.
Install the bearing race (Item 1) and O-ring (Item 2) as

shown in [Figure 30-40-40].
Figure 30-40-41
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-41]

and cover.

Assembly (Cont'd)
Figure 30-40-43
2
N-17243
Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-40-45].
Install the four mounting bolts and tighten to 18-22 ft.-lb.

Figure 30-40-44 (24-30 Nm) torque.
Figure 30-40-46
N-17244
N-17242
Install the bearing race (Item 1) and O-ring (Item 2) at
the lower trunnion as shown in [Figure 30-40-44].
Install the snap ring (Item 1) [Figure 30-40-46] on the
pump shaft.

Assembly (Cont'd) 1 1
Figure 30-40-47
3
2
1 1
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-40-49]

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 30-40- and install into the ball guide retainer (Item 3) [Figure 30-
47] on the pump shaft. 40-49].
Figure 30-40-48 Figure 30-40-50
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
40-48]. 30-40-50] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-48].

Assembly (Cont'd)
1
2
Figure 30-40-51
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) in the charge pump [Figure 30-40-
53].
Assemble the piston assemblies into the slipper guide. Figure 30-40-54
Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
40-51].
Figure 30-40-52
2 1
N-17196
The bearing cage (Item 1) [Figure 30-40-54] will

protrude from 0.08-0.10 inch (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 40-54] will protrude from 1.65-0.185 inch (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 30-40-52].

Assembly (Cont'd)
1 1
Figure 30-40-55
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-57] to 35-45 ft.-
lb. (47-61 Nm) torque.
Coat the backside of the valve plate with petroleum jelly Figure 30-40-58
to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-55].
The notch (Item 1) [Figure 30-40-55] on the valve plate

must engage the locating pin.
Figure 30-40-56 1
2
1
N-19571
1 Install the two small O-rings (Item 1) [Figure 30-40-58].
Install the large new O-ring (Item 2) [Figure 30-40-58].
N-19551 Install the pump coupler (Item 3) [Figure 30-40-58].
Coat a new end cap gasket (Item 1) [Figure 30-40-56]

with petroleum jelly and install onto the end cap.

Assembly (Cont'd)
Figure 30-40-59
N-19570
Install the two pumps together [Figure 30-40-59].
Figure 30-40-60
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-40-60] to 35-45


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 30-41-1
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

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
Hydraulic Controller Removal And Installation
The loaders right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loaders 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
on Page 10-20-1.)
Disconnect all of the electrical harness connectors (Item
Place the loader on jack stands. ((See Procedure on 1) [Figure 30-41-3] from the loader harness.
Page 10-10-1.)
Removal:
WARNING
IMPORTANT
of the frame before running the engine for service. When repairing hydrostatic and hydraulic systems,
Failure to use jackstands can allow the machine to clean the work area before disassembly and keep all
fall or move and cause injury or death. parts clean. Always use caps and plugs on hoses,
W-2017-0286
damage the system.
I-2003-0888
Raise the operator cab. ((See Raising The Operator Cab
on Page 10-30-1.) Figure 30-41-4
Figure 30-41-2
1
P-64426
P-64425
from the hydraulic controller.
Locate the two hydraulic controllers (Item 1) [Figure 30-
41-2] on the hydrostatic pumps.

Hydraulic Controller Removal And Installation 1

(Cont'd)
Figure 30-41-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-41-7] 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 30-41-5] from the hydrostatic pumps must be calibrated. (See
pump. Hydraulic Controller Neutral Adjustment on
Page 30-41-28.)
Remove the controller gaskets (Item 2) [Figure 30-41-5]
from the pump. Figure 30-41-8
Installation:
Figure 30-41-6
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 30-41-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-41-5] 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- Nm) torque.
41-6].
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 30-41-5].
Be sure the pump surface is clean.

Remove the hydrostatic pump/engine assembly from the

loader. ((See Removal And Installation on Page 70-80-
1.)
IMPORTANT 1

P-64345
damage the system.
I-2003-0888 Loosen the washer and nut (Item 1) [Figure 30-41-10] on
the hydrostatic pump drive shaft.
Figure 30-41-9
Installation: Tighten the nut to 175-200 ft.-lb. (237-271
Nm) torque
1 Figure 30-41-11
P-64344
1
Loosen the tensioner mount bolt (Item 1) [Figure 30-41-

9]. P-64346
Remove the drive belt (Item 2) [Figure 30-41-9].

Use a puller (Item 1) [Figure 30-41-11] to loosen the
Installation: (See Drive Belt Replacement on Page 30- pulley from the pump drive shaft.
50-3.)
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.

Figure 30-41-12
1 1 1 P-64343
Remove the mounting bolt (Item 1) [Figure 30-41-14] at

P-64348 the hydraulic pump mounting bracket.
Remove the hydrostatic pump from the mounting bracket

Figure 30-41-13 and drive belt housing.
NOTE: The mounting bolt is a special purpose bolt.

Only replace with original Bobcat Parts.
1 1 Figure 30-41-15
P-64337 P-64338 1

12] and nuts (Item 1) [Figure 30-41-13].
P-64458
Installation: Tighten the mounting bolts and nuts to 65-
Remove the air bleed plugs (Item 1) [Figure 30-41-15].
Make sure the key (Item 2) [Figure 30-41-12] is
installed. BEFORE START UP: 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 start up.
Assembly: Tighten plugs to 18 ft.-lb. (25 Nm) torque.

HYDROSTATIC PUMP (SJC) (CONT'D)
3 1
1. O-ring 5 4
2. Bolt
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
24 23 22 26
20
25
18
26
18
27
32 19 29
28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
6 22. Plug
2
7 23. Screen
24. Plug
25. Orifice
30 26. Dowel Pin
27. Charge Pressure Relief
4 28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
B25010

High Pressure Relief and By-Pass Valve
Figure 30-41-16
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-41-18]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-18] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-41-16] in the back of the hydrostatic pump.
Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-16].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 111-125 ft.-lb. (150-170 Nm) replacement is required, replace as an assembly .
torque.
Factory setting on the relief valve is 5250 PSI (362 bar).
Figure 30-41-17
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-17], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-41-17]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-41-17] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-41-19 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-41-21] for damage or foreign material. Ensure
the poppet moves freely in its bore.
The charge relief valve (Item 1) [Figure 30-41-19] is Inspect the sealing ring (Item 3) [Figure 30-41-21] 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 30-41-21].
Nm) torque.
NOTE: 1.0 mm shim (Item 5) [Figure 30-41-21] = 43.5
Figure 30-41-20 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 30-41-20].

Remove the hydrostatic pump/engine assembly from the

2
loader. ((See Removal And Installation on Page 70-80-
1.)
Figure 30-41-22
1
1
1
P-64439
Remove the bolts (Item 1) mounting the steel covers

(Item 2) [Figure 30-41-24].
Assembly: Tighten bolts to 38 ft.-lb. (51 Nm) torque.
P-64458 Figure 30-41-25
Remove the hydraulic controllers (Item 1) [Figure 30-41-

22]. (See Hydraulic Controller Removal And Installation 1
on Page 30-41-2.)
Figure 30-41-23
2 2
1 1
1
P-64440
Remove the mounting bolts and washers for the

swashplate angle sensor (Item 1) [Figure 30-41-25].
Assembly: Tighten bolts to 27.4 in.-lb. (3,1 Nm) 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 30-41-23].
Note the connectors facing each other.
Note the steel covers facing direction.

Disassembly and Assembly (Cont'd)
Figure 30-41-26
P-64442
Both swashplate angle sensors and associated hardware

P-64441 removed from the hydrostatic pump. [Figure 30-41-28]
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 30-41-
26]
Note the machined section of the swashplate angle

sensor shaft faces the center of the hydrostatic pump.
Figure 30-41-27
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 30-41-
27].

Right End Housing
Figure 30-41-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
41-31].
1
P-64445
Left End Housing
Figure 30-41-30
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 30-41-29] and [Figure 30-41-30]
Assembly: Alternately, tighten mount bolts to 96 ft.-lb.

(130 Nm) torque.

Figure 30-41-32
1 2
1
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole

P-64465 in case housing (Item 2) [Figure 30-41-34] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-41-32].
Figure 30-41-33
P-64466
Ensure servo follower (Item 2) [Figure 30-41-32] is

swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-41-33].

HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-41-35
RIGHT SIDE
P-64454
Figure 30-41-36
LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-41-35] and

[Figure 30-41-36] 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

30-41-35] and [Figure 30-41-36] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.


RIGHT SIDE
Figure 30-41-37
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-41-40
P-64455
LEFT SIDE
Figure 30-41-38 1
2
LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64502 37] and [Figure 30-41-38] in the case housing with the
notch (Item 1) [Figure 30-41-39] and [Figure 30-41-40]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-41-37] and [Figure 30-41-38] with the beveled edge
on the valve plate (Item 2) [Figure 30-41-39] and [Figure
30-41-40].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

Figure 30-41-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-43].

B25012
Figure 30-41-44
Right Side Rotating Group [Figure 30-41-41].
Figure 30-41-42
1
P-64475
Remove the pistons (Item 1) [Figure 30-41-44] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-41-42].


1
Figure 30-41-45
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64476 47].
Figure 30-41-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-41-45] in the
1
slippers, are not plugged.
Figure 30-41-46
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-48]. 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 30-41-46].


3
Figure 30-41-49
1
1
P-64479
Inspect mating surface for the slippers on the swashplate

P-64474 (Item 1) [Figure 30-41-51].
Remove the swashplate from the endcap housing (Item

Inspect the sperical washer for scoring and wear (Item 1) 2) [Figure 30-41-51].
[Figure 30-41-49].
Remove the slide ring (Item 3) [Figure 30-41-51], ensure
Figure 30-41-50 it pivots freely.
Figure 30-41-52
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-50] 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 30-41-52].
Visually ensure spring (Item 2) and c-clip (Item 3)
[Figure 30-41-50] are not bent or damaged.

Disassembly and Assembly (Cont'd) 2

1 1
Figure 30-41-53
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64481 55].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-41-55] on them. The edges face towards
swashplate (Item 1) [Figure 30-41-53]. the outside of the endcap housing
Figure 30-41-54 Inspect bearing surfaces for scratches or scoring.
P-64482
Remove the shell bearing (Item 1) [Figure 30-41-54].
Inspect individual roller bearings and machined surfaces

(Item 2) [Figure 30-41-54] on swashplate.

Disassembly and Assembly (Cont'd) LEFT SIDE

Figure 30-41-56
1
2
1
P-64486
Figure 30-41-59
P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-41-56].
Figure 30-41-57
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-41-58] and

[Figure 30-41-59] from the end housing.
Figure 30-41-60
P-64485
Pull the positioning pin from the end housing.
Replace O-ring (Item 1) [Figure 30-41-57].
Inspect wear surfaces (Item 2) [Figure 30-41-57] 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 30-41-60] is removed by

inserting a screw into the seal and prying out.

Figure 30-41-61
P-64488
The drive shaft can be tapped out of the end housing with
B25013
a rubber mallet.
Inspect wear surfaces for scratches, and inspect splines

Servo Piston Assembly [Figure 30-41-62].
for excessive wear.
Figure 30-41-63
Inspect bearing (Item 1); if bearing needs replacement,
remove snap ring (Item 2) [Figure 30-41-61] and remove
bearing.
The Servo Piston Assembly [Figure 30-41-62] cannot be

removed unless the hydraulic controller and rotating
group is removed first.
1 1
P-64489
Remove servo piston mounting bolts (Item 1) [Figure 30-

41-63].
Installation: Tighten bolts to 7.7 ft.-lb. (10,4 Nm) torque.

Figure 30-41-64
P-64492
Slide the servo piston assembly out of the bore. [Figure

P-64490 30-41-66].
Measure and record servo piston depth at the adjustment

screw [Figure 30-41-64].
Figure 30-41-65
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-41-65].

Figure 30-41-67 1
2
1
P-64493
Remove the bushings (Item 1), seals and O-rings (Item

P-64467 2) [Figure 30-41-69] from the pump housing.
Figure 30-41-70
Figure 30-41-68
3
P-64494
P-64466
Assembly: Align the servo piston so the guide slot Each servo has a pair of bushings (Item 1), O-rings (Item
(Item 1) [Figure 30-41-68] is parallel to the driveshaft 2) and square-cut seals (Item 3) [Figure 30-41-70].
centerline. Measure with a straight-edge [Figure 30-41-
67].

Figure 30-41-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-41-73] from the
P-64495 servo piston.
Figure 30-41-74
Remove the lock nut (Item 1) [Figure 30-41-71] from the
servo piston.
1
Assembly: Tighten lock nut to 22 ft.-lb. (30 Nm) torque. 2
Figure 30-41-72
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-41-74] from the servo piston.
P-64496 Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-41-74]

Remove the servo cover (Item 1) [Figure 30-41-72] from
the servo piston.

Figure 30-41-75
1
1
2 1
3
P-64499
Remove the four control pressure plugs (Item 1) [Figure

P-64461 30-41-77] at the top of the case housing to gain access to
the four orifices (Item 1) [Figure 30-41-78].
Remove the plug (Item 1) from the top center of the case Replace O-rings on plugs.
housing. Replace O-ring (Item 2) [Figure 30-41-75].
Assembly: Tighten plugs to 18 ft.-lb. (25 Nm) torque.
Assembly: Tighten plug to 45 ft.-lb. (10 Nm) torque.
Figure 30-41-78
Remove internal screen (Item 3) [Figure 30-41-75].
Assembly: Tighten internal screen to 7.4 ft.-lb. (62 Nm)

1
torque.
Figure 30-41-76
P-64500
Ensure the four orifices (Item 1) [Figure 30-41-78] in

case housing are clean and not plugged.
P-64462
Ensure screen is clean [Figure 30-41-76].

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 30-41-79 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 30-41-79] 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 30-41-79]. support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

on Page 10-30-1.)

10-60-1.)
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
and possibly death if proper medical treatment by a
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Contd)
Figure 30-41-80
1
P-64438
Remove the plugs (Item 1) [Figure 30-41-82] 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 30-41-80] Figure 30-41-83

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 30-41-81
1
1
1 1
P-64977
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-41-83]. 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 30-41-81] from the setting.
MB ports on the front side of the pump, and install 7500
PSI (241 bar) pressure gauges.

Mechanical Neutral Adjustment (Contd)
Figure 30-41-84
1
P-64457
Turn the adjustment screw (Item 1) [Figure 30-41-86]

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 30-41-84]. Figure 30-41-87
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 30-41-85
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.
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Contd) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-41-88 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 30-41-88] to 22 ft.-lb.
(30 Nm) 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
Nm) torque. of the frame before running the engine for service.
Remove the pressure gauges from the MA and MB ports fall or move and cause injury or death.
on the pump. Install the plugs and tighten to 18 ft.-lb. (25
Nm) torque. W-2017-0286
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 Lift Arm Support Device
Neutral Adjustment is done. (See Hydraulic
on Page 10-20-1.)
Controller Neutral Adjustment on Page 30-41-
28.)
on Page 10-30-1.)

10-60-1.)
WARNING
and possibly death if proper medical treatment by a
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Contd)
Figure 30-41-89
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 30-41-92

[Figure 30-41-89] from the loader wiring harness for the
hydraulic controller you are adjusting.
Figure 30-41-90
1 1
P-64459
Loosen the locking screw (Item 1) [Figure 30-41-92].

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 30-41-90] 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

Hydraulic Controller Neutral Adjustment (Contd)
Figure 30-41-93
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 30-41-96
in system pressure. Mark the position of the adjustment
screw.
2
Figure 30-41-94
P-64459
While holding the adjustment screw (Item 1) in position,

P-64459 tighten the locking screw (Item 2) [Figure 30-41-96] to
4.5 ft.-lb. (6,1 Nm) torque.
Turn the adjustment screw (Item 1) [Figure 30-41-94] 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
Nm) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

Calibration Procedure (ACS) on Page 60-160-11.)

DRIVE BELT Adjusting
Shield Removal And Installation To adjust the drive belt between the flywheel and the
hydrostatic pump pulley, use the following procedure:
Figure 30-50-1
Stop the engine. Open the rear door.
Disconnect the negative (-) battery cable.
Remove the belt shield. (See Shield Removal And

Installation, Page 30-50-1.)
The pulley tensioner is located between the flywheel and

1 pump pulley.
Figure 30-50-3
P-48001 1
2
Remove the three drive belt shield mounting clips
(Item 1) [Figure 30-50-1] .
Figure 30-50-2
1 P-48478
Loosen the bolt (Item 1) [Figure 30-50-3] on the spring

loaded drive idler.
NOTE: The pointer (Item 2) [Figure 30-50-3] will be at

the 1 o'clock position when the idler is not
under spring tension.
P-48000
Remove the belt shield (Item 1) [Figure 30-50-2].

DRIVE BELT (CONTD) Figure 30-50-5
Adjusting (Contd)
Figure 30-50-4
P-48480
Raise the idler assembly slightly so that the pulley is

P-48479 operating on spring tension and not against the stop.
Tighten the mounting bolt (Item 1) [Figure 30-50-5] to

Using the Belt Tensioner Bar (MEL1405) or a pry bar 25-28 ft.-lb. (34-38 Nm) torque.
push the idler assembly against the belt, the pointer (Item
1) [Figure 30-50-4] will be at the 3 o'clock position when NOTE: Do not set the idler against the travel stop in
the idler stop is bottomed out. Do not pry directly on the the 3 o'clock position.
pulley, pry on the 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 tensioner mounting bracket, manually
move the arrow towards the 3 oclock position Readjust if necessary.
with a screwdriver while putting tension on
the bracket to help get it started. After the idler 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.

Drive Belt Replacement

1
Figure 30-50-6
2
P-48478
Remove the fan drive belt (Item 1) [Figure 30-50-7].

P-48000
Remove the air conditioner belt if so equipped.
Stop the engine. Open the rear door. The belt tensioner is located between the flywheel and
pump pulley. Loosen and remove the bolt (Item 2)
Raise the operator cab. (See Raising The Operator Cab [Figure 30-50-7] from the belt tensioner.
on Page 10-30-1.)
Remove the belt tensioner assembly.
Remove the negative (-) cable from the battery. The
battery may be removed for additional working clearance. Figure 30-50-8
(See Removal And Installation on Page 60-20-1.)
Remove the belt shield [Figure 30-50-6]. (See Shield

P-48481
Remove the drive belt from the pump pulley and flywheel.
Remove the drive belt from the loader [Figure 30-50-8].
Install the new drive belt. Install the belt tensioner

assembly.
Install the fan drive belt.
Adjust the drive belt. (See Adjusting, Page 30-50-1.)
Reinstall belt shield and connect the negative (-) cable to

the battery.

Tensioner Pulley Removal And Installation
Figure 30-50-9
1
P-48478
Loosen and remove the tensioner pulley mounting bolt

P-48000 (Item 1) [Figure 30-50-10].
Installation: Tighten the bolt to 25-28 ft.-lb. (34-38 Nm)

Stop the engine. Open rear door. torque.
Remove the negative (-) cable from the battery. the Remove the belt tensioner pulley from the housing.
battery may be removed for additional working clearance.
(See Removal And Installation on Page 60-20-1.) Reverse the removal procedure to install the drive belt
tensioner.
Remove the belt shield [Figure 30-50-9]. (See Shield

DRIVE BELT (CONTD)
Tensioner Pulley 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: Drive idler parts are not 5 14

available individually. Consult
parts catalog for available 15
sub-assemblies. 7
8 16
17
9
18
10
19
20
E-2296

Tensioner Pulley Disassembly
Figure 30-50-11
3
1
1
4
P-8861
Remove the two pins (Item 1) from the hub assembly

P-8858 (Item 2) [Figure 30-50-13] only if they have been
damaged.
Remove the grease cover (Item 1) [Figure 30-50-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-50-13] with a plastic hammer.
Figure 30-50-12
Figure 30-50-14
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 30-50-14].
assembly (Item 5) [Figure 30-50-12].

Tensioner Pulley Assembly
Figure 30-50-15
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-50-17] into the hub.
Figure 30-50-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-50-15] as shown.
Figure 30-50-16
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 30-50-18].
[Figure 30-50-16] over the alignment pin on the bracket.

Tensioner Pulley Assembly (Cont'd)
Figure 30-50-19
1
1
P-8877
Press the grease cap (Item 1) onto the pulley assembly

P-8875 (Item 2) [Figure 30-50-21]. 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 30-50-19] over the roll pins. assembly, do not press down on the arrow
indicator plate. Support the hub assembly so
Figure 30-50-20 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 30-50-20].
Tighten the bolt to 28-32 ft.-lb. (38-45 Nm) torque.
Fill the grease cap 1/4 full (approximately 1/2-3/4 oz.) of

grease.

OIL COOLER Figure 30-60-2
WARNING
damage the system.
I-2003-0888
N-19346
Remove the rear grill from the loader. (See Removal And
Figure 30-60-3
Figure 30-60-1
1
2
P-45242
N-19345
Slide the rubber sleeve in toward the radiator. The

Install tool MEL 1558 (Item 1) to outside of rubber sleeve connector will release [Figure 30-60-2] & [Figure 30-60-
(Item 2) [Figure 30-60-1]. 3].

OIL COOLER (CONTD)
Figure 30-60-4
1
2
1
P-45101
Disconnect the inlet and outlet hoses (Item 1) [Figure 30-

60-4] from the oil cooler (Item 2) [Figure 30-60-4].
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.

DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disk Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Switch Operated Parking Brake. . . . . . . . . . . . . . . . . . . . . 40-10-2 SAFETY &
MAINTENANCE
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . 40-30-3
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . 40-30-4
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 DRIVE
SYSTEM
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1
Axle Sprocket And Bearings Removal And Installation . . . 40-20-3
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . 40-20-8
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS
OTHERWISE SPECIFIED. SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS

BRAKE Figure 40-10-2
Disk Removal And Installation
on Page 10-20-1.)
WARNING
N-19105
W-2059-0598
Inspect the traction lock guides (Item 1) [Figure 40-10-2]
and the brake disc for damage or wear and replace as
Raise the loader operator cab. (See Raising The necessary.
(See Inspecting on Page 60-110-3.)
Disconnect and remove the engine speed control. (See
Remove the control panel from the loader. (See Removal



Figure 40-10-1
N-19081
The parking brake discs (Item 1) [Figure 40-10-1] are

located beneath the center chaincase cover.

BRAKE (CONTD) Switch Operated Parking Brake
Disk Removal And Installation (Contd) Figure 40-10-5
Figure 40-10-3
2 1
P-21944
N-19082
The parking brake switch in the front panel (Item 1)
[Figure 40-10-5] replaced the pedal parking brake. (See
Figure 40-10-4 INSTRUMENT PANEL on Page 60-50-1.)
N-19083
A snap ring pliers with 90 tips are necessary for

removing the parking brake disc.
Remove the snap ring (Item 1) [Figure 40-10-3] from the

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-3] off the sprocket

(Item 1) [Figure 40-10-4] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

DRIVE COMPONENTS 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- 3.)
Use a wrench with the puller and remove the axle hub
Lift and block the loader. (See Procedure on Page 10-10- 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.
Installation: Tighten the wheel mounting nuts to 105-115

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

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.
DRIVE COMPONENTS (CONTD) Figure 40-20-5
Axle Seal Removal And Installation (Contd)
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.

DRIVE COMPONENTS (CONTD) Remove the eight front cover mounting bolts (Item 1) and
the front cover (Item 2) from the chaincase [Figure 40-
Axle Sprocket And Bearings Removal And 20-6].
Installation
Figure 40-20-7
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

front axle, bearings and sprocket. This
procedure can also be used for the rear axle,
bearings and sprocket. (See Rear Cover
Use jackstands to support the rear of the loader. (The

loader wheels should remain on the ground.) 1
P-4147
WARNING Loosen the axle sprocket mounting bolt (Item 1) [Figure

40-20-7].
the lift arms are secured by an approved lift arm Lift and block the loader. (See Procedure on Page 10-10-
support device. Failure to use an approved lift arm 1.)
to fall and cause injury or death. Remove the fluid from the chaincase. (See Removing
W-2059-0598
The Oil on Page 40-30-1.)
Raise the lift arms and install an approved lift arm Remove the axle hub. (See Axle Seal Removal And
support device. (See Installing Lift Arm Support Device Installation on Page 40-20-1.)
on Page 10-20-1.)
Remove the sprocket mounting bolt (Item 1) [Figure 40-
Raise the operator cab. (See Raising The Operator Cab 20-7].
on Page 10-30-1.)
Installation: Tighten the sprocket mounting bolt to 300-
Remove the control panel. (See Removal and Installation 330 ft.-lb. (407-447 Nm) torque.
on Page 50-100-1.)
Figure 40-20-6
P-34255

DRIVE COMPONENTS (CONTD) Installation: Pack both axle bearings with grease before
installing them.
Axle Sprocket And Bearings Removal And
Installation (Contd) Figure 40-20-10
Figure 40-20-8
P-4170
1
P-4158
A bearing puller (Item 1) [Figure 40-20-10] is needed for
the following procedure:
Install the MEL1242 power ram (Item 1) [Figure 40-20-8]
between the two sprockets. Put the axle/outer bearing assembly in the bearing puller
as shown and put in the hydraulic press [Figure 40-20-
Put a spacer between the power ram and axle. Push the 10].
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure Figure 40-20-11
until the axle is free from the sprocket and inner bearing.
Figure 40-20-9
2 P-4171
1
P-4162 Be sure the bearing puller makes good contact with the
inner race of the bearing and press the bearing off the
mounting surface of the axle.
Remove the drive chain from the sprocket (Item 1)
[Figure 40-20-9] and remove the sprocket from the Be sure to hold onto the axle during removal as it will
chaincase. slide freely along the axle shaft after removal from the
bearing mounting surface and until the bearing contacts
Remove the inner bearing (Item 2) [Figure 40-20-9] and the spline on the shaft.
remove the axle from the axle tube. (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20- Press the splined end of the axle free from the bearing
3.) [Figure 40-20-11].

Axle Sprocket And Bearings Removal And

Figure 40-20-12
4
3
P-4175
2 When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated
P-4169 [Figure 40-20-13].
Installation: A piece of round tubing (Item 1) [Figure 40-

20-12] is needed to install the bearing on the axle shaft.
The tubing needs to measure approximately 0.500 inch
(12,7 mm) to 1.0 inch (25,4 mm) in length. The inside
diameter of the tubing should not be under 2.100 inches
(53,3 mm) and the outside diameter should not be over
2.400 inches (60 mm),
A bearing puller (Item 2) [Figure 40-20-12] is also

needed to install the bearing on the axle.
Put the tubing (Item 1) [Figure 40-20-12] on the bearing

puller (Item 2) [Figure 40-20-12].
Put the bearing (Item 3) [Figure 40-20-12] on the tube as

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.

DRIVE COMPONENTS (CONTD) After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
Axle Sprocket And Bearings Removal And [Figure 40-20-15] on the tool.
Figure 40-20-16
Figure 40-20-14
P-4180
P-4172
Use the slide hammer and remove the bearing cup from
Use the tools provided in the MEL1202B Axle Bearing the axle tube [Figure 40-20-16].
Service Set for bearing cup removal and installation. A
slide hammer is also necessary for this procedure.
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].
Figure 40-20-15
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.
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].

DRIVE COMPONENTS (CONTD) 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-4174
Figure 40-20-18
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].

Chain Removal And Installation

2
WARNING
1
W-2059-0598
P-4152
support device.(See Installing Lift Arm Support Device on
Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 40-20-
1.)
Remove the six carrier mounting bolts (Item 2) [Figure
Raise the loader operator cab. (See Raising The 40-20-20] from inside the chaincase.
Figure 40-20-21

on Page 50-100-1.)

1
Remove the front (or rear) chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-2.)
P-4167
Remove the front (or rear) axle and sprocket. (See Axle
Sprocket And Bearings Removal And Installation on
Page 40-20-3.) 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.

DRIVE COMPONENTS (CONTD)
Chain Removal And Installation (Contd)
Figure 40-20-22
B-13504
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 Nm)
torque.
WARNING
DO NOT exceed the recommended torque of 130 ft.-
lb. (176 Nm). The tool may fail under too much
torque. Put cloth around the tool to protect yourself
from flying debris.
W-2233-0296

CHAINCASE Removing The Oil
Checking And Adding Oil Figure 40-30-2
Figure 40-30-1
P-64141
P-34453
Remove the chaincase cover (Item 1) [Figure 40-30-
2](See Front Cover Removal And Installation on Page
The chaincase contains the final drive sprockets and 40-30-2.)
chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See HYDRAULIC/HYDROSTATIC Use a vacuum pump to extract the fluid from the chain
FLUID SPECIFICATIONS on Page SPEC-50-1.) case.
To check the chaincase oil level, use the following

procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 40-30-1] 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 oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

CHAINCASE (CONTD) Figure 40-30-3
General Information
3 3
Early chaincase designs were assembled with gaskets
and polyurethane sealant between the chaincase covers
and chaincase housing. This was due to a weld that ran
down the middle of the top of the chaincase.The gasket 1
helps seal around the welded area. The polyurethane
sealant should be used with the gasket to ensure a good 2
seal.
Later chaincase designs do not use a gasket because 3

3
the weld was moved to the top edge of the chaincase.
This creates a flat top, on the chaincase, for the cover
to seal against. Polyurethane sealant is all that is needed P-34255
to seal the covers.
Note: Both the later flat top and early chaincase Remove the front chaincase cover mounting screws
designs should use polyurethane sealer on (Item 1) [Figure 40-30-3].
the screw threads, to ensure a good seal.
Remove the front chaincase cover (Item 2) [Figure 40-
Front Cover Removal And Installation 30-3] from the loader.
Raise the loader lift arms and install an approved lift arm Note: On later flat top chaincases there are
support device. (See Installing Lift Arm Support Device machined recesses (Item 3) [Figure 40-30-3]
on Page 10-20-1.) on the bottom side of the cover to help pry the
covers off.
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.) Installation: Install a new gasket (if equipped). When
installing a cover on flat top chaincases, apply
polyurethane sealer to mating surfaces. Polyurethane
sealant should be applied to the screw threads and
gasket (if equipped) to stop oil leakage. Tighten the
mounting screws to 15-20 ft.-lb. (20-27 Nm) torque.
WARNING
W-2059-0598

CHAINCASE COVERS (CONTD)
Center Cover Removal And Installation

WARNING
support device. (See Installing Lift Arm Support Device Never work on a machine with the lift arms up unless
on Page 10-20-1.) the lift arms are secured by an approved lift arm
Raise the loader operator cab. (See Raising The support device can allow the lift arms or attachment
Operator Cab on Page 10-30-1.) to fall and cause injury or death.
W-2059-0598
Figure 40-30-5
3 3
1
1
on Page 50-100-1.)
Figure 40-30-4 1
3 3
4
P-34446
3
Remove the chaincase cover mounting screws (Item 1)
[Figure 40-30-5].
2 1
Remove the center chaincase cover (Item 2) [Figure 40-
30-5] from the loader.
Note: On later flat top chaincases there are

machined recesses (Item 3) [Figure 40-30-5]
P-34257
on the bottom side of the cover to help pry the
covers off.
Disconnect the lift control cross bar (Item 1) [Figure 40- Installation: Install a new gasket (if equipped). When
30-4] from the lift pedal linkage. installing a cover on flat top chaincases, apply
Disconnect the lift control cross bar (Item 2) [Figure 40- sealant should be applied to the screw threads and
30-4] from the lift spool on the main control valve. gasket (if equipped) to stop oil leakage. Tighten the
mounting screws to 15-20 ft.-lb. (20-27 Nm) torque.
Disconnect the electrical connector (Item 3) [Figure 40-
30-4] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-

30-4].
Remove the crossbar and wire harness from the center

chaincase cover.

CHAINCASE COVERS (CONTD) Figure 40-30-6
Rear Cover Removal And Installation
support device. (See Installing Lift Arm Support Device 3
3
on Page 10-20-1.)
1
2
3
3
P-34259
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-6].
Remove the rear chaincase cover (Item 2) [Figure 40-

WARNING 30-6].
Note: On later flat top chaincases there are

Never work on a machine with the lift arms up unless machined recesses (Item 3) [Figure 40-30-6]
the lift arms are secured by an approved lift arm on the bottom side of the cover to help pry the
support device. Failure to use an approved lift arm covers off.
to fall and cause injury or death. Installation: Install a new gasket (if equipped). When
W-2059-0598 installing a cover on flat top chaincases, apply
Disconnect the front steering linkage bars from the rear sealant should be applied to the screw threads and
linkage bars. (See Removal and Installation on Page 50- gasket (if equipped) to stop oil leakage. Tighten the
100-1.) mounting screws to 15-20 ft.-lb. (20-27 Nm) torque.
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.

MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 SAFETY &
MAINTENANCE
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS). . . 50-111-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . . . . . 50-111-5
Control Handle Removal and Installation. . . . . . . . . . . . . . . . . . . 50-111-4
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-7
Control Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . 50-111-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . 50-111-2
DRIVE
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 SYSTEM
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1 MAIN FRAME

Joystick Removal (Right & Left). . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2
Joystick Testing (Right & Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Lever Assembly Removal (Right & Left) . . . . . . . . . . . . . . . . . . . 50-112-3 ELECTRICAL
SYSTEM &
CONTROL PANEL (ADJUSTABLE PINTLES) . . . . . . . . . . . . . . . . . 50-101-1 ANALYSIS
Linkage Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-17
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-13
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-101-7 ENGINE
Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 50-101-11 SERVICE
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-2
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-101-6
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5 SPECIFICATIONS
CONTROL PANEL (NON-ADJUSTABLE PINTLES) . . . . . . . . . . . . 50-100-1
Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-12
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Crossbar Linkage Removal and Installation . . . . . . . . . . . . . . . . . 50-90-2
Lift Foot Pedal Linkage Removal and Installation . . . . . . . . . . . . . 50-90-3
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Tilt Foot Pedal Linkage Removal and Installation . . . . . . . . . . . . . 50-90-3
Continued On Next

MAIN FRAME (CONTD)
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . 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
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Fill Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
LIFT ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-50-5
Stabilizer Bar Removal And Installation. . . . . . . . . . . . . . . 50-50-6
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION). . . . . . . . . . . . . . . . . . . . 50-31-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-4
Cushion 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
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . 50-41-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Adjusting The Striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . 50-70-3
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . 50-70-2
SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . 50-10-4

SEAT BAR Figure 50-10-3
Figure 50-10-1
P10564 P10563
Loosen the nut (both sides) at the front corners of the

N-19225 operator cab [Figure 50-10-3].
Remove the nuts and plates (both sides) [Figure 50-10-

Raise the seat bar (Item 1) [Figure 50-10-1]. 3].
Figure 50-10-2 Installation: Tighten the nuts to 40-50 ft.-lb. (54-68 Nm)
torque.
Figure 50-10-4
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

P-31858
from the cab harness.
Lower the seat bar. Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].

SEAT BAR (CONTD) Assembling Components
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 Nm) 3
torque. 6
2 10
7
1
Figure 50-10-6
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)
Magnetic Bushing Assembly (Item 5)
N-19224 Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Remove the seat bar (Item 1) [Figure 50-10-6] from the Sensor Mounting Bolt (Item 9)
operator cab. Mounting Nut (Item 10)
Reverse the above procedure to install the seat bar into Installation: Tighten the mounting bolt (Item 2) [Figure
the operator cab. 50-10-7] & [Figure 50-10-8] to 50-70 in.-lb. (5,6-7,9 Nm)
torque.

SEAT BAR (CONTD)
Assembling Components (Contd)
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
Nm) torque.

SEAT BAR (CONTD) 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)

OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING 1
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
P1518 P1528
Remove the cab nut and holddown plate (Item 1) [Figure

50-20-2] (both sides).
1
torque.
Figure 50-20-3
N-19165
Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1].
Start the engine.
WARNING
W-2059-0598
P-31965
Raise the lift arms. (See Installing Lift Arm Support
Device on Page 10-20-1.)
Install a strap (Item 1) [Figure 50-20-3] to the cab
Install an approved lift arm support device. handles to prevent the cab from falling forward.
Stop the engine. Raise the operator cab (See Raising The Operator Cab
on Page 10-30-1), to release the tension on the gas
cylinder.

Gas Cylinder Removal And Installation (Contd) SINGLE GAS CYLINDER
Figure 50-20-4
1
2
P-48262A
Figure 50-20-6
DUAL GAS CYLINDER
P-31966
Install a strap (Item 1) [Figure 50-20-4] from the operator

cab to the loader main frame to prevent the cab from
tipping forward when the gas cylinder(s) are removed.
1 2
P-43354A
Loosen the front bolt (Item 1) and remove the rear bolt
(Item 2) [Figure 50-20-5] and [Figure 50-20-6] from the
gas cylinder mounting bracket.

Gas Cylinder Removal And Installation (Cont'd) SINGLE GAS CYLINDER

Figure 50-20-7
1
N-20618
Figure 50-20-9
N-19184 DUAL GAS CYLINDER
Rotate the mounting bracket forward to relieve any 1

remaining tension on the gas cylinder(s) [Figure 50-20-
7].
Remove the front bolt (Item 1) [Figure 50-20-7] from the

gas cylinder mounting bracket. 2
Installation: Tighten the bolts to 100-130 in.-lb. (11,3-
14,7 Nm) torque.
P-39601
Remove the retaining pin(s) (Item 1) [Figure 50-20-8]

and [Figure 50-20-9] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-8]

and [Figure 50-20-9] from the operator cab.
Reverse the above procedure to install the gas cylinders

onto the operator cab.

OPERATOR CAB (CONTD) Removal And Installation
Gas Cylinder Disassembly Figure 50-20-12
Figure 50-20-10
2
1
P1008
Remove the clevis (Item 1) [Figure 50-20-10] and

washer (Item 2) [Figure 50-20-10] from the end of the
gas cylinder.
Remove the gas cylinder from the outer housing.
Assembly: Install a replacement cylinder inside the

cylinder housing.
P-31965
Figure 50-20-11
Remove the operator cab gas cylinder(s). (See Gas
Cylinder Removal And Installation on page 50-20- 1.)
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
P1006 W-2245-0796
Apply a small amount of LOCTITE on the threads of the Use the hoist connected to the operator cab grab handles
cylinder rod [Figure 50-20-11]. to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-12].
Reinstall the washer and clevis on the cylinder rod.

Figure 50-20-13
1
N-19231
Install lift eye (Item 1) [Figure 50-20-15] (both sides) to

P-34227 the cab.
Figure 50-20-16
Remove bolt (Item 1) [Figure 50-20-13] from the cab
ground.
Remove any tie-straps connected to the harness [Figure

50-20-13]. 1
Figure 50-20-14
P-31966
N-19185
Remove the strap (Item 1) [Figure 50-20-16] preventing

Remove the mounting bolt (Item 1) [Figure 50-20-14] the cab from tipping forward.
(both sides) to the cab access hole covers.
Lower the cab.
Start the engine.
Remove the lift arm support device. (See Removing Lift

Arm Support Device on Page 10-20-2.)
Stop the engine.

Figure 50-20-17
2 1
1
N-19202
N-19165
Remove the rear mounting bolt (Item 1) [Figure 50-20-

18] (both sides) and nut from the operator cab.
Installation: Tighten the bolt and nut to 25-35 ft.-lb. (34-

47 Nm) torque.
Figure 50-20-19
1
P-31967
Connect the slings (Items 1 & 2) [Figure 50-20-17] to a

chain hoist. P-34038
Lift the operator cab up and forward.
Disconnect the cab harness connector (Item 1) [Figure

50-20-19].
Remove the operator cab from the loader.
Reverse the above procedure to install the operator cab.

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
on Page 10-30-1.)
on Page 10-30-1.) 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

Nm) 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 Nm) torque. Tighten nut (Item 2) [Figure 50-
P10564 P10563 30-4] to 34 ft.-lb. (46 Nm) 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.

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 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)
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

Nm) 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.

OPERATOR SEAT (SUSPENSION) (CONTD) Cushion Removal And Installation
Slide Rail Removal And Installation Figure 50-31-6
Figure 50-31-5
1 1
2 2
1
1
N-18579
N-18587
Press the two buttons (Item 1) [Figure 50-31-6] &
[Figure 50-31-7] and lift the seat cushion.
on Page 10-30-1.)
Remove the operator seat. (See Removal And

Remove the two slide rail mounting bolts (Item 1) [Figure

50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the

bottom of the seat frame.

seat slide rail.

OPERATOR SEAT (SUSPENSION) (CONTD) Figure 50-31-9
Cushion Removal And Installation (Contd)
Figure 50-31-7
1 1
N-18580
Inspect the seat ride adjustment [Figure 50-31-9].

N-18582
seat back.
Figure 50-31-8
N-18581
Remove the cushion (Item 2) [Figure 50-31-7] from the

seat frame (Item 1) [Figure 50-31-8].

OPERATOR SEAT (SUSPENSION) (CONTD) Shock Removal And Installation
Back Removal And Installation Figure 50-31-12
Figure 50-31-10
2
1
P-43118
N-18583
on Page 10-30-1.)
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-10] and tilt the seat back all the way forward. Remove the operator seat. (See Removal And
Figure 50-31-11
Remove the seat shock mounting bolts (Item 1) [Figure
50-31-12] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-12].

seat shock.
1 1
N-18578

31-11] from the seat back and remove the back.

seat back.

OPERATOR SEAT (SUSPENSION) (CONTD) Figure 50-31-14
3-Point Seat Belt Removal And Installation

on Page 10-30-1.)
Remove the operator seat. (See Removal And 2

Figure 50-31-13 1
3
2
P16284
Remove the seat belt retractor (Item 2) [Figure 50-31-

1 14]
3 Installation: Be sure tether strap (Item 3) [Figure 50-31-

14] is on the seat belt stud behind the seat belt retractor.
P16285
Remove the end release buckle (Item 2) [Figure 50-31-

13]
Installation: Be sure tether strap (Item 3) [Figure 50-31-

13] is on the seat belt stud behind the end release
buckle.

OPERATOR SEAT (SUSPENSION) (CONTD)
3-Point Seat Belt Removal And Installation (Contd)
Figure 50-31-15
OUTSIDE OF CAB
P16131
Remove the mounting bolt (Item 1) [Figure 50-31-15]
Figure 50-31-16
1 2
P16126
INSIDE OF CAB
P16128
Remove the shoulder harness retractor (Item 1) [Figure

50-31-16]
Installation: Line up the bolt (Item 1) [Figure 50-31-15]

with the mounting bracket (Item 2) [Figure 50-31-16] on
the inside of the cab.

BOB-TACH Figure 50-40-3
Figure 50-40-1
P-48132
Remove the grease zerk (Item 1) (both sides)

N-18544 [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.
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-40-1]. Figure 50-40-4
Lower the Bob-Tach onto the blocks.

nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25-30 ft.-
Figure 50-40-2
1
N-18547
1
2
Strike the head of the bolt (Item 1) [Figure 50-40-4] to
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
N-18545 Bob-Tach.
Remove the Bob-Tach from the lift arms.

Remove the pivot pin (Item 1) [Figure 50-40-2] from the
tilt cylinder rod end (both sides).
Remove the Bob-Tach pivot pin (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
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

Nm) torque.
BOB-TACH (CONTD) Figure 50-40-7
Bob-Tach Lever And Wedge
Figure 50-40-5
1
N-18560
1
Remove the Wedge (Item 1) [Figure 50-40-7].
N-18558
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-40-8
Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.
Figure 50-40-6
1
3
2
1
N-18561
Remove the lever mounting nut (Item 1), washer (Item 2),
N-18559 spring (Item 3) and lever (Item 4) [Figure 50-40-8].

Use a punch and hammer, remove the roll pin (Item 1) torque.
[Figure 50-40-6] from the Bob-Tach Wedge and spring
clevis.

BOB-TACH (CONTD)
Bob-Tach Lever And Wedge (Contd)
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.
Figure 50-40-10
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-40-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Bob-Tach

lever and wedge [Figure 50-40-10].

POWER BOB-TACH Figure 50-41-2
Figure 50-41-1 1
2 3
P-48185
1
Remove the pivot pin (Item 1) [Figure 50-41-2] from the
P-48131
tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-41-1]. Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob-
Tach pivot pin.
Lower the Bob-Tach onto the blocks.
Installation: Tighten the bolt to 175-190 ft.-lb. (240-260
Remove the hoses to the cylinder fittings Nm) torque.
[Figure 50-41-1].
Figure 50-41-3
NOTE: The hose with the 45 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.
1
nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25-28 ft.-

P-48132
Remove the grease zerk (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.

POWER BOB-TACH (CONTD) Figure 50-41-6
Figure 50-41-4
1
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)

N-18547 [Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis.
Strike the head of the bolt (Item 1) [Figure 50-41-4] to Figure 50-41-7
push the pivot pin into the Bob-Tach frame.
Remove the bolt.
Use a long punch to push the pivot pins all the way into
the Bob-Tach frame.
Remove the Bob-Tach from the lift arms. 1
Remove the Bob-Tach pivot pin (both sides).
Power Bob-Tach Lever And Wedge
Figure 50-41-5
N-18560
Remove the Wedge (Item 1) [Figure 50-41-7].
Always replace bent or broken wedges.
P-48135
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-41-5], spring and
wedge.

POWER BOB-TACH (CONTD) Figure 50-41-9
Power Bob-Tach Lever And Wedge (Contd)
Figure 50-41-8
4
1
2
3 2
N-20625
3
5 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
4
P-48135 or clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise.
Remove the washers and bolts (Item 1) [Figure 50-41- Remove the bolt and replace the damaged parts as
8]. needed.
Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm) Figure 50-41-10
torque.
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]. 1

torque.
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].

LIFT ARM Figure 50-50-3
Figure 50-50-1
N-18850
Mark the tubelines for correct installation (both sides).

P-31849 Pull the tubelines down, disconnect the hoses (Item 1)
[Figure 50-50-3] (both sides).
Roll the Bob-Tach fully forward. Stop the engine. Install plugs into the hose and tubeline ends.
Remove the Bob-Tach frame from the lift arms. (See Figure 50-50-4
Install jackstands under the rear of the loader [Figure 50-

50-1].
Figure 50-50-2
1
P-31832
1
Remove the front auxiliary mount mounting bolts (Item 1)
[Figure 50-50-4].
N-18805 Remove the front auxiliary tubelines from the lift arms.
Remove the tubeline clamps (Item 1) [Figure 50-50-2]

under the lift arms (both sides).

LIFT ARM (CONTD) Figure 50-50-7
Figure 50-50-5
1
P-34136
Remove the tilt cylinder mounting bolt base end (Item 1)

N-18792 [Figure 50-50-7].

Remove the three front step mounting bolts (Item 1) on Page 10-30-1.)
[Figure 50-50-5].
Remove the tilt cylinders and tilt tubelines from the
Figure 50-50-6 loader.
Figure 50-50-8
N-18793
N-18851
Remove the tilt port block mounting bolt (Item 1) [Figure
50-50-6] under the step.
Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-8].

Figure 50-50-9
1 1
P-31973
Use a slide hammer remove the lift cylinder rod end pivot
N-18806 pin (Item 1) [Figure 50-50-11] (both sides).
Strap the lift cylinders to rear of the uprights.

nut from the lift arm pin (both sides).

27 Nm) torque.
Use a drift pin and hammer remove the lift arm pivot pin
Figure 50-50-10
P-31972

nut from the lift cylinder rod end pivot pin (both sides).

27 Nm) torque.

Figure 50-50-12
1
1
P-31970
2
Connect a nylon lift strap, chain and chain hoist to the lift
P-31971 arms (Item 1) [Figure 50-50-12] & [Figure 50-50-13].

the stabilizer pivot pin.
Use a slide hammer, remove the stabilizer pivot pin (Item

2) [Figure 50-50-12] (both sides).
Remove the chain from the front axle.
Remove the lift arms from the loader.
Reverse the removal procedure to install the lift arm.

Link Removal And Installation
Figure 50-50-14
1
2
P-31974
Connect a chain and chain hoist on the lift arm link

N-18806 [Figure 50-50-15].

Lower the lift arms. Stop the engine. nut from the lift arm link pivot pin.
Remove the retainer bolt (Item 1) [Figure 50-50-14] and Installation: Tighten to 18-20 ft.-lb. (24-27 Nm) torque.
nut from the lift arm pivot pin.
Figure 50-50-16
Use a drift pin and hammer, remove the lift arm pivot pin
WARNING
of the following conditions exist: 1
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
P-31975
Tools are being used.
W-2019-1285
Open the rear door.
Raise the radiator cover part way to gain access to the

pivot pin.
Use a drift pin and hammer, remove the lift arm pivot pin
Lower the rear grill. Close the rear door.
Raise the lift arm link with the chain hoist and remove it
from the loader frame.
Reverse the removal procedure to install the lift arm link

on the loader.
LIFT ARM (CONTD) Remove the stabilizer link pivot pin (Item 2) [Figure 50-
50-18].
Stabilizer Bar Removal And Installation
Figure 50-50-19
Figure 50-50-17
P-31969
N-18851

Lower the lift arms. the stabilizer link pivot pin.
Raise the operator cab. (See Raising The Operator Cab Installation: Tighten to 18-20 ft.-lb. ( 24-27 Nm) torque.
on Page 10-30-1.)
Figure 50-50-20
Connect a chain to the front of the lift arm and around the
axle [Figure 50-50-17].
NOTE: The Bob-Tach and front wheel are removed in

photo [Figure 50-50-17] for clarity purpose 2
only. The Bob-Tach and front wheel do not
need to be removed to remove the stabilizer
link.
Figure 50-50-18 1
P-31968
1
Use a slide hammer (Item 1), remove the stabilizer link

2 pivot pin (Item 2) [Figure 50-50-20].
Remove the stabilizer link (Item 2) [Figure 50-50-20]

from the lift arm.
Reverse the above procedure to install the stabilizer link.

N-18813

the stabilizer link pivot pin.
Installation: tighten to 18-20 ft.-lb. ( 24-27 Nm) torque.

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.

REAR DOOR Connect a chain hoist (Item 2) [Figure 50-70-2] to the
lifting chain.
Figure 50-70-3
Figure 50-70-1
2
2
P-34606
P-48519
Remove the top and bottom door hinge mounting bolts

Disconnect the light harness connector (Item 1) [Figure (Item 1) [Figure 50-70-3] and nuts.
50-70-1] from the engine harness.
NOTE: Install the door stop (Item 2) and the door stop
Remove both rear lights (Item 2) [Figure 50-70-1] from retainer (Item 3) in the top hinge as shown
the door. (See Rear Removal And Installation on Page [Figure 50-70-3].
60-60-2.)
Installation: Tighten the mounting bolts and nuts to 25-
Figure 50-70-2 28 ft.-lb. (34-38 Nm) torque.
Lift the door away from the loader frame and put the door
flat on the floor.
2
P-34588
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.

REAR DOOR (CONTD) Adjusting The Striker
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].
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.

REAR DOOR (CONTD) 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.
Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

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
installed over the fuel drain near the rear of the Remove the two mounting bolts (Item 1) [Figure 50-80-
chaincase. 3] from the battery holder.
Installation: Tighten the cover mounting bolts to 190-240 Installation: Tighten the battery holder mounting bolts to
in.-lb. (21,5-27 Nm) torque. 190-240 in.-lb. (21,5-27 Nm) 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)
P-28144
[Figure 50-80-2].
Remove the mounting bolts (Item 1) [Figure 50-80-4]

from the fuel tank retainer bracket.

(21,5-27 Nm) torque.

FUEL TANK (CONTD) Installation: tighten the fuel level sender to 50-60 in.-lb.
(5,7-6,8 Nm) torque.
Fuel Fill Screen
Figure 50-80-5
Figure 50-80-7
2
1
P13876
P13874
Disconnect fuel sender.

Remove the clamp (Item 1) [Figure 50-80-7] and remove
Disconnect fuel venthose. the fuel fill hose (Item 2) [Figure 50-80-7] from the tank.
Disconnect fuel fillhose. Figure 50-80-8
Lift the fuel tank up and remove the tank from the loader
[Figure 50-80-5].
Fuel Level Sender

1
Figure 50-80-6
1 P13875
Remove the fuel fill screen (Item 1) [Figure 50-80-8]

from the tank. Check the screen for damage and replace
if necessary.
P13870
Loosen the fuel level sender (Item 1) [Figure 50-80-6]

with a wrench.
Turn the fuel level sender out and remove it from the fuel
tank. Check the fuel level sender for damage and replace
if necessary.

FUEL TANK (CONTD)
Fuel Fill Screen (Contd)
Figure 50-80-9
P13873
Remove the fitting (Item 1) [Figure 50-80-9] and

grommet from the tank.
Figure 50-80-10
1
P13872
Remove the fuel supply screen (Item 1) [Figure 50-80-

10] from the hose. Check the screen for damage and
replace if necessary.

CONTROL PEDALS Figure 50-90-2
Figure 50-90-1 1
P-34375

P-26008 2] from the pedal mounting bracket.
Remove the pedal assembly from the loader.

Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the pedal linkage. Remove the pedal assembly from the loader.
Installation: Tighten the bolt and nut to 21-25 ft.-lb. (28- Pedal Adjustment
34 Nm) torque.
After installing the pedal, adjust the pedal so that there is
Check the rubber bushing in the pedal for wear and clearance under the rear of the pedal. The valve spool
replace as needed. must travel full stroke without the pedal hitting the floor
panel.

CONTROL PEDALS (CONTD) Figure 50-90-4
Crossbar Linkage Removal and Installation
WARNING P-34260
Never work on a machine with the lift arms up unless Remove the hairpin clip and cross-pin (Item 1) [Figure
the lift arms are secured by an approved lift arm 50-90-4] from the control valve lift spool.
support device can allow the lift arms or attachment Disconnect the crossbar from the control valve.
W-2059-0598 Figure 50-90-5

Page 10-20-1.)

on Page 10-30-1.)
Figure 50-90-3
2
1
1
P-34376
Remove the crossbar from the pivot [Figure 50-90-5].
Installation: Check the nylon bushing (Item 1) [Figure

50-90-5] for wear and replace as needed.
P-34257
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].

CONTROL PEDALS (CONTD) Tilt Foot Pedal Linkage Removal and Installation
Lift Foot Pedal Linkage Removal and Installation Figure 50-90-8
Figure 50-90-6
1 1
P-34258
P-34257
Remove the hairpin clip and cross-pin (Item 1) [Figure
50-90-8] from the control valve tilt spool.
Remove the bolt and nut (Item 1) [Figure 50-90-6] to
disconnect the lift foot pedal linkage from the crossbar Figure 50-90-9
linkage.
Figure 50-90-7
P-26008
P-24759 Remove the bolt and nut (Item 1) [Figure 50-90-9] to

disconnect the lift foot pedal.
Remove the bolt and nut (Item 1) [Figure 50-90-7] to Installation: Tighten the bolt and nut to 21-25 ft.-lb. (28-
disconnect the lift foot pedal. 34 Nm) torque.

34 Nm) torque.

CONTROL PEDALS (ACS) Figure 50-91-3
Foot Sensor Removal And Installation
Figure 50-91-1
2 1
P-21936
P-21927
1 Remove the two bolts (Item 1) [Figure 50-91-3] from the

P-21938 foot sensor shield.
Installation: Tighten the bolts to 80-90 in.-lb. (9,0-10,2

Pull the pin (Item 1) [Figure 50-91-1] holding the foot Nm) torque.
pedal linkage to the sensor.
Disconnect the two connectors (Item 2) [Figure 50-91-1]

from the sensor and lock solenoid.
Figure 50-91-2
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Remove the foot pedal and sensor assembly from the

loader.

CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Contd) 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 Nm)
lubed torque. 1
Remove the two bolts (Item 2) [Figure 50-91-4] from the
bracket and sensor assembly. P-21935A

torque.
Remove the sensor assembly.

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See P-21934
Calibration Procedure (ACS) on Page 60-160-
11.)
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.

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].

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Disconnect the control harness connectors (Item 4)
[Figure 50-100-1] from right control levers.
WARNING
W-2017-0286
WARNING Figure 50-100-2

1
W-2059-0598

on Page 10-20-1.)

P-48277
on Page 10-30-1.)
Remove the engine speed control. (See Removal And Disconnect the control harness connectors (Item 1)
Installation on Page 70-20-1.) [Figure 50-100-2] from left control levers.
Figure 50-100-1
2
1
3
P-48462
Loosen the jam nut (Item 1) from the by-pass control

knob (Item 2) [Figure 50-100-1].
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-1].

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Figure 50-100-4
(CONTD)

3
Figure 50-100-3 1 1
2
2 2
1 1 P-26323
Remove the fuse/relay mounting bolts (Item 1) [Figure

50-100-4].
P-48235
Remove the fuse/relay shield (Item 2) [Figure 50-100-4].
Scribe a mark across the top of the steering linkage bars Remove the fuse/relay cover (Item 3) [Figure 50-100-4].
steering shaft on the control panel. Figure 50-100-5

[Figure 50-100-3].

P-26325
Remove the fuse/relay block [Figure 50-100-5].

(CONTD)
Figure 50-100-6
1
1
1
1
1
P-26327
Remove the control panel mounting bolts (Item 1)

[Figure 50-100-6], [Figure 50-100-7] & [Figure 50-100-
P-34363 8] from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to

Figure 50-100-7 15-20 ft.-lb. (20-27 Nm) torque.
Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
P-26329

(CONTD)
Shock Removal And Installation
Figure 50-100-9
1 3
2
3
1
P-4146
Remove Control Handle Lever (Item 1) [Figure 50-100-

2 10]. (See Control Lever Removal And Installation on
P-34365 Page 50-110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

Remove the mounting nut (Item 1) [Figure 50-100-9] 100-10] from both sides of the control panel.
from the end of the shock connected to the steering
linkage. Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38
Nm) torque.
from the other end of the shock connected to the bracket Remove the steering shaft from the control panel.
on the control panel.
Shaft Disassembly And Assembly
(34-38 Nm) torque. Figure 50-100-11
Shaft Removal And Installation
NOTE: The steering shaft can be removed without

removing the control panel from the loader.
Photo [Figure 50-100-10] shows the control
panel removed for clarity purpose only. 1
1
Remove the steering linkage mounting bolts (Item 3)
[Figure 50-100-9].
Remove the steering shock mounting nuts (Item 2) 1

[Figure 50-100-9].
P-4154
Disassemble the right and left steering shafts from the

cross shaft assembly [Figure 50-100-11].
Assembly: Install new nylon bushings (Item 1) [Figure

50-100-11] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left steering shaft.

CONTROL PANEL (NON-ADJUSTABLE PINTLES) Linkage Removal And Installation
(CONTD)
Figure 50-100-13
Shaft Disassembly And Assembly (Contd)
Figure 50-100-12
2 1
P-3729
1
P-26331 Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-13].
To remove the steering shaft mounting bracket (Item 3) Remove the shoulder bolt/spring assembly.
[Figure 50-100-10], remove the three mounting bolts
(Item 1) [Figure 50-100-12] from the front of the control Installation: Tighten the centering spring shoulder bolt
panel. and a NEW lock nut to 25-28 ft.-lb. (34-38 Nm) torque.
Remove the steering shaft mounting bracket from each Figure 50-100-14
side of the control panel.

(20-27 Nm) torque.
1
2
3 2
P-3736
Slide the plate (Item 1) to the right and remove it from the
two guide pins (Item 2) [Figure 50-100-14].
NOTE: The two guide bushings (Item 3) will be loose

and can fall out of the plate (Item 1) as soon as
it is removed from the guide pins (Item 2)
[Figure 50-100-14].

(CONTD)
Linkage Removal And Installation (Contd) 1
Figure 50-100-15
1
2
5
6
4 2
1
N-15312
Check the wear on the centering blocks (Item 1) [Figure

2 50-100-16].
2 3 N-15310
If the centering blocks need replacement, remove the
bolts (Item 2) [Figure 50-100-16]. Remove the centering
The centering plate/centering spring assembly consists blocks.
of the following parts;
Installation: Tighten the centering block bolts to 25-28
ITEM DESCRIPTION ft.-lb. (34-38 Nm) torque.
1 Shoulder Bolt
Figure 50-100-17
2 Bushings
3 Spring
4 Lock Nut
2
1
5 Centering Plate
6 Guide Bushings
2
1
P-3733
If the surface of any of the four pintle cams (Item 1) are

worn, loosen the bolt (Item 2) [Figure 50-100-17] and
rotate the cams 1/4 turn.
Tighten the bolts to 45-50 ft.-lb. (62-68 Nm) torque.
When replacing the old style pintle levers, wear cams

and cam bolts, install the latest style parts.

(CONTD)
Linkage Removal And Installation (Contd)
Figure 50-100-18
1
3
2 1
P-34365
Remove the nuts (Item 1) [Figure 50-100-20] from both

shock absorber ball joint ends.
P-3733
Remove the shock absorbers.
Remove the nut (Item 1) [Figure 50-100-18] from the Installation: Tighten the nuts to 25-28 ft.-lb. (34-38 Nm)
torsion bushing/linkage bar. The bolt is threaded into the torque.
linkage bar, remove the bolt from underneath the pintle
lever. Remove the nuts (Item 2) from the linkage bar mounting
bolt. The bolts (Item 3) are threaded into the linkage bars,
Installation: Tighten the bolt to 11-13 ft.-lb. (21-25 Nm) remove the bolts (Item 3) [Figure 50-100-20].
torque, then tighten the nut to 21-25 ft.-lb. (28-33 Nm)
torque. The torsion bushings can now be removed from the
steering bell cranks.
Figure 50-100-19
torque, then tighten the nuts to 21-25 ft.-lb. (28-33 Nm)
torque.
2 The linkage and the centering plate must be readjusted

for neutral after the components have been reassembled.
(See Page 50-100-12 for the neutral adjustment
procedure.)
P-3734
Remove the linkage bar (Item 1) and remove the torsion

bushing (Item 2) [Figure 50-100-19].

(CONTD)
Linkage Adjustment
WARNING
1
Never work on a machine with the lift arms up unless the lift
arms are secured by an approved lift arm support device. 2
Failure to use an approved lift arm support device can allow
1
the lift arms or attachment to fall and cause injury or death.
W-2059-0598 3
P-34365
on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-10-
1.)

WARNING on Page 10-30-1.)
Put jackstands under the front axles and rear corners Connect the remote start tool (MEL1429). (See
of the frame before running the engine for service. Procedure on Page 10-60-1.)
fall or move and cause injury or death. Pre-load tension in the torsion bushings must be
W-2017-0286 removed before adjusting the steering linkage.
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt

(Item 2). The bolt (Item 2) is threaded into the linkage bar
(Item 3). The bolt (Item 2) [Figure 50-100-21] must be
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Figure 50-100-22
2
3
3
P-3726

(Item 2). The bolt (Item 2) is threaded into the linkage bar
freely between the pintle arm and the linkage bar.
(CONTD)
Linkage Adjustment (Contd)
Figure 50-100-23
1
1 3
P-3723
Move the right side steering lever forward and install a

15/16 inch (24 mm) thick spacer (Item 1) between the
P-37574 center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-25].
Remove access plug from the top of the control valve. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-23] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 inch (10 mm) thick spacer (Item 1)
[Figure 50-100-25].
Figure 50-100-24
Figure 50-100-26
4
2
1
3
3 1 2
4
P-3724
P-3730
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the pintle arm
arm cam (Item 2) and the centering block (Item 3) mounting bolt (Item 1) is tight, 25-28 ft.-lb. (34-38 Nm)
[Figure 50-100-24]. torque and that there is no play between the pintle arm
(Item 2) and the square pump shaft (Item 3). Also check
that the cam mounting bolts (Item 4) [Figure 50-100-26]
are tight, 45-50 ft.-lb. (62-68 Nm) torque.

(CONTD)
Linkage Adjustment (Contd)
Figure 50-100-27
P-3728
1
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
P-3727 pintle arm is rotated to the front as far as possible
[Figure 50-100-28]. Use a locking plier and clamp the
two linkage bars together.
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
27] on each steering linkage bar. Installation: Tighten the nuts and bolts to 25-28 ft.-lb.
(34-38 Nm) 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 procedure for the right side linkage.
After both sides of the linkage have been adjusted, the

feel of both levers at full stroke should be the same.
Readjust the linkage if necessary.
Figure 50-100-29
P-3723
Remove the spacer (Item 1) [Figure 50-100-29].
Disconnect the remote start tool.

CONTROL PANEL (NON-ADJUSTABLE PINTLES)
(CONT'D)
Linkage Adjustment (Cont'd)
Figure 50-100-30
P-37574
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-30] in until it
touches the U-bolt holding the control lever.
Repeat steps on the other control lever.
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 50-100-30] 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 excess 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.

(CONTD)
Linkage Neutral Adjustment
The following tool listed will be needed to do the following 2 1

1 2
procedure:
MEL1563 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See

Procedure on Page 10-60-1.)
WARNING P-3731

Loosen the four bolts (Item 1) [Figure 50-100-32] holding
the two centering blocks. Move the right hand centering
block to the right as far as possible.
W-2017-0286
NOTE: Bolt holes (Item 2) [Figure 50-100-32] are
slotted for pintle arm centering adjustment.
Figure 50-100-31
Figure 50-100-33
2
3
4
P-3726
P-3725
Loosen the nut (Item 1) a couple of turns, then loosen the

bolt (Item 2). The bolt (Item 2) is threaded into the linkage Adjust the left centering block first [Figure 50-100-33].
bars (Items 3 & 4) [Figure 50-100-31].
The bolt (Item 2) [Figure 50-100-31] must be loose

enough to allow the torsion bushing to turn freely
between the pintle arm and the linkage bar.

(CONTD)
Linkage Neutral Adjustment (Contd)
Figure 50-100-34
P-3732
Adjust the right centering block [Figure 50-100-35].
P16121 Move the right control lever until the tires do not turn
(neutral position).
Start the engine and run at high RPM. Move the right centering block to the left until it contacts
both pintle cams and the control lever is still in the neutral
Move the traction lock override switch (Item 1) [Figure position [Figure 50-100-35].
50-100-34] to the OFF position so the traction function is
unlocked. The wheels are now able to turn. Tighten the bolts to 25-28 ft.-lb. (34-38 Nm) torque.
Move the left control lever until the tires do not turn Test both levers by moving them backward and forward
(neutral position). and letting them return to neutral by the return spring
force.
Move the left centering block to the left until it contacts
both pintle cams and the control lever is still in the neutral If the levers do not return to neutral and the tires do not
position [Figure 50-100-33]. come to a complete stop, repeat the adjustment
procedure again.
Tighten the bolts to 25-28 ft.-lb. (34-38 Nm) torque.
Stop the engine.
NOTE: If the centering blocks are worn, they can be
removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.

(CONTD)
Figure 50-100-36
1
1
P-34365
2
Tighten the two bolts to 11-13 ft.-lb. (15-17 Nm) torque,
then tighten the two nuts to 21-25 ft.-lb. (28-33 Nm)
P-3726 torque at the steering cross shaft (Items 1 & 2) [Figure
50-100-37].
Tighten the two bolts (Item 1) to 11-13 ft.-lb. (15-17 Nm)

torque, then tighten the two nuts (Item 2) [Figure 50-100-
36] to 21-25 ft.-lb. (28-33 Nm) torque.

CONTROL PANEL (ADJUSTABLE PINTLES)
Description
Figure 50-100-1
P-54658
The steering system [Figure 50-101-1] 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. Earlier designs use
steering input to the loader. a spring return adjustment, later designs use a thread
return adjustment.
The steering levers are attached to pivoting bellcranks
that pivot on a steering shaft and plastic bushings. The The steering system returns the levers to their starting
bellcranks have grease fittings. position by means of the centering spring and the
returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts.
NOTE: Torsion bushings need to be replaced if torn
The bellcranks are attached to steering linkage bars with or rotating in the housing. Loosen torsion
rubber torsion bushings pressed into the bellcranks. bushing bolts slightly before adjustments are
Bellcranks mount to the control panel. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
Steering linkage bars are a two-piece design. Steering been made first.
linkage bars are adjustable in length for full travel
adjustment. Sequence of steering adjustments:
1. Set neutral of pintle arms, creep
Steering linkage bars attach to the pintle arms where a
2. Set full travel at steering linkage bars
rubber torsion bushing is pressed into the pintle arms.
3. Set drift at drift adjustment bolts
CONTROL PANEL (ADJUSTABLE PINTLES) Figure 50-101-2
(CONT'D)
2 1
P-48462
WARNING Raise the lift arms and install an approved lift arm
Never work on a machine with the lift arms up unless on Page 10-20-1.)
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising The Operator Cab
support device can allow the lift arms or attachment on Page 10-30-1.)
W-2059-0598 Remove the engine speed control. (See Removal And
Loosen the jam nut (Item 1) from the by-pass control

WARNING knob (Item 2) [Figure 50-101-2].
Remove the control knob (Item 2), jam nut (Item 1) and
Put jackstands under the front axles and rear corners rubber washer (Item 3) [Figure 50-101-2].
Failure to use jackstands can allow the machine to Figure 50-101-3
W-2017-0286
P-48277
Disconnect the control harness connectors (Item 4)

[Figure 50-101-2] & [Figure 50-101-3] from the control
levers.

(CONT'D)
Removal and Installation (Cont'd)

2
Figure 50-101-4
1 1
2 2 3
P-26323
1 1
Remove the fuse/relay mounting bolts (Item 1) [Figure
50-101-5].
P-54609
Remove the fuse/relay cover (Item 2) and fuse/relay
block retaining bracket (Item 3) [Figure 50-101-5].
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-101-4] which are connected to the Figure 50-101-6
steering shaft on the control panel.

[Figure 50-101-4].

40 ft.-lb. (47,5-54,2 Nm) torque.
P-26325
Remove the fuse/relay block [Figure 50-101-6].

(CONT'D)
Removal and Installation (Cont'd) 1
Figure 50-101-7
11
P-26329
P-26328 P-26329
1
Remove the control panel mounting bolts (Item 1)
[Figure 50-101-7], [Figure 50-101-8] & [Figure 50-101-
P-26326 9] from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to

Figure 50-101-8 15-20 ft.-lb. (20-27 Nm) torque.
Reverse the removal procedure to install the control

panel.
1
P-26327

CONTROL PANEL (ADJUSTABLE PINTLES) Shaft Removal And Installation
(CONTD)
NOTE: The steering shaft can be removed without
Shock Removal And Installation removing the control panel from the loader.
Photo [Figure 50-101-11] shows the control
Figure 50-101-10 panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-101-10].
1 Remove the steering shock mounting nuts (Item 2)

[Figure 50-101-10].
3
Figure 50-101-11
P-48275

from the end of the shock connected to the steering
3
linkage.
Remove the mounting nut (Item 2) [Figure 50-101-10] 1 2

from the other end of the shock connected to the bracket
P-48278
on the control panel.
Installation: Tighten the mounting bolts to 25-28 ft.-lb. Remove Control Handle Lever (Item 1) [Figure 50-101-
(34-38 Nm) torque. 11]. (See Control Lever Removal And Installation on
Page 50-110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

101-11] from both sides of the control panel.
Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38

Nm) torque.
Remove the steering shaft from the control panel.

(CONTD)
Shaft Disassembly And Assembly 1
Figure 50-101-12
2
2
1
1 P-26331
2
To remove the steering shaft mounting bracket (Item 3)
[Figure 50-101-11], remove the three mounting bolts
P-4154 (Item 1) [Figure 50-101-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks Remove the steering shaft mounting bracket.
(Item 1) from the cross shaft assembly [Figure 50-101-
12]. Installation: Tighten the mounting bolts to 15-20 ft.-lb.
(20-27 Nm) torque.
Assembly: Install new nylon bushings (Item 2) [Figure
50-101-12] 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.

(CONTD)
Linkage Removal And Installation
WARNING 2 2
arms are secured by an approved lift arm support device.
1 1
W-2059-0598
P-54609
WARNING Scribe a mark across the top of the steering linkage bars
Put jackstands under the front axles and rear corners steering shaft on the control panel.
Failure to use jackstands can allow the machine to Remove the four steering linkage mounting bolts (Item 2)
fall or move and cause injury or death. [Figure 50-101-14].
W-2017-0286
Raise the lift arms and install an approved lift arm 40 ft.-lb. (47,5-54,2 Nm) torque.
on Page 10-20-1.) NOTE: After removal and installation of the linkage,
the linkage neutral adjustment procedure
Lift and block the loader. (See Procedure on Page 10-10- must be performed. See Page 50-101-13 for
1.) Linkage Neutral Adjustment procedure.

(CONTD)
Linkage Removal And Installation (Contd) 7

6 8
Figure 50-101-15 3 1 4
2
5
2
P-48630
The centering plate/centering spring assembly consists

of the following parts:
2
P-48631
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering 1 Bolt
spring shoulder bolt (Item 2) [Figure 50-101-15].
2 Bushings
Remove the bolt/spring assembly. 3 Washer
4 Bushing Spacer
Installation: Tighten the centering spring bolt and a
NEW lock nut to 25-28 ft.-lb. (34-38 Nm) torque. 5 Spring
6 Lock Nut
Figure 50-101-16
7 Centering Plate
8 Guide Bushings
1
P-48632
Slide the centering plate (Item 1) [Figure 50-101-16] 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.

(CONTD)
SPRING RETURN STYLE
Figure 50-101-18 2
1
6 3
3
2
5
1
2 4
1
1 P-48627
2
If the surface of any of the four solid pintle cams (Item 1)
are worn, loosen the bolt (Item 2) and rotate the cams 1/4
P-48629 turn [Figure 50-101-19].
Remove the bolts and washers (Item 3) [Figure 50-101-

Check the wear on the centering blocks (Item 1) [Figure 19] from the pintle.
50-101-18].
Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2
If the centering blocks need replacement, remove the Nm) torque.
bolts (Item 2) [Figure 50-101-18]. Remove the centering
blocks. Loosen the creep adjustment bolt (Item 4) [Figure 50-
101-19].
Installation: Tighten the centering block bolts to 35-40
ft.-lb. (47,5-54,2 Nm) torque. Remove the pintle arm (Item 5) from the pintle base.
(Item 6) [Figure 50-101-19].
NOTE: The washers go between the bolts and the
centering plate. Figure 50-101-20
NOTE: If the centering blocks are worn, they can be

removed and rotated 180 degrees and SPRING RETURN STYLE
reinstalled. If the solid cams are worn, they
can be loosened and rotated 90 degrees and
reinstalled. 1
3 4
P-48625
NOTE: When installing the pintle arm (Item 1) onto

the pintle base (Item 2) align the rear of pintle
arm (engine side) (Item 3) into the spring (Item
4) [Figure 50-101-20]. (Spring Return Style
Only)

(CONTD)
SPRING RETURN STYLE
1
Figure 50-101-21
THREAD RETURN STYLE 3
2
2
P-48621
3
Remove and inspect the spring (Item 1) [Figure 50-101-
23]. Spring return style only.
P-54617
Figure 50-101-24
Remove the bolts and washers (Item 1) [Figure 50-101-

21] from the pintle. THREAD RETURN STYLE
Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2

Nm) torque. 3
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-101-21].
Figure 50-101-22
1 2
P-54615
2
Loosen the bolt (Item 2) and remove the pintle base (Item
3) [Figure 50-101-23] and [Figure 50-101-24].
4
3
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-101-22].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering control link (Item 4) for damage and replace as
needed [Figure 50-101-22].
NOTE: The washers (Item 2) [Figure 50-101-22] are

hardened, and should only be replaced
through Bobcat Parts.

CONTROL PANEL (ADJUSTABLE PINTLES) Pintle Arm Disassembly and Assembly
(CONTD)
Figure 50-101-26
2
Figure 50-101-25
2
1
3
P-54625
1
P-48659 Remove the bolt (Item 1) from the pintle solid cams (Item
2)_[Figure 50-101-26] and inspect the pintle solid cams
for damage or excessive wear.
NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2
will not line up with the bolt (Item 3) [Figure Nm) torque.
50-101-25].
Figure 50-101-27
Installation: Install the pintle base (Item 1) onto the
pump shaft (Item 2) [Figure 50-101-25]. The top of the
2
pintle base should be level with the top of the pump shaft.
3
Tighten the bolt to 35-40 ft.-lb. (47,5-54,2 Nm) torque.
NOTE: After installing the linkage onto the

hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
See Page 50-101-13 for Linkage Neutral 2
Adjustment procedure.
3
1
P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-101-

27] 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 50-101-27].
Inspect the torsion bushing (Item 3) [Figure 50-101-27]

for damage and replace as needed.
Installation: Tighten the nuts to 35-40 ft.-lb. (47,5-54,2

Nm) torque.

(CONTD)
Pintle Arm Disassembly and Assembly (Contd)
Figure 50-101-28
1 3
4 2
2
P-48619
3
Using a bushing driver (Item 1) remove the torsion

bushing (Item 2) by pressing the bushing through the
P-54626 pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-101-29].
Remove the base pintle (Item 1) [Figure 50-101-28] from Installation: Install the torsion bushing (Item 2) [Figure
the pump shaft. 50-101-29] into the pintle arm using the same procedure
as the removal.
Remove the retaining bolt (Item 2), adjusting screw (Item
3) and neoprene dampener (Item 4) [Figure 50-101-28] NOTE: When the torsion bushing is installed, the
from the base pintle. amount of bushing on each side of the pintle
arm should be the same.
Inspect parts for wear and damage, replace as needed
[Figure 50-101-28].
NOTE: Anti-sieze should be used on the adjusting

screw to prevent corrosion and allow free
movement while adjusting.

(CONTD)
Linkage Neutral Adjustment

1
The following tool listed will be needed to do the following
procedure:
MEL1563 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See


1.)
P-48448
Figure 50-101-30
3 Loosen the bolt/nut (Item 1) [Figure 50-101-31] only until

the tension is released from the torsion bushing.
Figure 50-101-32
2
1
P-48450
2
Tool that may assist in the neutral adjustment [Figure

50-101-30].
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 50-101-30] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-101-32].
A steering centering block (Item 3) [Figure 50-101-30] 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 50-101-32] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

(CONTD)
Figure 50-101-33
2
P16121
Using the remote start tool, turn the key (Item 1) [Figure
2 50-101-35] to the run position.
P-54614
Move the traction lock override switch (Item 2) [Figure
50-101-35] so the traction function is unlocked. (The
Loosen the two bolts (Item 1) holding the right centering traction lock override switch light will be ON.) On a
block. Move the right hand centering block (Item 2) standard loader the wedge brake will unlock.
[Figure 50-101-33] until both pintle cams contact the
centering block. NOTE: When the engine is started, the wheels/tracks
may begin to move.
NOTE: The left centering block is not adjustable. By
adjusting the right centering block the left NOTE: In loaders equipped with manual steering and
centering block will also become aligned hydraulic brake, the steering levers may have
properly. to be moved during engine start-up to reduce
the amount of creep. This reduction in creep
Figure 50-101-34 will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key (Item 1) [Figure
50-101-35] and start the engine and run at low idle.
1 Tighten bolts (Item 3) [Figure 50-101-34] to 35-40 ft.-lb.

(47,5-54,2 Nm).
2 NOTE: Check for slack between centering blocks and

pintle cams. If there is excessive slack repeat
above steps [Figure 50-101-33] & [Figure 50-
101-34].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-101-30] 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 50-101-
34] around both centering blocks.
Lock the C-Clamp in place.

(CONTD)
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 50-101-36
1 1
2
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

adjustment on the left side of the loader. The
P-48632 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
counterclockwise until forward creep is seen.
(Item 2) [Figure 50-101-36].) Loosen the bolts enough to
allow free movement between the pintle arm and the
pintle base.
counterclockwise to a point between forward and reverse
where there is zero creep.
NOTE: If the bolts are too loose or too tight, the
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.

CONTROL PANEL (ADJUSTABLE PINTLES)
(CONTD)
Figure 50-101-38
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-101-38] to 35-40 ft.-lb. (47,5-54,2 Nm).
Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-101-38] to 35-40 ft.-lb. (47,5-54,2 Nm).
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-

101-38] 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 Nm). 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 50-101-17.)

(CONTD)
Linkage Travel Adjustment

2
NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
adjustment procedure, check the torsion 1
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.
2
1
WARNING
P-48448
arms are secured by an approved lift arm support device.
W-2059-0598
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm Figure 50-101-40
on Page 10-20-1.)
1
WARNING
2
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10- P-54613
1.)
Raise the operator cab. (See Raising The Operator Cab Loosen the nut (Item 1) only until the tension is released
on Page 10-30-1.) from the torsion bushing (Item 2) [Figure 50-101-40].
Pre-load tension in the torsion bushings must be The bolt must be loose enough to allow the torsion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-101-40] to turn freely
between the torsion bushing and the linkage bar.

(CONTD)
Linkage Travel Adjustment (Contd) 2
Figure 50-101-41
1 3 4
P-51174
Move the right side steering lever forward and install a

15/16 inch (24 mm) thick spacer (Item 1) between the
P-37574 center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-101-43].
Remove access plug from the top of the control panel. This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-101-41] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 inch (10 mm) thick spacer (Item 4)
[Figure 50-101-43].
Figure 50-101-42
Figure 50-101-44
3 2
2
4
1
P-51173 1
P-51133
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the base pintle
arm cam (Item 2) and the centering block (Item 3) arm mounting bolt (Item 1) and both of the upper pintle
[Figure 50-101-42]. mount bolts (Item 2) [Figure 50-101-44] and tighten to
35-40 ft.-lb. (48-54 Nm) 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 50-101-42] are tight, 35-40 ft.-lb. (48-54 Nm)
torque .

(CONT'D)
Linkage Travel Adjustment (Cont'd)
Figure 50-101-45
1
1 1
P-51175
Remove the spacer (Item 1) [Figure 50-101-47].
P-54609
Disconnect the remote start tool. (See Procedure on
Page 10-60-1.)
Loosen the two bolts and nuts (Item 1) [Figure 50-101-
45] on each steering linkage bar. Figure 50-101-48
Figure 50-101-46 2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35-40
ft.-lb. (47,5-54,2 Nm) [Figure 50-101-48].
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 50-101-46]. 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 Nm) 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.

(CONT'D)
Linkage Travel Adjustment (Cont'd)

1
Figure 50-101-49
1 P-37574
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-101-50] in until it
P-48448 touches the U-bolt holding the control lever.
Repeat steps on the other control lever.

Tighten the two bolts and nuts (Items 1 & 2) [Figure 50-
101-49] to 35-40 ft.-lb. (47,5-54,2 Nm) torque at the Drive the loader forward and check for drift.
steering bell cranks.
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 50-101-50] 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.

CONTROL PANEL (SJC) Figure 50-102-1
WARNING
fall or move and cause injury or death. 1
W-2017-0286
P-64311
Remove the lift arm by-pass control knob and rubber

Figure 50-102-2
2
1
WARNING 1

support device can allow the lift arms or attachment 4
W-2059-0598 3
3
Raise the lift arms and install an approved lift arm P-64319
on Page 10-20-1.)
Remove the fuse cover mount screws (Item 1) [Figure
Raise the operator cab. (See Raising The Operator Cab 50-102-2].
on Page 10-30-1.)
Installation: Tighten screws to 8-11 ft.-lb. (11-15 Nm)
Remove the engine speed control. (See Removal And torque.
Remove the fuse/relay cover (Item 2) [Figure 50-102-2].
Remove the fuse/relay shield mounting screws (Item 3)

[Figure 50-102-2].
Installation: Tighten screws to 15-20 ft.-lb. (20-27 Nm)

torque.
Remove the fuse/relay shield (Item 4) [Figure 50-102-2]

CONTROL PANEL (SJC) (CONTD) Figure 50-102-5
Figure 50-102-3
1
1 1
P-64298
1
Disconnect the left joystick wire harness connector (Item
P-64309 1) [Figure 50-102-5].

Remove the control panel mount screws (Item 1) [Figure
50-102-3] from the both sides of the control panel.
Installation: Tighten the control panel mounting screws

Figure 50-102-4
P-64328
Disconnect the right joystick wire harness connector

(Item 1) [Figure 50-102-4].

CONTROL HANDLE Control Lever Boot
Control Lever Removal And Installation Figure 50-110-3
Figure 50-110-1
N-18884
1
P-48462
To replace the rubber boot (Item 1) [Figure 50-110-3] on
the control panel, remove the control lever (See above
Disconnect the electrical connectors from the control procedure).
lever [Figure 50-110-1].
Drill out the four rivets (Item 2) [Figure 50-110-3] located
Figure 50-110-2 on the flange of the rubber boot and remove the old boot.
Install the new boot and reinstall the control lever.
1 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.
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
operator cab when lowering or raising the cab.

CONTROL HANDLE (ADVANCED CONTROL Figure 50-111-2
SYSTEM) (ACS)
Components Identification
Figure 50-111-1
P-21879
Handle Sensor (Item 1) [Figure 50-111-2].

sensor, actuator or ACS Controller. (See
11.)
P16572
Control Handle (Item 1) [Figure 50-111-1].

SYSTEM) (ACS) (CONT'D)
Handle Sensor Removal And Installation

1
Figure 50-111-3
1 P-21836
Disconnect the harness connector (Item 1) [Figure 50-

111-5] from the handle sensor connector.
P-21864
111-5] from the handle lock solenoid connector.
Loosen the nuts (Item 1) [Figure 50-111-3].
Figure 50-111-6
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. 1
Figure 50-111-4
P-21861
1
Remove the handle sensor connector (Item 1) [Figure
50-111-6] from the clip.
P-21837 NOTE: Pry out with a small screw driver and push the
connector down.
Tilt the control handle (Item 1) [Figure 50-111-4] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-4].

Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-7
P-21880
Remove one of the two mounting screws (Item 1) [Figure

1 50-111-9] from the handle sensor.
P-21860
Installation: Tighten bolt to 32-38 in.-lb. (3,6-4,3 Nm)
torque.
Remove the handle lock solenoid connector (Item1)
[Figure 50-111-7] from the clip. Figure 50-111-10
NOTE: Pry out with a small screw driver and push the
connector down.
4
Figure 50-111-8 3 8
1
1
5 4
2 3
4
5 6
2
P-21882
3
Remove the handle sensor (Item 1) [Figure 50-111-10]

1 from the handle assembly.
P-21862
NOTE: The handle sensor (Item 1) [Figure 50-111-10]
can only be replaced as a complete assembly.
Remove one of the two mounting screws (Item 1) [Figure
50-111-8] from the handle sensor. Check the spacer (Item 2) and screws (Item 3), mounting
pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
Installation: Tighten screws to 32-38 in.-lb. (3,6-4,3 (Item 7), stop strap (Item 8) and replace as needed
Nm) torque. [Figure 50-111-10].
While removing the mounting pin (Item 2) from the

handle sensor, remove the one plastic spacer (Item 3),
the spring (Item 4) and washer (Item 5) [Figure 50-111-
8].

CONTROL HANDLE (ADVANCED CONTROL Control Handle Removal and Installation
Figure 50-111-13
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-11
3
2
1 P-21879
P-21878 Remove the handle sensor (Item 1) [Figure 50-111-13].

(See Handle Sensor Removal And Installation on Page
50-111-2.)
Figure 50-111-12
Figure 50-111-14
3
2
1
P-21799
P16534
Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle Remove the switch handle (Item 1) [Figure 50-111-14].
wire harness (Item 1) [Figure 50-111-11] & [Figure 50- (See Switch Handle Removal on Page 60-120-7.)
111-12] to assure proper return of the control handle to
neutral and minimize harness movement.
NOTE: Route wires (Item 2) [Figure 50-111-11] &

[Figure 50-111-12] as shown away from stop
strap (Item 3) [Figure 50-111-11] & [Figure 50-
111-12] to avoid wire damage.

11.)

CONTROL HANDLE (ADVANCED CONTROL Control Handle Disassembly and Assembly
Figure 50-111-17
Control Handle Removal And Installation (Cont'd)
Figure 50-111-15
2
1
N-17394
N-17384 Remove the handle sleeve (Item 1) and bushings (Item

2) from the handle [Figure 50-111-17].
Remove the rubber handle cover (Item 1) [Figure 50- Check all parts for wear and replace as needed.
111-15] from the handle.
Figure 50-111-18
Figure 50-111-16
2 2
N-22796
N-17385
Check the mounting bolt (Item 1) [Figure 50-111-18] that

Using a small screwdriver, hold the handle spacer (Item connects the handle to the handle sensor for wear,
1) and remove the allen head screws (Item 2) [Figure replace as needed.
50-111-16] from the handle assembly.
Installation: Tighten the allen head screws to 35 in.-lb.

(4 Nm) torque.

Control Lever Removal and Installation

1
Figure 50-111-19
1
1
1
1
N-22658
Figure 50-111-21
N-22667
Disconnect the electrical connectors (Item 1) [Figure 50-

111-19] from the control lever switch handle.
Remove the electrical connectors from the control lever 18.25

switch handle. (See ADVANCED CONTROL SYSTEM
(ACS) on Page 60-120-1.)
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-111-20]

nuts.
Installation: Tighten the u-bolts so the lever can not be

seat. Control lever end (Item 2) [Figure 50-111-20]
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 inches [Figure 50-111-21].
Remove the control lever from the cross shaft and control
panel.

CONTROL HANDLE (ADVANCED CONTROL Control Lever Boot
Figure 50-111-23
Control Lever Removal And Installation (Cont'd)
Figure 50-111-22
2
2
1
1
N-22659
P13734 To replace the rubber boot (Item 1) [Figure 50-111-23]

on the control panel, remove the control lever. (See
Control Lever Removal And Installation on Page 50-110-
The control lever (Item 1) [Figure 50-111-22] must be 1.)
replaced as a complete unit.
Drill out the four rivets (Item 2) [Figure 50-111-23]
The connector clip (Item 2) [Figure 50-111-22] can be located on the flange of the rubber boot and remove the
replaced separately from the control lever. old boot.
Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-110-
1.)

CONTROL HANDLE (SJC) Figure 50-112-3
Joystick Testing (Right & Left)

1
Figure 50-112-1
P-28312
Disconnect the joystick harness connector (Item 1) from

P-28301 the loader wiring harness (Item 2) [Figure 50-112-3].
Install the test harness (Item 3) [Figure 50-112-3]

The tools listed will be needed to do the following between the two connectors.
procedure:
Turn the remote start key to ON position without starting
MEL1608-Joystick Test Harness [Figure 50-112-1] the loader.
MEL1563-Remote Start Tool
Multimeter Check the voltage between pin 3 and pin 5 on the joystick
test harness (Item 3) [Figure 50-112-3].
support device. (See Installing Lift Arm Support Device The voltage should be between 2.45 and 2.55 volts.
on Page 10-20-1.)
Figure 50-112-4
on Page 10-30-1.)
Connect the remote start tool to the loader. (See

Figure 50-112-2
P-64328
1
Repeat the procedure at the right joystick wiring harness

connector (Item 1) [Figure 50-112-4]. (If needed.)
P-64298
At the back side of the control panel, locate the left

joystick wire connector (Item 1) [Figure 50-112-2].

CONTROL HANDLE (SJC) (CONT'D) Figure 50-112-7
Joystick Removal (Right & Left)
When replacing joystick assemblys, they are available as

a complete assembly with the boot and lever already
1
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.

on Page 10-20-1.)

on Page 10-30-1.) P-26222
Figure 50-112-5
Remove the two outside joystick mount screws (Item 1)
[Figure 50-112-7].
Figure 50-112-8
P-26220A
Roll the joystick rubber boot (Item 1) [Figure 50-112-5]

down from the joystick handle. P-26223A
Figure 50-112-6
Remove the joystick from the rubber boot [Figure 50-
112-8].
1
P-26221
Remove the two inside joystick mount bolts (Item 1)

[Figure 50-112-6].

CONTROL HANDLE (SJC) (CONT'D) Lever Assembly Removal (Right & Left)
Joystick Removal (Right & Left) (Cont'd) Raise the lift arms and install an approved lift arm
Figure 50-112-9 on Page 10-20-1.)

1 on Page 10-30-1.)
Figure 50-112-10
P-26224
Disconnect the electrical harness (Item 1) [Figure 50-

112-9] from the joystick.
P-64328
Remove the joystick from the loader.
Disconnect the joystick wiring harness connectors (Item

1) on both the right and left hand joysticks [Figure 50-
112-10].

CONTROL HANDLE (SJC) (CONT'D)
Lever Assembly Removal (Right & Left) (Cont'd)
Figure 50-112-11
P-64303
Remove the two control lever mounting bolts (Item 1)

[Figure 50-112-11].
The mounting bolts are secured with lock-nuts on the

back of the control panel. Once removed, they need to be
replaced with new.
Figure 50-112-12
P-64308
Remove the control lever from the loader [Figure 50-

112-12].

ELECTRICAL SYSTEM
ADVANCED CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . 60-120-1

Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-120-12
ACS Controller Removal And Installation . . . . . . . . . . . . 60-120-5 SAFETY &
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-16 MAINTENANCE
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Controller, Connector And Wire Identification . . . . . . . . . 60-120-4
Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-120-20
Foot Lock Solenoid Removal And Installation . . . . . . . . 60-120-19
Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-18
Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-120-18
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6 DRIVE
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-120-15 SYSTEM
Handle Lock Solenoid Disassembly And Assembly. . . . 60-120-14
Handle Lock Solenoid Removal And Installation . . . . . . 60-120-14
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-7
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-120-9
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 ELECTRICAL

Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 SYSTEM
Alternator Regulator Test. . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-9 ENGINE
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2 SERVICE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-30-5 SPECIFICATIONS
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3

ELECTRICAL SYSTEM (CONTD)
BICS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Additional Inspection For Loaders With Advanced Hand Controls (ACS) 60-90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED
- Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS Controller (Engine STOPPED - Key ON) . . . . . . 60-90-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . 60-90-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . 60-90-1
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Calibration Procedure (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5
Lift and Tilt Calibration Procedure (SJC) . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . 60-71-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-4
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-2
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . . . . 60-130-1

Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK

CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1
Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

ELECTRICAL SYSTEM (CONTD)
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . . 60-50-10
Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Front Accessory Panel Removal And Installation . . . . . . . . . . . . . 60-50-12
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option And Field Accessory Panels (If Equipped) . . . . . . . . . . . . . . 60-50-8
Passwords (Deluxe). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Right Panel (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . . 60-50-2
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . . . 60-50-5
Standard & Deluxe Panel Removal And Installation (Left Side) . . 60-50-11
Standard Panel Removal And Installation (Right Side) . . . . . . . . . . 60-50-9
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

BICS Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting The Service PC To Remote Start Tool . . . . . . . . . . . . 60-150-1
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description Of The Control System . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-7
Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-5
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
Inspecting The Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER C
BUZZER
C422
START
START
OPEN
DATA
4380 1 1
DATA
7.7 ohm
PWM
WIRING SCHEMATIC 2
REAR BASE 2380 2
C414
HIGH FLOW BICS HYDRAULIC LOCK
1 1 4440
G
C
D
E
B
A
K
E
F
F
J
J
7.5 ohm
C415
12V
C420
7.5 ohm A A 4460 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 BLUE TIE STRAP 2410 B B 12V
(Without Options)
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B
S175 (S/N 525211001 - 525218874) ACROSS CONNECTORS
2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B YELLOW TIE YELLOW TIE
(S/N 525311001 - 525316211) B A
YELLOW TIE
STRAP
STRAP STRAP
LOCK VALVE
2340 2 2 PWM
C416A
C416
2450 2 2 2450 2450 2
S185 (S/N 525011001 - 525022472) 4450 1 1 4450 4451 4455 1
2
1
3600 A A SPEED
SOME CONNECTOR SENSOR MAIN
3610 B B
(S/N 525111001 - 525115404)
WORKLIGHTS
BODIES NOT SHOWN FRAME
GREEN TIE GREEN TIE GREEN TIE
FRONT
FOR DRAWING CLARITY STRAP LOCK VALVE HYDRAULIC
Here (PRINTED JULY 2005) STRAP STRAP
C108
C417A
Printable Version Click 3300 A A TEMPERATURE
C417
4480 1 1 4480 4481 4485 1 1
SWITCH
SENDER
BRAKE
3310 B B
V-0440
1930
RED = RED 2 2 2 500-3000 ohm
2000
2480 2480 2480 2
RNG = ORANGE
BLK = BLACK REAR AUXILIARY
C435
RIGHT
LBL = LIGHT BLUE 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
ARE CONNECTED IN SERIES FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE
LGN = LIGHT GREEN
HARNESS 7101973 A SEE C113 6120 A A
SWITCHED POWER 1000-1999 RNG FRONT AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C424
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4490 AIR FILTER BAR 6110 A A
LEFT
11 ohm
4330
4360
4340
PNK = PINK
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2490 B B
2110
3700
3200
2750 B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE B
4470
4460
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER -
2450 3100 A A +8 2910
ENGINE 8000-8999 TAN PUR = PURPLE 30-270 ohm
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT PWM +8V ENG SPEED 28
LOCK ANALOG 1 ROD TEMP SIGNAL SUPPLY SIGNAL
GROUND Tx RIGHT SERIAL IN
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15 11 9110 D
C105
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND REAR SPARE SYSTEM LH AUX SPARE AIR FILTER RH FRONT
3010 23
SERIAL IN BASE ANALOG 2 POWER Rx LEFT DIGITAL 1 SIGNAL
PWM -
DETENT
9400 F See C492
B B 3410 23
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 42 9410 G
B 9110 4440 1200 9200 4820 3700 4310 4920
2410 FRONT REAR STATUS SEAT BAR LH SKI FUEL PWM RH SKI
3910
SEE J2 COMPUTER
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL DOWN
BASE ROD IN +8v DOWN SENDER
2380 2390
POWER
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
2800 SWITCH B B 14 1200

41 42 43 44 45 46 47 48 49 50
3610 4410 9410 4640 9340 3920 4500 3300
24 1900
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN OPEN SPARE
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER RELAY PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2
2 3 4 5 66 7 8 9 10
5 9100
3430 4910 4390 6410 8510 4110

15 9200
2110
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B
30 4930
2720 0.5-7.5 V B B 3510 TRAVEL F&R AUX RESERVED
SPARE
DIGITAL 2
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF
UNSWITCHED
(SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V HYD CHARGE ENG OIL RESERVED
SPARE
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
B B 3210 26
500-3000 ohm 41 42 43 44 45 46 47 48 49 50
180 A 1800 16 4820
SUPPLY 0
A 1400 8000 9800 3420 7200 3520
1020
J1 6 4810
C110
G A A J2
E3
D3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
ALTERNATOR 2010 6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
C
C101
2800
1490
2520
4240
1010 A A 8800 A A 8800
STARTER 0.3 ohm B B 8100 B B 8100
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
8250 B B 8250
Traction Lock C410 C409
B S
8200 A A
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
RGN
YEL
DBL
LGN
RGN
GLOW PLUGS 4100 B B PULL 0.3 ohm
1.0 ohm each
F
+ -
B 2600
HR HR HR HR
PWM
FLOAT
6200
SHIFT
H
SKI CTRL
SIDE
8590
8580
8570
8560
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1700 1055 4220 M M
7200 J J
C489
TO OPTIONS B 2720 SWITCHED MARKER REAR GLOW FUEL

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L
CONNECTOR) A 1720 1720
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 7101181 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 5
FUSE 3 FUSE 6 G 9410 S S 9420
25A 15A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12
1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A
F
A
D 9110 F
1080
1040
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
30A 15A 25A 1050

G
D
C
- F
E
A
B
+ 1300
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR V-0440 (7-12-05)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
PROTECTED POWER E
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx
12V
GROUND
2 2 2430 2370 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER C
BUZZER
C422
START
START
OPEN
DATA
4380 1
DATA
WIRING SCHEMATIC 2
REAR BASE 2380
C414
1 1 4440
G
C
D
K
A
B
B
A
K
E
F
F
J
J
7.5 ohm
12V
C420
C415
(With ACS Option)
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
PWM
B B
S175 (S/N 525211001 - 525218874) ACROSS CONNECTORS
2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
YELLOW TIE YELLOW TIE
A B YELLOW TIE
(S/N 525311001 - 525316211) B A
STRAP
STRAP STRAP
LOCK VALVE 2340 2 2 PWM
C416A
C416
2450 2 2 2450 2450 2 2
S185 (S/N 525011001 - 525022472) 4450 1 1 4450 4451 4455 1 1
3600 A A SPEED
SOME CONNECTOR SENSOR MAIN
3610 B B
(S/N 525111001 - 525115404)
WORKLIGHTS
BODIES NOT SHOWN FRAME
GREEN TIE GREEN TIE GREEN TIE
FRONT
FOR DRAWING CLARITY STRAP STRAP STRAP LOCK VALVE HYDRAULIC
(PRINTED JULY 2005)
C417A
C108
3300 A A TEMPERATURE
C417
Printable Version Click Here 4480 1 1 4480 4481 4485 1 1
SWITCH
SENDER
BRAKE
3310 B B
V-0441
1930
RED = RED 2480 2 2 2480 2480 2 2 500-3000 ohm
2000
RNG = ORANGE
BLK = BLACK REAR AUXILIARY
C435
RIGHT
LBL = LIGHT BLUE 2760 B B
ARE CONNECTED IN SERIES FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE
LGN = LIGHT GREEN
HARNESS 7101973 A SEE C113 6120 A A
SWITCHED POWER 1000-1999 RNG FRONT AUX RELIEF
C405 C406
C424
CAB
2530 YEL = YELLOW 4490 A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 11 ohm AIR FILTER BAR 6110 A A
LEFT
4330
4360
4340
PNK = PINK
4410
4440
4430
12V
4420
2470 HYDRAULIC 4000-4999 LGN B B B B SWITCH
2770
2490 SEE J1 B 3710
3300
2110
3700
3200
2750 B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE B
4470
4450
4460
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER -
2450 3100 A A +8 2910
ENGINE 8000-8999 TAN PUR = PURPLE 30-270 ohm
J1 J2 2920 2900
C
2930
A
2430 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
COOLANT PWM +8V ENG SPEED 28
LOCK ANALOG 1 ROD TEMP SIGNAL SUPPLY SIGNAL
GROUND Tx RIGHT SERIAL IN
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A 15
C105
HYDRAULIC CHARGE A 3400 3400 11 9110 D
C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
See C492
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 42 9410 G
B 9110 4440 1200 9200 4820 3700 4310 4920
2410 FRONT REAR STATUS SEAT BAR LH SKI FUEL PWM RH SKI
3910
SEE J2 COMPUTER
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL DOWN
BASE ROD IN +8v DOWN SENDER
2380 2390
POWER
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
2200 BUCKET
OPEN POSITION OPEN
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
2800 SWITCH B B 14 1200

41 42 43 44 45 46 47 48 49 50
3610 4410 9410 4640 9340 3920 4500 3300
24 1900
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN OPEN SPARE
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER RELAY PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2
2 3 4 5 66 7 8 9 10
5 9100
3430 4910 4390 6410 8510 4110

15 9200
2110
44 9340
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B
30 4930
2720 0.5-7.5 V B B 3510 TRAVEL F&R AUX RESERVED
SPARE
DIGITAL 2
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF
UNSWITCHED
(SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V HYD CHARGE ENG OIL RESERVED
SPARE
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
B B 3210 26
500-3000 ohm 41 42 43 44 45 46 47 48 49 50
180 A 1800 16 4820
SUPPLY 0
A 1400 8000 9800 3420 7200 3520
1020
J1 6 4810
C110
G A A J2
E3
D3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION J1
SHUTOFF
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010 A A 8800 A A 8800
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
8250 B B 8250
Traction Lock C410 C409
B S
8200 A A
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C C
WHT
2200
WHT
PUR
DGN
RGN
YEL
DBL
LGN
RGN
TO OPTIONS C465 C466
GLOW PLUGS 4100 B B PULL 0.3 ohm
A
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8580
8570
8560
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
AHC LIFT RIGHT
E 6400 HALL SENSOR TURN SIGNAL
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
7100 A TO OPTIONS C450
DGN
C
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
C
A
B
SWITCH) C407 C449
C
B
E
C
A
D
B
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
C
B
A
L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
F 4730 CONNECTOR) CONNECTOR)
1510
4650
2650
D 4235
C488
TO OPTIONS N 6300 13 ohm

(ACCESSORY 12V
C 4275
CONNECTOR) FOOT PEDAL LOCK TILT ACTUATOR LIFT ACTUATOR
E 4550
S 1700 M M
A 1140 1740
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
6
(ALTERNATOR
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L 4275
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2260
2270
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 B 1740 2280
1740 B H
MAINFRAME HARNESS 7101181 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4670
4750
4650
4770
FRONT &
MARKER
1160
1730
9800
9510
9610
9710
2710
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
D
C
- F
E
A
B
+ 1300 B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0441 (7-12-05)
BATTERY
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
WIRING SCHEMATIC
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
WIRES CONNECT BY LETTER 12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
(Without Options)
PWM
BUZZER
BUZZER
ACROSS CONNECTORS
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
A B PWM
REAR BASE 2380 2 2
B A
C414
1 1 4440
S175 (S/N 525218875 AND ABOVE)
G
C
D
E
B
A
K
E
F
J
7.5 ohm
C415
12V
C420
SOME CONNECTOR
(S/N 525316212 AND ABOVE) BODIES NOT SHOWN
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
FOR DRAWING CLARITY BUCKET POSITIONING FRONT ROD
S185 (S/N 525022473 AND ABOVE)
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
12V
PWM
(S/N 525115405 AND ABOVE) B B 2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1
Printable Version Click Here 3.3 ohm
CAB 6727178
UNSWITCHED POWER 1000-1999 RED RED = RED
(PRINTED JULY 2005) FUSED, UNSWITCHED POWER 1000-1999 RED/WHT RNG = ORANGE 2340 2 2 PWM
SWITCHED POWER 1000-1999 RNG BLK = BLACK

RELAY GROUNDS 2000-2060 V-0717 GROUND 2000-2999 BLK LBL = LIGHT BLUE DIVERTER
3600 A A
C416
MONITORING 3000-3999 LBL DBL = DARK BLUE SPEED
ARE CONNECTED IN SERIES 4450 A A 7.5 ohm MAIN
HYDRAULIC 4000-4999 LGN LGN = LIGHT GREEN 3610 B B SENSOR
WORKLIGHTS
ATTACHMENT CONTROLS 5000-5999 YEL YELLOW TIE STRAP 2450 B B 12V FRAME
2530 DGN = DARK GREEN
GROUNDS LIGHTS 6000-6999 PNK
FRONT
YEL = YELLOW
2470 ACCESSORIES 7000-7999 WHT PNK = PINK
ENGINE 8000-8999 TAN WHT = WHITE
SWITCH
BRAKE
2460 COMMUNICATION 9000-9999 PUR FRONT AUX RELIEF
2800 BRN = BROWN
1930
2000
C424
2450 TAN = TAN 4490 A A H SEE C110
3610 11 ohm
2440 2400 2300 PUR = PURPLE GREEN TIE 12V
C435
2490 B B J SEE C110
RIGHT
3510 GRY = GRAY STRAP 2760 B B
2430
2600 A SEE C113 6120 A A
2340 REAR AUX RELIEF
C405 C406
2110 SEAT
C417
CAB
2330 3700 A A
A A
C434
4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
2520
4360
4340
4410
4440
4430
4420
12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
3700
2740
3200
B B
3600
2750
4470
4460
4450
2100 3110 FUEL
2730 B B
2120 SENDER - +8
2720 3100 A A 30-270 ohm 2910
2420 J1 J2 2920 2900
C
2710 2930
A
2410 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2350 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2380 2390 3100 2760
SPOOL SPARE COOLANT ENG SPEED 28
2370
HARNESS 7112802 LOCK ANALOG 1
FRONT
ROD
COMPUTER
GROUND
SYSTEM
Tx
LH AUX
RIGHT
L HAND
SERIAL IN
TEMP SIGNAL
PWM +8V
SUPPLY SIGNAL
HYDRAULIC 1 2 3 4 5 6 7 8 9 10
C105 C108
2200 TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 4360 4330 2900 9100 4810 9210 3200 4300 3600
11 9110 D N K G L B R P S F E D C M A J H
2000 SENDER
B B 3310 2 2 3310 J 7 9210 E
500-3000 ohm
R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F See C492 C408
2240
N K G L B R P S F E D C M A J H
+
A 11 12 13 14 15 16 17 18 19 20
G
C110
A A 3400 3 3 3400 15 1200 9200 4820 3700 4310 4920 42 9410
HYDRAULIC CHARGE C 9110 4440
PRESSURE SENDER - C C 3420 5 5 3420 47 FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
0.5 - 7.5 V B BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
B B 3410 4 4 3410 3010 23
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
4430 9400 1900 3900
P05 4830 3100 4320 4930
B 4340
BUCKET 35 3910 SEE FUSE/RELAY
OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND
LH SKI
UP OPEN GROUND OPEN
RH SKI
UP
A CENTER
SWITCH
45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3440 34 9350
6 6 3430 3 HYD LOCK STATUS
HEADLIGHT BRAKE SW HYDRAULIC
SWITCH
SEATBAR
IN
OPEN TEMP OPEN OPEN
SWITCH B B SIGNAL
14 1200
41 42 43 44 45 46 47 48 49 50
4410 9410 4640 9340 3920 4500 3300 24 1900
RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) OPEN BLINKER RELAY PULL / 963
SWITCH MAKE-UP OUTPUT 1
5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
-
B 4930
0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
ALTERNATOR 2010 6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
C
4300
4320
4310
4910
4920
4930
4940
4230
2530
2800
C101
1490
2520
4240
1010 A A 8800 A A 8800
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
B 8250 B B 8250 C410 C409

S Brake Valve
8200 A A 6732781
G
H
C
D
G
E
D
C
H
F
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200 2200 B
WHT
PUR
DGN
B
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B OPEN
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M

7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 7112824 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040

FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
30A 15A 25A 1050

G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR V-0717 (7-12-05)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
2 2 2430 2370 2
GROUND G
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
WIRING SCHEMATIC 2
REAR BASE 2380
C414
1 1 4440
G
C
D
E
A
K
E
F
7.5 ohm
12V
C415
C420
(With ACS Option)
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
PWM
B B 2 2
S175 (S/N 525218875 AND ABOVE) ACROSS CONNECTORS
2420 2330 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
(S/N 525316212 AND ABOVE) B A
2340 2 2 PWM
S185 (S/N 525022473 AND ABOVE) DIVERTER

3600 A A
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY
Printable Version Click Here (PRINTED JULY 2005)
SWITCH
BRAKE
FRONT AUX RELIEF
V-0718
1930
RED = RED
2000
C424
RNG = ORANGE 4490 A A 11 ohm H SEE C110
BLK = BLACK GREEN TIE 12V
C435
2490 B B J SEE C110
RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN
SWITCHED POWER 1000-1999 RNG REAR AUX RELIEF
C405 C406
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4460
4450
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
J1 J2 2920 2900
C
2930
A
2430 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330
1 2 3 4 5 6 7 8 9 10
2520 HARNESS 7112802 4360 4330 2900 9100 4810 9210 3200 4300 3600
2100 HYDRAULIC 9210 E
7
C105 C108
TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F
See C492 C408
SENDER B
B 3310 2 2 3310 J 11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 500-3000 ohm 42 9410 G
+ 9110 4440 1200 9200 4820 3700 4310 4920
2410 A
C110
A A 3400 3 3 3400 15 FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE C BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
2380 2390 PRESSURE SENDER C 5 5 47
POWER +8v
J2
-
B C 3420 3420 21 22 23 24 25 26 27 28 29 30
2370 0.5 - 7.5 V
9400 1900 3900
P05 4830 3100 4320 4930
B B 3410 4 4 3410 3010 23 4340 4430
2200 BUCKET
B OPEN POSITION OPEN
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
HYD LOCK STATUS

34 9350
SOLENOID OUT FLOAT OPEN TEMP
SWITCH SIGNAL IN OPEN OPEN
14
C112
2800 HYDRAULIC OIL A A 3440 1200
6 6 3430 3 41 42 43 44 45 46 47 48 49 50
FILTER (DIFFERENTIAL)
3610 B B 4410 9410 4640 9340 3920 4500 3300 24 1900
SWITCH
2300
3510 RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) OPEN BLINKER RELAY PULL / 963
SWITCH MAKE-UP OUTPUT 1
2600 5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
2110
44 9340
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C
40 4940
2730 SENDER C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
C113
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION J1
SHUTOFF
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010 A A 8800 A A 8800
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
B 8250 B B 8250 C410 C409

S Brake Valve
8200 A A
G
H
C
D
G
E
D
C
H
6732781
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C
WHT
2200 C
WHT
PUR
DGN
YEL
2200
RGN
B
DBL
LGN
RGN
B C465 C466
TO OPTIONS GLOW PLUGS 4100 B B OPEN
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
C 7100 A TO OPTIONS C450
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
C
B
A
L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
F 4730 CONNECTOR) CONNECTOR)
1510
4650
2650
D 4235
C488
TO OPTIONS N 6300 13 ohm

(ACCESSORY 12V
C 4275
CONNECTOR) FOOT PEDAL LOCK TILT ACTUATOR LIFT ACTUATOR
E 4550
S 1700 M M
A 1140 1740
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
(ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L 4275
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
MAINFRAME HARNESS 7112824 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0718 (7-12-05)
BATTERY
WIRING SCHEMATIC
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
HIGH FLOW REAR ROD (NOT Used For This Model)
CLOCK/LATCH
CLOCK/LATCH A
C413
C421
HEADLIGHTS
1 1 1
C415
A 4430 4370
(With SJC Option)

A 4460 7.5 ohm
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
7.5 ohm LIFT SPOOL LOCK
SYSTEM Tx
12V
GROUND
12V 2 2 2430 2370 2
GROUND
B B 2460 BLUE TIE STRAP BROWN TIE STRAP (Not Use For This Model )
BUZZER
BUZZER
C422
START
START
OPEN
1
DATA
4380
DATA B
2
S175 (S/N 525218875 AND ABOVE) REAR BASE 2380
C414
1 1 4440 BICS HYDRAULIC LOCK
G
C
D
E
K
A
B
E
F
F
J
J
7.5 ohm
(S/N 525316212 AND ABOVE) 12V
C420
WIRES CONNECT BY LETTER 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
ACROSS CONNECTORS 2410 B B 12V
S185 (S/N 525022473 AND ABOVE)
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
A B BUCKET POSITIONING FRONT ROD
C423
C418
(S/N 525115405 AND ABOVE) B A 9.8 ohm
12V
A
B
A
B
4420 4330 1 1 3.3 ohm
PWM
2420 2330 2 2 FRONT BASE
Printable Version Click Here (PRINTED JULY 2005)
C419 C106
SOME CONNECTOR 4340 1 1 3.3 ohm
CAB 6727178
BODIES NOT SHOWN 2340 2 2 PWM
RELAY GROUNDS 2000-2060 V-0719 FOR DRAWING CLARITY

ARE CONNECTED IN SERIES DIVERTER
3600 A A
C416
RED = RED SPEED
UNSWITCHED POWER 1000-1999 RED
4450 A A 7.5 ohm SENSOR MAIN
RNG = ORANGE 3610 B B
WORKLIGHTS
2530 GROUNDS 12V FRAME
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT BLK = BLACK YELLOW TIE STRAP 2450 B B
FRONT
2470 SWITCHED POWER 1000-1999 RNG LBL = LIGHT BLUE
GROUND 2000-2999 BLK DBL = DARK BLUE
2460 MONITORING 3000-3999 LBL LGN = LIGHT GREEN
SWITCH
BRAKE
2450 HYDRAULIC 4000-4999 LGN FRONT AUX RELIEF
DGN = DARK GREEN
1930
2000
C424
ATTACHMENT CONTROLS 5000-5999 YEL
2440 2400 2800 LIGHTS 6000-6999 PNK
YEL = YELLOW 4490 A A 11 ohm H SEE C110
PNK = PINK GREEN TIE 12V
C435
3610 ACCESSORIES 7000-7999 WHT 2490 B B 3310 J SEE C110
RIGHT
2430 WHT = WHITE STRAP 2760 B B
2300 ENGINE 8000-8999 TAN
2340 3510 COMMUNICATION 9000-9999 PUR BRN = BROWN A SEE C113 6120 A A
TAN = TAN
2330 2600 REAR AUX RELIEF
PUR = PURPLE
C405 C406
SEAT
C417
CAB
2520 GRY = GRAY A A 3700 A A
C434
4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
2110
4330
4360
4340
4410
4440
4430
4420
12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
2100
3700
3200
B B
3600
2750
4470
4460
4450
2740 3110 B B FUEL
SENDER - +8
2420 2730 3100 A A 30-270 ohm 2910
2120 J1 J2 2920 2900
C
2720 2930
A
2410
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2380 2390 2710 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
3100 2760
2370 2350 SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2200 1 2 3 4 5 6 7 8 9 10
2000 HARNESS 7112800 4360 4330 2900 9100 4810 9210 3200 4300 3600
HYDRAULIC 7 9210 E
C408
C105 C108
R HAND SPARE PROTECTED SYSTEM SPARE

2240 TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 SERIAL IN
REAR
ANALOG 2 POWER Rx
LH AUX
LEFT DIGITAL 1
AIR FILTER
PWM -
RH FRONT
DETENT See C492
BASE SIGNAL
23 9400 F
SENDER
B B 3310 2 2 3310 J 11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
500-3000 ohm 1200 9200 3700 4920 42 9410 G
9110 4440 4820 4310
+
A PWM RH SKI
C110
FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE A A 3400 3 3 3400 15 BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
C POWER +8v
J2
PRESSURE SENDER C C 3420 5 5 3420 47 21 22 23 24 25 26 27 28 29 30
0.5 - 7.5 V
-
B
4430 9400 1900 3900
P05 4830 3100 4320 4930
23 4340
B B 3410 4 4 3410 3010
BUCKET
LH SKI RH SKI 35 3910
A
OPEN POSITION OPEN
KEY/ENTER
SWITCH
SEATBAR
GROUND UP OPEN GROUND OPEN UP
SEE FUSE/RELAY
B 45 3920 CENTER
31 32 33 34 35 36 37 38
38 39 40
C407
C112
HYDRAULIC OIL A A 3440 25 3900

4420 9350 3910 4840 2110 4940
FILTER (DIFFERENTIAL)
SWITCH B B HYD LOCK STATUS
34 9350
SOLENOID OUT FLOAT OPEN TEMP
SWITCH SIGNAL IN OPEN OPEN
14 1200
6 6 3430 3 41 42 43 44 45 46 47 48 49 50
4410 9410 4640 9340 3920 4500 3300 24 1900
C111
HYDRAULIC OIL B B 3440 GLOW PLUG TRACTION LOCK 46 4500

RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT
FILTER (DIFFERENTIAL) (AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) OPEN
MAKE-UP BLINKER RELAY PULL / 963
SWITCH A A 3430 OUTPUT 1

5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
44 9340
4 2900
11 12 13 14 15 16 17 18 19 20
40 4940 2530 H
ENGINE OIL A A 3500 3500 37 8250 1110 9500 3400 6510 4200 4460 6210 8800
C107
PRESSURE C 30 4930 4930 J

C C 3520 3520 49 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
SENDER -
B
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920 4920 E
0.5-7.5 V B B 3510 21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310 4310 C
29 4320 4320 D
C409
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300 4300 B
NOT USED FOR
THIS MODEL
31
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640 2530 K
ENGINE t 8150 1130 9700 8550 2100
C104
COOLANT A A B A 36 4840 4910 F

C113
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
B B 3210
OUTPUT 2
26 4830 4230 G
500-3000 ohm 41 42 43 44 45 46 47 48 49 50
180 16 4820 1490 A
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2 4640 D
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800 4840 C
FUEL
EXCITATION J1 4830 B
SHUTOFF
ALTERNATOR 2010 4910 4820 G
6736515
HOLD PULL
4730
4110
7200
6510
6410
4200
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
1400 K
C410
10.9 ohm 2800 C C 2800
C101
NOT USED FOR

1010 A A 8800 A A 8800 6732781 Brake Valve 1480 A THIS MODEL
STARTER 0.3 ohm B B 8100 B B 8100 4200 A A 4200 A A 4810 F
C425
2200 C C 2200 B B J
M R
C109
B 8250 B B 8250 4100 B B OPEN 4240 H

S
8200 A A 8200 2520 E
TO OPTIONS 6736808
GLOW PLUGS
BATTERY CABLE
(ACCESSORY 1.0 ohm each 2580 3 3 2580 3 3 GRD
C454
CONNECTOR) 1
C454
5 1540 1 1 1540 1 1 PWR LEFT SIDE
F 1
3
3020 2 2 3020 2 2 SIG WHEEL SPEED
B 2600 3 4 4
HR HR HR HR DRIVE 0
3080 4 3080 4 SIG
H 6200
8590
8570
8560
8580
CONTROLLER 9 2570 3 2570 3 GRD

C103
3 3
A 6310
C453
1
C453
7 1530 1 1 1530 1 1 PWR RIGHT SIDE
E 6400 1
3000 2 2 3000 2 SIG WHEEL SPEED
4 2
D 6500 2 4 4
9
2510 3070 4 3070 4 SIG
G 6600 3
8500
3020
C404
SEE CAB
FUSE 10
FUSE 11
FUSE 12
3
UNSWITCHED
FUSE 9
ATTCHMNT
ALT & KITS
C 7100 A TO OPTIONS 3 7114735

CONNECTOR
25A
25A
25A
25A
3080 1810 2 2
ACS
(BACKUP ALARM RED TIE

B 4
C407 4
C350
SWITCH) 1640 STRAPS
LEFT RIGHT 0 2810 4 4 2810 1 1 GRD
C356
SAFETY STEERING STEER SWASHPLATE SWASHPLATE 4 RIGHT SWASH PLATE
A IN OPEN OPEN MODE OPEN MODE 1 ANGLE ANGLE OPEN OPEN
9 4720 3 3 4720 3 3 SIG
POSITION SENSOR
J 2730 1 2 3 4 5 6 7 8 9 10 2
3000 1 1
STARTER
1710 1710 2 2 PWR

SWITCH
3
POWER
9400 4550 4220 4950 4720

P 6600 2 1820
LEFT
CAN HIGH LEFT LEFT 3070 2 2
6000
FORWARD STEER
4
C360
DRIVE OPEN OPEN OPEN OPEN JOYSTICK X JOYSTICK Y
M 6500 GND MODE 2 OPEN
4 4
1 4720 2860 2860 1 1 GRD
C355
11 12 13 15 16 17 18 19 20 8
4 LEFT SWASH PLATE
L 6400 9530 4275 4530 4540 3 3 4950
2670
LEFT BRAKE
7 4950 3 3 SIG
POSITION SENSOR
R QUAD
F 4730 FORWARD CAN LOW R QUAD TWO LIGHT DRIVE DRIVE MAIN SENSER
1770 1 1 1770
DRIVE DRIVE A DRIVE B DRIVE SPEED 1 OUTPUT GRND GRND GRND OPEN 3 2 2 PWR
D 4235 21 22 23
2
4
25 J5 26 27 28 29 30 4
C351 C352 C354 C353

TRACTION
4270 9630 3000 3070 4350 4210 2470 2490 2510 3

4260 1 1 4260 1 1
C488
RIGHT FORWARD DRIVE SOLENOID

LIGHT
TO OPTIONS N 6300
REAR
4
PULL
LEFT CAN SENSER

REVERSE SHIELD L QUAD L QUAD SAFETY BACK-UP SUPPLY 1 2660 2 2 2660 2 2
(ACCESSORY DRIVE DRIVE A DRIVE B DRIVE OUT ALARM OPEN OPEN OPEN +5V 2
C 4275 4
CONNECTOR) 31 32 33 34 35 36 37 38 39 40
4
4250 3 3 4250 1 1
C500
E 4550 4280 9730 3020 3080 9410 7100 1640 4 RIGHT REVERSE DRIVE SOLENOID
LEFT RIGHT RIGHT RIGHT RIGHT
5
2650 4 4 2650 2 2
REVERSE FORWARD FORWARD REVERSE REVERSE TWO UNSWITCHED UNSWITCHED SWITCHED
S 1700 3
GND GND DRIVE DRIVE GND SPEED 2 BATTERY BATTERY OPEN BATTERY
1
4280 5 5 4280 1 1
1740 41 42 43 44 45 46 47 48 49 50 LEFT REVERSE DRIVE SOLENOID
A 1140 4
2680 6 6 2680 2 2
FRONT &
MARKER
2680 2660 4260 4250 2650 4390 1250 1260 1750 1

LIGHT
PULL
1150
FUEL
H 2
1
4270 7 7 4270 1 1
R J5 DRIVE 1 LEFT FORWARD DRIVE SOLENOID
1
2670 8 8 2670 2 2
B 2 2 4 4 3 1 3 2 1 5 1 2 2 3 3 4 3 3 1 1 2
1 4 6 2 5 4210
7 8 7 8 5 6 2 2 2 0 0 5 0 7 8 6 9 6 9 8 6
G
TO OPTIONS
A 6 6 6 6
2490
1250
1260
4275
4390
4540
4530
2470
9400
9410
4550
4220
9730
9630
9530
4350
7100
K
1750
(ALTERNATOR (BRAKE LIGHT)
& KITS) C474 4 4 4 4
GLOW
1800 9210 9010 HDL SW

PLUG
C449
FUSE 11
C459
25A 4530 2 2 4750 2 2 X
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
LEFT
1700 1055 4220 M A 1170 4540 3 3 4650 3 3 Y
JOYSTICK
7200 J G 9210 2080 5 5 2070 5 5 GRD
C489

FUSE 2
FUSE 3
1 1 1 1
FR & MK LT
FUSE 1
FUSE 4
236
COMPUTER
PLUG STARTER
235
(ACCESSORY POWER LIGHT PULL TRACTION 4275 L R 9400 1520 1510 PWR
REAR LT
LIGHT
HEATER
0
0
25A
15A
25A
15A

87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P S 9410
(ATTACHMENT)
(COMPUTER)
6510 N K 4550 B A B A B A
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 6 6 6 6
FUSE 5
C441 C437 C404

FUSE 6
M 4220
FUSE 7
FUSE 8
4550 K
FUEL PULL
TRACTION
1730 4 4 4 4
30A
30A
9110 9010 HDL SW

1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
C450
9720 E L 4275 TO OPTIONS
C460
NOT USED NOT USED
(HEATER FOR THIS FOR THIS (BACKUP 4750 2 2 4750 2 2 X
9620 D P 6410 B
C497
) MODEL MODEL ALARM) RIGHT
3 3 3 3
C492
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5 4650 4650 Y
15A
G 9410 S N 6510 A TO OPTIONS JOYSTICK
15A 30A 30A 2070 5 5 2070 5 5 GRD
120
1140 25A F 9400 R J 7200 C (HORN/BLINKER)

1510 1 1 1510 1 1 PWR
E 9210 G E 9720
1150 1160 9520 C D 9620
2630 1 1 GND
1070 2240 H C 9520
MAINFRAME HARNESS RELAY GROUNDS 2000-2060 4670 2 2 SIG
LIFT ACTUATOR
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 1610
7112824 FUSE / RELAY CENTER 25A 25A 3 3 PWR
C429
(UNSWITCHED 1170 A H 2240 4
4
POWER) (ACS) F 9110 4680
D 9110 F 5 5 RED
6 6
M
1080
1040
7 7
4690 8 8 BLK
2770 1 1 GND
4770 2 2 SIG
TILT ACTUATOR
1160
1730
9800
9510
9610
9710
2710
1630 3 3 PWR
4790
1190
1180
2260
2270
4680
4780
4690
1760
4750
4650
4670
2280
9540
9640
9740
2250
4770
1500
C428
4 4
1050 4780 5 5 RED
G
-
D
C
E
A
B
1300
F
+ B C G E J H F D A K H J C B D E F A G K A B D C G F H E J K
6 6
1060 TO OPTIONS M
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
J3 (Gray) J1 J2 (Black)
4790
7
8
7
8 BLK
1310
ACD & REMOTE ACS Controller
Printed in U.S.A. START CONNECTOR
1040
BATTERY 1080 V-0719 (7-12-05) SJC HARNESS 7110406

WIRING SCHEMATIC
OPTIONS TO ENGINE OR MAINFRAME AIR CONDITIONER SWITCH
THERMOSTAT
S175 (S/N 525211001 AND ABOVE) 7100 C 3100 A A
C630
2650 F
C612
OFF A 7010 B B
C103
6600 G
S185 (S/N 525011001 AND ABOVE) LOW
2100
B 2310 2205 C C
6400 E MEDIUM
(S/N 525111001 AND ABOVE) BACK-UP
ALARM 6310 A
TO OPTIONS (AC)
HIGH
(PRINTED JULY 2005) 6500 D
C433
C433
(TO "D" PIN)
(TO "B" PIN)

V-0442 A RNG A
C410
C431
6200 H HERE OR TO OPTIONS
(HVAC JUMPER) HEATER VALVE C LGN C 4640
2600 B
DBL A A 3200 1300 A A RED 10 B BLK B
- +
C613
Printable Version Click Here WHT B B 7200 D D WHT 8 M
6340
C614
2620
7000
2610
6610
6320
6620
6330
2640
C BLK C C 2110 2130 C C BLK 7
1110
POTENTIOMETER B B
2630 6210 1000 B E E ADVANCED HAND CONTROL ADVANCED HAND CONTROL

E F C A B D F E D C B A F F
C604 C605 REGISTRATION LEFT WORK RIGHT WORK
G SERIES JUMPER G SERIES FLOAT
L BLOWER MOTOR
E F C A B D F E D C B A LAMP
M
5000
1200
3
2
3
2
YEL
RED
HARNESS - 6728742 HARNESS - 6727328
C611
H 1010 1 1 RNG M
2200 4 4 BLK
DELUXE EUROPEAN BLOWER SWITCH
5 5
POWER RELAY
TO OPTIONS
(DELUXE ACCESSORY)
LEFT TAILLIGHT RIGHT TAILLIGHT

TAILLIGHT HARNESS - 6718198 6 6
1740
85 86
2210
A C426
87 To Mainframe
C617
30 SSL 7-PIN
87A 1190 B CAN CONNECTOR Harness
D F C E A B G
HVAC HARNESS - 6725933 2740 C
9800
1160
9700
1710
9500
9600
2710
SSL 7-PIN
C426 To Mainframe TO HORN
C705
Harness CONNECTOR KEY "RUN" D 9800 PUR J1 - 8-PIN
CAN CONNECTOR D F C E A B G
UNSW POWER F 1160 RED/WHT 2720 H GROUND
C412
2750 B
HORN RELAY 1730 A CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
SW POWER E 1730 RNG 9 1720 B SW POWER ACD
9800
1160
9700
1710
9500
9600
2710
85 86 9 Machine
2770 7200 CAN LOW B 9620 PUR 9610 E CAN LOW
87 14 Connector to
2750 CAN HIGH A 9520 PUR 9510 D CAN HIGH
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A
30
2760 ADDITIONAL POWER
GROUND G 2730 BLK 13 C OPEN
Engine
Compartment
CONNECTOR
UNSW POWER 2 1160 RED/WHT 2720 H GROUND
Connector 7-PIN A OPEN
C666 ATTACHMENT
C490
E 85 86 2740 B
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD 2780 6415 on Loader
87 CONNECTOR G OPEN
SW POWER 1 1730 RNG 1720 B SW POWER ACD D 6410 6410 30 1740 A Boom
C411
87A 6020 J
Machine C
CAN LOW B 9620 PUR 9610 E CAN LOW BOOM-MOUNTED
Connector N
CAN HIGH A 9520 PUR 9510 D CAN HIGH B 6000 ACD CONNECTORS
TO AWS TO MAINFRAME SW POWER K 1740
C401or
3 C A 6510 B C A
C402
GROUND 2730 BLK OPEN
RIGHT BLINKER CONTROLS GROUND B 2740 C703 J2 - 10-PIN BLACK
C489
7-PIN 2720 B
A OPEN RELAY C497
C666 ATTACHMENT
CONNECTOR G OPEN 85 86
1720 A E OUTPUT E 5100 5100 C E OUTPUT
2790 6515 F OUTPUT F 5350 5350 H F OUTPUT
J 6510
87
BOOM-MOUNTED 30 G OUTPUT G 5400 5400 J G OUTPUT
N 87A 6010
ACD CONNECTORS H OUTPUT H 5050 5050 B H OUTPUT ACD
SW POWER K 1740 Output
C OUTPUT C 5300 5300 G C OUTPUT
GROUND B 2740 C703 J2 - 10-PIN BLACK AWS HORN/BLINKER HARNESS - 6726662 D OUTPUT D 5150 5150 D D OUTPUT
Connector to
Engine
E OUTPUT E 5100 5100 C E OUTPUT
A OUTPUT A 5250 5250 F A OUTPUT Compartment
F OUTPUT F 5350 5350 H F OUTPUT
M OUTPUT M 5200 5200 E B OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT
ID (K TO L) L 5910 5000 A J OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD TO OPTIONS TO OPTIONS 12
Output (HVAC)
ID (K TO P) P 5510 5450 K K OUTPUT
C OUTPUT C 5300 5300 G C OUTPUT (DELUXE ACCESSORY)
Connector 11
D OUTPUT D 5150 5150 D D OUTPUT C 2740 C C506 14-PIN
C704
C636
C642
ATTACHMENT J3 - 10-PIN GRAY
Connector
C417
A OUTPUT A 5250 5250 F A OUTPUT B 1140 B 1 4480 4481 4485 1 CONNECTOR
TO REAR AUX.
on Loader 5900 J ID #1
M OUTPUT M 5200 5200 E B OUTPUT A 1740 A TO MAIN 2 2480 2480 2 RELIEF SOLENOID
FRAME Boom 5500 A ID #2
ID (K TO L) L 5910 5000 A J OUTPUT
HARNESS B ID #3 ACD
C418
ID (K TO P) P 5510 5450 K K OUTPUT
HVAC/ACCESSORY 1 4450 4451 4455 1 TO REAR AUX.
DIVERTER SOLENOID
C ID #4 Input
2 2450 2
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY HARNESS - 6725390
2450
D ID #0 Connector to
Engine
CONNECTOR
5900 J ID #1
DELUXE ATTACHMENT E OPEN
Compartment
F OPEN
5500 A ID #2 CONTROL HARNESS - G OPEN
B
C
ID #3
ID #4
ACD REAR AUX. JUMPER HARNESS - 6732730 H OPEN
Input K OPEN
D ID #0 Connector
M
FRONT WIPER
BOTTLE AND TANK
7101973 Rev. none
E OPEN
F OPEN FRONT WIPER
MOTOR
G OPEN
H OPEN
V
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K OPEN
M
C622
7200 or YEL
7150 or DGN
2765 or BRN
LEFT TAILLIGHT
L X RIGHT TAILLIGHT
BACK-UP
ALARM
TO OPTIONS
2745
TO (DELUXE ACCESSORY)
POWER BOB-TACH MAINFRAME C 7310
TO ENGINE OR
C404
SOLENOID B
PARK
HIGH
TO OPTIONS B 2735 2755 B B A B C D E F REGISTRATION MAINFRAME RIGHT WORK A B C D E F
C610
LEFT WORK
C667
7100 A
C606
A 7000 A A 9.8 ohms E 7150 7160 C C ACCESSORY STOP LIGHT

DOOR SENSOR C604 C103 C605
D 2760 B B A 7210 A A
C601
BACK-UP ALARM 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
C F 7190 7180
SWITCHES 2 2 2 2
D 4710
C607
B 7010 B B POWER BOB-TACH 7110 TO 1 1 4720 1 1
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
SOLENOID MAINFRAME
E 2770 A A
WIPER HARNESS - 6730885
C402
1720 1730 A
9.8 ohms 2720 B
BACK-UP ALARM
POWER BOB-TACH HARNESS - SWITCHES HARNESS -
ADDITIONAL POWER
CONNECTOR TO ENGINE OR MAINFRAME
C491
6730770 6718820 or 7107544 1740

B
A
RNG C
RNG/DGN F 46 C C 6430 A A 6520
G
C103
41 B B 6730 B B 6720
BACK-UP E 40 A A 2660 OPEN C C 6620
ALARM A HARNESS 6713993 2630 D D 2620
REAR LIGHT HARNESS 6716419 M
FRONT WIPER
BOTTLE AND TANK BACK-UP ALARM D 40 A A 2640 OPEN E E OPEN
F H 42 B B 6330 F F 6320
RIGHT
WORKLIGHT
2620 6200 2600 B HARNESS - 6715659 B HARNESS 6713994 HARNESS 6731239
6210 6200 H 46 C C 6430 A A 6430
LEFT
WORKLIGHT
2630 6210 6310 A 41 B B 6730 B B 6830
E 40 A A 2660 OPEN C C 6630
RIGHT
TAILLIGHT
2610 6320 D HARNESS 6713993 2630 D D 2630
C622 FRONT WIPER
2650 G MOTOR
TO ATTACHMENT 40 A A 2640 OPEN E E OPEN
LEFT L X
2640 6330 7100 C B 42 B B 6330 F F 6330
TAILLIGHT V
J HARNESS 6713994 HARNESS 6731239
TO MAINFRAME M
BACKUP N
ALARM TO OPTIONS
2745
6800
2670
6700
2660
(DELUXE ACCESSORY) P
6360
2650
1370
2640
C 7310 M TO OLDER 2620
B 2735 2755 B B MODEL ATTACHMENTS 2630
A
C610
C506
C667
87A 87 86 87A 87 86
DOME LIGHT E 7160 C C D WHT S LEFT RIGHT 2640 87A 87 86 87A 87 86
TO OPTIONS SWITCH FLASHER FLASHER
A 7210 A A C BRN LT 2610 2650
C623
C608
A RED LIGHT LIGHT

D E BLK TM To Engine Ground
2660
B BLK 30 85 30 85
F WIPER HARNESS - 6729739 F DBL CENTER 2670 30 85 30 85
DOME LIGHT G RED GD 2730
6350
6340
TO OPTIONS
H YEL RT
1370
6210
6310
2790
2795
(EXTERIOR CAB)
L RNG
1020
1320
1020
1320
1020
1320
K RNG
6440 1
C669
2785 2
TO OPTIONS (HVAC)
GRADER HARNESS - 6540 3 A B A B A B
C631
C612
B B 2310 2300 B
A A 7030 A 6707303 4 WAY FLASHER To Starter "B" Terminal
Left Marker Fuse 10A
STROBE OR
BEACON
HARNESS - 6718873 1010
Right Marker Fuse 10A Signal Fuse 10A
DIODE HARNESS 6726430

AIR CONDITIONER
CLUTCH SOLENOID ADDITIONAL POWER CONNECTOR ROAD LIGHTS
C490
1740 A
2 1 2740 B
C609
7020
7010
2 1 TO TO MAINFRAME SSL 7-PIN

STROBE/BEACON (ACCESSORY CONNECTOR) CAN CONNECTOR
TO OPTIONS 1730 1720 A KEY "RUN" D 9800 D

C402
6700 E 2720 B RED = RED WIRES CONNECT BY

C668 OR C670
UNSW POWER 2 1160 F

2775
B A RNG = ORANGE
A C BLK = BLACK LETTER ACROSS
TO OPTIONS CAN SHIELD 9700 C
C632 (4 WAY FLASHER) C LBL = LIGHT BLUE CONNECTORS
ALARM SW POWER 1 1710 E To Mainframe
DBL = DARK BLUE A B
B A 2 2785 2780 D HORN TO HANDLE CONNECT0R Harness
CAN LOW B 9600 A LGN = LIGHT GREEN BATTERY FEED 1000-1999 RED, RED/WHT, RNG
C669
B A
C412
1 6440 F 2730 B DGN = DARK GREEN GROUND 2000-2999 BLK

CAN HIGH A 9500 B YEL = YELLOW MONITORING 3000-3999 LBL
A
AIR CONDITIONER 3 6540 B 7200
GROUND 3 2700 G PNK = PINK
SOME CONNECTOR HYDRAULIC 4000-4999 LGN
FRONT HORN HARNESS - Connector
7-PIN WHT = WHITE BODIES NOT SHOWN ATTACHMENT CONTROLS 5000-5999 YEL
HARNESS - 6726888 EXTERIOR CAB HARNESS - on Loader C666

ATTACHMENT
CONNECTOR C426 BRN = BROWN FOR DRAWING CLARITY LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
6727498 Boom
TAN = TAN
PUR = PURPLE ENGINE 8000-8999 TAN
EVAPORATOR (AC)
6718872 GRY = GRAY
COMMUNICATION 9000-9999 PUR
PRESSURE SWITCH
CONTROL HARNESS - 6718426
V-0442 (7-12-05)
WIRING SCHEMATIC
OPTIONS
S175 (S/N 525211001 AND ABOVE) TO OPTIONS
(POWER BOB-TACH)
(S/N 525311001 AND ABOVE) POWER BOB-TACH 2770 E
S185 (S/N 525011001 AND ABOVE) FLASHER SWITCH
2760 D
C601
(S/N 525111001 AND ABOVE) 1
7000 A
BEACON SWITCH 2
(PRINTED JULY 2005) C
6
V-0443 5 HAZARD SWITCH 3
7010 B
4
Printable Version Click Here 1130 6010
2 1
6430 5
4
3 X L
1180 3
RED = RED TO OPTIONS 1 2
WIRES CONNECT BY 4
6530
6
RNG = ORANGE (EXTERIOR CAB)
BLK = BLACK LETTER ACROSS 5
6 2750
E 6700 TO MAINFRAME
LBL = LIGHT BLUE CONNECTORS ACS SWITCH
2755
DBL = DARK BLUE A B D 2780 1
C670
LGN = LIGHT GREEN 4550 E
B A B 6540 2
DGN = DARK GREEN 3 R
YEL = YELLOW F 6440 2745
SOME CONNECTOR 4
PNK = PINK A
2755 4235 D
BODIES NOT SHOWN 5
WHT = WHITE 4275 C
6
BRN = BROWN FOR DRAWING CLARITY C
K
C488
TAN = TAN
PUR = PURPLE G
GRY = GRAY B
2730 J
1700 S
6400 L
6500 M
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1150 H
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL N
HYDRAULIC 4000-4999 LGN P
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK F
ACCESSORIES 7000-7999 WHT A
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR STANDARD ACCESSORY HARNESS - 6727468
TO OPTIONS
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH E
BEACON SWITCH
SWITCH
2770 V
1 2760 D M
2745 6420
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
2 3 4 7220
5 SWITCH
4 1
4 5 2
6530 3
TO OPTIONS 5 6 1730
6 2750 2 1
(EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
D 2780 6 5
4
C670
7310
B 6540 5
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A
C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411
(FRONT WIPER)
PLUG
6000 B C
C F
E
C667
7210 A
ACS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2
3 R 2735 B
4
2755 4235 D
5 4275
6 C
K
G
B
C488
2730 J
6400 L
6500 M
1150 H
6300 N
6600 P
TO EUR0. LIGHTS 4730 F
CONNECTOR 1140 A
1700 S
DELUXE ACCESSORY HARNESS - 6727190
V-0443 (7-12-05)
Printed in U.S.A.
ELECTRICAL SYSTEM INFORMATION
S175 WIRING SCHEMATIC S185 WIRING SCHEMATIC

(WITHOUT ACS OPTION) (WITHOUT ACS OPTION)
S/N 525211001 AND ABOVE S/N 525011001 AND ABOVE
(PRINTED NOVEMBER 2003) (PRINTED NOVEMBER 2003)
V-0440 V-0440

(WITH ACS OPTION) (WITH ACS OPTION)
V-0441 V-0441

OPTIONS OPTIONS
(PRINTED MAY 2004) (PRINTED MAY 2004)
V-0442 V-0442

OPTIONS OPTIONS
V-0443 V-0443

ELECTRICAL SYSTEM INFORMATION (CONTD)
WARNING
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. 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-2003-0199
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.

ELECTRICAL SYSTEM INFORMATION (CONTD) Figure 60-10-3
Description
Figure 60-10-1
P-26323
The electrical system is also protected by fuses and

P-24651 relays under the fuse panel cover (Item 1) [Figure 60-10-
3] located in the cab on the control panel.
Figure 60-10-2 The fuse panel cover (Item 1) [Figure 60-10-3] & [Figure
60-10-5] has a decal inside to show the location and amp
ratings.
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
P-13848A
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by a
100 amp master fuse (Item 1) [Figure 60-10-1] & [Figure
60-10-2] to protect against serious system overloads that
could lead to burned up harness or loader damage. This
fuse is located in the left-hand side engine compartment,
just forward of the engine harness connector.

ELECTRICAL SYSTEM INFORMATION (CONTD) The location and sizes are shown in [Figure 60-10-4] &
[Figure 60-10-5].
Fuse Location
REF Description Amp.
Figure 60-10-4
F1 Heater 25
F2 Front & Marker Lights 15
F3 Rear Lights 15
F4 Bobcat Controller 25
F5 Traction 30
F6 Fuel Shutoff 30
F7 Not Used --
1 F8 Not Used --
F9 Unswitched Attach. 25
F10 Switched Attach. 25
F11 Alternator & Kits 25
P-28846
F12 ACS Power 25
Relay Switch Location
F5 F1 E D C B F9 Remove the cover to check or replace the relays.
F6 F2 F10 The location is shown in [Figure 60-10-4] & [Figure 60-

10-5].
F7 F3 F G H J F11 REF Description

B Switch Power
F8 F4 F12 C Rear Lights
Fuses Relays Fuses D Front & Marker Lights
E Not Used
N-18465A F Glow Plugs
G Fuel Shutoff
Figure 60-10-5 H Traction
J Starter
P-28903
Remove the cover to check or replace the fuses (Item 1)

[Figure 60-10-5].

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. 1
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
P-48528
minutes.
If electrolyte is taken internally drink large quantities Disconnect the positive (+) battery cable (Item 1) [Figure
of water or milk! DO NOT induce vomiting. Get 60-20-2].
prompt medical attention.
W-2065-1296
Figure 60-20-3
Figure 60-20-1
P-48529
P-48527
Remove the battery from the loader [Figure 60-20-3].
Open the rear door.
Disconnect the negative (-) battery cable (Item 1) [Figure

60-20-1].
Remove the battery hold down clamp (Item 2) [Figure

60-20-1].

BATTERY (CONTD) Servicing
Installation
WARNING
Figure 60-20-4
rubber gloves to keep acid off body.

minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
W-2065-1296
P9589 Figure 60-20-6
Figure 60-20-5
P9588
P9590 The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
Always clean the terminals and cable ends when water solution [Figure 60-20-6].
installing a new battery [Figure 60-20-4] & [Figure 60-
20-5]. Clean the terminals and cable ends as shown in figure
[Figure 60-20-4] and [Figure 60-20-5].
When installing the battery in the loader, do not touch
any metal parts with the battery terminal posts. Check the electrolyte level in the battery. Add distilled
water as needed.
Connect and tighten the battery cables. Connect the
negative (-) cable last to prevent sparks. Put battery saver or grease on the battery terminals and
cable ends to prevent corrosion.
Install the battery holddown clamp.

BATTERY (CONTD) Figure 60-20-7
Using A Booster Battery (Jump Starting)

2
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 (Standard Panel) OR the

STOP Button must be pressed (Deluxe Panel). The 41
booster battery must be 12 volt.
P-31861
WARNING
3 1
minutes.
P-31860
prompt medical attention. Connect the end of the first cable (Item 1) to the positive
W-2065-1296 (+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-7] to the
positive terminal on the loader starter.
WARNING Connect the end of the second cable (Item 3) to the

negative (-) terminal of the booster battery. Connect the
other end of the same cable (Item 4) [Figure 60-20-7] to
Keep arcs, sparks flames and lighted tobacco away the engine.
from batteries. When jumping from booster battery
make final connection (negative) at engine frame. Keep cables away from moving parts. Start the engine.
(See REMOTE START on Page 10-60-1.)
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F (16C) before After the engine has started, remove the ground (-) cable
connecting to a charger. Unplug charger before (Item 4) [Figure 60-20-7] first.
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. Remove the cable from the positive terminal (Item 2)
[Figure 60-20-7].
Battery gas can explode and cause serious injury.
W-2066-1296

BATTERY (CONTD)
Using A Booster Battery (Jump Starting) (Contd)
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

ALTERNATOR Alternator Identification
Adjusting The Alternator Belt Figure 60-30-2
Figure 60-30-1
2 2
P-24416
1
4
1
3 P-24417
1
P-24543
Figure 60-30-3
Stop the engine.

4
on Page 10-30-1.)
Loosen the alternator mounting bolt (Item 1) [Figure 60-

3
30-1].
Loosen the adjustment bolt (Item 2) [Figure 60-30-1]
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lb. (66 1 1
Nm) of force. 1
2 P-24542
Tighten the adjustment bolt and mounting bolt.
Lower the operator cab. (See Lowering The Operator The black cover has been removed to show alternator
Cab on Page 10-30-2.) rectifier/regulator assembly. The alternator contains field
coil diodes (low current) (Item 1) [Figure 60-30-2],
grounded heat sink (Item 2) [Figure 60-30-2] & [Figure
60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] &
[Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] &
[Figure 60-30-3], and four pair of large power diodes
(Item 1) [Figure 60-30-3] on the underside of the
rectifier.
NOTE: The rectifier/regulator assembly has been

removed from the alternator and flipped over
for component identification [Figure 60-30-3].

ALTERNATOR (CONTD)
Charging System Check
WARNING

minutes.

W-2065-1296
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60F (16C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.

W-2066-1296
IMPORTANT
disconnected.
charger or when welding on the loader. (Remove
connected wrong.
I-2023-1285

ALTERNATOR (CONTD) 2. If the test light lights up, there is a short (drain) in the
electrical system of the loader. The short must be
Charging System Check (Contd) repaired before the charging system can be checked.
Figure 60-30-4 3. Disconnect the alternator B+ terminal (Item 1) and L

& S terminal connector (Item 2) [Figure 60-30-4] and
if the test light goes out, the alternator is faulty. If the
test light stays on, find the short in the system and
2 repair it.
Alternator Voltage Test

1 Figure 60-30-5
P-24547
If the charging system malfunctions check the following:
Check the condition and tension of the alternator belt.

(See Adjusting The Alternator Belt on Page 60-30-1.) If
belt is worn or deteriorated replace.
P-34676
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and
tight. Open the rear door.
Check the fuse for the alternator in the fuse panel. If fuse Connect the remote start tool to the loader. (See
is burned, find the cause and repair/replace. If fuse is in Procedure on Page 10-60-1.)
doubt, remove it and check for continuity.
Turn the engine on with the remote start tool and run at
Check the electrolyte level in the battery. Add distilled idle. With a voltmeter, check the voltage between the B+
water as needed. (Does not apply to maintenance free terminal and ground at the starter [Figure 60-30-5].
batteries.)
The voltage must be higher than 13.5 volts but lower than
Verify the charge of the battery. Make sure battery is fully 14.7 volts at 70F (Alternator Temperature).
charged.
If the voltage is higher that 14.7 volts, proceed to the
Disconnect the battery cables (negative first, then following high voltage test.
positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery If the voltage is lower than 13.5 volts, run the engine at
and cables with a sodium bicarbonate and water high idle and recheck voltage. If voltage is still below 13.5
solution. Put grease on the cable ends and battery volts, proceed with the following low voltage test.
terminals to prevent corrosion. Reconnect the cable to
the positive terminal.
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
and proceed to alternator voltage test. (See Below.)

ALTERNATOR (CONTD) High Voltage Test
Low Voltage Test Figure 60-30-8
Figure 60-30-6 1
P-24568
1
P-34679 P-34678
P-24547
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] off the alternator. Check the continuity between the "S" terminal (Item
1) [Figure 60-30-8] and the positive (+) terminal on
Turn the remote start tool key to the ON position. the battery or starter terminal (Item 2) [Figure 60-30-
8]. There should be continuity. If no continuity,
Figure 60-30-7 replace wire harness.
If voltage is still above 14.7 volts at 70F (Alternator

Temperature), then remove alternator for replacement or
repair. To repair, (See Rectifier Continuity (Diode) Test
on Page 60-30-5.) for further component testing.
2
1 P-24566
P-24566
Place jackstands under the rear corners of the loader.
P-34677
Check the voltage across the "L" terminal (Item 1) and

ground (Item 2) [Figure 60-30-7]. 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 Rectifier Continuity (Diode) Test on Page 60-
WARNING
30-5.) for further component testing.
W-2059-0598

ALTERNATOR (CONTD) Figure 60-30-10

1
IMPORTANT
2
disconnected.
charger or when welding on the loader. (Remove 3
P-24543
connected wrong.
I-2023-1285
Remove the adjustment bolt (Item 1) [Figure 60-30-10]
Figure 60-30-9 from the mounting bracket.
Remove the alternator belt (Item 2) [Figure 60-30-10]

from the alternator pulley.
2
Remove the mounting bolt (Item 3) [Figure 60-30-10].
Rectifier Continuity (Diode) Test
Figure 60-30-11
1
3
P-24547 2
Raise the lift arms and install an approved lift arm 1

on Page 10-20-1.)

on Page 10-30-1.) 1
P-24416
Disconnect the negative (-) cable from the battery.
Disconnect the red wire (Item 1) [Figure 60-30-9] from Remove the two screws (Item 1), nut/washer (Item 2)
the alternator which comes from the battery. and the plastic cover (Item 3) [Figure 60-30-11] from the
alternator.
Disconnect the wiring harness connector (Item 2) [Figure
60-30-9] from the alternator. NOTE: In the diode tests there should be continuity
in one direction only. Meter readings should
be different when probes are reversed. If the
diode being tested shows no continuity or
continuity in both directions, replace the
rectifier assembly.

ALTERNATOR (CONTD) Figure 60-30-14
Rectifier Continuity (Diode) Test (Contd)
Figure 60-30-12
1
1
P-24558
Touch one probe to the diode (Item 1) [Figure 60-30-14]

P-24532 and the other probe to each heat sink and read the
meter.
NOTE: Use the diode function (Item 1) [Figure 60-30- Reverse the probes to check the diode in the other
12] on the multimeter. direction.
Figure 60-30-13 Meter readings should be different when probes are

reversed.
Alternator Regulator Test

1
Figure 60-30-15
1
2
P-24527
Touch the probes to the terminals (Item 1) [Figure 60-30- 1

13] of each diode and read the meter.
P-24533
Reverse the probes to check the diode in the other
direction.
Touch one probe to the "L" terminal (Item 1) and the
Meter readings should be different when probes are other probe to the ground (Item 2) [Figure 60-30-15].
reversed.

ALTERNATOR (CONTD) Disassembly
Alternator Regulator Test (Contd) Figure 60-30-17

1.Alternator 11. Bearing
Figure 60-30-16
2.Nut 12. Stator
3.Pulley 13. Bracket
4.Spacer 14. Sleeve
5.Bolt 15. Regulator
6.Bracket 16. Rectifier
7.Bolt 17. Cover 7
8.Bearing 18. Spacer
3 6
9.Retainer 19. Nut
10.Rotor
4 7 13 14
12 5
2
1
11
10
9
P-24535 8
Reverse the probes to check in the other direction 1819

[Figure 60-30-16].
17
There should be continuity in one direction only. Meter
readings should be different when probes are reversed. If 16
15
there is no continuity or continuity in both directions, C-3529
replace regulator.
Disassemble the alternator. (See Parts Identification

Figure [Figure 60-30-17].)
Remove the regulator cover.
Remove the four bolts holding halves together.
Pry the halves apart (use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley

nut.
Remove front case half from the rotor using a plastic

hammer or press.
Unsolder the stator leads from the rectifier. Remove the

stator.
Unsolder the two leads between the rectifier and

regulator. Remove the regulator from rectifier.

ALTERNATOR (CONTD) Rotor Continuity Test
Stator Continuity Test Figure 60-30-20
Figure 60-30-18
P-24524
P-24537
Touch the probes to the slip rings [Figure 60-30-20].
Use an ohmmeter to test the stator. The ohmmeter should read between 3.0-4.0 ohms.
Touch the probes to two of the bare stator wires [Figure If there is no continuity, replace the rotor.
60-30-18].
Move one of the probes to the third wire. Rotor Ground Test
The readings should be the same. Figure 60-30-21
If there is no continuity, replace the stator.
Stator Ground Test
Figure 60-30-19
P-24525
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-21].
P-24538 There should be no continuity.
Replace the rotor if there is continuity.

Touch one probe to a bare stator lead and the other
probe to the bare metal surface of the stator [Figure 60-
30-19].
There should be no continuity.
Replace the stator if there is continuity.

ALTERNATOR (CONTD)
Assembly
Figure 60-30-22
P-24557
Reverse the order of disassembly.
Do not assemble the rear case half.
Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-30-22]. Tighten to 72 + 14.5 ft.-lb. (98
+ 20 Nm) torque.
Install the rear case half and the remaining parts.

STARTER Figure 60-40-3
Checking
Figure 60-40-1
2
1
Bat
S
M
Cranking
Motor
P-34673
Disconnect the negative cable from the battery. (See

A-1992 Removal And Installation on Page 60-20-1.)
Disconnect the S terminal on the starter (Item 1) [Figure

The key switch must be in the OFF position. 60-40-3].
The battery must be at full charge. Hold-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the mounting bolt
The cable connections on the battery must be clean and (Item 2) [Figure 60-40-3] on the magnetic switch
tight. (solenoid). If there is no continuity replace the magnetic
switch (solenoid).
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1]. Figure 60-40-4
If the starter turns but does not turn the engine, the
starter drive has a defect. 2
Figure 60-40-2 1
P-34675
1
Bat
S
M
Cranking
P-34674
Motor
Disconnect the negative cable from the battery. (See

A-1991
Disconnect the S terminal on the starter (Item 1) [Figure
60-40-4].
Connect a jumper wire (of at least 4 gauge in size)
between the M terminal and the BAT terminal [Figure 60- Pull-In Test: Use circuit tester, touch one probe to the S
40-2].
terminal (Item 1) and one probe to the starter motor
If the starter turns, the defect is in the solenoid. terminal (Item 2) [Figure 60-40-4]. If there is no
continuity replace the magnetic switch (solenoid).
If the starter does not turn, the starter is defective.
STARTER (CONTD)
Figure 60-40-5
4
2
1
P-34385
Remove the negative (-) and positive (+) cables from the
battery.
Disconnect the ground wire (Item 1) [Figure 60-40-5]

from the starter.
Disconnect the engine harness power wire and positive

(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-40-5].
Installation: Tighten the nut to 10.8-12.3 ft. lb. (14,7-

16,7 Nm) torque.
Disconnect the tan wire (Item 3) [Figure 60-40-5] from

the R terminal on the starter solenoid.
Disconnect the brown wire (Item 4) [Figure 60-40-5]

from the S terminal on the starter solenoid.
Remove the mounting bolts (Item 5) [Figure 60-40-5]

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.

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

STARTER (CONT'D) Figure 60-40-8
Figure 60-40-6
1
1
1
2
P-34596
Remove the bolts (Item 1) from the brush cover (Item 2)

P-34594 [Figure 60-40-8].
Remove the cover (Item 2) [Figure 60-40-8].

Remove the cable (Item 1) [Figure 60-40-6] from the
magnetic switch. Figure 60-40-9
Remove the bolts (Item 2) [Figure 60-40-6].
Installation: Tighten the bolts to 63-129 in.-lb. (7,1-14,6 2

Nm) torque.
Figure 60-40-7
1
1 2
4
3
3
N-00980
Using a needle nose pliers, pull the brush springs (Item

1) back and remove the brushes (Item 2) [Figure 60-40-
9].
P-34595 NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
Remove the armature, yoke, brush holder and rear positive brushes).
bracket assemblies (Item 1) from the front assembly
(Item 2) [Figure 60-40-7]. Remove the brush holder (Item 3) [Figure 60-40-9] from
the end of the armature.
NOTE: When separating the parts there will be a steel
ball (Item 3) located at the end of the armature
shaft (Item 4) [Figure 60-40-7].
Installation: Apply grease to the steel ball (Item 3) and

install into the end of the armature shaft (Item 4) [Figure
60-40-7] .


1
Figure 60-40-10
2
3
2 P-34600
Inspect the magnetic switch (Item 1), the spring (Item

P-34598 2),and the plunger (Item 3) [Figure 60-40-12] for wear
Remove the armature (Item 1) [Figure 60-40-10] from Figure 60-40-13

the frame.
Remove the bearing (Item 2) [Figure 60-40-10] from the

end of the armature.
Figure 60-40-11
3 2
1
P-34601
Remove the center bracket (Item 1) [Figure 60-40-13]
P-34599
Remove the bolts (Item 1) [Figure 60-40-11] from the

magnetic switch.
Installation: Tighten bolts to 34-69 in.-lb. ( 3,8-7,8 Nm)

torque.
Remove the front assembly (Item 2) from the magnetic

switch (Item 3) [Figure 60-40-11].

Figure 60-40-14
1
3
2
2 2 4
P-34604
1 Remove the snap ring (Item 3) [Figure 60-40-15] &

P-34602 [Figure 60-40-16]
Remove the retainer (Item 2) [Figure 60-40-15] &

Remove the rubber retainer (Item 1) [Figure 60-40-14]. [Figure 60-40-16] and pinion (Item 1) [Figure 60-40-15]
& [Figure 60-40-16].
Remove the planetary gears (Item 2) [Figure 60-40-14]
and inspect for damage. Remove the spring (Item 4) [Figure 60-40-16].
Figure 60-40-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Press down on the pinion (Item 1) [Figure 60-40-15] &

[Figure 60-40-16] and retainer (Item 2) [Figure 60-40-
15] & [Figure 60-40-16].

Inspection And Repair
Figure 60-40-17
N-00997
Armature Winding Continuity Test: Use a circuit tester,

B-14455 touch the probes to two commutator segments [Figure
60-40-19]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.
Figure 60-40-20
Inspect the pinion teeth for wear and damage.
Armature Short-Circuit Test: Use a growler tester, put the

armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-17]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
Figure 60-40-18
B-14458
Commutator Run-Out Test: check the commutator run-

out as shown in [Figure 60-40-20].
Service Limit - 0.003 inch (0,07 mm)
If the commutator exceeds the service limit, repair as

needed.
N-00996
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-18]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.

Inspection And Repair (Cont'd)
Figure 60-40-21
N-00999
Check the field windings for wear and damage.

B-14460
Check all the connections for clean and tight solder
joints.
Measure the segment mica depth (Item 1) [Figure 60-40-
21]. Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
Service Limit - 0.012 inch (0,3 mm) other probe to the surface of the frame [Figure 60-40-
22]. There should be no continuity. If there is continuity,
If it is worn, replace the armature. the field windings are grounded.
Check the commutator surface for burned spots which Replace the frame.
usually indicates an open-circuit, and correct it using
#400 sand paper. Figure 60-40-23
N-15005
Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the other probe to the brush
[Figure 60-40-23]. There should be continuity. If there is
no continuity, the field windings are open-circuited.
Replace the frame.

STARTER (CONT'D) No Load Test
Inspection and Repair (Cont'd) Figure 60-40-25
Figure 60-40-24 Ammeter
S
M.T.
Starter B-14440
N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Clamp the starter in a vise. Using a 12 volt battery and
Replace the brush holder and yoke if the brushes need ammeter, connect the positive wire of the battery, and the
replacement. ammeter to the terminal [Figure 60-40-25]. Connect the
negative wire to the starter body. Using a jumper wire,
Check brush spring, for damage or rust. Replace as connect the S terminal to the main terminal.
needed.
The starter should show smooth and steady rotation
Brush Holder Insulation Test: Use a circuit tester, touch immediately after the pinion is engaged, it should draw
one probe to the positive brush holder plate and the other less than the specified current.
probe to the holder plate [Figure 60-40-24]. There
should be no continuity. If there is continuity, replace or Service Limit - 1150 Amp. Maximum @ Stall Condition
repair.
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.

INSTRUMENT PANEL The left instrument panel is the same for both the
Standard and Deluxe Instrument Panels [Figure 60-50-
Left Panel 1].
Figure 60-50-1 The table below shows the DESCRIPTION and

FUNCTION/OPERATION for each of the components of
2
the left panel.
1
3 Press and hold LIGHTS button (Item 4) [Figure 60-50-1]
for two seconds to view SERVICE CODES in the
4 5 6 7 8 HOURMETER/CODE DISPLAY (Item 2) [Figure 60-50-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.
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*
GLOW PLUG COUNTDOWN relating to the loader monitoring system. COUTNTDOWN - Glow Plug time remaning
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 seonds 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 2 seconds to
view BASE or SHTDN ( SHUTDOWN) feature in HOURMETER/CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW (Option) Press to engage the HIGH FLOW auxiliary hydraulics. Press again to disengage.
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 Press and hold for two seconds. The engine wil stop. Hydraulic pressure will be released in the rear auxiliary (If
so equipped) or right side front auxiliary circuit (If so equipped).
BOBCAT INTERBLOCK CONTROL SYSTEM (BICS)
(SEE TROUBLESHOOTING GUIDE ON PAGE 60-90-4.)

9 PRESS TO OPERATE LOADER Press to activate BICS System when the Seat Bar is down and operator is seated in operating position.
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 (Function 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 60-110-1.) Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or SHUTDOWN condition.

INSTRUMENT PANEL (CONTD) The right instrument panel shown [Figure 60-50-2] is the
Standard Panel.
Right Panel (Standard) (With Key Switch)
The table below shows the Icons and other components
Figure 60-50-2 of the Right Standard Panel
15 17 19 21 23 25 27
* These functions are monitored and have SERVICE
CODES associated with them. (See DIAGNOSTICS
SERVICE CODES on Page 60-80-1.)
16 18 20 22 24 26 28
29
B-15552B
ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
LIGHT
Advanced ON 3 Beeps * Error Error with Advanced Control System (ACS)
Control System
15
(ACS)
Attachment FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
16 Control
Device (ACD)
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 very high. Engine will stop in 10 seconds.
18 NOT USED
Fuel ON 3 Beeps * Error Fuel level sender system fault.
19 Level FLASHING 3 Beeps * WARNING Fuel level low.
Glow ON --- - --- Glow plugs are energized.

20 Plugs FLAHSING 3 Beeps * Error Error with glow plugs
System Voltage ON 3 Beeps * WARNING Voltage low, high or very 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 very 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 very 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 very 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 very 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.

INSTRUMENT PANEL (CONT'D) Figure 60-50-4
Right Panel (Deluxe) (With Keyless Start)
Figure 60-50-3
1 3 ENTER PASSWARD
LANGUAGES
B-16165
4
6 The first screen you will see on your new loader will be as
5 B-15553B shown in [Figure 60-50-4].
When this screen is on the display you can enter the

The right instrument panel shown [Figure 60-50-3] is the password and start the engine or change the Display
Deluxe Panel. Panel setup features.
1. Display Panel: The Display Panel is where all system NOTE: Your new loader (with Deluxe Instrument
setup, monitoring, troubleshooting, and error Panel) will have a Owner Password. Your
conditions are displayed. dealer will provide you with this password.
Change the password to one that you will
2. Function Icons: The lower left area of the Deluxe easily remember to prevent unauthorized use
Panel has the same Icons as the Standard Panel of your loader. (See ELECTRICAL SYSTEM
(See Right Panel (Standard) (With Key Switch) on SERVICE MANUAL.) Keep your password in a
Page 60-50-2.) These Icons are only visible when the safe place for future needs.
monitoring system has detected an error.
Start Engine: Use the Keypad to enter the numbers
3. Selection Buttons: The four Selection Buttons allow (letters) of your password and press the RUN / ENTER
you to select items from the Display Panel and scroll key (Item 5) [Figure 60-50-3].
through screens.
Press and hold the START Button (Item 6) [Figure 60-
4. Keypad: The numeric keypad (Item 4) [Figure 60-50- 50-3] until the engine starts.
3] has two functions:
Change Language: Press the Selection Button at the end
(a) To enter a number code (password) to allow of the arrow [Figure 60-50-4] to go to the next screen.
starting the engine (Keyless Start).
(b) To enter a number as directed for further use of

the Display Panel.

INSTRUMENT PANEL (CONT'D)
Right Panel (Deluxe) (With Keyless Start) (Contd)
Figure 60-50-5
ENGLISH / INGLES
Use keypad to select languages
1. English
2. Espanol
3. Francaia
4. Deutsch
5. Italiano
6. Nederlands
EXIT
B-16160
Use the Keypad to select the number of the language

[Figure 60-50-5]
Press EXIT. The screen will return to [Figure 60-50-4].

You can then enter the password and start the engine.

INSTRUMENT PANEL (CONT'D)
Right Panel Setup Display Options (Deluxe)

ICON DESCRIPTION
Icon Identification LOCK/UNLOCK: Allows machine to be
locked/unlocked. You must lock machine to
Figure 60-50-6 activate security system.
SELECTION BUTTON 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.
EXAMPLE Use to set clock, check system warnings,
select language, set passwords, etc.
? 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.
B-16162
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one screen.
Make selection by pressing SELECTION BUTTON
opposite the Icon [Figure 60-50-6]. OUTLINE ARROWS: No screen available
(backward/forward).
SELECTION ARROW: Use to select menu

item.
NEXT Goes to the NEXT screen in series.

EXAMPLE: the next Active Warning screen.
INFO Goes to more information about an
attachment.
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.

INSTRUMENTATION PANEL (CONTD) All new machines with Deluxe Instrumentation arrive at
Bobcat Dealerships with the panel in locked mode. This
Deluxe Panel Setup means that a password must be used to start the engine
[Figure 60-50-7].
Display Options
Passwords (Deluxe)
Figure 60-50-7
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.
Press
TOOL/SETUP Owner Password:
Allows for full use of the loader and to setup the
Deluxe Panel. Owner can select a password to allow
starting & operating the loader and modify the setup
of the Deluxe Panel. Owner should change the
password as soon as possible for security of the
loader.
Press User Password:

LOADER FEATURES Allows starting and operating the loader; cannot
change password or any of the other setup features.
Press
DISPLAY OPTIONS
Press
ADJUST CONTRAST
Press
UP OR DOWN
Arrow to
change contrast.
Press EXIT to
return to
previous level
menu.
B-16163/B16164/B-16161/B-16166/B-16167

INSTRUMENTATION PANEL (CONTD) More EXAMPLES:
Passwords (Deluxe) (Contd) Clocks
Figure 60-50-8 TOOL/SETUP [Figure 60-50-8]

Changing the Password Right Instrument Panel
Display Screen LOADER FEATURES.
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Press TOOL/SETUP Use the keypad to set time.
Press RUN/ENTER to set clock.
Press EXIT to return to previous level menu.
RESET JOB CLOCK (Password required)

Press PASSWORD Press CLEAR to reset job clock to zero.
UTILITIES Press LOCK/UNLOCK to unlock.
Enter Password and press RUN/ENTER.
Languages
Press MODIFY OWNER TOOL/SETUP

or
MODIFY USER LOADER FEATURES.
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN/ENTER.
Press EXIT to return to previous level menu.
Vitals (Monitor engine, hydraulic/hydrostatic,

electrical functions when engine is running.)
TOOL/SETUP
LOADER FEATURES.
VITALS
Press SELECTION ARROW to select METRIC or
Enter Password on ENGLISH (M/E) readouts
Keypad
You can monitor real-tim readouts of:
Press Enter to Continue Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Re-enter new password. Hydraulic Ouil Temperature
Press Enter to Continue System Voltage
(See left.) Engine Speed
The Display Panel is easy to use. Continue to set

your own preferences for running/monitoring your
Bobcat loader.
Press Enter to Continue
(See left.)
B-16163/B16164/B-16171/B-16172/B-16173/B-16174

INSTRUMENTATION PANEL (CONTD) Side Accessory Panel [Figure 60-50-9] and [Figure 60-
50-10].
Option And Field Accessory Panels (If Equipped)
REF.
DESC. FUNCTION/OPERATION
Figure 60-50-9 NO.
1. POWER Provides a 12V receptacle for accessories.
SIDE ACCESSORY PANEL PLUG
2. NOT USED ---
3. FRONT Press the top of the switch to start the front
WIPER 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.
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.
8. AIR COND. Press top of switch to start; bottom to stop. Fan
SWITCH Motor (Item 7) must be ON for A/C to operate.
1 2 3 4 5 6 P-16000
P16000 9. TEMP. Turn clockwise to increase the temperature;
CONTROL counterclockwise to decrease.
Figure 60-50-10 Front Accessory Panel [Figure 60-50-11]

SIDE ACCESSORY PANEL
REF.
DESC. FUNCTION/OPERATION
NO.
10. ADVANCED Press the top to select Hand Controls; bottom to
CONTROL select Foot Controls.
SYSTEM
(ACS)
11. NOT USED ---
12. POWER Press and hold the up arrow to disengage the
BOB-TACH (If the Bob-Tach wedges. Press and hold the down
Equipped) arrow to engage the wedges into the mounting
frame holes.
13. PARKING Press the top to engage the PARKING BRAKE;
BRAKE bottom to disengage.
14. TURN Indicates left or right TURN SIGNALS are ON.
7 8 9 SIGNAL
P16000
INDICATORS
15. HAZARD Press the left side (or top) to turn the HAZARD
LIGHTS LIGHTS ON; right side (or bottom) to turn OFF.
Figure 60-50-11 16. ROTATING Press the left side (or top) to turn the
BEACON ROTATING BEACON ON; right side (or bottom)
FRONT ACCESSORY PANEL
to turn OFF.
10 11 12 13 14 15 16 17. SELECTABLE Press the top to select ISO Control Pattern;
JOYSTICK bottom to select H Control Pattern.
CONTROL
(SJC)
17 OR
B-15993C
B-15993

INSTRUMENTATION PANEL (CONTD) Figure 60-50-14
Standard Panel Removal And Installation (Right

Side)
Figure 60-50-12 1
1
N-20140
Ignition Switch Removal and Installation (Standard

Panel)
P-28360A
Disconnect the key switch wiring harness (Item 1)
[Figure 60-50-14] from the back of the control panel.
Remove the three mounting bolts (Item 1) [Figure 60-50-
12]. Figure 60-50-15
Installation: Be careful to not overtighten the instrument

panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-13
2
1
1
P-28360
Remove the ignition key (Item 1) from the switch.

Remove the ignition switch retaining nut (Item 2) [Figure
60-50-15] from the switch.
N-20158
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-13] from
the panel.
Remove the panel from the loader cab.

INSTRUMENTATION PANEL (CONTD) Figure 60-50-18
Standard Panel Removal And Installation (Right

Side) (Contd)
Ignition Switch Removal And Installation Standard Panel

(Cont'd)
Figure 60-50-16
N-20163
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-18] from
the panel.
Remove the panel from the loader cab.

N-20141
Figure 60-50-19
Remove the ignition switch (Item 1) [Figure 60-50-16]

from the control panel.
Deluxe Panel Removal And Installation (Right Side)
Figure 60-50-17
1
1 N-20142
NOTE: The instrument panel (Item 1) [Figure 60-50-

19] must be replaced as a complete unit.
N-20103
Remove the three mounting bolts (Item 1) [Figure 60-50-

17].

panel mounting bolts to prevent stripping of the threaded

INSTRUMENT PANEL (CONT'D) Figure 60-50-22
Standard & Deluxe Panel Removal And Installation

(Left Side)
Figure 60-50-20
1
1
N-20144
Alarm Removal and Installation
N-18409 Remove the left side instrument panel.
Remove the retaining nut (Item 1) [Figure 60-50-22]

Remove the three mounting bolts (Item 1) [Figure 60-50- from the loader alarm.
20].
Remove the alarm from the loader instrument panel.
panel mounting bolts to prevent stripping of the threaded Figure 60-50-23
Figure 60-50-21
1
2 N-20145
N-20165 Bulb Removal And Installation
Remove the left side instrument panel.

Pull the left instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-21] from Remove the two light bulb covers (Item 1) [Figure 60-50-
the loader alarm. 23] from the back of the instrument panel.
Disconnect the wire harness connector (Item 2) [Figure

60-50-21] from the loader instrument panel.
NOTE: The wiring harness (Item 3) [Figure 60-50-21]

is an optional accessory harness.
Remove the instrument panel from the loader.

INSTRUMENT PANEL (CONT'D) Front Accessory Panel Removal And Installation
Standard & Deluxe Panel Removal And Installation Figure 60-50-26

(Left Side) (Cont'd)
Figure 60-50-24
1
1
P-26255
N-20146 Remove the two mounting bolts (Item 1) [Figure 60-50-

26].
With a flat blade screw driver, turn the light bulb Installation: Be careful to not overtighten the front
counterclockwise [Figure 60-50-24] and remove from accessory panel mounting bolts to prevent damage to the
the panel. plastic panel.
Figure 60-50-25 Figure 60-50-27
2
1
N-20147 P-26251
To install the bulbs, place them in the sockets and turn Pull the front accessory panel down and disconnect the
clockwise [Figure 60-50-25]. 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.

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

Removal And Installation on Page 60-20-1.).
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.

LIGHTS (CONTD)
Rear Removal And Installation
Figure 60-60-4
P-48519
Remove the bulb assembly (Items 1 & 2) from the light

housing (Item 3) [Figure 60-60-4] by turning bulb
assembly a 1/4 turn.
Figure 60-60-5
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
Reverse this procedure for installation.

BOBCAT CONTROLLER
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
31
J1 50
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

BOBCAT CONTROLLER (CONTD)
Identification Chart (Contd)
Harness Connector View
41
J1 50
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 50
J2
4410 9410 4640 9340 3920 4500 X 3300 X X
31 X 4420 X 9350 3910 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

BOBCAT CONTROLLER (CONTD) 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.
NOTE: The connectors are keyed and will only plug

in one way.
1
Figure 60-70-3
1
1
N-19390
Raise the lift arms and install an approved lift arm 2

on Page 10-20-1.)
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)
P-34843

on Page 10-30-1.) Remove the top mounting bolt (Item 1) [Figure 60-70-3].
Remove the left front side panel (Item 1) [Figure 60-70- Loosen the two mounting bolts (Item 2) [Figure 60-70-3]
1]. of the system controller.
Installation: Tighten the nuts to 12-14 ft.-lb. (16,3-19

Nm) torque.
Remove the system controller.
Reverse the above procedure to install the system

controller.

CONTROLLER (SELECTABLE JOYSTICK CONTROL) Figure 60-71-2
(SJC)
WARNING
1
W-2059-0598
P-64327

support device. (See Installing Lift Arm Support Device Remove the inside access panel (right side) (Item 1)
on Page 10-20-1.) [Figure 60-71-2].
Raise the operator cab. (See Raising The Operator Cab Figure 60-71-3
on Page 10-30-1.)
Figure 60-71-1
1
P-64297
P-64300 Remove the top controller mounting bolt (Item 1). Loosen
the two bottom controller mounting bolts (Item 2) [Figure
60-71-3] from the right side fender.
Remove the foot portion of the engine speed control
(Item 1) [Figure 60-71-1]. (See Removal And Installation Lift and remove the controller from the fender.
on Page 70-20-1.)
Installation: Tighten the mounting bolts to 12-14 ft.-lbs
(16-19 Nm) torque.

CONTROLLER (SELECTABLE JOYSTICK CONTROL) Figure 60-71-6
(SJC) (CONTD)
Figure 60-71-4
P-64325
Remove the SJC controller [Figure 60-71-6].
P-64322 Figure 60-71-7
Pull the controller out from the fender and loosen the
connector screw (Item 1) [Figure 60-71-4] to release the
connector.
Installation: Tighten the connector screw to 30-35 in.-lb. J S

(3,39-3,96 Nm) torque. DO NOT OVERTIGHTEN!
Figure 60-71-5
P-64324
1
The wire location (Item 1) [Figure 60-71-7] is printed on
the connector, in the locations shown.
P-64325
Installation: Note the keyed hole in the controller socket.

(Item 1) [Figure 60-71-5]. The keyed hole matches a tab
on the connector on the wire harness.

(SJC) (CONTD)
P-64295

(SJC) (CONTD)
Identification Chart (Cont'd)
P-64296

DIAGNOSTICS SERVICE CODES
Display
Figure 60-80-1
B-15551B
The left instrument panel is the same for both the

Standard and Deluxe Instrumentation [Figure 60-80-1].
NOTE: Corroded or loose grounds can cause

multiple service codes and/or abnormal
symptoms. All dash lights flashing, buzzer
going off, headlights and taillights flashing,
could indicate a bad ground. The same
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If
you observe these symptoms, check grounds
and positive leads first.
Press and hold LIGHTS Button (Item 1) [Figure 60-80-1]

HOURMETER/CODE DISPLAY (Item 2) [Figure 60-80-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.
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.

(Deluxe instrument panel only.)
ERROR The wrong password was entered. (Deluxe

instrument panel only.)

DIAGNOSTICS SERVICE CODES (CONT'D)
Number Codes List
CODE CODE
01-16 Air filter not connected 10-16 Hydraulic Charge filter not connected
01-17 Air filter plugged 10-17 Hydraulic Charge filter plugged
02-16 Hydraulic implement filter not connected 11-05 Seat bar sensor short to battery
02-17 Hydraulic implement filter plugged 11-06 Seat bar sensor short to ground
03-09 Battery voltage low 12-21 Front auxiliary PWM switch out of range high
03-10 Battery voltage high 12-22 Front auxiliary PWM switch out of range low
03-11 Battery voltage extremely high 12-23 Front auxiliary PWM switch not in neutral
03-14 Battery voltage extremely low
03-22 Battery voltage out of range low 13-05 Fuel shut-off hold solenoid short to battery
13-06 Fuel shot-off hold solenoid short to ground
04-09 Engine oil pressure low 13-07 Fuel shut-off solenoid open circuit
04-14 Engine oil pressure extremely low
04-15 Engine oil pressure shutdown level 14-02 Fuel shut-off pull solenoid error ON
04-21 Engine oil pressure out of range high 14-03 Fuel shut-off pull solenoid error OFF
04-22 Engine oil pressure out of range low
15-02 Traction lock pull solenoid error ON
05-09 Hydraulic charge pressure low 15-03 Traction lock pull solenoid error OFF
05-10 Hydraulic charge pressure high
05-11 Hydraulic charge pressure extremely high 16-05 Traction lock hold solenoid short to battery
05-14 Hydraulic charge pressure extremely low 16-06 Traction lock hold solenoid short to ground
05-15 Hydraulic charge pressure shutdown level 16-07 Traction lock hold solenoid open circuit
05-21 Hydraulic charge pressure out of range high
05-22 Hydraulic charge pressure of range low 17-05 Hydraulic lock valve solenoid short to battery
06-10 Engine speed high 17-06 Hydraulic lock valve solenoid short to ground
06-11 Engine speed extremely high 17-07 Hydraulic lock valve solenoid open circuit
06-13 Engine speed no signal
06-15 Engine speed shutdown level 18-05 Spool Lock Solenoid short to battery
06-18 Engine speed out of range 18-06 Spool Lock Solenoid short to ground
07-10 Hydraulic oil temperature high 18-07 Spool Lock Solenoid open circuit
07-11 Hydraulic oil temperature extremely high
07-15 Hydraulic oil temperature shutdown level 19-02 Bucket position solenoid error ON
07-21 Hydraulic oil temperature out of range high 19-03 Bucket position solenoid error OFF
07-22 Hydraulic oil temperature out of range low
20-02 Two-speed solenoid error ON
08-10 Engine coolant temperature high 20-03 Two-speed solenoid error OFF
08-11 Engine coolant temperature extremely high
08-15 Engine coolant temperature shutdown level 21-02 Glow plug error ON
08-21 Engine coolant temperature out of range high 21-03 Glow plug error OFF
08-22 Engine coolant temperature out of range low
22-02 Starter error ON
09-09 Fuel level low 22-03 Starter error OFF
09-21 Fuel level out of range high
09-22 Fuel level out of range low 23-02 Rear base solenoid error ON
23-03 Rear base solenoid error OFF

Number Codes List (Contd)
CODE CODE
32-57 Lift actuator reduced performance
24-02 Rear rod solenoid error ON 32-58 Tilt actuator reduced performance
24-03 Rear rod solenoid error OFF 32-59 Lift actuator wrong direction
32-60 Tilt actuator wrong direction
25-02 Rear auxiliary relief solenoid error ON 32-61 Handle lock short to ground
25-03 Rear auxiliary relief solenoid error Off 32-62 Handle lock short to battery
32-63 Pedal lock short to ground
26-02 Front base solenoid error ON 32-64 Pedal lock short to battery
26-03 Front base solenoid error OFF 32-65 Sensor supply voltage out of range
32-66 Battery voltage out of range
27-02 Front rod solenoid error ON 32-67 Switch flipped while operating
27-03 Front rod solenoid error OFF 32-68 Lift handle information error
32-69 Control pattern switch flipped while operating
28-02 Diverter solenoid error ON 32-70 Right drive handle short to ground
28-03 Diverter solenoid error OFF 32-71 Right drive handle short to battery
32-75 Interrupted unswitched power
29-02 High flow solenoid error ON
29-03 High flow solenoid error OFF 33-23 Main Controller (Bobcat Controller) not
programmed
30-28 Controller Memory failure 34-04 Deluxe panel no communication to Bobcat

controller
31-28 Interrupted power failure 35-02 Hydraulic fan error ON

35-03 Hydraulic fan error OFF
32-04 ACS not communicating with Bobcat Controller
32-23 ACS Not calibrated 36-48 ACD multiple controllers present
32-31 Tilt actuator fault
32-32 Tilt actuator wiring fault 37-02 Two-speed secondary error ON
32-33 Tilt handle wiring fault 37-03 Two-speed secondary error OFF
32-34 Tilt actuator not in neutral
32-35 Tilt handle/pedal not in neutral
32-36 Lift actuator fault
32-37 Lift actuator wiring fault
32-38 Lift handle wiring fault
32-39 Lift actuator not in neutral
32-40 Lift handle/pedal not in neutral
32-41 No communication
32-49 Lift actuator short to ground
32-50 Tilt actuator short to ground
32-51 Lift actuator short to battery
32-52 Tilt actuator short to battery
32-53 Lift handle/pedal short to ground
32-54 Tilt handle/pedal short to ground
32-55 Lift handle/pedal short to battery
32-56 Tilt handle/pedal short to battery

CODE CODE
38-04 No communication from joystick controller 38-53 Left forward drive solenoid error OFF
38-05 Left joystick X axis not in neutral 38-54 Left reverse drive solenoid error OFF
38-06 Right joystick X axis not in neutral 38-55 Right forward drive solenoid error OFF
38-07 Left joystick Y as not in neutral 38-56 Right reverse drive solenoid error OFF
38-08 Right joystick Y axis not in neutral 38-57 Front right extend steering solenoid error OFF
38-09 Control pattern switch - Short to Battery or Ground 38-58 Front right retract steering solenoid error OFF
38-11 Lift actuator not in neutral 38-59 Front left extend steering solenoid error OFF
38-12 Tilt actuator not in neutral 38-60 Front left retract steering solenoid error OFF
38-13 Lift actuator fault 38-61 Rear right extend steering solenoid error OFF
38-14 Tilt actuator fault 38-62 Rear right retract steering solenoid error OFF
38-15 Right wheel speed fault 38-63 Rear left extend steering solenoid error OFF
38-16 Left wheel speed fault 38-64 Rear left retract steering solenoid error OFF
38-17 Tilt actuator reduced performance 38-65 Steering pressure solenoid error OFF
38-18 Lift actuator reduced performance 38-66 Back-up alarm error OFF
38-19 Left joystick X axis out of range high 38-67 No communication from Bobcat controller
38-20 Right joystick X axis out of range low 38-68 Wheel angles (alignment) not calibrated
38-21 Left joystick Y axis out of range high 38-69 Lift & tilt actuators not calibrated
38-22 Right joystick Y axis out of range high 38-70 Interrupted power
38-23 Front right steering sensor out of range high 38-71 Battery out of range
38-24 Front left steering sensor out of range high 38-72 Drive pump not calibrated
38-25 Rear right steering sensor out of range high 38-73 Steering mode / drive mode switch flipped while
operating
38-26 Rear left steering sensor out of range high 38-74 Uncommanded right wheel speed error ON
38-27 Lift actuator out of range high 38-75 Uncommanded left wheel speed error ON
38-28 Tilt actuator out of range high 38-76 Undercurrent steer pressure solenoid
38-29 Left joystick X axis out of range low 38-77 Undercurrent front right extend steer solenoid
38-30 Right joystick X axis out of range low 38-78 Undercurrent front right retract steer solenoid
38-31 Left joystick Y axis out of range low 38-79 Undercurrent front left extend steer solenoid
38-32 Right joystick Y axis out of range low 38-80 Undercurrent front left retract steer solenoid
38-33 Front right steering sensor out of range low 38-81 Undercurrent rear right extend steer solenoid
38-34 Front left steering sensor out of range low 38-82 Undercurrent rear right retract steer solenoid
38-35 Rear right steering sensor out of range low 38-83 Undercurrent rear left extend steer solenoid
38-36 Rear left steering sensor out of range low 38-84 Undercurrent rear left retract steer solenoid
38-37 5 volt sensor supply 1 out of range low 38-85 5 Volt sensor supply 1 out of range high
38-38 5 volt sensor supply 2 out of range low 38-86 5 Volt sensor supply 2 out of range high
38-39 Lift actuator short to ground / out of range low 38-87 Front right wheel blocked (steering mechanical failure)
38-40 Tilt actuator short to ground / out of range low 38-88 Front left wheel blocked (steering mechanical failure)
38-41 Tilt actuator wrong direction 38-89 Rear right wheel blocked (steering mechanical failure)
38-42 Lift actuator wrong direction 38-90 Rear left steering error
38-43 Left forward drive solenoid error ON 38-91 Right speed sensor missing pulses
38-44 Left reverse drive solenoid error ON 38-92 Left speed sensor missing pulses
38-45 Right forward drive solenoid error ON 38-93 Unresponsive right speed sensor
38-46 Right reverse drive solenoid error ON 38-94 Unresponsive left speed sensor
38-47 Front right steering solenoid error ON 38-95 Left speed sensor reverse direction
38-48 Front left steering solenoid error ON 38-96 Right speed sensor reverse direction
38-49 Rear right steering solenoid error ON 38-98 Controller in drive calibration mode
38-50 Rear left steering solenoid error ON 38-99 Controller in wheel position calibration mode.
38-51 Steering pressure solenoid error ON
38-52 Back-up alarm error ON

CODE CODE
39-04 Left joystick no communication to Bobcat 50-38 Front reverse error OFF
controller
50-39 Rear PWM error on
40-04 Right joystick no communication to Bobcat 50-41 Rear PWM no signal
controller
50-42 Rear PWM not calibrate
44-02 Horn error ON 50-43 Rear forward error ON
44-03 Horn error OFF 50-44 Rear forward error OFF
50-45 Rear reverse error ON
45-02 Right blinker error ON 50-46 Rear reverse error OFF
45-03 Right blinker error OFF 50-47 Two speed error OFF
50-48 Two speed error ON
46-02 Left blinker error ON 50-49 Brake solenoid error ON
46-03 Left blinker error OFF 50-50 Brake solenoid error OFF
50-51 Brake solenoid no signal
47-21 8 volt sensor supply out of range high 50-52 Brake light relay error ON
47-22 8 volt sensor supply out of range low 50-53 Brake light relay error OFF
50-54 Differential lock error ON
48-02 Front light relay error ON 50-55 Differential lock error OFF
48-03 Front light relay error OFF 50-56 CAN communications fault
50-57 Drive controller not calibrated
49-02 Rear light relay error ON
49-03 Rear light relay error OFF 50-59 Front speed sensor missing pulses
50-60 Rear speed sensor missing pulses
50-01 Travel pedal out of range high
50-02 Travel pedal out of range low
50-03 Travel pedal not calibrated 50-63 Front angle sensor not calibrated
50-04 Brake Pedal out of range high
50-05 Brake Pedal out of range low
50-06 Brake Pedal not calibrated 50-66 Rear angle sensor not calibrated
50-07 Drive selector switch no signal 50-67 Front forward no signal
50-08 Drive selector switch multiple inputs 50-68 Front reverse no signal
50-09 Front wheel speed sensor out of range high 50-69 Rear forward no signal
50-10 Front wheel speed sensor out of range low 50-70 Rear reverse no signal
50-11 Rear wheel speed sensor out of range high 50-99 In calibration mode
50-12 Rear wheel speed sensor out of range low
50-13 Front wheel speed sensor no signal 60-21 Rear auxiliary control out of range high
50-14 Rear wheel speed sensor no signal 60-22 Rear auxiliary control out of range low
50-15 Dual wheel speed sensor fault 60-23 Rear auxiliary control not returning to neutral
50-24 Battery voltage over voltage
50-27 5V sensor #1 over voltage 62-04 Load moment monitoring in error
50-28 5V sensor #1 under voltage
50-29 5V sensor #2 over voltage 63-05 Short to battery
50-30 5V sensor #2 under voltage 63-06 Short to ground
50-31 Front PWM error on
50-33 Front PWM no signal 64-02 Switched power relay error ON
50-34 Front PWM not calibrate 64-03 Switched power relay error OFF
50-35 Front forward error ON
50-36 Front forward error OFF
50-37 Front reverse error ON

CODE CODE
65-02 Workgroup lockout error on 75-74 Left wheel speed uncommanded motion
65-03 Workgroup lockout error off 75-75 Right wheel speed uncommanded motion
65-05 Workgroup lockout short to battery 75-76 No communication from ACS Controller
65-06 Workgroup lockout short to ground 75-77 Left speed sensor out of range high
65-07 Workgroup lockout open circuit 75-78 Right speed sensor out of range high
75-79 Left speed sensor out of range low
66-05 Pilot pressure short to battery 75-80 Right speed sensor out of range low
66-06 Pilot pressure short to ground 75-85 5 volt sensor supply 1 out of range high
75-91 Left swash plate sensor reversed
74-72 Bobcat controller in boot code 75-92 Right swash plate sensor reversed
74-73 Left hand panel system RX error 75-93 Unresponsive right speed sensor
75-94 Unresponsive left speed sensor
75-04 No communication from Drive Controller 75-95 Left speed sensor reversed direction
75-05 Left joystick X-Axis not in neutral 75-96 Left speed sensor reversed direction
75-07 Left joystick Y-Axis not in neutral 75-98 Controller in Calibration Mode
75-08 Right joystick Y-Axis not in neutral
75-09 ISO/H pattern switch short to ground or battery 76-73 Left display panel RX error
75-17 Left swash plate not in neutral
75-18 Right swash plate not in neutral 77-48 Key Switch - Multiple
75-19 Left joystick X-Axis out of range high
75-21 Left joystick Y-Axis out of range high 78-74 Door/Transport Lock - Open/Active
75-22 Right joystick Y-Axis out of range high
75-27 Left swash plate out of position
75-28 Right swash plate out of position
75-29 Left joystick X-Axis out of range low
75-31 Left joystick Y-Axis out of range low
75-32 Right joystick Y-Axis out of range low
75-37 5 volt sensor supply 1 out of range low
75-39 Left swash plate sensor out of range high
75-40 Left swash plate sensor out of range low
75-41 Right swash plate sensor out of range high
75-42 Right swash plate sensor out of range low
75-43 Left forward drive solenoid error ON
75-44 Left reverse drive solenoid error ON
75-45 Right forward drive solenoid error ON
75-46 Right reverse drive solenoid error ON
75-52 Backup alarm error ON
75-53 Left forward drive solenoid error OFF
75-54 Left reverse drive solenoid error OFF
75-55 Right forward drive solenoid error OFF
75-56 Right reverse drive solenoid error OFF
75-66 Backup alarm error OFF
75-67 No communication from Bobcat Controller
75-69 Battery voltage out of range high
75-70 Interrupted power (also occurs after software
update)
75-71 Battery voltage out of range low
75-72 Drive pump not calibrated
75-73 ISO/H pattern switch flipped while operating

CODE CODE
80-02 ACD output A error ON
80-03 ACD output A error OFF
81-02 ACD output B error ON

81-03 ACD output B error OFF
82-02 ACD output C error ON

82-03 ACD output C error OFF
83-02 ACD output D error ON

83-03 ACD output D error OFF
84-02 ACD output E error ON

84-03 ACD output E error OFF
85-02 ACD output F error ON

85-03 ACD output F error OFF
86-02 ACD output G error ON

86-03 ACD output G error OFF
87-02 ACD output H error ON

87-03 ACD output H error OFF
90-02 Service tool output C error ON

90-03 Service tool output C error OFF
91-02 Service tool output D error ON

91-03 Service tool output D error OFF
92-02 Service tool output E error ON

92-03 Service tool output E error OFF
93-02 Service tool output F error ON

93-03 Service tool output F error OFF

BICS SYSTEM NOTE: Record what lights are blinking (if any) and
number of light flashes. See Troubleshooting
Inspecting The BICS Controller (Engine STOPPED Guide on Page 60-90-4.
- Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics
Figure 60-90-1 System (Engine STOPPED - Key ON)
3. Sit in the operator's seat, lower the Seat Bar, and

press the 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.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in the operator's seat, lower the seat bar, engage

the parking brake pedal and fasten the seat belt.
5. Start the engine and operate at low idle. Press the

PRESS TO OPERATE LOADER Button. While
N-18409 raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
6. Fasten the seat belt, disengage the parking brake

pedal, press the PRESS TO OPERATE LOADER
Button and raise the Seat Bar fully. Move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged. Lower the Seat Bar. Press
1 2 3 4
B-15551G the PRESS TO OPERATE LOADER Button.
7. Engage the parking brake pedal and move the control

WARNING
lock should be engaged.
NOTE: * The TRACTION light on the left instrument

AVOID INJURY OR DEATH panel will remain OFF until the engine is
The Bobcat Interlock Control System (BICS) must started, the PRESS TO OPERATE LOADER
deactivate the lift, tilt and traction drive functions. If it Button is pressed and the parking brake is
does not, contact your dealer for service. DO NOT disengaged.
modify the system.
W-2151-0394 Inspecting The Lift Arm By-Pass Control
8. Raise the lift arms 6 feet (2 meters) off the ground.

1. Sit in the operator's seat. Turn key ON (Standard
Stop the engine.
Panel), press RUN / ENTER Button (Deluxe Panel,
lower the Seat Bar and disengage the parking brake
Turn the lift arm by-pass control knob clockwise 1/4 turn.
pedal. Press the PRESS TO OPERATE LOADER
Pull up and hold the lift arm by-pass control knob until the
Button. Three BICS lights (Items 1, 2, & 3) [Figure
lift arms slowly lower.
60-90-1] [PRESS TO OPERATE LOADER, SEAT
BAR, and LIFT & TILT VALVE] on left instrument
panel should be ON [Figure 60-90-1].
2. Raise the Seat Bar fully. All four BICS lights (Items
1, 2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE
LOADER, SEAT BAR, LIFT & TILT VALVE and
TRACTION*] on left instrument panel should be OFF
[Figure 60-90-1]
BICS SYSTEM (CONT'D)
Additional Inspection For Loaders With Advanced

Hand Controls (ACS)
9. Sit in the operator's seat and fasten the Seat Belt.

Lower the Seat Bar, start the engine and press the
PRESS TO OPERATE LOADER Button.
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
11. Turn key OFF (Standard Panel), press the STOP

Button (Deluxe Panel, and wait for the engine to come
to a complete stop.
12. Turn key ON (Standard Panel), press RUN /ENTER

Button (Deluxe Panel. Press the PRESS TO
OPERATE LOADER Button, move the left hand
control toward the operator. The lift arms should not
lower.
13. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.

BICS SYSTEM (CONT'D)
WARNING
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 guide.(See Troubleshooting Guide on Page 60-90-4.)
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 seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.

BICS (CONT'D) Figure 60-90-2
Troubleshooting Guide
The following chart shows the effects which can happen

to the loader, and the probable causes when the BICS
Instrument Panel lights are off. See [Figure 60-90-2] for 6
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 60-90-2]
HOURMETER / CODE DISPLAY (Item 6) [Figure 60-90-
2]. If more than one SERVICE CODE is present, the 2 4
3
codes will scroll on the HOURMETER / CODE DISPLAY. 1 B-15551
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
1 PRESS TO PRESS TO Lift, tilt and ---- ---- ----
OPERATE OPERATE traction
LOADER Button LOADER Button functions will
is pressed. is not pressed. not operate.
2 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.
3 Control valve Control valve Lift, tilt and 1 17-07 Valve output circuit is open.
can be used. cannot be used. traction 2 17-05 Valve output circuit shorted to battery voltage*.
functions will 3 17-06 Valve output circuit shorted to ground.
not operate.
3 17-06 Controller not grounded or intermittent ground.
4 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).
SEAT BAR LIFT & TILT VALVE TRACTION 03-09
Continuous System voltage low
Flashing 03-10 System voltage high
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and
both battery connections.
ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay.
*Normal BICS operating voltage is less than the electrical system voltage.

SEAT BAR SENSOR
WARNING
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 MEL 1428 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.

SEAT BAR SENSOR (CONT'D) Figure 60-100-3
Test
Figure 60-100-1
1
P-4698
If there is no power light (Item 1) [Figure 60-100-3] on

N-18463 the sensor tester, check the tester or wiring harness.
Figure 60-100-4
Use Sensor Tester (MEL1428) and seat bar sensor
tester adatper (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 60-100-1].
Figure 60-100-2
P-4699
1
Lower the seat bar. The Sensor Test light (Item 1)

N-19557 [Figure 60-100-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1)

[Figure 60-100-4] 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 60-100-2]
inline, to the seat bar sensor connectors. See inset Replace the Seat Bar Sensor. (See Removal And
[Figure 60-100-2]. Installation on Page 60-100-3.)
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 BICS Circuit Test on Page 60-100-5.)
The toggle switch (Item 2) [Figure 60-100-3] can be in

either the Absent or Present position.

Figure 60-100-5
2
N-19224
Remove the seat bar (Item 1) [Figure 60-100-5] from the

N-19219
Remove the mounting bolt (Item 1) from the seat bar

mount (Item 2) [Figure 60-100-6].
Installation: Tighten the mounting bolt to 50-70 in.-lb.

(5,6-7,9 Nm) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-

100-6] and nut.

SEAT BAR SENSOR (CONT'D)
Figure 60-100-7
2
1
3
N-19383
Remove the keyed plastic bushing (Item 1) magnetic

bushing assembly (Item 2) and sensor bracket (Item 3)
[Figure 60-100-7].
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 60-100-7]
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.

BICS Circuit Test
Figure 60-100-8
3
1
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-100-9] 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 60-100-9] on the sensor tester to
[Figure 60-100-8]. the Present position.
NOTE: The sensor test light (Item 3) [Figure 60-100-9]

is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
BICS Circuit Test (Contd)
Figure 60-100-10
N-18409
The BICS seat bar indicator light (Item 1) [Figure 60-

100-10] should illuminate.
Figure 60-100-11
P-4699
Move the toggle switch (Item 1) [Figure 60-100-11] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-100-10] should go

off.
If the above test fails, there is a problem with the Bobcat

controller or the wiring harness.

TRACTION LOCK
WARNING
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
ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.)
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.

TRACTION LOCK (CONT'D) Inspecting The Control System
Description Of The Control System Fasten the seat belt, disengage the parking brake button,
press the PRESS TO OPERATE LOADER Button (Item
Figure 60-110-1 1) [Figure 60-110-1] and raise the Seat Bar fully. Move
the steering levers slowly forward and backward. The
TRACTION lock (Item 4) [Figure 60-110-1] should be
engaged. Lower the Seat Bar. Press the PRESS TO
OPERATE LOADER Button (Item 1) [Figure 60-110-1].
Engage the parking brake pedal and move the steering

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.
Figure 60-110-2
1 2 3 4
B-15551G
P-48521
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock Check the wire connections at the engine flywheel rpm
Control System is incorporated into the BICS System. speed sensor (Item 1) [Figure 60-110-2].
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 Adjustment on Page 60-140-1.), for Flywheel rpm

sensor adjustment.

TRACTION LOCK (CONT'D) Solenoid Removal And Installation
Inspecting
Fasten the seat belt, disengage the parking brake pedal,

press the green PRESS TO OPERATE Button and raise
WARNING
the Seat Bar fully. Move the control levers slowly forward
and backward. The Traction lock should be engaged. AVOID INJURY OR DEATH
Lower the Seat Bar. Press the green PRESS TO Do not modify the electrical wiring connected to the
OPERATE Button. traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
Engage the parking brake pedal and move the control function of the parking brake. Service work on the
levers slowly forward and backward. The Traction lock traction lock system should only be performed by a
should be engaged. qualified technician. Use only genuine Bobcat
Company parts if repair is necessary.
W-2165-0100

Figure 60-110-3
P-4712
P-34256
NOTE: The loader control panel and crossbar linkage

has been removed for clarity purpose only.
The traction lock can be removed without
removing the control panel.

110-3] from the electric solenoid mounting bracket.
Installation: Tighten the mounting screws to 80-90 in.-lb.

(9-10 Nm) torque.
Remove the electric solenoid (Item 2) from the chaincase

cover [Figure 60-110-3].

TRACTION LOCK (CONT'D) Figure 60-110-6
Solenoid Removal And Installation (Cont'd)
Figure 60-110-4
N-19079
Inspect the guides (Item 1) [Figure 60-110-6] for wear or

P-34377 damage. Replace if necessary .
Figure 60-110-7
Remove the bracket (Item 1) [Figure 60-110-4] from the
chaincase cover.
1
Installation: Tighten the mounting bolts to 25-28 ft.-lb. 2
(34-38 Nm) torque.
Be sure the solenoid mounting bracket is installed in the 3

same position. The solenoid mounting surface has a
slight angle which tips the top of the solenoid toward the
rear of the loader when installed correctly. See inset
photo [Figure 60-110-3].
Figure 60-110-5
P7926
1
Remove and inspect the compression spring (Item 1)
and spring cap washer (Item 2) [Figure 60-110-7] for
wear or damage. Replace if necessary. The spring may
also stay with the shaft when the electric solenoid and
bracket are removed from the chaincase.
Installation: Install the compression spring (Item 1)

[Figure 60-110-7] on the collar located on the electric
solenoid.
N-19108 Remove the traction lock assembly (Item 3) [Figure 60-

110-7] from the chaincase.
Remove the traction lock assembly (Item 1) [Figure 60-

110-5] from the chaincase.

TRACTION LOCK (CONT'D) Guide Removal
Solenoid Removal And Installation (Cont'd) The part number listed below will be needed to do the
following procedure:
Figure 60-110-8
P/N 6633583 - Polyurethane
2 Raise the loader lift arms and install an approved lift arm
3 support device.(See Installing Lift Arm Support Device on
Page 10-20-1.)
1 WARNING
P-7964
W-2059-0598
Remove the shaft mounting bolt (Item 1), spring from the
assembly shaft (Item 2). Remove the wedge (Item 3) Raise the operator cab. (See Raising The Operator Cab
[Figure 60-110-8] and inspect all parts for damage or on Page 10-30-1.)
wear. Replace if necessary.
Installation: Thoroughly clean and dry the shaft Installation on Page 70-20-1.)
mounting bolt (Item 1), the shaft (Item 2) and wedge
(Item 3) [Figure 60-110-8]. Use LOCTITE #242 when Remove the control panel from the loader. (See Removal
assembling these parts to the traction lock assembly. and Installation on Page 50-100-1.)
Remove the traction lock solenoid assembly. (See

Solenoid Removal And Installation on Page 60-110- 3.)
IMPORTANT
Failure to use LOCTITE may allow the traction lock
assembly to loosen up which can cause damage to WARNING
the traction lock system.
I-2090-1095 AVOID INJURY OR DEATH
Do not modify the electrical wiring connected to the
Install the engine speed control. (See Removal And traction lock solenoid or any part of the traction lock
Installation on Page 70-20-1.) system. The traction lock provides the locking function of
the parking brake. Service work on the traction lock system
Lower operator cab. (See Lowering The Operator Cab on should only be performed by a qualified technician. Use
Page 10-30-2.) only genuine Bobcat Company parts if repair is necessary.
W-2165-0100
Perform the BICS inspection procedure. (See BICS
SYSTEM on Page 60-90-1.)

Guide Removal
Figure 60-110-9
1
1
P11330
To remove the traction lock guides remove the four bolts

N-19079 (Item 1) [Figure 60-110-11].
Figure 60-110-12
Remove the center chaincase cover [Figure 60-110-9]
(See Center Cover Removal And Installation on Page 40-
30-3.) 1
3
Figure 60-110-10
1
2
2
P11332
Thoroughly clean the polyurethane from the chaincase

cover (Item 1), bolts (Item 2) and traction lock guides
P11331 (Item 3) [Figure 60-110-12] and dry.
NOTE: Bolt (Item 1) is on the rear of the chaincase

cover, notice the direction of the groove (Item
2) [Figure 60-110-10] in the traction lock
guides.

Guide Installation INCORRECT CORRECT

Figure 60-110-13
3
2
N-19106 N-19105
Install the traction lock guides (Item 1) to the chaincase

P11333 cover (Item 2) [Figure 60-110-15] using the four bolts
(removed earlier).
Apply a bead of polyurethane (P/N 6633583) on the Do not tighten at this time.
traction lock guides and bolts [Figure 60-110-13].
Figure 60-110-16
Figure 60-110-14
1
2
3
2
4 4
1
P11337
P11334
Install the traction wedge assembly (Item 1) into the

Install the electric solenoid/bracket assembly (Item 1) to solenoid and traction lock guides (Item 2) [Figure 60-
the center chaincase cover (Item 2) [Figure 60-110-14]. 110-16].
NOTE: Bolt (Item 3) [Figure 60-110-14] & [Figure 60- After the bolts have been tightened recheck to make sure
110-15] represents the rear of the chaincase the shaft assembly is moving freely in the guides.
cover.
Remove the wedge assembly (Item 1) [Figure 60-110-
Install and tighten the two bolts (Item 4) [Figure 60-110- 16].
14].
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 Nm) torque.

Guide Installation (Cont'd)
Figure 60-110-17
1
2
1
2
N-19109
Install the wedge assembly (Item 1) [Figure 60-110-19]

P11334 into the grooves in the traction lock guides making sure
that there is no binding.
Remove the two bolts (Item 1) and remove the electric Install the gasket (Item 2) [Figure 60-110-19].
solenoid (Item 2) [Figure 60-110-17] from the center
chaincase cover.
Figure 60-110-18
1
2
N-19079
Install the chaincase cover (Item 1) using the ten

mounting bolts (Item 2) [Figure 60-110-18].
NOTE: Thoroughly clean and dry the bolts and apply

polyurethane sealant to the bolt threads.
Install a new gasket between the chaincase
cover and the chaincase. Apply polyurethane
sealant to the gasket also.

ADVANCED CONTROL SYSTEM (ACS) Figure 60-120-2
Components Identification
2
Figure 60-120-1
1
11
2
P-21938 P-21939
Foot control/sensor assembly (Item 1) [Figure 60-120-2].

P-16536 P-21879
Foot sensor (Item 2) [Figure 60-120-2].
The Advanced Control System (ACS) is a selectable foot/ NOTE: The calibration procedure must be followed
hand control system. when replacing handle sensor, foot pedal
The ACS system allows the operator to quickly switch Calibration Procedure on Page 60-120-16.)
between foot and hand control modes.
Figure 60-120-3
Control Handle (Item 1) [Figure 60-120-1].
Handle sensor (Item 2) [Figure 60-120-1].

1
Calibration Procedure on Page 60-120-16.)
1
P-24203
Control Valve Actuators (Item 1) [Figure 60-120-3].


ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Figure 60-120-5
Components Identification (Cont'd)
Figure 60-120-4
P-21769
1
ACS error indicator (Item 1) [Figure 60-120-5].
P-21767
NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
ACS Controller (Item 1) [Figure 60-120-4]. (See DIAGNOSTICS SERVICE CODES on
Page 60-80-1.)

ADVANCED CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting Guide
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 60-80-1.)

Controller, Connector And Wire Identification
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 FOR-
WARD
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 FOR-
WARD
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

ACS Controller Removal And Installation
Figure 60-120-6
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 60-120-6]. NOTE: The calibration procedure must be followed
Remove the right front panel (Item 1) [Figure 60-120-6] sensor, actuator or ACS Controller. (See
from the loader. Calibration Procedure on Page 60-120-16.)
Figure 60-120-7
P-21843
Disconnect the wiring harness connectors (Item 1)

[Figure 60-120-7] from the controller.

Handle Sensor Connector
Figure 60-120-9
2
3
1
1
P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-120-

P16578 11] and pull the wire from the connector.
Installation: Install the wires into the connector as listed

The wire connector (Item 1) [Figure 60-120-9] can be below [Figure 60-120-11]:
removed from the handle sensor wires, using the
following procedure. 1-Terminal - Red
Figure 60-120-10 2-Terminal - Black
3-Terminal - Green
1
1
P13725 P13732
Remove the wedge (Item 1) [Figure 60-120-10] from the

connector.

Switch Handle Removal
Figure 60-120-12
1
3
2
P13735
1
2
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-120-14] and pull the wire from the connector.
Figure 60-120-15
NOTE: Switch handle can be removed and installed
while in loader.

120-12] from the handle sensor connector.

Figure 60-120-13 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.

Switch Handle Removal (Cont'd)
Figure 60-120-16
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
P13735 3 & 4) [Figure 60-120-18] from the loader wiring harness
connectors.
Using a pointed tool, press down on the tab (Item 1) Figure 60-120-19
[Figure 60-120-16] and pull the wire from the connector.
Figure 60-120-17
2 2
N-22783
2
N-17779 Roll the pistol grip handle cover (Item 1) [Figure 60-120-
19] down.
Disconnect the right switch handle connectors (Items 1 & Using a small screwdriver, lift the handle tabs (Item 2)
2) [Figure 60-120-17] from the loader wiring harness [Figure 60-120-19] and slightly rotate the switch handle.
connectors.

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-120-22
Figure 60-120-20
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 60-120-20] from the control lever. The switch handle comes with a 6 inch piece of heat
shrink tube slid over the end of the wires. Remove the
Cut the wires (Item 2) [Figure 60-120-20] below the heat shrink tube from the end of the wires before routing
switch handle and remove switch handle. the 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 120-22] 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 60-120-21
P-24234
If the harness has been cut: pull the harness (Item 1)

[Figure 60-120-21] out through the bottom of the control
lever tube.

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Install the wires into the connectors as listed below:
Switch Handle Installation (Cont'd) Right Switch Handle
Figure 60-120-23 Ten-Pin Connecter

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 60-120-23] 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 60-120-24
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

inches of heat shrink tube (Item 1) [Figure 60-120-24]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-120-

24] and re-bend tabs if necessary.

Switch Handle Installation (Cont'd)
Figure 60-120-25
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-
120-27]
Figure 60-120-26
1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
1
Figure 60-120-28
3 1
N-17772
2
Connect the handle harness connectors (Item 1) [Figure

60-120-25] & [Figure 60-120-26] to the loader harness
connectors.
P13735
Left and Right Control Lever Switch Handle [Figure 60-

120-28]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

Switch Handle Installation (Cont'd)

1
Figure 60-120-29
N-18940
Check the mounting block (Item 1) [Figure 60-120-31]

P-21804 and bolts for wear and replace as needed.
Connect the handle harness connectors to the sensor

and lock solenoid connectors [Figure 60-120-29].
Actuators Disassembly and Assembly
Figure 60-120-30
N-18912

on Page 50-100-1.)
Remove the actuator (Item 1) [Figure 60-120-30] from

the hydraulic control valve. (See Actuator Removal And
Installation: Tighten the mount bolts to 90-100 in.-lb.

(10,2-11,3 Nm) torque.

Actuators Disassembly and Assembly (Contd)
Figure 60-120-32
1
N-17742 N-17741
Check the actuator wiring harness connector (Item 1)

[Figure 60-120-32] and replace if broken.

below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-120-32].
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)

when replacing a handle sensor, foot pedal
sensor, actuator or ACS controller. (See

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-120-35
Figure 60-120-33
P-21878A
1
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-120-35].
120-33] 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 Nm) lubed
Disconnect the harness connector (Item 2) [Figure 60- torque.
Figure 60-120-36
Figure 60-120-34
1 P-21789
P-21832
Check the O-ring (Item 1) [Figure 60-120-36] for

Remove the two screws (Item 1) [Figure 60-120-34] 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

Nm) torque.
Remove handle lock solenoid assembly from handle.

Handle Lock Solenoid Connector
Figure 60-120-37
1 3
2
P-21802
1 With a pointed tool, lift the tab (Item 1) [Figure 60-120-

P-21787 39] and pull the wire from the connector.

The wire connector (Item 1) [Figure 60-120-37] can be below [Figure 60-120-39].
removed from the solenoid, using the following
procedure: 1 - Terminal - Black
2 - Terminal - Open
Figure 60-120-38 3 - Terminal - Black
1 1
P-21801

connector.

Calibration Procedure
The new 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.
NOTE: This calibration procedure must be followed

2
when replacing a handle sensor, actuator or
ACS controller. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
1
Figure 60-120-40
B-16627
Push the PRESS TO OPERATE button (Item 1) [Figure

60-120-42] to unlock the hand controls.
Figure 60-120-43
1
Stroke Both Handles Fully In and Hold Them
P-24182
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-120-40] in

the hand control mode.
B-16628
Figure 60-120-41
Fully stroke both control handles in toward the center of

the cab and hold the handles [Figure 60-120-43].
Lift the seat bar, high enough for the PRESS TO

Turn the Key On OPERATE light (Item 2) [Figure 60-120-42] to go OFF.
or Lower the seat bar.
Press the RUN/ENTER
B-16626
With the seat bar down, turn the ignition key ON (keyless
panel press RUN/ENTER) [Figure 60-120-41].
NOTE: Do not start the engine.

Calibration Procedure (Cont'd)
Figure 60-120-44 Stroke Both Handles Fully In and Hold Them
2 2
1
1
B-16628
Fully move both handles in toward the center of the cab

B-16627 and hold the handles for one second (Item 1) [Figure 60-
120-45].
Push the PRESS TO OPERATE button (Item 1) [Figure Fully move both handles out toward the cab side screens
60-120-44] to begin calibration. and hold for one second (Item 2) [Figure 60-120-45].
NOTE: The ACS icon will light up and if you listen Allow both handles to return to neutral.
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the Figure 60-120-46
ignition key is cycled or the loader is started
and a function is operated.
NOTE: During the calibration cycle, the system will 1

beep three times. The calibration process
generates two codes 32-35 (tilt handle not in
neutral) and 32-40 (lift handle not in neutral).
Ignore these two codes, this is normal during
the calibration procedure.
Release the control handles.

2
NOTE: The remaining portion of the procedure must
be completed in twenty seconds or less. If not
the handles and pedals will lock and the B-16628
procedure must be started over from the
beginning.
Fully press the toe of the lift and tilt pedals (Item 1)
[Figure 60-120-46] down and hold for one second.
Fully press the heel of the lift and tilt pedals (Item 2)
Allow both pedals to return to neutral.
At the end of the twenty second time frame, the handles

and pedals will lock.
Calibration is complete.

ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Connector
Foot Sensor Disassembly And Assembly Figure 60-120-49
Figure 60-120-47
1
P-24271
1
P-24269
The wire connector (Item 1) [Figure 60-120-49] can be
removed from the sensor wires, using the following
Remove the two bolts (Item 1) [Figure 60-120-47] from procedure:
the end of the foot sensor.
Figure 60-120-50
Installation: Tighten the bolts to 90 in.-lb. (10,2 Nm)
torque. Apply LOCTITE 242 to the threads.
Figure 60-120-48 1
1
1
4
P-24272 P-24273
P-24273
3
2
1 connector.
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-120-48].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-120-48]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

Foot Sensor Connector (Cont'd)

1
Figure 60-120-51
1
2
1 3
2
P-21939
Disconnect the foot lock solenoid connector (Item 1)

P-24274 [Figure 60-120-53] from the harness.
Remove foot lock solenoid (Item 2) [Figure 60-120-53].

51] and pull the wire from the connector. Installation: Apply a drop of oil on the solenoid threads
and tighten the solenoid to 35-40 ft.-lb. (47-54 Nm)
Installation: Install the wires into the connector as listed lubed torque.
below [Figure 60-120-51]:
Figure 60-120-54
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green
Foot Lock Solenoid Removal And Installation
Figure 60-120-52
2
P-21790
Check the O-ring (Item 1) [Figure 60-120-54] for

damage. Replace as necessary.
1
P-21938
Remove the two bolts (Item 1) [Figure 60-120-52] from

the foot sensor shield.
Installation: Tighten the bolts to 80-90 in.-lb. (9,0-10,2

Nm) torque.

Foot Lock Solenoid Connector

removed from the solenoid wires, using the following
procedure:
Figure 60-120-55
1 1
P-21800 P-21801

connector.
Figure 60-120-56
1 3
2
P-21802

56] and pull the wire from the connector.

below [Figure 60-120-56]:
2 - Terminal - Open

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
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
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.

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
(CONTD)
Solenoid Hydraulic Wiring
Controls Identification Chart (Contd)
Number Coupler Number
Front
1 Female 4340
(Base)
Front
S175, S185 2 Male 4330
(Rod)
Diverter &
6 3 4450/4480
Bleed
4 Rear Aux
1 4 4440
2 Base
5 Rear Aux Rod 4430
6 High Flow 4460
3 5
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.

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC)
Controls Identification Chart
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

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) (CONTD)
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.

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) (CONTD)
Solenoid Hydraulic Wiring

Number Coupler Number
S175, S185 Front
1 Female 4340
6 (Base)
Front
4 1 2 Male 4330
2 (Rod)
Diverter &
3 4450/4480
Bleed
Rear Aux
4 4440
3 Base
5
5 Rear Aux Rod 4430
6 High Flow 4460
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.

FLYWHEEL RPM SENSOR Figure 60-140-2
Adjustment
Figure 60-140-1
2 P-48666
Turn the RPM sensor and the jam nut out from the
P-48665 flywheel. Set a clearance of .050 inch (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-140-2].
When reinstalling the RPM sensor, turn the rpm sensor
(Item 1) [Figure 60-140-1] in until it makes contact with NOTE: New RPM sensors have a plastic tip which is
the engine flywheel. used as a gauge during installation. The
plastic tip is designed to come off after the
Turn the jam nut (Item 2) [Figure 60-140-1] until it engine is started.
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.

SERVICE PC (LAPTOP COMPUTER)
Connecting The Service PC To Remote Start Tool
Figure 60-150-1
1 2
P16119
Tools that will be needed to complete the following steps

are:

MEL1565 - Service Tool Harness Control
MEL1566 -Service Tool Harness Communicator
(Computer Interface)
NOTE: Make all connections with the key in the OFF

position.
The Service PC (Item 1) with the remote start tool (Item

2) [Figure 60-150-1]. When connected to the loader, the
Service PC is used to monitor, conduct diagnostic and
load software.
Connect the Service Tool Harness Communicator

(MEL1566) (Item 3) [Figure 60-150-1] to the designated
serial port on the Service PC.
NOTE: The recommended serial cable length should

not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the remote

start tool.


CALIBRATION Actuator Testing
Description The Actuator Test is performed with the Service PC and

Remote Start Tool. The Actuator Test should be used if
Calibration procedures must be followed when replacing reduced performance codes are present and when
a handle sensor, actuator, or any controller. Failure to replacing a controller or actuator. The Actuator Test
calibrate after component replacement may result in poor should be used as the preferred method of actuator and
performance or reduced life of actuator(s). valve spool calibration.
Figure 60-160-1 NOTE: Warm the hydraulic oil to room temperature

72oF (22oC), stop the engine and clear all
active service codes before running the test.
Control Valve Actuators Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the
test will be performed and the results can be viewed on
the Service PC (Laptop) monitor.
This test will engage both actuators to fully stroke the

spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to
move the spools just past the neutral points then allow
the centering springs to return the spools to neutral.
When complete, the Actuator Test will show a pass mode

P-24203 or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a
[Figure 60-160-1] Excessive actuator loading can occur combination of three problems below.
if the actuator and valve spool components are
misaligned. Misalignment may reduce spool stroke Actuator slow return to neutral. The spool returns
performance and reduce the life of the actuator. Starting to neutral too slowly.
with version 36, the Bobcat Service Analyzer software
will be able to perform tests to diagnose actuator and Actuator did not fully extend/retract. During the
valve spool misalignment. test, the spool was not able to fully stroke in both
directions.
The Actuator Test is performed with the Service PC and
Remote Start Tool. The Actuator Test should be used if Actuator out of neutral. The spool did not return to
reduced performance codes are present and when the neutral window during the test.
replacing a controller or actuator. The Actuator Test
should be used as the preferred method of actuator and NOTE: A time out will occur if the test cannot be
valve spool calibration. completed within 8 seconds. If this happens,
retry the test.
If a Service PC is not available,: See Lift and Tilt
Calibration Procedure (SJC) on page 60-160-4 or See
Calibration Procedure (ACS) on page 60-160-11.

CALIBRATION (CONTD) Figure 60-160-3
Actuator Testing (Contd) Pin Spool Hole

Actuator
Figure 60-160-2
Run Actuator Test
Pass Fail
Retest With Warm Hydraulic Oil
Pass Fail
Adapter
Loosen Actuator Bolts

N-18940
Pass Fail [Figure 60-160-3] If the Actuator Test fails after the
hydraulic oil is warmed, go to the next step and loosen
the bolts that mount the actuator to the control valve.
Column 1 Column 2 Loosen the bolts just enough so the actuator can be
Probable Cause Probable Cause moved slightly up/down or side/side.
1 - Misaligned Assembly 1 - Actuator
Rerun the Actuator Test, if the test passes, check the
2 - Adapter / Pin 2 - End Cap / Center Spring
3 - Wire Harness following probable causes in Column 1 [Figure 60-160-
3 - Spool
4 - Controller 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
Rerun the test to verify.
[Figure 60-160-2] If the initial Actuator Test results in a
fail mode due to a slow return to neutral, follow the 1. Actuator and spool misalignment. Re-tighten the two
troubleshooting tree to pinpoint the probable cause. bolts evenly, turn the first bolt one turn, then turn the
other bolt one turn until both bolts are tight.
Figure 60-160-4
Thickness Difference
on Opposite Sides
Must be Within
0.004 (0.102mm)
P-54928B
2. [Figure 60-160-4] The adapter may not be machined

correctly. Adapters with a large difference in
thickness measured on opposite sides should be
replaced.
The pin may be too large. Oversized pins exceeding
0.248 (6.30mm) in diameter should be replaced.

CALIBRATION (CONTD) If the initial Actuator Test results in the fail mode
actuator did not fully extend/retract, check the
Actuator Testing (Contd) following.
Figure 60-160-5 1. The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
This spool hole is not centered.
rerun the Actuator Test.
2. The actuator may be weak, replace the actuator.
3. The end cap may be defective or the centering spring

The Hole may be broken. Inspect the end cap and the
is Shifted centering spring, replace if necessary.
Off Center
If the initial Actuator Test results in the fail mode
actuator out of neutral, check the following.
1. The actuator may be defective, replace the actuator.
P-54927 2. The end cap may be defective or the centering spring

may be broken. Inspect the end cap and the
3. [Figure 60-160-5] The spool hole may not be centering spring, replace if necessary.
centered, visually inspect both sides. Replace the
spool if the hole is not centered. This letter is provided as technical information. Normal
warranty applies.
NOTE: Later model spools have a slotted hole to
reduce misalignment.
If the Actuator Test failed due to a slow return to neutral

after checking the probable causes in Column 1 [Figure
60-160-2], check the following probable causes in
Column 2 [Figure 60-160-2].
1. The actuator may be weak, replace the actuator.
2. The end cap may be defective or the centering spring

may be broken. Inspect the end cap and the
centering spring, replace if necessary.
3. The wire harness or connectors may have an

intermittent short. Check the connections and wire
harnesses.
4. The controller may be defective, replace the

controller.

Lift and Tilt Calibration Procedure (SJC)
NOTE: This calibration procedure must be followed

when replacing the lift or tilt actuator, SJC
controller or joystick. Failure to calibrate after
performance or reduced life of actuator(s).
Figure 60-160-6
P-26475
1
Figure 60-160-9
P-45240
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is so equipped.) 1

Place the loader Control Pattern Switch (Item 1) [Figure
60-160-6] in the ISO position. P-26480
Figure 60-160-7
Turn the key (Item 1) [Figure 60-160-8] to the RUN
position or press the RUN/ENTER button (Item 1)
[Figure 60-160-9] for power, without starting the loader.
The loader Control Pattern Switch (Item 1) [Figure 60-

160-6] will start flashing and will continue to flash until the
calibration procedure is completed.
B-19874
P-28063
Move the right joystick to the forward-right corner position

[Figure 60-160-7] and hold in position.

CALIBRATION (CONTD) Hydrostatic Pump Calibration (SJC)
Lift and Tilt Calibration Procedure (SJC) (Contd)
Figure 60-160-10 WARNING

2 Failure to use jackstands can allow the machine to
W-2017-0286
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
Operator must be in the seat and the seat bar down.
1 Figure 60-160-11
P-26477A
At the left panel, press the PRESS TO OPERATE Button

(Item 1) [Figure 60-160-10] while holding the right 1
joystick in position.
Release the joystick.

2
An audible beep will sound and an error code (Item 2)
[Figure 60-160-10] (32-35 & 32-40) will be displayed if
the operator presses the HOLD FOR CODES, (LIGHTS)
switch.
The SJC controller will cycle the actuators. P-45238
The lift and tilt calibration is complete.

Close the cab door. (If loader is so equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-11] in the ISO position.
Verify the parking brake (Item 2) [Figure 60-160-11] is

OFF.

CALIBRATION (CONT'D) Figure 60-160-14
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-12
1
1 P-45238
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-26475 14] will start flashing.
Figure 60-160-15
Figure 60-160-13
1 B-19873
P-26476
P-26480
Move the left joystick to the forward-left corner position

Turn the key (Item 1) [Figure 60-160-12] to the RUN [Figure 60-160-15] and hold in position.
position or press the RUN/ENTER button (Item 1)
[Figure 60-160-13] for power, without starting the loader.

Figure 60-160-16
1
P-26477A
1
Press the PRESS TO OPERATE LOADER Button (Item
P-26477A 1) [Figure 60-160-18] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-16] while holding the left joystick in
position. Figure 60-160-19
Three audible beeps will sound.
Figure 60-160-17
B-19873
P-26474
Allow the left joystick to go to the neutral position [Figure

P-26476 60-160-19].
Move the left joystick to the reverse-right corner position

[Figure 60-160-17] and hold in position.

Figure 60-160-20
2 75-98
3
P-34548
1
Move the throttle (Item 1) [Figure 60-160-22] to high idle.
P-26477A
NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift
Press the PRESS TO OPERATE LOADER Button (Item the seat bar, or return the joystick to the
1) [Figure 60-160-20]. neutral position.
Three audible beeps will sound and the error code (Item The calibration procedure will stop.
2) (75-98) will be displayed if the operator presses the
HOLD FOR CODES (LIGHTS) switch (Item 3) [Figure To return to calibration mode, the operator
60-160-20]. must start the complete procedure from the
beginning.
Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.
WARNING
Figure 60-160-21
W-2017-0286
1
P-45238
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

21] will stop flashing, and will remain ON for the rest of

Figure 60-160-23 1 2
B-19873
P-64321
The loader speed will ramp up quickly (Item 1)

P-26482 [Figure 60-160-24] and slow down 3 times in a row.
The loader will then stair step the speed (Item 2)

Move and hold the left joystick to the forward position [Figure 60-160-24] until it reaches full speed and then
[Figure 60-160-23] until the forward calibration is come to a stop.
completed.
Continue to hold the left joystick in the forward position
until the loader tracks come to a stop and an audible
beep is heard.
Forward calibration is complete.
NOTE: If the wheels 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.
Figure 60-160-25
B-19873
P-26483
Move and hold the left joystick to the reverse position

[Figure 60-160-25] until the reverse calibration is
completed.

CALIBRATION (CONT'D) NOTE: If the wheels do not stop moving in Full Speed
Reverse in 2 minutes or less, there was an
Hydrostatic Pump Calibration (SJC) (Cont'd) error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-26 the calibration procedure from the beginning.
There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
1 2 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.
The calibration procedure is completed.
Press the PRESS TO OPERATE LOADER button. Move

the left joystick to forward position [Figure 60-160-23]
and check for normal forward wheel rotation.
P-64321
Move the left joystick to the reverse position [Figure 60-
160-25] and check for normal reverse wheel rotation.
The loader speed will ramp up quickly (Item 1)
[Figure 60-160-26] and slow down 3 times in a row. Stop the engine, and remove the loader from jackstands.
The loader will then stair step the speed (Item 2) Start the loader, press the PRESS TO OPERATE
[Figure 60-160-26] until it reaches full speed and then LOADER button and return to normal loader operation.
come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels come to a stop and an audible
beep is heard.
Reverse calibration is complete.

Calibration Procedure (ACS)
The new 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.
NOTE: This calibration procedure must be followed 2

when replacing a handle sensor, actuator or
ACS controller. Failure to calibrate after
performance or reduced life of actuator(s). 1
Figure 60-160-27 B-16627
Push the PRESS TO OPERATE button (Item 1) [Figure

60-160-29] to unlock the hand controls.
Figure 60-160-30
1
Stroke Both Handles Fully In and Hold Them
P-24826
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-160-27] in

the hand control mode.
Figure 60-160-28 B-16628
Fully stroke both control handles in toward the center of

the cab and hold the handles [Figure 60-160-30].
Turn the Key On Lift the seat bar, high enough for the PRESS TO
OPERATE light (Item 2) [Figure 60-160-29] to go OFF.
or
Lower the seat bar.
Press the RUN/ENTER
B-16626
With the seat bar down, turn the ignition key ON (keyless
panel press RUN/ENTER) [Figure 60-160-28].
NOTE: Do not start the engine.

Calibration Procedure (ACS) (Cont'd)
Figure 60-160-31 Stroke Both Handles Fully In and Hold Them
2 2
1
1
B-16628
Fully move both handles in toward the center of the cab

B-16627 and hold the handles for one second (Item 1) [Figure 60-
160-32].
Push the PRESS TO OPERATE button (Item 1) [Figure Fully move both handles out toward the cab side screens
60-160-31] to begin calibration. and hold for one second (Item 2) [Figure 60-160-32].
NOTE: The ACS icon will light up and if you listen Allow both handles to return to neutral.
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the Figure 60-160-33
ignition key is cycled or the loader is started
and a function is operated.
NOTE: During the calibration cycle, the system will 1

beep three times. The calibration process
generates two codes 32-35 (tilt handle not in
neutral) and 32-40 (lift handle not in neutral).
Ignore these two codes, this is normal during
Release the control handles.

2
NOTE: The remaining portion of the procedure must
be completed in twenty seconds or less. If not
the handles and pedals will lock and the B-16628
procedure must be started over from the
beginning.
Fully press the toe of the lift and tilt pedals (Item 1)
Fully press the heel of the lift and tilt pedals (Item 2)
Allow both pedals to return to neutral.
At the end of the twenty second time frame, the handles

and pedals will lock.
Calibration is complete.

SPEED SENSOR Testing
Description Figure 60-170-2
Figure 60-170-1
1
P-28302
P-64765
procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
170-1] is used by the loaders controllers to sense if the MEL1609-Wheel Speed Sensor Test Harness
drive motor is rotating. The end of the sensor is magnetic [Figure 60-170-2]
and counts the magnetic pulses as a rotating disc
attached to the motor carrier shaft rotates by the sensor MEL1563-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
[Figure 60-170-1] to keep hydraulic oil inside the motor support device. (See Installing Lift Arm Support Device
carrier and dirt out. on Page 10-20-1.)

on Page 10-30-1.)
Connect the remote start tool to the loader. ((See


SPEED SENSOR (CONT'D) Figure 60-170-4
Testing (Contd)
Figure 60-170-3
3
2
1
2
1
P-64976
Connect the speed sensor test harness (Item 1) [Figure

P-64762 60-170-4] in line, between the loader wiring harness and
the speed sensor harness.
Locate the speed sensor (Item 1) [Figure 60-170-3] on Turn the remote start key to ON position without starting
the 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
60-170-3], to loosen the connector clamp. sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-170-4].
Installation: Tighten screw to 15-20 ft.-lb. (20-27 Nm)
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 60-170-3] from the loader harness wire sensor. (If needed.)
connector.

SPEED SENSOR (CONT'D) Disconnect the speed sensor electrical harness
Figure 60-170-7
Figure 60-170-5
P-64764
P-64762
Lift the speed sensor (Item 1) [Figure 60-170-7] out from

Raise the lift arms and install an approved lift arm the motor carrier. DO NOT pull on the wires, gently pry
support device. (See Installing Lift Arm Support Device up with a screwdriver if necessary.
on Page 10-20-1.)
Figure 60-170-8
on Page 10-30-1.)
Remove the two, speed sensor mount bolts (Item 1)

[Figure 60-170-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-170-5].
Figure 60-170-6
1 P-64765
Remove the speed sensor [Figure 60-170-8].
P-64762
Remove the transmission cover screw (Item 1) [Figure

60-170-6], to loosen the connector clamp.
Installation: Tighten screw to 15-20 ft.-lb. (20-27 Nm)

torque.

SPEED SENSOR (CONT'D) Figure 60-170-11
Removal and Installation (Cont'd)
Figure 60-170-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)

P-26293 [Figure 60-170-11] pointing toward the transmission
case.
The electrical connector can be replaced. Figure 60-170-12
Remove the connector wedge (Item 1) [Figure 60-170-

9].
Figure 60-170-10
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 60-170-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-170-10].
Wire Code
1 Red
2 White
3 Black
4 Blue

ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Blower Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Blower Housing Grill Removal And Installation . . . . . . . . . . . . . . . . 70-60-4
Drive Tension Pulley Removal And Installation . . . . . . . . . . . . . . . . 70-60-1
Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-12
Gearbox/Blower Housing Removal And Installation . . . . . . . . . . . . 70-60-2
Gearbox Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Checking Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal And Installation (Non-Turbo) . . . . . . 70-70-8
Fuel Injection Pump Removal And Installation (Turbo) . . . . . . . . . . 70-70-5
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-70-14
Fuel Shut-Off Solenoid, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3 ENGINE
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . . . . . . . . 70-70-4 SERVICE
Glow Plugs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Nozzle Spraying Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16
Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

ENGINE SERVICE (CONTD)
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T

(TURBO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Camshaft Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . 70-100-19
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . 70-100-25
Crankshaft And Bearings Removal And Installation . . . 70-100-25
Crankshaft And Bearings, Servicing . . . . . . . . . . . . . . . 70-100-27
Crankshaft Gear Removal And Installation . . . . . . . . . . 70-100-17
Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . 70-100-31
Cylinder Head Disassembly And Assembly. . . . . . . . . . . 70-100-4
Cylinder Head Removal And Installation . . . . . . . . . . . . . 70-100-1
Cylinder Head Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . 70-100-5
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . 70-100-17
Fuel Camshaft Removal And Installation. . . . . . . . . . . . 70-100-16
Idler Gear And Camshaft Removal And Installation . . . 70-100-13
Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . 70-100-15
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . 70-100-18
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-18
Piston And Connecting Rod Removal And Installation . 70-100-20
Piston And Connecting Rod Servicing . . . . . . . . . . . . . . 70-100-22
Reconditioning The Valve And Valve Seat . . . . . . . . . . . 70-100-8
Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . 70-100-10
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . 70-100-16
Timing Gearcase Cover Removal And Installation . . . . 70-100-10
Valve Guide Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Valve Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-20
Water Pump Disassembly And Assembly . . . . . . . . . . . 70-100-32
Water Pump Removal And Installation . . . . . . . . . . . . . 70-100-32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
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

TROUBLESHOOTING (CONTD)
Chart (Contd)

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 enought 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

ENGINE SPEED CONTROL Figure 70-20-2
WARNING P-4072
Never work on a machine with the lift arms up unless Pull the speed control away from the loader frame and
the lift arms are secured by an approved lift arm disconnect the speed control rod (Item 1) [Figure 70-20-
support device. Failure to use an approved lift arm 2] from the control.
to fall and cause injury or death. Installation: Be sure to install the control rod in the
W-2059-0598 bottom hole of the speed control.
1
1 1
2
N-18878 P-34156
Raise the lift arms and install an approved lift arm device. Installation: Install the stop bracket (Item 1) [Figure 70-
(See Installing Lift Arm Support Device on Page 10-20- 20-3] in the same location. It is necessary for the front
1.) and rear stop on the bracket to be located correctly.
Raise the operator cab. (See Raising The Operator Cab Reverse the removal procedure to install the engine
on Page 10-30-1.) speed control.
Remove the two mounting bolts (Item 1) [Figure 70-20- Disassembly

1] and nuts from the speed control mounting bracket.
Loosen the two control lever mounting bolts (Item 2)
Installation: Tighten the mounting bolts and nuts evenly [Figure 70-20-1] and remove the mounting nuts (Item 2)
until the speed control lever moves back and forth at a [Figure 70-20-3].
comfortable tension.
Assembly: Do not lubricate the engine speed control.
Replace any worn or damaged parts if necessary.

MUFFLER
Figure 70-30-1
3
3
2
1
P-48866
Open the rear door and raise the rear grill.
Remove the exhaust pipe clamp (Item 1) from the muffler (Item 2) [Figure 70-30-1].
Disconnect the exhaust pipe from the muffler.
Remove both muffler mounting bolts (Item 3) [Figure 70-30-1] from the muffler.
Installation: Tighten the muffler mounting bolts to 25-28 ft.-lb. (34-38 Nm) torque.
Remove the muffler from the loader.
Reverse the removal procedure to install the engine muffler.

AIR CLEANER Figure 70-40-3
Figure 70-40-1
1
1
2
P-28915
2
Remove the lower mounting bolt (Item 1) and engine
P-34449 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Installation: Tighten the three mounting bolts to 25-28
70-40-1] from the air cleaner sensor on the air cleaner. ft.-lb. (34-38 Nm) torque.
Loosen the clamp (Item 2) [Figure 70-40-1] from the Remove the air cleaner from the engine compartment.
hose on the engine manifold.
Reverse the removal procedure to install the air cleaner.
Figure 70-40-2
2
1
P-34450
Loosen the hose clamp (Item 1) [Figure 70-40-2] on the

air cleaner hose.

2] from the top mount of the air cleaner.

RADIATOR Figure 70-50-2

1
Remove the rear grill. (See Removal And Installation on
Page 50-60-1.)
Remove the oil cooler. (See Removal and Installation on

Page 30-60-1.)
WARNING P-48551
Do not remove radiator cap when the engine is hot.

You can be seriously burned. Open the drain valve (Item 1) [Figure 70-50-2] on the
W-2070-1285
engine block and drain the coolant into a container.
1
P-45245 P-48242
Loosen the radiator cap (Item 1) [Figure 70-50-1] from Remove the two sta-straps (Item 1) [Figure 70-50-3]
the pressurized expansion tank. holding the pressurized expansion tank fill hose (Item 3)
[Figure 70-50-4].

RADIATOR (CONT'D) Figure 70-50-6
Figure 70-50-4
1
1
3
2
2
P-48570
P-48554
Remove the hose clamp (Item 1) [Figure 70-50-6] from

P-45245 the inlet hose.
Remove the radiator mounting bolt and block off plate

Remove the two pressurized expansion tank mounting (Item 2) [Figure 70-50-6].
bolts (Item 1) [Figure 70-50-4].
Installation: Tighten the radiator mounting bolt to 11-13
Disconnect the pressurized expansion tank fill hose ft.-lb. (15-17 Nm) torque. Use sealant on the block off
(Item 3) [Figure 70-50-4] at the radiator end. plate and bolt head (Item 2) [Figure 70-50-6].
Remove the pressurized expansion tank (Item 2) with the Figure 70-50-7
pressurized expansion tank fill hose (Item 3) attached.
[Figure 70-50-4].
Figure 70-50-5
3
2
1
P-48553
Remove the clamp (Item 1) [Figure 70-50-7] from the

P-48552 hydraulic fill tube.
Remove the radiator mounting bolt (Item 2) [Figure 70-

Remove the hose clamp (Item 1) [Figure 70-50-5] from 50-7].
the outlet hose.
Remove the two hydraulic fill tube mounting bolts (Item 3)
[Figure 70-50-7].

RADIATOR (CONT'D)
Figure 70-50-8
P-48841
Remove the hydraulic fill tube (Item 1) [Figure 70-50-8].
Lift the radiator up and remove it from the loader.
Reverse the above procedure to install the radiator.

COOLING FAN Figure 70-60-3
Drive Tension Pulley Removal And Installation
Figure 70-60-1
1
P0581
Installation: Put a small amount of grease around the

P0580 P0585 outside edge (Item 1) [Figure 70-60-3] on the grease
rings.
Loosen the idler pulley bolt [Figure 70-60-1]. Figure 70-60-4
Installation: Install the retainer bracket (Item 1) [Figure

70-60-1] for the fan belt at the 3 o'clock position. 6
3
Figure 70-60-2
1 3
4 2
1
N-00303
Remove the bolt (Item 1) [Figure 70-60-2] & [Figure 70-

60-4] from the idler pulley pivot arm (Item 6) [Figure 70-
P0582 60-4].
Remove the thrust washer (Item 2), O-rings (Item 3) and

Remove the spacers, bolt and washer from the arm spring (Item 4) [Figure 70-60-4].
[Figure 70-60-2].
Check all parts for damage or wear and replace them as
needed.
NOTE: When making any repairs, replace the

bushing (Item 5) [Figure 70-60-4] with a new
bushing, if worn. Clean all parts and assemble
dry. Do not lubricate
Installation: Reverse the removal procedure to install

the tension pulley.

COOLING FAN (CONT'D) Figure 70-60-6
Gearbox/Blower Housing Removal And Installation
1
2
WARNING
N-19188
Remove the nuts (Item 1) [Figure 70-60-6] from the u-

Never work on a machine with the lift arms up unless bolt which mounts the fan belt shield (Item 2) [Figure 70-
the lift arms are secured by an approved lift arm 60-6] to the blower fan.
support device can allow the lift arms or attachment Remove the fan belt shield (Item 2) [Figure 70-60-6]
to fall and cause injury or death. from the blower fan.
W-2059-0598
Installation: Be sure to tighten the shield so it does not

Figure 70-60-5 interfere with the fan belt.
Figure 70-60-7
1
1
N-19169
Oil Level N-19375

Put jackstands under the rear corners of the loader.
Raise the lift arms and install an approved lift arm device. Disconnect the breather hose (Item 1) [Figure 70-60-7]
(See Installing Lift Arm Support Device on Page 10-20- from the electrical harnesses on the loader frame.
1.)
Installation: Make sure the breather hose is unrestricted
Raise the operator cab. (See Raising The Operator Cab when routing.
on Page 10-30-1.)
Remove the fan drive belt (Item 2) [Figure 70-60-7] from
Remove the left gas cylinder mounting bracket (Item 1) the pulley on the blower fan.
[Figure 70-60-5]. (See Gas Cylinder Removal And
Installation on Page 50-20-1.) NOTE: When checking the fan gearbox oil level, be
sure the level does not go above the top of the
shaft in the gearbox [Figure 70-60-7]. Use a
light colored 90W gear lube if the level is low.
Gearbox/Blower Housing Removal And Installation

(Cont'd)
Figure 70-60-8
4
1
P13920
3 1 Lower the blower fan from the housing until it rests on the
steering linkage plate [Figure 70-60-10].
N-19376
Figure 70-60-11
Figure 70-60-9
N-19378
P-4301
Remove the strip of sealant along the top of the blower
housing [Figure 70-60-11].
8] and the two spacer tubes (Item 2) [Figure 70-60-8] Installation: Use R.T.V. sealant to reseal the blower
from the blower fan. housing.
Remove the rear mounting bolt (Item 3) [Figure 70-60- Loosen the electrical harnesses from the frame of the
8]. loader.
Remove the front mounting bolt (Item 4) [Figure 70-60- Slide the blower fan and housing forward and remove
8]. both from the loader.
NOTE: Mounting bolts (Items 3 & 4) [Figure 70-60-8]

use wave washer (Item 1) [Figure 70-60-9] to
prevent tubes and bolts from falling out of the
housing during installation.
Installation: Tighten the four mounting bolts 25-28 ft.-lb.

(34-38 Nm) torque.

COOLING FAN (CONT'D)
Blower Housing Grill Removal And Installation

WARNING
Figure 70-60-12
Wear safety goggles to prevent eye injury when
drilling or grinding.
W-2108-1186
Figure 70-60-14
1
2
1
P-43448
1
To replace the blower housing grill, remove the four

mounting bolts (Item 1) [Figure 70-60-12] from the grill.
Install the new grill and replace the mounting bolts.

P3006
Blower Disassembly And Assembly

Use the following procedure to remove the fan from the
Figure 70-60-13 shaft.
Install the nut (Item 1) [Figure 70-60-14] on the tapered

shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-60-14].
As the center bolt (Item 2) [Figure 70-60-14] is tightened,

periodically strike the bolt head to loosen the fan from the
shaft.
CD-9952
Remove the lock nut and spacer [Figure 70-60-13].

torque.

Blower Disassembly And Assembly (Cont'd)
Figure 70-60-15
CD-8954
Installation: Clean the surface where the blower housing

CD-9953 contacts the loader frame. Put a bead of R.T.V. sealant
on the blower housing [Figure 70-60-17].
Remove the fan from the tapered shaft [Figure 70-60-

15].
Figure 70-60-16
1
CD-9954
To remove the blower housing mounting plate, remove

the six bolts (Item 1) [Figure 70-60-16].

Gearbox Parts Identification
1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.)
7. Long Key 1
8. Shaft (Short)
9. Short Key
10. Long Housing 18
11. Nut
12. Gear
13. Washer 1 6
14. Screw 2
3
15. Square Shim 4
7 4
16. Short Housing 5
17. Bolt
18. Snap Ring (Large)
19. Cap 8
20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug 22
4
12
13 9
15
14 *16
10
21
11
17
12
20
13
14
18
19
TS-1002A
*Individal Part not available. (See Gearbox Disassembly on Page 70-60-7.)

Gearbox Disassembly
Figure 70-60-18
Part Number
2 Tag
P2983
3
1 Remove the four mounting bolts and the part number tag
P-37891 [Figure 70-60-19].
Remove the oil from the gearbox.

NOTE: When repairing the gearbox order the
following as needed.
1.
2.
Complete Assembly
Long Housing Assembly
WARNING
3. Long Housing
4. Short Housing Assembly (See Note Below) AVOID INJURY OR DEATH
5. Internal Parts Wear safety goggles to prevent eye injury when
NOTE: The short housing is only available as an W-2108-1186
assembly. (See Gearbox Parts Identification
on Page 70-60-6.) (Order parts from Bobcat Figure 70-60-20
Parts.)
NOTE: Be sure to count the number and thickness of

shims during disassembly. Install the shims
in the original location during assembly.
NOTE: Always replace seals during assembly.

Replace the parts in the gearbox as needed.
Remove the fan and blower housing mounting plate.

(See Gearbox/Blower Housing Removal And Installation
on Page 70-60-2.)
Long Housing
P2999
Loosen the set bolts (Item 1) and remove the pulley (Item
2) [Figure 70-60-18].
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide
Remove the long key (Item 3) [Figure 70-60-18]. hammer tool to remove the seal [Figure 70-60-20].

COOLING FAN(CONT'D) Figure 70-60-23
Gearbox Disassembly (Cont'd)
Figure 70-60-21
P2966
Remove the screw and washer from the shaft [Figure

P2964 70-60-23].
Figure 70-60-24
Remove the small snap ring [Figure 70-60-21].
Figure 70-60-22
P3004
P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-24].
Remove the small shims [Figure 70-60-22]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.


WARNING
Figure 70-60-25
Wear safety goggles to prevent eye injury when
W-2108-1186
Figure 70-60-27
P3298
Support the bearing and press the shaft from the bearing
[Figure 70-60-25].
Figure 70-60-26
P2996
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide

hammer tool to remove the seal [Figure 70-60-27].
Figure 70-60-28
P2997
Short Housing
Remove the end cap [Figure 70-60-26].

P2970
Use care not to damage the housing.
Remove the large snap ring from the flange end of the
housing [Figure 70-60-28].

Figure 70-60-29
P2973
Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-31].
Figure 70-60-32
Remove the large shims from the housing [Figure 70-60-
29].
NOTE: Use the same size and thickness of shims

during assembly.
Figure 70-60-30
1
P2998
Press the shaft from the housing [Figure 70-60-32].
NOTE: Both bearings may come out of the housing

with the shaft. If one bearing remains in the
P2978 housing use a non metal object to tap the
bearing from the housing.
Remove the screw and washer (Item 1) [Figure 70-60-

30] from the shaft.

Figure 70-60-33
P2972
Remove the key from the shaft [Figure 70-60-35].

P3088
Press the bearing from the tapered end of the shaft

[Figure 70-60-33].
Figure 70-60-34
P3001
Press the bearing, shims and gear from the shaft [Figure
70-60-34].

Gearbox Assembly
Figure 70-60-36
P2960
Install the long housing on the shaft [Figure 70-60-37].

P2961
Be sure the bearing is seated in the bore at the lower end
of the housing.
NOTE: When ordering parts for the Fan Gearbox,
(See Gearbox Disassembly on Page 70-60-7.) Figure 70-60-38
NOTE: Do not install the seals and cap in the housing

until after the backlash has been checked.
NOTE: Use care when pressing the bearings into the

aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of LOCTITE

#242 adhesive, thoroughly clean and dry
LOCTITE #242.
Long Housing
P2962
Press a bearing on the short keyed end of the long shaft
[Figure 70-60-36].
Install a bearing on the long keyed end of the shaft
[Figure 70-60-38].
Support the lower bearing and press the other bearing in

the housing until the bearings seat in the housing [Figure
70-60-38].

Gearbox Assembly (Cont'd)
Figure 70-60-39
P2965
Install the gear key in the flange end of the shaft [Figure
P2963 70-60-41].
Figure 70-60-42
Install on the bearing, the same number and size shims
that were removed during disassembly [Figure 70-60-
39].
Figure 70-60-40
P2967
Align the key and gear. While supporting the bearing on

the other end, press the gear on the shaft until it seats
P2964 against the bearing [Figure 70-60-42].
Install the small snap ring in the groove above the shims
[Figure 70-60-40].

Figure 70-60-43
P2969
Install the large shims on the bearing (flanged end)

P2966 [Figure 70-60-45]
Figure 70-60-46
Install the washer (Item 1) [Figure 70-60-43].
Put liquid adhesive (LOCTITE #242) on the screw

threads. Install and tighten the screw [Figure 70-60-43].
Short Housing
Figure 70-60-44
P2970
Install the large snap ring in the groove above the shims
[Figure 70-60-46].
P2968
Install a bearing in the flanged end of the housing

[Figure 70-60-44].

Figure 70-60-47
P2976
1
Install the shaft in the housing, tapered end in the bearing
P2971 at the round flange end of the housing [Figure 70-60-49].
Figure 70-60-50
Install the short key (Item 1) [Figure 70-60-47].
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [Figure 70-60-47].
Figure 70-60-48
P2977
Install on the shaft, the same number and size shims that
were removed during disassembly [Figure 70-60-50].
P2975
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-48].
NOTE: This will prevent damage to the shims when

the bearing is installed later.

Figure 70-60-51
P2978
Install the washer (Item 1) on the shaft. Put liquid

P2974 adhesive (LOCTITE #242) on the screw threads and
install the screw (Item 2) [Figure 70-60-53].
Install a bearing on the gear end of the shaft [Figure 70-

60-51].
Figure 70-60-52
P2973
Install the snap ring in the groove above the bearing

[Figure 70-60-52].

Gearbox Checking Backlash
Figure 70-60-54
P2981
Install the same size and number of square shims (if

P2987 present during disassembly) between the two housings
[Figure 70-60-55].
NOTE: For procedures requiring the use of LOCTITE Set the long housing on the short housing with the
#518 adhesive, thoroughly clean and dry sealant.
LOCTITE #518. LOCTITE #518 is a gasket NOTE: If square shims are used, put a small amount
eliminator that cures to a flexible seal of (LOCTITE 518) on both sides of all shims.
between the mounting surfaces.
Figure 70-60-56
The backlash tolerance between the gears should be
0.005-0.008 inch (0,127-0,203 mm).
To check the gear backlash use the following procedure:
Put the short housing in a vise, square flange facing up

as shown [Figure 70-60-54].
Part Number
Tag
P2983
Install the four mounting bolts through the flange holes

[Figure 70-60-56].
Install the part number tag [Figure 70-60-56].
Install and tighten the nut to 25-28 ft.-lb. (34-38 Nm)

torque.

Gearbox Checking Backlash (Cont'd)
Figure 70-60-57
2 1
1.000
(25,4mm)
P-37893
1 Using a magnetic based dial indicator mounted on a

P-37894 bench vise, touch the dial stem on the bolt (Item 1)
[Figure 70-60-59].
Install the long key (Item 1) and the pulley (Item 2) Hold the locking pliers against the long housing and
[Figure 70-60-57]. rotate the pulley back and forth to read the dial gauge
[Figure 70-60-59].
Install a bolt in the set screw hole to maintain a 1.0 inch
(25,4 mm) distance from the shaft center to the bolt head If the backlash is GREATER than 0.008 inch (0,203 mm),
(to be used with a dial indicator) [Figure 70-60-57]. do the following:
Figure 70-60-58 1. Remove a square shim(s) (if present) between the

two housings.
2. Remove a large shim(s) from the tapered end of the

short shaft and add a small shim (s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
If the backlash is LESS than 0.005 inch (0,127 mm) do

the following:
1 1. Add a square shim(s) between the two housings.
2. Remove a small shim(s) between the bearing and the

gear on the screw end of the short shaft and add a
P-37892 large shim(s) of the same thickness between the snap
ring and the bearing on the tapered end of the shaft.
Put the fan nut (Item 1) [Figure 70-60-58] on the shaft
and tighten snugly.
Install a locking pliers on the fan nut and support the

handle against the long housing [Figure 70-60-58].

Gearbox Checking Backlash (Cont'd) LONG HOUSING
Figure 70-60-60
P2985
Figure 70-60-62
P3089
SHORT HOUSING
When the backlash is correct, install the seals, cap and

gear oil as follows:
Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (LOCTITE #242) on the outside

diameter of the seal(s) [Figure 70-60-60].
P2986
Install the seal(s) flush with the housing surface [Figure

70-60-61] & [Figure 70-60-62].
Clean any oil from the flange surface.
Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 25-28 ft.-lb. (34-38 Nm)

torque.
NOTE: When filling the fan gearbox with oil, be sure

the level does not go above the top of the
shaft in the gearbox. Use a light colored 90W
gear lube.

ENGINE COMPONENTS AND TESTING Figure 70-70-2
Compression Checking
Figure 70-70-1
P-48710
Connect the compression gauge to the adapter [Figure

P-48709
70-70-2].
Make sure the engine speed control is fully backward

(engine idle).
procedure: Disconnect the fuel stop solenoid.
MEL10630 - Engine Compression Kit Crank the engine with the starter cranking rpm.
MEL1631 - Compression Adapter
If the measurement is below the allowable limit, check
The engine must be at operating temperature. the cylinder, piston ring, top clearance, valve and cylinder
head.
Remove the glow plugs. (See Glow Plugs Removal And Compression Pressure should be 427-469 PSI (2944,1 -
Installation on Page 70-70-2.) 3233,6 kPa)
Install the correct compression adapter (Item 1) [Figure Allowable Limit (minimum) is 341 PSI (2351,1 kPa)
70-70-1] into the cylinder head.
No more than 10% variance among cylinders.
Figure 70-70-3
P-48711
Push the button on the compression gauge to release

pressure [Figure 70-70-3].
Connect the fuel stop solenoid.

ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Removal And Installation
Glow Plugs Checking Figure 70-70-6
Figure 70-70-4
2 3
P-48698
P-48702
Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-70-6] from the top of
each glow plug.
Use an ohmmeter to check the glow plugs [Figure 70-70-
4].The resistance should be approximately one ohm. Disconnect the engine harness wire (Item 2) [Figure 70-
70-6] from the glow plug.
Figure 70-70-5
Remove the glow plug connecting strap (Item 3) [Figure
70-70-6].
Figure 70-70-7
1
P-48701
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug (Item 1) [Figure 70-
P-48699
70-5].
Repeat the procedure for each glow plug. Loosen and remove the glow plug (Item 1) [Figure 70-
70-7].
Installation: Tighten the glow plug to 14.5-18.1 ft.-lb.

(19,6-24,5 Nm) torque.

ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-10
Glow Plugs Removal And Installation (Contd)
Figure 70-70-8
P-48706
The reading between electrical connector terminal C and

P-48708 terminal A must be between approximately 15.6 ohms
[Figure 70-70-10].
Photo [Figure 70-70-8] shows the glow plug assembly The reading between electrical connector terminal C and
removed from the engine. Inspect the glow plugs and terminal B must be between approximately .35-.4 ohms.
replace when necessary.
Fuel Shut-Off Solenoid, Checking
Figure 70-70-9
P-48586
Stop the engine and open the rear door [Figure 70-70-9].
Disconnect the connector (Item 1) [Figure 70-70-9] from

the fuel shut-off solenoid.
Use an ohmmeter to check the fuel shut-off solenoid.

ENGINE COMPONENTS AND TESTING (CONT'D)
Fuel Shut-Off Solenoid Removal And Installation
Figure 70-70-11
P-48586
Disconnect the connector (Item 1) [Figure 70-70-11].
Figure 70-70-12
P-48704
Remove the mounting nuts (Item 1) [Figure 70-70-12] of

the fuel shut-off solenoid.
Reverse the above procedure to install the fuel shut-off

solenoid.

Fuel Injection Pump Removal And Installation

(Turbo)
1
Figure 70-70-13
2
3
1
1
3
P-48705
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-14] from the injection pump
P-48700 vent .
Cap the inlets on the injection pump vent where the

Clean the area around the injection pump thoroughly. hoses were removed [Figure 70-70-14].
Disconnect the high pressure fuel lines (Item 1) [Figure Remove the four oil fill bolts (Item 3) [Figure 70-70-14].
70-70-13] from the fuel injectors.
Figure 70-70-15
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 1
I-2029-0289
P-48730
Remove the high pressure fuel lines (Item 1) [Figure 70-

70-15] from the injection pump.


(Turbo) (Cont'd)
Figure 70-70-16
P-51683
2
1 Remove the high-idling body (Item 1) [Figure 70-70-17]
from the engine block.
P-48826
Installation: Tighten the high-idling body to 32.6-36.3 ft.-
Remove the seven mounting bolts (Item 1) from the
intake manifold (Item 2) [Figure 70-70-16]. Figure 70-70-18

(22-27 Nm) torque.
Remove the intake manifold from the engine.
Installation: Replace the manifold gasket if it is worn or

damaged.
Remove the fuel shut-off solenoid. (See Fuel Shut-Off

Solenoid Removal And Installation on Page 70-70-4.)
1 2
P-4357
Remove the four mounting bolts (Item 1) and two nuts

(Item 2) [Figure 70-70-18] from the injection pump.

(22-27 Nm) torque.

Fuel Injection Pump Removal And Installation CORRECT 2

(Turbo) (Cont'd) 1
Figure 70-70-19
2
2 1
1
1
P-51628
1
Figure 70-70-21
P-51626 INCORRECT
NOTE: Before removing the injection pump

assembly, be sure to remove the stop
solenoid and high idling body. Also check to
see if the stop solenoid guide (Item 1) touches
the boost lever (Item 2) [Figure 70-70-19].
1
Remove the injection pump and shim(s) from the engine.
P-51627
Installation: Check to see if the stop solenoid guide

(Item 1) [Figure 70-70-20] and [Figure 70-70-21]
touches the boost lever (Item 2) [Figure 70-70-20].

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (Non-
Turbo)
(Turbo) (Cont'd) Figure 70-70-24
Figure 70-70-22
1
1
P-51933
P-4364
Clean the area around the injection pump thoroughly.
Install the shim(s) (Item 1) [Figure 70-70-22] on the Disconnect the high pressure fuel lines (Item 1) [Figure
injection pump mounting surface. For information on the 70-70-24] from the fuel injectors.
number of shims used. (See Timing The Injection Pump
on Page 70-70-12.)
Figure 70-70-23
IMPORTANT
2 Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
1
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 70-70-23].
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

Fuel Injection Pump Removal And Installation (Non-

Turbo) (Cont'd)
Figure 70-70-25 2
1
2
3
P-48820
Remove the mounting bolts (Item 1) from the intake

manifold (Item 2) [Figure 70-70-27].
3
P-51944
(22-27 Nm) torque.
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) from the injection pump vent [Figure 70- Remove the intake manifold from the engine.(See
70-25]. Removal And Installation on Page 70-80-1.)
Cap the inlets on the injection pump vent where the Installation: Replace the manifold gasket if it is worn or
hoses were removed [Figure 70-70-25]. damaged.
Remove the four oil fill tube bolts (Item 3) [Figure 70-70- Figure 70-70-28
25].
Figure 70-70-26
1
2
P-51942
P-51945 Remove the fuel shut-off solenoid (Item 1) [Figure 70-

70-28]. (See Fuel Shut-Off Solenoid Removal And
Remove the high pressure fuel lines (Item 1) [Figure 70-
70-26] from the injection pump.
Note: Do not loosen the clamp screws (Item 2)

[Figure 70-70-15] on the injection pump. This
is to be done only when the entire injection
pump is sent out to be serviced.


Turbo) (Cont'd)
Figure 70-70-29
P-51952
P-51953
1
Remove the stop solenoid guide (Item 1) [Figure 70-70-
31].
P-51683
Figure 70-70-32
Remove the high-idling body (Item 1) [Figure 70-70-29]

from the engine block.
Figure 70-70-30
1 2
3
P-4357
2
Remove the four mounting bolts (Item 1) and two nuts
(Item 2) [Figure 70-70-32] from the injection pump.
P-51951
(22-27 Nm) torque.
Remove the cover plate bolts (Item 1) and nuts (Item 2)
[Figure 70-70-30].
Remove the cover plate (Item 3) [Figure 70-70-30].


Turbo) (Cont'd)
Figure 70-70-33 1
P-4364
1
Install the shim(s) (Item 1) [Figure 70-70-35] on the
injection pump mounting surface. For information on the
P-4359 number of shims used. (See Timing The Injection Pump
on Page 70-70-12.)
Remove the injection pump (Item 1) [Figure 70-70-33]
and shim(s) from the engine. Figure 70-70-36
NOTE: The pin (Item 2) [Figure 70-70-33] located on

the control rack, needs to be installed
correctly during installation. See the following
procedure for correct installation.
IMPORTANT 1

I-2028-0289
Figure 70-70-34 P-48779
The size of shims are identified by a symbol (Item 1)

[Figure 70-70-36] on the shims.
(1) Two holes means .0008 in (.20 mm) shim.
(2) One hole means .0010 in (.25 mm) shim.
1 (3) Without hole means .0012 in (.30 mm) shim.
2 (4) Three holes means .0014 in (.35 mm) shim.
1
P-51944
Installation: Remove the bolts (Item 1) that secure the

fill cover (Item 2) [Figure 70-70-34] from the injection
pump chamber.


Turbo) (Cont'd)
Figure 70-70-37
1 1
P-54133
Turn the fuel supply lever (Item 1) [Figure 70-70-38] to

the ON position.
P-64218
Figure 70-70-39
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 70-70-37].
1
Timing The Injection Pump
IMPORTANT
P-4361
I-2028-0289
Timing the injection pump is done by changing the Install a short plastic tube (Item 1) [Figure 70-70-39] in
number of shims between the injection pump and the the number one cylinder port of the injection pump. The
injection pump mounting surface. tube should fit securely in the port and point upward.
Disconnect the number one cylinder high pressure line

from the injection pump.

Timing The Injection Pump (Contd)
Figure 70-70-40
1
Rotation
Direction
1 P-4364
Add or subtract shim(s) (Item 1) [Figure 70-70-41] as

P-48726 needed to adjust the fuel delivery timing.
NOTE: Adding or removing one shim will vary the

Rotate the engine in the direction shown [Figure 70-70- timing by 1.5. Adding shims retards timing.
40].
Figure 70-70-42
Continue rotation until flywheel timing mark just appears
in the window (Item 1) [Figure 70-70-40].
NOTE: The flywheel has three timing marks.
The first mark to appear in the window with

the rotation is 9.25 which is used for loaders
with the Kubota V2003T engine. 1
The second mark to appear in the window is

8.2 which is used for loaders with the Kubota
V2203 engine.
The third mark to appear in the window is

6.75 which is used for loaders with the P-48779
Kubota V2403 engine.
Rotate slowly until fuel just starts to flow upward into the The size of shims are identified by a symbol on the
plastic tube. shims.
At this instant, the 9.25 BTDC timing mark on the (1) Two holes means .0008 in (.20 mm) shim.
flywheel should be aligned with the mark in the window
(Item 1) [Figure 70-70-40] for the V2003T engine. (2) One hole means .0010 in (.25 mm) shim.
OR (3) Without hole means .0012 in (.30 mm) shim.
The 8.2 BTDC on the flywheel should be aligned with (4) Three holes means .0014 in (.35 mm) shim.
the mark in the window (Item 1) [Figure 70-70-40] for the
V2203 engine.

Fuel Injector Removal And Installation

IMPORTANT
Do not bend the high pressure fuel injection tubes
WARNING when removing or installing them.
I-2029-0289

penetrate skin or eyes, causing serious injury or Figure 70-70-44
from a physician familiar with this injury. 1
W-2072-0496
Figure 70-70-43
1 1
2 P-48727
Remove the four retainer bolts from the top of the fuel
injectors (Item 1) [Figure 70-70-44].
Remove the fuel return tube (Item 2) [Figure 70-70-44]

from the fuel injectors.
P-48712 Figure 70-70-45
The following are some problems caused by faulty

injectors:
1
-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-

43] from the injectors.
Disconnect the high pressure fuel lines (Item 2) [Figure

70-70-43] from the fuel injectors and from the injection
P-48728
pump.
Remove the high pressure fuel lines from the engine. Remove the injector nozzle holder bolt (Item 1) [Figure
70-70-45] from the cylinder head.
Pull on the injector nozzle to remove the injector nozzle

from the cylinder head.

ENGINE COMPONENTS AND TESTING (CONT'D) Checking Nozzle Injection Pressure
Fuel Injector Removal And Installation (Cont'd) The tool listed will be needed to do the following
procedure:
Figure 70-70-46
OEM1064 - Injector Nozzle Tester
Figure 70-70-47
1
2
P-37583
[Figure 70-70-46] shows the injector nozzle removed

3EEABAC1P012A
from the cylinder. Inspect the injector and replace if
necessary.
Set the injection nozzle to the nozzle tester.
Check and replace the injector nozzle O-rings (Item 1)
and the nozzle washer (Item 2) before installing new or Slowly move the tester handle to measure the pressure
used injectors. [Figure 70-70-46]. at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory

specifications, replace the injection nozzle assembly.
NOTE: Injection nozzle gasket must be replaced

when the injection nozzle is removed for
checking.
Injection Factory 18.6 to 20.1 MPa

pressure spec. 190 to 205 kgf/cm
2702 to 2916 PSI

ENGINE COMPONENTS AND TESTING (CONT'D) Valve Seat Tightness
Nozzle Spraying Condition The tool listed will be needed to do the following
procedure:
procedure: OEM1064 - Injector Nozzle Tester
OEM1064 - Injector Nozzle Tester Figure 70-70-49
Figure 70-70-48
Correct Incorrect
3EEABAC1P014A
3EEABAC1P013A
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. cm, 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/cm
2418 PSI

Valve Clearance Adjustment
Figure 70-70-50
1 2 3 4 5 6 7 8
2 1
B-05569
Figure 70-70-52
3
B-5568
Cylinder Number 1 2 3 4
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [Figure 70-70-50].

Valve Number 1 2 3 4 5 6 7 8
until the correct clearance is obtained.
Valve
NOTE: The clearance is measured between the I=Intake I E I E I E I E
rocker arm and valve stem tip (Item 3) [Figure E=Exhaust
70-70-50].
Adjust the valve clearance as follows:
0.0071 -0.0087 inch (0,18 - 0,22 mm) Intake &

Exhaust
Use the following sequence to set the valves [Figure 70-

70-51] & [Figure 70-70-52]:
1. With the rocker arm rocking (valves 7 & 8) on No. 4

cylinder set clearance at No. 1 cylinder (valves 1 & 2).




Valve Timing, Checking
Figure 70-70-53
4
3
1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
Remove the engine. (See Removal And Installation on

Page 70-80-1.)
Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 70-
100-10.)
Make sure the timing marks are in correct alignment

[Figure 70-70-53].

ENGINE Figure 70-80-1
1
2
3
P-48519
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 lights electrical connector (Item 2)
the lift arms are secured by an approved lift arm [Figure 70-80-1].
support device can allow the lift arms or attachment Remove the bracket mounting bolts (Item 3) [Figure 70-
to fall and cause injury or death. 80-1] for the fuel fill to make installation easier.
W-2059-0598
Figure 70-80-2
Put jackstands under the rear corners of the loader.

on Page 10-20-1.)
1
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Replacing Hydraulic 2

Disconnect the steering linkage. (See Linkage Removal

P-48580
Remove the battery from the loader. (See Removal And

Remove the two mounting bolts (Item 1) to remove the oil
Drain the engine coolant from the cooling system. (See
ENGINE COOLING SYSTEM on Page 10-90-1.)
Remove the air cleaner. (See Removal And Installation

on Page 70-40-1.)
Remove the muffler. (See Removal And Installation on

Page 70-30-1.)

ENGINE (CONT'D) Figure 70-80-5
Figure 70-80-3
1
1
2
P-26965
3
Remove battery cable bracket (Item 1) [Figure 70-80-5].
P-28237
Figure 70-80-6
Disconnect the wires from the charge pressure sender

Disconnect the temperature sender connector (Item 2) 3

[Figure 70-80-3] from the filter housing.

Figure 70-80-4
1
2
P-34385
1
Disconnect negative battery cables from starter mount

bolt (Item 1) [Figure 70-80-6].
Disconnect positive battery cable (Item 2) from starter

terminal (Item 3) [Figure 70-80-6].
P-48581
Disconnect radiator hose (Item 1) [Figure 70-80-4].


2
Figure 70-80-7
2
1
3
P-48595
2
1
Disconnect glow plug wire (Item 1) [Figure 70-80-9].
P-48586
Disconnect and plug fuel return line (Item 2) [Figure 70-
80-9].
Disconnect the fuel stop wire harness (Item 1) [Figure
70-80-7]. Remove the tie strap (Item 3) [Figure 70-80-9] from
wiring harness clamp and move the wire harness to the
Remove the tie straps (Item 2) [Figure 70-80-7] from left side of loader to allow clearance for engine removal.
wiring harness clamp.
Figure 70-80-10
Disconnect engine oil pressure wire harness (Item 3)
[Figure 70-80-7].
Figure 70-80-8 1
3
4
P-48593
1
2
Disconnect engine coolant hose (Item 1) [Figure 70-80-
P-48585 10].
Cap or plug all hoses and fittings.

Disconnect fuel line (Item 1) [Figure 70-80-8].
Cut tie straps (Item 2) [Figure 70-80-8].
Mark and disconnect loader harness wire connectors

(Item 3) [Figure 70-80-8].
Disconnect engine speed harness (Item 4) [Figure 70-

80-8].

Figure 70-80-11
2
1
3
1
P-26957
Remove fan belt shield (Item 1) [Figure 70-80-13].

P-48845
Figure 70-80-14
Disconnect power Bob-Tach hoses (Item 1) [Figure 70-

80-11] and solenoid connectors (If so equipped).
Disconnect outlet hose (Item 2) [Figure 70-80-11].
Disconnect high flow outlet hose (Item 3) [Figure 70-80-

11] (If so equipped).

1
Figure 70-80-12
P-26958
1
Remove fan belt (Item 1) [Figure 70-80-14] from pulley.
P-28137
Disconnect inlet hydrostatic motor hose from hydraulic

filter tubeline (Item 1) [Figure 70-80-12].


1
Figure 70-80-15
P-28142
1
Mark and disconnect the left drive motor hoses (Item 1)
P-26068 [Figure 70-80-17].

Disconnect inlet gear pump hose (Item 1) [Figure 70-80-
15]. NOTE: Due to the left drive motor hoses (Item 1)
[Figure 70-80-17] orientation, hoses may not
Cap or plug all hoses and fittings. be completely removed from fittings until
engine and pump is partially removed.
Figure 70-80-16
Installation: Install the left drive motor hoses prior to
alignment with engine mount bolts.
Figure 70-80-18
P-26959 1
Mark and disconnect the two right drive motor hoses

(Item 1) [Figure 70-80-16].
P-26068
Remove the mounting bolt and nut (Item 1) [Figure 70-

80-18] from the right front engine mount.
Installation: Tighten the mounting bolt to 70 ft.-lb. (95

Nm) torque.

Figure 70-80-19
2 1
P-28231
1
P-48583

P-28139 80-20] from the right rear engine mount.
Installation: Tighten the mounting bolt to 70 ft-lb. (95

Remove the mounting bolt (Item 1) [Figure 70-80-19] Nm) torque.
and nut from the left front engine mount.
Figure 70-80-21
Installation: Slide the engine mount slot (Item 2) [Figure
70-80-19] in between engine mount washer and nut.
Tighten the mounting bolt to 70 ft.-lb. (95 Nm) torque.
NOTE: To aid in the removal of the left front engine

mount bolt, remove the control panel. (See
Use 1/2 inch drive impact wrench, with a 12 1

inch extension, on a 3/4 inch flex socket.
Removal will be accomplished by reaching under

the hydraulic reservoir to the engine mount bolt.
P-28140

80-21] from the left rear engine mount.
Installation: Tighten the mounting bolt to 70 ft-lb. (95

Nm) torque.

Figure 70-80-22
13
2.5
1-1/2 I.S. Dia.
2-1/2 O.S. Dia. 1
2.5
1-1/2 Square Tubing 1/4 (4)

Thick Gusset
1 P-48594
28
Fasten securely one end of the chain to the lifting eye

(Item 1) [Figure 70-80-23].
4 Figure 70-80-24
2
45 9
1
4
2
1
.5 1
.375
.3125 (2)
Use Two 3/8 x 1-1/4 Bolts MC-1799

for Drilled and Tapped Holes.
A tool needs to be fabricated to use in the removal P-48592

procedure. This tool allows the engine/hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
dimensions shown in [Figure 70-80-22] to make the Fasten securely one end of the chain to the other lifting
engine removal tool. eye (Item 1) [Figure 70-80-24].
NOTE: You may need to adjust the chain which

fastens to the engine a couple of times to
reach the correct lifting position.

ENGINE (CONT'D)
Figure 70-80-25
P-48596
Install the chain hoist on the eyelet [Figure 70-80-25] of

the removal tool.
Fasten a chain to other end of the removal tool with two

bolts as shown in (Item 1) [Figure 70-80-25].

loader.
Reverse the removal procedure to install the engine.

Engine Mount Replacement

Engine
Figure 70-80-26 Mounting
Bracket
Washer
2
1
Loader
3 Frame Engine
Mount
4
Spacer
5 Snubbing
Washer
MC-1765
6
Install the new engine mount as shown in the cut away

7
MC-1771 side view [Figure 70-80-27].
Tighten the mounting bolts to 70 ft.-lb. (95 Nm) 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 70-80-26]:
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)

FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-90-2
Remove the drive belt shield. (See Shield Removal And

Remove the drive belt. (See Drive Belt Replacement on

Page 30-50-3.)
Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-50-4.)
Figure 70-90-1
1
P-48850
The ring gear (Item 1) [Figure 70-90-2] on the flywheel is

an interference fit. Heat the ring gear enough to expand
1 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 70-90-1].
correctly.
Installation: Apply engine oil to the threads and seats
before tightening. Tighten to 72-80 ft.-lb. (98-108Nm)
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.

FLYWHEEL AND HOUSING (CONTD) Figure 70-90-4
Housing Removal And Installation
Remove the drive belt shield. (See Shield Removal And

Remove the engine/hydrostatic pump package from the

loader.(See Removal And Installation on Page 70-80-1.)
Remove the drive belt. (See Drive Belt Replacement on

Page 30-50-3.)
Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-50-4.)
P-48651A
Remove the starter. (See Removal And Installation on
Page 60-40-2.)
Install a puller in the drive pulley and remove the pulley
Remove the flywheel. (See Flywheel Removal And from the hydrostatic pump shaft [Figure 70-90-4].
Installation: Install the pulley key in the shaft before
Figure 70-90-3 installing the drive pulley.
P-48651
Remove the hydrostatic pump drive pulley mounting nut

(Item 1) [Figure 70-90-3] and washer.
Installation: Tighten the mounting nut to 175-200 ft.-lb.


FLYWHEEL AND HOUSING (CONTD) Figure 70-90-7
Housing Removal And Installation (Contd)
Figure 70-90-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
P-48650 90-7] which fasten the housing on the engine.

Remove the two mounting bolts (Item 1) [Figure 70-90- (48-54 Nm) torque.
5] from the drive belt housing which mount the
hydrostatic pump to the housing. Remove the bolt (Item 2) [Figure 70-90-7] which fasten
the two drain hoses to the housing.
(88-95 Nm) torque. Installation: Tighten the mounting bolts to 60-65 ft.-lb.
(82-88 Nm) torque.
Figure 70-90-6
Remove the housing.
Reverse the removal procedure to install the housing.

2
P-4231
Remove the mounting bolt (Item 1) [Figure 70-90-6] from

engine coolant tubeline mounting bracket which is
attached to the belt shield housing.
Installation: Tighten the mounting bolt to 25-28 ft.-lb.

(34-38 Nm) torque.
Remove the blower fan drive belt tensioner assembly

(Item 2) [Figure 70-90-6] from the housing.

RECONDITIONING THE ENGINE-V2203-M-DI AND Figure 70-100-3
V2003-M-DI-T (TURBO)
Cylinder Head Removal And Installation
Figure 70-100-1
1
2 4
2
3
1
P-47243
Remove the glow plugs (Item 1) and fuel injector holder

assemblies (Item 2) [Figure 70-100-3].
P-47241
Installation: Tighten the glow plugs to 11-14.5 ft.-lb. (15-
19.6 Nm) torque.
Remove the glow plug lead (Item 1), breather hose (Item
2), and valve cover bolts (Item 3) [Figure 70-100-1]. Tighten the injector holders to 19-22 ft.-lb. (25.5-29.4
Nm) torque.
Remove the valve cover (Item 4) [Figure 70-100-1] and
gasket. Figure 70-100-4
Installation: Tighten the valve cover bolts to 5-8 ft.-lb. (7-

11 Nm)
1
Figure 70-100-2
2
2
2
2
B-14332
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-100-4].
P-47242
Installation: Tighten the bolts to 17-20 ft.-lb. (23.5 - 27.5

Nm) torque.
Loosen the bolts on the clamps (Item 1) and remove the
injection tubes (Item 2) [Figure 70-100-2]. Remove the pushrods (Item 2) [Figure 70-100-4].
Remove the overflow tube assembly.

RECONDITIONING THE ENGINE V2203-M-DI AND Figure 70-100-7
V2003-M-DI-T (TURBO) (CONTD)
14 6 3 11
Cylinder Head Removal And Installation (Cont'd)
18 10 2 7 15
Figure 70-100-5
2 16
17 9 1 8
13 5 4 12
P-47247
Remove the cylinder head bolts in order of #18 to #1

[Figure 70-100-7].
P-47245
NOTE: (A) is the gearcase side, (B) is the flywheel
side.
Installation: The push rod (Item 1) must be seated in the
tappet (Item 2) [Figure 70-100-5] correctly or the push Installation: Put oil on the bolt threads. Tighten the bolts
rods will be damaged. in the correct sequence in order of #1-#18 to 68-72 ft.-lb.
(93-98 Nm).
After installing the rocker arm assembly and push rods,
the valve lash must be adjusted. (See Valve Tappets on NOTE: Re-tighten the cylinder head bolts in the
Page 70-100-20.). correct sequence after the engine has been
run for 30 minutes.
Figure 70-100-6
Figure 70-100-8
1
1
P-47246
P-47248
Remove the clamps (Item 1) and remove the hose (Item

2) [Figure 70-100-6]. Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-100-8].

Gasket Size
Cylinder Head Removal And Installation (Cont'd) Piston Protrusion
(Number)
0.475 to 0.525 mm
Figure 70-100-9 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 70-100-11].
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 70-100-9] as the
original gasket. If the highest measurement exceeds the piston
protrusion of the selected gasket, use the gasket which is
When replacing the gasket after an engine rebuild, the one size larger. If the measurement exceeds gasket size
piston protrusion must be measured. 35, the engine must be disassembled, clearances
checked, and reassembled.
(See Cylinder Head Top Clearance on Page 70-100-5.)
If the measurement is two sizes smaller than the selected
Figure 70-100-10 gasket or smaller than gasket size 15, the engine must
be disassembled, clearances checked, and
reassembled.
1 After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
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 70-100-10]. Find the
average of each piston, then find the combined average
of the four pistons.

Cylinder Head Disassembly And Assembly 2 1

1
Figure 70-100-12 3
4
5
7
6
8
5 7
5 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-100-14].
PI-9987
Remove bolts (Item 5), nut (Item 6), top and bottom
housing (Item 7), and gasket (Item 8) from the cylinder
Use a valve spring compressor to compress the valve head [Figure 70-100-14].
spring [Figure 70-100-12].
Figure 70-100-13
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 70-100-12] & [Figure 70-100-13].
Remove the valve spring retainer (Item 3) and the spring

(Item 4) [Figure 70-100-12] & [Figure 70-100-13].
Remove the seal (Item 6) and the valve (Item 5) [Figure

70-100-12] & [Figure 70-100-13].

RECONDITIONING THE ENGINE V2203-M-DI AND Cylinder Head Top Clearance
Figure 70-100-17
Cylinder Head Servicing
Clean the surface of the cylinder head.
Figure 70-100-15 2
1 3
P-51631
2
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-100-17] being checked at T.D.C.
P-51629
Put 3 pieces of 0.06 inch (1,5 mm) diameter solder (Item
2) [Figure 70-100-17] on the top of the piston. Use
Put a straight edge (Item 1) [Figure 70-100-15] on the grease to hold them in position.
cylinder head.
NOTE: Put the solder in position so they do not touch
NOTE: Do not put the straight edge across the valves.
combustion chambers.
Turn the piston to bottom dead center.
Put a feeler gauge (Item 2) [Figure 70-100-15] between
the straight edge and the surface of the cylinder head. Install the cylinder head and tighten to the correct torque
in the correct sequence. (See Cylinder Head Removal
Figure 70-100-16 And Installation on Page 70-100-1.)
Turn the crankshaft until the piston exceeds T.D.C.

Remove the cylinder head.
Remove the solder wire (Item 3) [Figure 70-100-17] and

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 inch (0,6-0,7

mm)
PI-9988
Put the straight edge on the cylinder head's four sides

and two diagonal as shown in figure [Figure 70-100-16].
The maximum distortion of the head surface is 0.002

inch ( 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

Valve Guide Checking
Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
70-100-4.)
Clean the valve seat and combustion chamber.
Figure 70-100-18
B-14335
Measure the valve stem O.D. [Figure 70-100-20].
Measure the valve guide I.D. [Figure 70-100-20].
Calculate the clearance. If the clearance exceeds the

allowable limit, replace the valve and/or valve guide.
Valve Guide I.D. 0.3156-0.3161 inch

P-51632 (8,015-8,03 mm)
Valve Stem O.D. 0.3134-0.3140 inch
Install the valve into the guide. Measure the valve (7,96-7,98 mm)
recessing or protrusion with a depth gauge [Figure 70- Clearance Between 0.0016-0.0028 inch
100-18]. Valve Stem and Guide (0,04-0,07 mm)
Allowable Limit 0.004 inch
Figure 70-100-19 (0,1 mm)
1. Cylinder Head
Surface
2. Recessing
3. Protrusion
PI-9990
If the measurement exceeds the allowable limit, replace

the valve or cylinder head [Figure 70-100-19].
Protrusion 0.002 inch (0,5 mm)

Recessing 0.006 inch (0,15 mm)
Allowable Limit (Recessing) 0.016 inch (0,4 mm)
Remove the carbon from the valve guide.

Valve Guide Checking (Contd)
Figure 70-100-21
8.86 (225 mm)
0.787 2.76 (70mm) 1.77 1

(20 mm) (45 mm)
0.460-0.468 2
(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) PI-9992
Press the used valve guide out of the cylinder head using
0.263-0.275 0.98 0.490-0.50
(6,7-7 mm) (25,0 mm) (12.5-12.8 mm) the special driver tool [Figure 70-100-22].
MC-1364
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
To remove and replace the valve guide, make the driver top side. Use the special driver tools (Items 1 & 2)
tool as shown in figure [Figure 70-100-21]. [Figure 70-100-22], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

1 2
Reconditioning The Valve And Valve Seat
15 Exhaust
30 Intake
Figure 70-100-23
PI-9995
Check the seat surface and valve face (Item 1) [Figure

70-100-25].
PI-9993
(a) identical dimensions above and below the valve seat
Grind the valve face to the correct angle using a valve re- If the seat surface (b) is too wide, use a 30 degree cutter
facer [Figure 70-100-23]. (Item 2) on the intake, and a 15 degree cutter on the
exhaust to get the correct width (Item 3) [Figure 70-100-
Figure 70-100-24 25].
Valve Seat Width
Intake 0.0835 inch (2,12 mm)

Exhaust 0.0835 inch (2,12 mm)
Valve Seat & Face Angle

45 Exhaust
15 Exhaust 60 Intake Intake 60
30 Intake
Exhaust 45
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-100-24].

Valve Spring
Figure 70-100-26
A-2759
Put the spring on a tester and compress to specified

length [Figure 70-100-27].
B-3680
Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the
Measure the length of the valve spring. If the spring.
measurement is less than the allowable limit, replace the
spring [Figure 70-100-26].
Setting Length 1.378 inch (35,0 mm)
Setting Load 26.4 lb. (117,6 N)
Free Length 1.6417-1.6614 inch (41,7-42,2 mm)
Allowable Limit 22.5 lb. (100,0 N)
Allowable Limit 1.622 inch (41,2 mm)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-100-26].
Rotate the spring and measure the maximum tilt. If the

measurement excess the allowable limit, replace the
spring.
Tilt Allowable Limit 0.039 inch (1,0 mm)

RECONDITIONING THE ENGINE V2203-M-DI AND Timing Gearcase Cover Removal And Installation
Remove the fuel injection pump. (See Fuel Injection
Rocker Arm And Shaft Checking Pump Removal And Installation (Turbo) on Page 70-70-
5.)
Figure 70-100-28
Remove the cylinder head, rocker arms and push rods.
(See Cylinder Head Removal And Installation on Page
70-100-1.)
1 Figure 70-100-29
2
7.87 (200 mm)
B-3697
Measure the rocker arm I.D. (Item 1) [Figure 70-100-28]

with an inside micrometer.
P-47254
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-
100-28] with an outside micrometer.
Bend a hook on the end of a 7.87 inch (200 mm) long,
If the clearance exceeds the allowable limit, replace the 0.050 inch (1.2 mm) diameter hard wire [Figure 70-100-
bushing. 29].
If the clearance still exceeds the allowable limit after the Figure 70-100-30
bushing is replace, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm

& Shaft 0.0006-0.0018 inch
(0,016-0,045 mm)
(0,10 mm)
1
Rocker Arm Shaft O.D. 0.5501-0.5506 inch
(13,973-13,984 mm)
Rocker Arm I.D. 0.5512-0.5519 inch
(14,0-14,02 mm)
P-47255
Disconnect the two governor springs (Item 1) [Figure 70-

100-30].

Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 70-100-31
P-47258
1
Use a puller and remove the crankshaft pulley. [Figure
70-100-33].
P-47256 Figure 70-100-34
Remove the speed control plate (Item 1) [Figure 70-100-

31].
Figure 70-100-32
1
2
1
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2)

[Figure 70-100-34].
P-47257 Remove the bolts from the timing gearcase cover.
Installation: Tighten the bolts to 13-15 ft.-lb. (18-20 nm)

Remove the wire (Item 1) [Figure 70-100-32] from the torque.
springs.
Installation: Do not drop the governor springs into the

gear case.
Remove the crankshaft pulley nut.
Installation: Tighten the nut to 101-116 ft.-lb. (137-157

Nm) torque.

Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 70-100-35
Oil Seal O-Rings
B-3617B
Installation: Install new O-rings and oil seal into the

timing gearcase cover [Figure 70-100-37].
P-47259
Remove the timing gearcase cover [Figure 70-100-35].
Figure 70-100-36
3
2
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2)

and oil slinger (Item 3) [Figure 70-100-36].

Idler Gear And Camshaft Removal And Installation

2
100-10.)
Figure 70-100-38 1
2
1
P-47262
Align the holes (Item 1) on the camshaft gear with the

camshaft retainer plate bolts (Item 2) [Figure 70-100-40].
Remove the bolts.
Installation: Tighten the camshaft retainer bolts to 18-20

P-47260
Remove the camshaft from the engine block.

Remove the snap ring (Item 1) and collar from the idler
gear shaft (Item 2) [Figure 70-100-38]. Figure 70-100-41
Installation: Make sure the timing marks are in correct

alignment when installing the timing gears [Figure 70-
100-38].
Figure 70-100-39
PI-10002B
Installation: Check the camshaft end play. If clearance

exceeds the allowable limit, replace the camshaft retainer
plate [Figure 70-100-41].
B-3699
Camshaft End Play 0.0028-0.0087 inch

Remove the idler gear (Item 1) [Figure 70-100-39]. (0,07-0,22 mm)
Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
collar.
Idler Gear End Play 0.0047-0.0189 (0.12-0.48mm)

Allowable Limit 0.0354 (0,9 mm)

Camshaft Servicing
Figure 70-100-42
B-5001
Measure the cam lobes at their highest point [Figure 70-

100-44].
P-47263
If the measurement is less than the allowable limit,
replace the camshaft.
Measure the cylinder block bore in the engine block
[Figure 70-100-42].
Cam Lobe Height 1.3346 inch (33,9 mm)
Figure 70-100-43 Allowable Limit 1.3327 inch (33,85 mm)
Figure 70-100-45
A-2761
A-2760
Measure the camshaft journal [Figure 70-100-43].
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 70-100-45].
Turn the camshaft at a slow rate. If the misalignment

Cylinder Block Bore I.D. 1.5748-1.5758 inch
exceeds the allowable limit, replace the camshaft.
(40,0-40,03 mm)
Journal O.D. 1.5722-1.5728 inch
Camshaft Alignment Allowable Limit 0.0004 inch
(39,93-39,95 mm)
(0,01 mm)
Oil Clearance of Camshaft Journal
0.002-0.0036 inch
(0,05-0,091 mm)
(0,15 mm)

Idler Gear And Shaft Servicing

1.49 (38 mm)
Figure 70-100-46
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

shown in figure [Figure 70-100-47].
PI-10003
Figure 70-100-48
Measure the O.D. of the idler gear shaft [Figure 70-100-

46].
Measure the I.D. of the idler gear bushing [Figure 70-

100-46].
If the clearance exceeds the allowable limit, replace the

bushing.
Idler Gear Shaft O.D. 1.4945-1.4951 inch

(37,96-37,98 mm)
Idler Gear Bushing I.D. 1.4961-1.4970 inch
(38,0-38,03 mm)
Clearance Between Idler Shaft & PI-10004
Gear Bushing 0.001-0.0026 inch

(0,025-0,07 mm) Use a press and special driver tool, to remove the old
Allowable Limit 0.0039 inch bushing and install the new bushing [Figure 70-100-48].
(0,1 mm)

RECONDITIONING THE ENGINE V2203-M-DI AND Fuel Camshaft Removal And Installation
Timing Gears Checking Backlash Gearcase Cover Removal And Installation on Page 70-
100-10.)
When the gears are installed, check the backlash of the
gears. Remove the idler gear. (See Idler Gear And Camshaft
Figure 70-100-49
Figure 70-100-50
P-47264 1 1
P-47265
Install a dial indicator [Figure 70-100-49].

Remove the three bolts (Item 1) [Figure 70-100-50].
Hold one gear while turning the other gear [Figure 70-
100-49]. Remove the two bolts and fuel camshaft retainer plate
(Item 2) [Figure 70-100-50].
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is Figure 70-100-51
correct, replace the gear.
Crank Gear & Idler Gear 0.0016-0.0044 inch

(0,042-0,112 mm)
(0,15 mm)
Cam Gear & Idler Gear 0.0016-0.0045 inch
(0,042-0,115 mm)
(0,15 mm)
Injection Pump Gear & Idler Gear
0.0016-0.0045 inch
(0,042-0,115 mm)
Allowable Limit 0.0059 inch P-47266
(0,15 mm)
Oil Pump Gear & Crankgear 0.0016-0.0043 inch Remove the fuel camshaft and fork lever assembly at
(0,042-0,109 mm) the same time [Figure 70-100-51].
(0,15 mm)

RECONDITIONING THE ENGINE V2203-M-DI AND Crankshaft Gear Removal And Installation
Fuel Camshaft Governor Gearcase Cover Removal And Installation on Page 70-
100-10.)
The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to Remove the idler gear. (See Idler Gear And Camshaft
the engine according to changes in the load. Removal And Installation on Page 70-100-13.)
Figure 70-100-52 Figure 70-100-53
B-3686
Remove the crankshaft gear with a puller [Figure 70-

1. Start Spring 100-53].
2. Governor Spring
3. Governor Spring Remove the crankshaft key.
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 70-100-52].
Check all the parts for wear or damage and replace as

needed.

RECONDITIONING THE ENGINE V2203-M-DI AND Oil Pump Service
Figure 70-100-55
Oil Pump Removal And Installation

100-10.)
Remove the crankshaft gear.
Figure 70-100-54
B-3616
2
Measure the clearance between the lobes of the inner
rotor and outer rotor [Figure 70-100-55].
Figure 70-100-56
B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-100-54].
Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 70-100-54].
Installation: Tighten the oil pump mounting bolts to 60-

72 in.-lb. (6,9-8,1 Nm) torque.
A-2732
Measure the clearance between the outer rotor and

pump body [Figure 70-100-56].

oil pump.
Clearance Between Inner & Outer Rotor

0.0012-0.0055 inch
(0,03-0,14 mm)
Clearance Between Outer Rotor & Body
0.0043-0.0075 inch
(0,11-0,19 mm)

RECONDITIONING THE ENGINE V2203-M-DI AND Checking Engine Oil Pressure
Remove the oil pressure sender.
Oil Pump Service (Contd)
Figure 70-100-58
Figure 70-100-57
PI-10010
PI-10009
Install a pressure gauge [Figure 70-100-58].

Put a piece of press gauge on the rotor face [Figure 70-
100-57]. Start the engine and run until it is at operating
temperature.
Install the cover and tighten the bolts.
If the oil pressure is less than the allowable limit, check
Remove the cover carefully. Measure the width of the the following items:
press gauge [Figure 70-100-57].
* Engine Oil Level Low
If the clearance exceeds the allowable limit replace the * Oil Pump Defective
oil pump. * Oil Galley Plugged
* Oil Strainer Plugged
End Clearance 0.0041-0.0059 inch (0,11-0,15 mm) * Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable Limit 7 PSI (0.50 Bar)

At Rated Speed 43-64 PSI (2.94-4.41 Bar)
Allowable Limit 36 PSI (2.45 Bar)

RECONDITIONING THE ENGINE V2203-M-DI AND Piston And Connecting Rod Removal And
V2003-M-DI-T (TURBO) (CONTD) Installation
Valve Tappets Remove the cylinder head. (See Cylinder Head Removal
Figure 70-100-59
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan.
Figure 70-100-61
1
1
2
P-47267
Remove the valve tappets (Item 1) [Figure 70-100-59].
Figure 70-100-60
P-47269
Remove the oil pump strainer (Item 1) and O-ring (Item

2) [Figure 70-100-61] by tapping the edge of the strainer
with a soft faced hammer.
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-47268
Measure the O.D. of the tappet [Figure 70-100-60].
Measure the ID of the tappet bore [Figure 70-100-60].

tappets.
Tappet OD 0.9433-0.9441 inch (23,96-23,98mm)

Tappet Bore ID 0.9449-0.9457 inch (24-24,02 mm)
Clearance
Between Tappet
and Tappet Bore 0.0008-0.0024 inch (0,02-0,06 mm)
Allowable limit 0.0028 inch (0,07 mm)

Piston And Connecting Rod Removal And 4

1 3
Figure 70-100-62
2
1
P-47270
Remove the piston rings [Figure 70-100-64].
Remove the snap ring (Item 1) and piston pin (Item 2)

PI-10013 [Figure 70-100-64].
Separate the piston (Item 3) from the connecting rod

Remove the rod cap and bearing [Figure 70-100-62]. (Item 4) [Figure 70-100-64].
Use a hammer handle and push the piston/connecting Figure 70-100-65

rod assembly out of the cylinder bore [Figure 70-100-
62].
2
NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore.
3
Figure 70-100-63
PI-10015
1
Installation: When installing new rings, assemble the
ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
A-2903 3) [Figure 70-100-65].
Installation: Make sure the marks on the connecting rod

and bearing are aligned when installing the bearing cap
[Figure 70-100-63].
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

RECONDITIONING THE ENGINE V2203-M-DI AND Piston And Connecting Rod Servicing
Figure 70-100-67
Piston And Connecting Rod Removal And
Figure 70-100-66
3
1
2
5 P-47272
4
Measure the I.D. of the piston pin bore in both horizontal
P-47271 and vertical directions [Figure 70-100-67].

Installation: When reassembling, align the marks (Item the piston.
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 Bore I.D. 0.9843-0.9848 inch
piston pin into position. Place the piston rings so that
(25,0-25,013 mm)
there are gaps every 120 (Items 3, 4 & 5) [Figure 70-
100-66] with no gap facing the piston pin in the cylinder. Allowable Limit 0.9862 inch
(25,05 mm)

1.38 (35 mm)
Piston And Connecting Rod Servicing (Contd)
1.063 (27 mm)
Figure 70-100-68
6.38 (162 mm)
1.378
1
(35 mm)
2 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

driver tool as shown in figure [Figure 70-100-69].
P-47273
Figure 70-100-70
Measure the O.D. of the piston pin (Item 1) [Figure 70-

100-68].
Measure the I.D. of the connecting rod small end (Item 2)

[Figure 70-100-68].
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 inch

(25,0-25,011 mm)
Bushing I.D. 0.9852-0.9858 inch
(25,03-25,04 mm) PI-10016
Oil Clearance Between 0.0006-0.0015 inch

Piston Pin & Bushing (0,014-0,038 mm) Use a press and special driver tool to remove the small
Allowable Limit 0.0059 inch end bushing [Figure 70-100-70].
(0,15 mm)
Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until
it is flush [Figure 70-100-70].

Piston And Connecting Rod Servicing (Contd)
Figure 70-100-71
PI-10017
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler
B-3622 gauge [Figure 70-100-72].

Install a piston ring into the lower part of the cylinder ring. If the clearance still exceeds the allowable limit,
bore. Measure the ring gap with a feeler gauge [Figure replace the piston.
70-100-71].
Kubota V2203-M-DI
If the gap exceeds the allowable limit, replace the ring.
Compression Rings 0.0020-0.0035 inch
Kubota V2203-M-DI
(0,05-0,09 mm)
Top Ring Gap 0.0079-0.0138 inch
Oil Ring 0.0012-0.0028 inch
(0,2-0,35 mm)
(0,03-0,07 mm)
Oil Ring Gap 0.0079-0.0157 inch
(0,20-0,40 mm)
Allowable Limit 0.0492 inch Kubota V2003-M-DI-T (Turbo)
(1,25 mm)
Second Ring Gap 0.0138-0.0197 inch Compression Rings 0.0037-0.0050 inch
(0.35-0,50 mm) (0,093-0,128 mm)
Kubota V2003-M-DI-T (Turbo) Oil Ring 0.0008-0.0024 inch
(0,02-0,06 mm)
Top Ring Gap 0.0079-0.0138 inch Allowable Limit 0.0059 inch (0,15 mm)
(0,2-0,35 mm)
Oil Ring Gap 0.0098-0.0177 inch
(0,25-0,45 mm)
(1,25 mm)
Second Ring Gap 0.0157-0.0217 inch
(0.40-0,55 mm)

RECONDITIONING THE ENGINE V2203-M-DI AND Crankshaft And Bearings Removal And Installation
Remove the piston and connecting rod assemblies. (See
Connecting Rod Alignment Piston And Connecting Rod Removal And Installation on
Page 70-100-20.)
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before Figure 70-100-74
doing this check.
Install the piston pin into the connecting rod. 2 5
Install the connecting rod on an alignment tool.

4
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-100-73 1
P-47274
Mark and remove the inside screws (Item 1) first, then

remove the outside screws (Item 2) [Figure 70-100-74].
NOTE: The inside bolts are different length than the

outside bolts.
Install two screws in the bearing case cover and remove

B-4067 the cover (Item 3) [Figure 70-100-74].
Remove the two gaskets (Item 4) and oil seal (Item 5)

If the gauge does not fit squarely against the face plate, [Figure 70-100-74] from the cover.
measure the space between the gauge and face plate
[Figure 70-100-73]. Figure 70-100-75

the connecting rod.
Rod Alignment 0.002 inch (0,05 mm)
P-47275
Installation: Install the gaskets (Item 1) & (Item 2)

[Figure 70-100-75] as shown.

Crankshaft And Bearings Removal And Installation

(Contd)
Figure 70-100-76 1
2
2
1
P-47278
Remove the main bearing case bolt (Item 1) [Figure 70-

100-78].
P-47276 Installation: Align the bearing case hole (Item 2) [Figure

70-100-78] with the hole in the block. Put oil on the bolt
threads and tighten to 51-54 ft.-lb. (69-73 Nm) torque.
Install the bearing case cover (Item 1) [Figure 70-100-
76] with the casting mark (Item 2) [Figure 70-100-76] in Figure 70-100-79
the upward position. Tighten the bolts to 17-20 ft.-lb.
(23.5-27.5 Nm) torque.
Figure 70-100-77
1
P-47279
Remove the crankshaft/main bearing assembly from the

P-47277 engine block [Figure 70-100-79].
NOTE: Turn the crankshaft as needed to allow the

Before removing the crankshaft/main bearings, check the crank pin journals to pass through the cut out
end play. Install a dial indicator. Move the crankshaft
[Figure 70-100-77] to the flywheel side, zero the dial (Item 1) [Figure 70-100-79] of the engine block.
indicator. Measure the end play by pulling the crankshaft
toward the gear case side. Mark the bearing case halves for correct installation.

the thrust washers [Figure 70-100-77].
End Play 0.0059-0.0138 inch

(0,15-0,35 mm)
(0,5 mm)

RECONDITIONING THE ENGINE V2203-M-DI AND Crankshaft And Bearings, Servicing
Figure 70-100-82
Crankshaft And Bearings Removal And Installation
(Contd)
Figure 70-100-80
A-2763
Put the crankshaft on V-blocks. Install a dial indicator on

B-4092 the center journal [Figure 70-100-82].
Turn the crankshaft at a slow rate to obtain the

Remove the two bearing case bolts [Figure 70-100-80]. misalignment (one half of the alignment measurement).
Remove the bearing case and bearing. If the misalignment exceeds the allowable limit, replace
the crankshaft.
Installation: Tighten the bearing case bolts to 34-38 ft.-
Alignment 0.0008 inch (0,02 mm)
Figure 70-100-81
Tighten the connecting rod bolts to 33-36 ft.-lb. (45-49
Nm) torque.
Figure 70-100-83
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 70-100-81]. The thrust

washers oil grooves must face outward.
Measure the crankpin bearing I.D. [Figure 70-100-83].

1
Crankshaft And Bearings, Servicing (Contd)
Figure 70-100-84
PI-10022
Check the wear on the crankshaft sleeve (Item 1) [Figure

70-100-85].
A-2716
If the wear exceeds the allowable limit or the seal leaks
oil, replace the sleeve.
Measure the crankpin O.D. [Figure 70-100-84].
Wear of Sleeve 0.0039 inch (0,1 mm)
Calculate the oil clearance.
The special tool set will be needed to replace the

Crankpin Bearing I.D. 1.8504-1.8522 inch
crankshaft sleeve.
(47,0-47,05 mm)
Crankpin O.D. 1.8488-1.8494 inch Remove the sleeve.
(46,96-46,98 mm)
Oil Clearance 0.0010-0.0034 inch
(0,025-0,087 mm)
Allowable limit 0.0079 inch (0,2 mm)

Figure 70-100-86
2 2
1 3
B-3618
Measure the O.D. of the crankshaft journal [Figure 70-

100-88].
PI-10023
Calculate the oil clearance.
Install the sleeve guide (Item 1) and stop (Item 2) [Figure If the clearance exceeds the allowable limit, replace the
70-100-86]. crankshaft bearing.
Heat the sleeve to approximately 300 F (150 C). Install Bearing 1:

the sleeve on the crankshaft using the special driver tool
(Item 3) [Figure 70-100-86].
Bearing I.D. 2.3614-2.3637 inch (59,98-60,04 mm)
NOTE: The sleeve is installed with the larger Journal O.D. 2.3591-2.3598 inch (59,92-59,94 mm)
chamfered surface to the front of the Oil Clearance 0.016-0.0046 inch (0,040-0,12 mm)
crankshaft (Item 1) [Figure 70-100-85 on Page Allowable Limit 0.0079 inch (0,2 mm)
28].
Figure 70-100-87
B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure

70-100-87].

Crankshaft And Bearings, Servicing (Contd) 1. Seam 4

2. Bearing
Figure 70-100-89 3. Engine Block
4. Bearing Recession
Removal Tool 3
5.31 (135 mm)
0.8
(20 mm)
2.354-2.358
(59,80-59.90 mm) 1
2.83 2 2
(72 mm)
P-48778
0.8 (20 mm)

2.551-2.555 Remove the front bearing with the special removal tool
1.57 0.4 (64,80-64,90 mm) [Figure 70-100-89].
(40 mm) (10 mm) MC-1367
Installation: Clean the new bearing (Item 2) and bore,
apply oil to the bearing and bore. Install the new bearing
To remove the front bearing make the tool as shown in with the seam (Item 1) [Figure 70-100-91] towards the
figure [Figure 70-100-89]. exhaust manifold side, using the installation driver tool.
Figure 70-100-90 Check the depth (Item 4) of the bearing (Item 2) from the
face of the engine block (Item 3) [Figure 70-100-91].
Installation Tool
This will ensure proper bearing alignment with the
5.12 (130 mm) crankshaft.
0.8
(20 mm) Bearing Number 1 0.1654-0.1772 inch
0.16
(4 mm) Recession (4,2-4,5 mm)
2.551-2.555
2.83 (64,80-64.90 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 (59,80-59,90 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 70-100-90].

RECONDITIONING THE ENGINE V2203-M-DI AND Cylinder Bore, Checking
Figure 70-100-93
Figure 70-100-92
B-4066
PI-10025 Use a gauge to check the inside measurement of the

cylinder bore [Figure 70-100-93].
Measure the flattened press gauge [Figure 70-100-92]. Figure 70-100-94

No. 2 crankshaft bearing.
Crankshaft Journal O.D. 2.3591-2.3598 inch

(59,92-59,94 mm)
Bearing I.D. 2.3614-2.3632 inch
(59,98-60,02 mm)
Oil Clearance 0.0016-0.0041 inch
(0,04-0,12 mm)
(0,2 mm)
A-2717
Measure the six points as shown in figure [Figure 70-

100-94] to find the maximum wear.
The factory specifications are:
Kubota V2203-M-DI
3.4252-3.4261 inch (87,0-87,022 mm)
The wear limit is: +0.0059 inch (+0,15 mm).
Kubota V2003-M-DI-T (Turbo)
3.2677-3.2686 inch (83-83,02 mm).
The wear limit is +0.0059 inch (+0,15 mm).
If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.

RECONDITIONING THE ENGINE V2203-M-DI AND Water Pump Disassembly And Assembly
Figure 70-100-96
Water Pump Removal And Installation
Drain the cooling system. 2
Remove the alternator belt. 1
Remove the water pump bolts. 3

4
Figure 70-100-95
B-14424
Remove the flange (Item 1) [Figure 70-100-96].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

100-96] out the impeller side of the water pump.
Remove the impeller (Item 3) [Figure 70-100-96] from

B-5318 the shaft.
Remove the seal (Item 4) [Figure 70-100-96].

Remove the water pump [Figure 70-100-95].
Install a new seal (Item 4) [Figure 70-100-96] when
Installation: Always use a new gasket when installing assembling the water pump.
the water pump.

TURBOCHARGER Figure 70-110-2
Checking
Inspect the turbine fins and the turbo housing for

damage.
1
Spin turbine by hand. Turbine should spin freely.
If the turbine is damaged replace the turbocharger.

2
Check the oil tubelines for leaks.
Description
P-48783
WARNING The oil flows from the fitting (Item 1) on the front of the
engine to the turbocharger and returns to the engine
Turbochargers, operate at high speed and high block through the fitting (Item 2) [Figure 70-110-2] .
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces. The turbocharger internal components are not
W-2257-1196 serviceable.
Figure 70-110-1
P16199
The turbocharger (Item 1) [Figure 70-110-1] is placed

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than
atmospheric pressure to the intake. It is lubricated by oil
from the main galley.

TURBOCHARGER (CONT'D) Figure 70-110-4
Remove the muffler. (See Removal And Installation on

Page 70-30-1.) 1
Figure 70-110-3
2 1
P-48598
Figure 70-110-5
P-48599
Remove the compressor outlet hose (Item 1) [Figure 70- 1

110-3] from the turbo.
Remove the air cleaner hose (Item 2) [Figure 70-110-3]

from the turbocharger.
P16230
Remove the oil supply line fitting (Item 1) [Figure 70-110-

4] and the brass washer(s) (Item 1) [Figure 70-110-5]
from the turbocharger.
Installation: Tighten to 12-15 ft.-lb. (16,0-20,3 Nm)

torque.

TURBOCHARGER (CONT'D) Figure 70-110-8
Figure 70-110-6
1 1 P-48780
Remove the mounting bolt (Item 1) [Figure 70-110-8]

P-48597 from the exhaust muffler flange.

Figure 70-110-9
1
1
2
P-48785
P-48781
Remove the mounting bolts (Item 1) [Figure 70-110-6] &
[Figure 70-110-7] from the oil return line (Item 2) [Figure
70-110-6] & [Figure 70-110-7]. Remove the mounting bolt (Item 1) [Figure 70-110-9]
from the exhaust muffler flange.
Installation: Tighten to 84-132 in.-lb. (9,5-15,0 Nm)
torque. Installation: Tighten to 17-20 ft.-lb. (23,0-27,0 Nm)
torque.

TURBOCHARGER (CONT'D)
Figure 70-110-10
1
1
P-48601
Remove the mounting nut and washer (Item 1) [Figure

70-110-10] from the turbocharger.

torque.
Figure 70-110-11
P16230
Remove the turbocharger assembly (Item 1) [Figure 70-

110-11] from the engine.

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SAFETY &
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 MAINTENANCE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-3
Cleaning The A/C Evaporator Coil & Heater Coil . . . . . . . 80-50-1
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-50-2 DRIVE
Engine Coolant By-Passing The Heater Valve . . . . . . . . 80-50-10 SYSTEM
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-11
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 ELECTRICAL

Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2 SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 ANALYSIS
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 ENGINE
SERVICE
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
EVAPORATOR/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 80-160-1 HVAC

EXPANSION VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-60-1

Component Replacement And Refrigeration Leaks. . . . . . 80-60-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-2
HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1

Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2

HEATING, VENTILATION, AIR CONDITIONING (CONTD)
HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1

Wire Connector Removal and Installation . . . . . . . . . . . . 80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1

PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Elements Removal And Installation . . . . . . . . . . . . . 80-40-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 80-100-1

Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-5
Charging Procedure With A Manifold Gauge Set . . . . . . 80-100-4
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1

Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2
TEMPERATURE/PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) See Chart on Page 80-10-3. where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Dessicant
3 Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas

b-16691

COMPONENTS Figure 80-20-3
Identification
Figure 80-20-1 2
1
1
P-24219
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-20-

P-24288 3] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-20-1] extra liquid refrigerant until it is needed by the
is the pump that circulates the refrigerant throughout the evaporator.
system. It raises the pressure of the refrigerant for heat
transfer through the condenser and evaporator. Figure 80-20-4
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-20-2
1
1
N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-20-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-20-
4] is a safety feature that is designed to open and release
P-48011 the A/C charge if the pressure reaches 535 PSI.
Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

COMPONENTS (CONT'D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
N-22087
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-24227 20-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-20-7]
1) [Figure 80-20-5] is located behind the loader cab. The controls the temperature of the evaporator coil.
unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heat & A/C Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
coils , thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-6
Figure 80-20-8
P-21902
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the Heater/Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-20-8] is used to push air through the heater and
evaporator coils and into the cab.

COMPONENTS (CONT'D) Figure 80-20-11
Identification (Cont'd)
1
Figure 80-20-9
2
3 4
P-24229
Pressure Switch: The pressure switch (Item 1) [Figure

N-22261 80-20-11] will disengage the compressor clutch at high
pressure readings over 384 PSI. (2647 kPa) on the high
side, or at very low pressure of 28 PSI (193 kPa) or less
Control Panel: The panel (Item 1) [Figure 80-20-9] has on the high side, which indicates loss of refrigerant.
three separate components.
Fan Switch: This is a four position rotary switch (Item 2)

[Figure 80-20-9]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-20-9]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

20-9] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-20-10
P-24232
Heater Valve: The heater valve (Item 1) [Figure 80-20-

10] is used to control the amount of engine coolant that
flows to the heater coil.

SAFETY
Safety Equipment
WARNING
Figure 80-30-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
"INSTANTLY". If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-30-2] to prevent frost bite if you should
get refrigerant on your hands.
P16398
Figure 80-30-2
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
P16399 knowledge, and experience to service refrigeration
equipment.
W-2373-0500
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
30-1] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Figure 80-40-3
Filter Elements Removal And Installation
Figure 80-40-1
P-28820
1
Remove the filter (Item 1) [Figure 80-40-3] from the

P-48012 cover.
The fresh air filter must be cleaned sometimes as often

Remove the two mount bolts (Item 1) [Figure 80-40-1] as twice a day, depending on the environment. The filter
from the fresh air filter cover at the rear of the loader cab. can be cleaned by removing and shaking it. A small
amount of air pressure can be used to clean the filter.
Figure 80-40-2 However the fresh air filter should be changed at least 2-
4 times per year in normal conditions. In extremely dusty
conditions the fresh air filter many need to be changed
weekly.
Figure 80-40-4
P-28819
Remove the filter cover and filter (Item 1) [Figure 80-40-

2 1
2] from the loader.
P-48005
Remove the two retaining knobs (Item 1) [Figure 80-40-

4] from the recirculating air filter cover, at the back of the
cab.
Remove the retaining cover (Item 2) [Figure 80-40-4]

from the loader cab.

REGULAR MAINTENANCE (CONTD) Compressor Drive Belt Inspection
Filter Elements Removal And Installation (Contd) Figure 80-40-7
Figure 80-40-5
P-48008
1
P-24288
P-48006
It is a good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Remove the recirculating air filter (Item 1) [Figure 80-40-
5] from the rear of the cab. Open the rear door.
Installation: Make sure the arrows on the filter are facing Remove the drive belt cover.
the front of the loader. (Inset) [Figure 80-40-5].
Remove the compressor drive belt cover.
Figure 80-40-6
Check the tension on the compressor belt (Item 1)
[Figure 80-40-7].
P-48007
The recirculating air filter is made of a paper filtering

media with a rubber seal. A small amount of air can be
used to clean the filter. It does not require cleaning as
frequently as the fresh air intake filter [Figure 80-40-6].

REGULAR MAINTENANCE (CONTD) Figure 80-40-10
Cleaning The Condenser
Figure 80-40-8
1
1
P-48010
With water or air, the condenser (Item 1) [Figure 80-40-

P-48011 10] can be cleaned.
Open the rear door.
Remove the rear grill on the loader.
Check the condenser (Item 1) [Figure 80-40-8] for mud

or dirt.
Figure 80-40-9
P-24213A P-48011
Lift the rear of the condenser and pull towards rear of

machine until the front tabs (Item 1) slide out of mount
(Item 2) [Figure 80-40-9].
With the condenser removed from the machine, the oil

cooler can also be lifted.

BASIC TROUBLESHOOTING Check the belt tension on the A/C compressor. ((See
COMPRESSOR on Page 80-110-1.)
Poor A/C Performance
Check the A/C condenser for dirt or mud, and clean if
Figure 80-50-1 necessary. (See CONDENSER on Page 80-120-1.)
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See EVAPORATOR on Page 80-190-1.)
Inspect the sight glass located on the receiver/drier for air

bubbles. (See RECEIVER/DRIER on Page 80-130-1.)
1 Check the engine coolant to see if it is bypassing the

heater valve. (See HEATER VALVE on Page 80-210-1.)
WARNING
N-22273
Figure 80-50-2 support device. Failure to use an approved lift arm
W-2059-0598
Cleaning The A/C Evaporator Coil & Heater Coil

on Page 10-20-1.)

on Page 10-30-1.)
Figure 80-50-3
N-22411
Start the loader, engage the parking brake. Engage the

A/C system with the blower fan on high. Run the loader at
full RPM for approximately 15 minutes, with the loader
cab door closed.
1
1
Check the temperature at the louvers (Item 1) [Figure
80-50-1] with a thermometer [Figure 80-50-2].
The louver temperature should be between 36-53F.

(2,2-11,6C) depending on the amount of humidity in the 2
air.
P-39463
If louver temperature is too high, (See SYSTEM
TROUBLESHOOTING CHART on Page 80-70-1.)
At the rear of the cab, Remove the six mounting screws
Check the blower fan for proper operation or noise, and (Item 1) [Figure 80-50-3].
replace if necessary. (See HEATER/AC FAN on Page
80-210-1.) Remove the access cover (Item 2) [Figure 80-50-3] from
the loader.

BASIC TROUBLESHOOTING (CONT'D) Compressor Drive Belt Inspection
Cleaning The A/C Evaporator Coil & Heater Coil Figure 80-50-6
(Cont'd)
Figure 80-50-4
1
1
P-48013
P-24288
P-48014 Regularly inspect (weekly) the compressor drive belt for

wear.
The access cover is sealed to the heater unit with a foam Open the rear door.
gasket (Item 1) that keeps out dirt and debris. Check the
gasket for rips and tears. Replace as needed. Remove the drive belt cover.
The cover is held in place with screws that are held to the Remove the compressor belt cover.
cover with plastic retainers (Inset) . These help hold the
screws when installing the cover. Check the tension on the compressor belt (Item 1)
[Figure 80-50-6].
Figure 80-50-5
2
1
P-39464
With air or water, clean the heater coil (Item 1) and

evaporator coil (Item 2) [Figure 80-50-5].
Replace the cover.


BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-9
Checking The Electrical System
Figure 80-50-7
1
2 1 P-24300

N-22284 support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Check to see if the compressor clutch is engaging. Raise the operator cab. (See Raising The Operator Cab
With an operator in the loader seat and the cab door on Page 10-30-1.)
open, turn the loader key switch to RUN (Standard
Panel) OR press the RUN/ENTER Button (Deluxe Disconnect the loader harness (Item 1) [Figure 80-50-9]
Panel),without starting the loader. from the compressor clutch wire.
Push the A/C switch (Item 1) to the ON position. Turn the
blower fan switch (Item 2) [Figure 80-50-7] to the first On Figure 80-50-10
position.
The compressor clutch should make a click sound, which

indicates the clutch is engaging.
Figure 80-50-8
P-24314
With a multimeter, check the resistance to the

compressor clutch (Item 1) [Figure 80-50-10].
P-21912
If there is no resistance value, replace the compressor
clutch.(See COMPRESSOR on Page 80-110-1.)
If the compressor clutch does not engage, check the
loader fuse (Item 1) [Figure 80-50-8] located on the
control panel in the loader cab.
Replace the fuse if burned out.

NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the power
for both the Heater and the A/C systems.
Checking The Electrical System (Cont'd)
Figure 80-50-11
1
1
P-24315
Using a multimeter check the loader wiring harness (Item

P-24314 1) [Figure 80-50-13] for voltage.
The voltage should be around 12 volts.

With a multimeter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-50-11] If there is no voltage at the wiring harness, check the
harness for broken wires.
The voltage reading should be around 12 volts.
Figure 80-50-14
If there is no power at the clutch, check the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
Figure 80-50-12
2
1
P-24315
1
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1) [Figure 80-50-14].
If there is no resistance value, check for low refrigerant

P-24299 level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-100-1.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is observed, the pressure switch is
switch (Item 2) [Figure 80-50-12]. good.
Reconnect the loader harness to the pressure switch.

Figure 80-50-15
N-22259
If there is voltage at the wiring harness, check the

N-22258 thermostat (Item 1) [Figure 80-50-17] for resistance.
The resistance value of the thermostat should be 10

Disconnect the thermostat wiring connector (Item 1) Ohms at 68 F (20 C).
[Figure 80-50-15] from the loader wiring harness.
If there is no resistance value, replace the thermostat.
Figure 80-50-16 (See THERMOSTAT on Page 80-170-1.)
If there is a resistance value, check the blower fan.
Figure 80-50-18
N-22259
1
Check the loader harness (Item 1) [Figure 80-50-16] for
voltage. The voltage should be 12 volts.
N-22130
If there is no voltage at the wiring harness, check the

harness for broken wires. Remove the mount bolt (Item 1) [Figure 80-50-18] from
the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-18]

from the loader.

Figure 80-50-19
1 1
N-22260
If there is voltage at the wiring harness, check the

N-22129 resistance to the blower fan at the blower fan wiring
Disconnect the blower fan wiring connector (Item 1) If there is no resistance value replace the blower fan.
[Figure 80-50-19] from the loader wiring harness. (See HEATER/AC FAN on Page 80-210-1.)
Figure 80-50-20 If there is a resistance value check the climate controls at

the control panel inside the loader cab.
Figure 80-50-22
1 1
N-22260 1
Check the loader harness (Item 1) [Figure 80-50-20] for

N-22261
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the Remove the three mount bolts (Item 1) [Figure 80-50-22]
harness for broken wires. from the cab control panel.

Figure 80-50-23
H C
M B
N-22288
If there is voltage at the wiring harness, check the blower

N-22262 switch [Figure 80-50-25] for resistance.
With the switch in the OFF position, there should be zero

Remove the control panel and wiring harness from the resistance between all terminals.
cab [Figure 80-50-23].
With the switch in the 1 position, there should be
Figure 80-50-24 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
80-50-25].

resistance between C terminal and the B terminal,
1 between the C terminal and the M terminal, and also
between the B terminal and the M terminal frame [Figure
80-50-25].

resistance between C terminal and the B terminal,
between the C terminal and the H terminal, and also
between the B terminal and the H terminal frame [Figure
N-22265 80-50-25].
If any of the above resistance tests fail, replace the

Disconnect the loader wiring harness (Item 1) [Figure blower switch.
80-50-24] from the blower switch.
If the above resistance tests are good, check the A/C
Check the loader harness for voltage. The voltage should switch.
be 12 volts.
If there is no voltage at the wiring harness, check the


BASIC TROUBLESHOOTING (CONT'D) If a resistance value is found, check the potentiometer.
Checking The Electrical System (Cont'd) Figure 80-50-28
Figure 80-50-26
1 1
N-22262
N-22264
The potentiometer will effect the A/C system and also
effect the operation of the heater.
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-50-26] from the A/C switch. If heater valve does not open, or close, or the A/C does
not work, check the potentiometer.
Check the harness for voltage. The voltage should be 12
volts.
At the loader cab, disconnect the loader harness (Item 1)
If there is no voltage at the wiring harness, check the [Figure 80-50-28] from the potentiometer.
Figure 80-50-29
Figure 80-50-27
1
1
2
N-22263
N-22289
If there is voltage at the wiring harness, check the A/C Check the loader harness (Item 1) [Figure 80-50-29] for
switch [Figure 80-50-27] for resistance. voltage. The voltage should be 12 volts.
With the switch in the OFF position there should be no If there is no voltage at the wiring harness, check the
resistance between any of the three terminals on the A/C harness for broken wires.
switch.
With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-50-27].
If no resistance value is found, replace the A/C switch.

Figure 80-50-30
C 1
A
N-22175
B
To check the resistance of the white wire, turn the
N-22290 potentiometer control (Item 1) to the full A/C position
[Figure 80-50-32].
If there is voltage at the wiring harness, check the Figure 80-50-33

potentiometer [Figure 80-50-30] for resistance.
The resistance should be 10 K Ohm's between wire

terminal A and wire terminal C frame [Figure 80-50-30].
If no resistance is found, replace the potentiometer.

C
Figure 80-50-31 A
N-22290
The resistance between the wire terminal A and wire

1 terminal B frame [Figure 80-50-33] should be
approximately 49 K Ohm's.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 80-50-33] should be
The white wire B, (Item 1) [Figure 80-50-31], on the

potentiometer, is a resistor wire.

BASIC TROUBLESHOOTING (CONT'D) Engine Coolant By-Passing The Heater Valve
Checking The Electrical System (Cont'd) Figure 80-50-36
Figure 80-50-34
2 3
1
1
N-22284
N-22175
To check the resistance of the white wire, turn the Page 10-20-1.)
potentiometer control (Item 1) [Figure 80-50-34] to the
full Heater position. Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to the High Speed position. Turn
Figure 80-50-35 the temperature control (Item 3) [Figure 80-50-36] to the
High A/C position, with the loader ignition switch OFF.
Figure 80-50-37
1
C
A
N-22290
Check the resistance between the wire terminal A and P-48009

wire terminal B frame [Figure 80-50-35] should be
on Page 10-30-1.)
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-50-35] should be
If the resistance is not found, replace the potentiometer. Start the loader and run at high idle, for ten minutes.
Check the heater hose (Item 1) [Figure 80-50-37] for

temperature.
If the hose is hot, the heater valve is leaking by, and

Heater Valve Not Opening Or Closing
Figure 80-50-38
1
P-48015
2 3
1 P-48009
Place the remote start tool on the left fender of the

N-22284 loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-50-39], as the key of
the remote start is turned to the ON position without
Raise the lift arms and install an approved lift arm starting the loader. The heater valve should rotate.
on Page 10-20-1.) If it does not rotate, check the potentiometer. (See
HEATER VALVE on Page 80-220-1.) for proper function.
Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to position 1. Turn the temperature Replace the heater valve. (See HEATER VALVE on
control (Item 3) [Figure 80-50-38] to the High A/C Page 80-220-1.)
position, with the loader ignition switch OFF.

on Page 10-30-1.)

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 80-50-39], as the key of
the remote start tool is turned to the ON position without
starting the loader. The heater valve should rotate. Place
a mark on the loader shaft.
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-50-38]

to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.

GENERAL AIR CONDITIONING SERVICE
GUIDELINES
Compressor Oil
Figure 80-60-1
N-22243
The compressor (Item 1) [Figure 80-60-1] is factory filled

with 150-170 cc's of PAG oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check

or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver-drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any oil related problems occur in the cooling

cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

GENERAL AIR CONDITIONING SERVICE Run the compressor for at least 20 minutes at 800-1200
GUIDELINES (CONT'D) RPM.
Compressor Oil Check Remove the compressor from the loader. (See
COMPRESSOR on Page 80-110-1.)
Figure 80-60-2
Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
[Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lb.

(13-15 Nm) torque.
Figure 80-60-4
1
N-22245
Figure 80-60-3
N-22246
NOTE: After draining the oil through the drain hole

and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
P-16534A
The compressor oil should be checked as follows when

oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See CONDENSER on Page 80-120-
1.)
Open the cab door and windows.
Run the blower at maximum speed.

GENERAL AIR CONDITIONING SERVICE Component Replacement And Refrigeration Leaks
GUIDELINES (CONT'D)
Figure 80-60-6
Compressor Oil Check (Cont'd)
Figure 80-60-5
P-24229
N-22245 Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver/drier
(Item 1) [Figure 80-60-6] must be changed.
Measure the drained oil in a measuring cylinder.
Never leave hose fittings, compressor fittings or
Check the oil for contamination, dirt, metal shavings, or components uncapped while working on the A/C system.
varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Add new compressor oil through the suction side

Installation: Add 150 -170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked

with an S and is the larger port on the
compressor.

SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate

Possible Cause Inspection Solution
1. Blown fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor malfunction. Check power into and out of the fan switch. Replace Fan Switch.
Blower motor operates normally, but air flow is insufficient
1. Evaporator inlet Check evaporator for plugging. Remove obstruction and clean
obstruction. evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
Insufficient cooling although air flow and compressor operation are normal
1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly
1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open oil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation.
components. thermostat, Relay, etc.

SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb, the high side pressure will be around eight times greater than the low side pressure.

Low pressure side The low pressure side pressure normally becomes too
too high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Dective compressor. The high and low pressure side gauge pressures Replace compressor.
equalize when the compressor is engaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valves inlet side is frosted. Moisture or Clean or replace the
expansion valve. other Contaminants can be the cause. expansion Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
performance. Operating. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.
High pressure side
Too low.
1. Low refirgerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receive drier. the refrigerant to the correct
level.

SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)

System pressures equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.

TEMPERATURE/PRESSURE
Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP F. PSIG TEMP F. PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature=90 degrees F.

90 degrees F.
+40 degrees F.
130 degrees F. condenser temperature=200 psig
Conditions and pressures will vary from system to system.

AIR CONDITIONING SERVICE
Chart
Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

SYSTEM CHARGING AND RECLAMATION Figure 80-100-3
Reclamation Procedure
1
Figure 80-100-1
N-23024
NOTE: Before reclaiming a refrigeration system, it is

P-24208 recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL 1592,
Open the rear door and locate the low pressure port Refrigerant Identifier (Item 1) [Figure 80-100-3]
(Item 1), and high pressure port (Item 2) [Figure 80-100- will determine, the kind of refrigerant and any
1]. possible harmful or dangerous substances
that may be present in the system. Thus
Figure 80-100-2
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL 1581 Recovery/Recycling/Recharging
Machine.
P-24230
NOTE: Do not use this port (Item 1) [Figure 80-100-2]

for testing or charging.
WARNING
a toxic gas.
W-2371-0500
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-5
Reclamation Procedure (Cont'd)
Figure 80-100-4
N-22291
IMPORTANT: Only A/C trained technicians should

P-24316 perform the reclaiming and recharging.
Remove the protective cap and connect the Refrigerant

Identifier to the low pressure hose (Item 1) [Figure 80-
100-4].
WARNING
Connect the Refrigerant Identifier to its power source. HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
Follow the steps displayed on the refrigerant identifier if it contacts the eyes and may cause serious
screen. frostbite if it contacts the skin.
Gaseous 134A becomes lethal (phosgene) gas
Allow two minutes for the refrigerant identifier to display when it contacts open flame or very hot
the type of refrigerant and air content. An alarm will substances.
sound if potentially flammable hydrocarbons are present NEVER SMOKE when there is the possibility of
and will also indicate on the visual display. even small amounts of 134A in the air.
Any servicing work that involves release or addition
Disconnect the refrigerant identifier from the loader A/C. of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
If the refrigerant is dangerous or flammable, it must be knowledge, and experience to service refrigeration
evacuated from the A/C system into a separate container equipment.
and properly and safely disposed of. W-2373-0500
If R134a is found , evacuate the system. Use an approved recovery/charging unit [Figure 80-100-
5] to evacuate the system.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-8
Reclamation Procedure (Cont'd)
Figure 80-100-6
N-22381
NOTE: The reclaimer unit, has a complete step by

P-24317 step set of instructions [Figure 80-100-8] to
follow for reclimation and recharging of the A/
C system. A trained technician should follow
Connect the reclaimer to the loader A/C charge ports. these instructions as they may very slightly
depending on the model and brand of
Connect the Red hose (Item 1) [Figure 80-100-6] to the reclaimer used.
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-100-6] to the

low pressure port and open the valve.
Figure 80-100-7
N-22292
Turn the reclaimer unit [Figure 80-100-7] to the ON

position and follow the on screen instructions.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Connect the gauges to the loader A/C charge ports.
Charging Procedure With A Manifold Gauge Set Connect the Red hose (Item 1) [Figure 80-100-10] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-100-10] to the

WARNING low pressure port and open the valve.
Figure 80-100-11
a toxic gas.
W-2371-0500
Figure 80-100-9 1
P-24320
Connect the Yellow hose (Item 1) [Figure 80-100-11] to

the vacuum pump.
1 Figure 80-100-12
P-24318
Open the rear door.
Check to see that the hand valves (Item 1) [Figure 80-

100-9] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation Procedure on Page 80-100-1.) 1
Figure 80-100-10
P-24321
Start the vacuum pump and open ISO-valve (Item 1)

[Figure 80-100-12] on the vacuum pump.
Run the vacuum pump for at least 5-10 minutes to insure

that a vacuum has been pulled on the system.
1 Close the ISO-valve (Item 1) [Figure 80-100-12] (which

2 isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump.
P-24319

SYSTEM CHARGING AND RECLAMATION (CONT'D) Start the vacuum pump and open ISO-valve on the
vacuum pump.
Charging Procedure
Be sure that both hand valves, and both charge port
Figure 80-100-13 valves are open.
Run the vacuum pump for at least 45 minutes to insure

that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
1
Remove the vacuum pump and thermister vacuum
gauge.
P-24319 Figure 80-100-15
NOTE: Vacuum pressure indicated on the low

pressure (Blue) gauge (Item 1) [Figure 80-100-
13]. Let stand for 5-10 min. and recheck the
pressure for changes. 1
If the pressure drops, this may be an indication of a leak 3

in the A/C system.
Determine the problem with the A/C system and repair it.
Figure 80-100-14 2
P-24323
Place a refrigerant container with R134a (Item 1) on a

charging scale (Item 2) [Figure 80-100-15] and zero out
the scale.
Connect the yellow hose (Item 3) [Figure 80-100-15]

from the manifold gauge set to the valve on the
refrigerant tank.
P-24322
A thermistor vacuum gauge (Item 1) [Figure 80-100-14]

can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
The thermistor vacuum gauge is used with the vacuum

pump [Figure 80-100-14].

SYSTEM CHARGING AND RECLAMATION (CONT'D) The A/C system holds 2.0 lb. (0,91 kg) of refrigerant.
Charging Procedure (Cont'd) Turn OFF the valve on the refrigerant container, and
hand valves on the manifold gauge set.
Figure 80-100-16
Turn OFF the engine, and remove the A/C charging
equipment from the loader.

P-24324
Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
80-100-16] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.
Figure 80-100-17
2
1
N-22284

Press the A/C (Item 1) [Figure 80-100-17] switch to ON

position.
Turn fan switch (Item 2) [Figure 80-100-17] to HIGH

position.
Start loader engine, with the remote start switch, and run
at medium speed.
Watch the scale and run system until the predetermined

amount of refrigerant is added to the A/C system.

COMPRESSOR

WARNING
Figure 80-110-1
a toxic gas.
W-2371-0500
Remove the compressor hoses (Item 3) [Figure 80-110-

1 2] from the compressor.
2
Installation: Tighten the compressor hoses to 22 ft.-lb.
(29,8 Nm) torque.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
P-24325
Figure 80-110-3
Remove drive belt guard.
Remove A/C belt guard (Item 1), by removing the

mounting bolt and nut (Item 2) [Figure 80-110-1].
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-100-1.) 1
Figure 80-110-2
P-24327
Remove the compressor mount bolt (Item 1) [Figure 80-

110-3].
3
Remove the compressor from the loader.
1
2
P-24326
Remove the compressor adjustment bolt (Item 1) [Figure

80-110-2].
Installation: Tighten the compressor adjustment bolt to

34 ft.-lb. (46 Nm) torque.
Remove the compressor belt (Item 2) [Figure 80-110-2].
Mark the compressor hoses for proper installation.

COMPRESSOR (CONT'D) Figure 80-110-6
Compressor Clutch Disassembly
Figure 80-110-4
1.32
1.32
1.32
2
1
1
N-22275
The armature plate puller, (Item 1) can be constructed by

N-22244 drilling three 10 mm holes in a flat circular plate, located
1.32 inches apart [Figure 80-110-6].
Remove the center armature bolt (Item 1) [Figure 80- Attach the puller to the armature plate using three 8 mm
110-4]. bolts (Item 2) [Figure 80-110-6].
Installation: Tighten the armature bolt to 8-10 ft.-lb. (12- Figure 80-110-7
14 Nm) torque.
Figure 80-110-5
N-22278
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-5] on the armature plate as shown in [Figure 80-
110-7].
To remove the armature plate (Item 1) [Figure 80-110-5]
from the clutch face, you must make an armature plate
puller.

Compressor Clutch Disassembly (Cont'd)
Figure 80-110-8
1
1 N-22283

N-22279 the pulley assembly.
Figure 80-110-11
Attach a slide hammer puller (Item 1) [Figure 80-110-8]
to the armature puller disk.
Remove the armature plate from the compressor clutch.
Figure 80-110-9
1
N-22369
Install the pulley puller tool MEL 1595 on the compressor

pulley [Figure 80-110-11].
N-22280
Remove the shims (Item 1) [Figure 80-110-9] from either

the armature shaft or armature plate.
Installation: Insure that the clutch has the correct

clearance by adding the shims (Item 1) [Figure 80-110-
9].
The specified clearance for the clutch is 0.01-0.02 in.

(0.3-0.6 mm). Adjusting shims are available in the
following thicknesses:
0.0039 in. (0.1 mm)
0.0118 in. (0.3 mm)
0.0197 in. (0.5 mm)

Figure 80-110-12
N-22373
Slide the wire grommet (Item 1) [Figure 80-110-14] from

N-22370 the wire holder.
Figure 80-110-15
Remove the pulley from the compressor [Figure 80-110-
12].
Figure 80-110-13
N-22374
Remove the coil lead wire (Item 1) [Figure 80-110-15]

N-22371 from the wire holder on the compressor.
The pulley assembly and bearing [Figure 80-110-13]

must be replaced as a complete unit.

COMPRESSOR (CONT'D)
Figure 80-110-16
1 1
N-22372
Remove the three coil mount bolts (Item 1) [Figure 80-

110-16] from the compressor.
Installation: Tighten the mount bolts to 2.9-4.3 ft.-lb. (4-6

Nm) torque.
Remove the coil from the compressor.
Figure 80-110-17
N-22375
The compressor [Figure 80-110-17] must be replaced as

a complete unit.

CONDENSER Figure 80-120-2
Figure 80-120-1
LIFT HERE
P-48011
Lift the rear of the condenser [Figure 80-120-2], and pull

P-48011 toward the rear of the loader until the front tabs (Item 1)
[Figure 80-120-4] slide out of bracket (Item 2) [Figure
80-120-4]
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page Figure 80-120-3
80-100-1.)
Open the rear grill on the loader.
Mark the two A/C hoses (Item 1) [Figure 80-120-1] for

proper installation.
WARNING
P-48010
a toxic gas. Remove the condenser from the loader [Figure 80-120-
W-2371-0500
3].
Disconnect the two hoses from the condenser (Item 1)

[Figure 80-120-1].
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.

CONDENSER (CONTD)
Figure 80-120-4
P-24303
Installation: Make sure to insert tabs (Item 1), into the

mounts (Item 2) [Figure 80-120-4], evenly for ease of
installation.

RECEIVER/DRIER Figure 80-130-2
WARNING 2

W-2059-0598
P-24298
Figure 80-130-1
Note the flow direction on the drier (Item 1) [Figure 80-

130-2] for proper installation.
1
WARNING
a toxic gas.
W-2371-0500
P-24299
Remove the two A/C hoses (Item 2) [Figure 80-130-2]
from the receiver/drier.
support device. (See Installing Lift Arm Support Device Cap and plug the hoses and the receiver/drier fittings
on Page 10-20-1.)) with the proper A/C caps and plugs.
Raise the operator cab. (See Raising The Operator Cab Loosen the hose clamps (Item 3) [Figure 80-130-2] that
on Page 10-30-1.) holds the receiver/drier to the mount.
Remove the refrigerant from the A/C system.(See Remove the receiver/drier from the loader.
SYSTEM CHARGING AND RECLAMATION on Page
80-100-1.) NOTE: When replacing a receiver/drier in an A/C
system 1 fl. oz. (30 cc) of PAG oil must be
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper added to the system when recharging.
installation.
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.

RECEIVER/DRIER (CONTD)
Figure 80-130-3
P-24295

from the receiver/drier mount bracket.

PRESSURE RELIEF VALVE Figure 80-140-2
Figure 80-140-1
N-22206
The pressure relief valve [Figure 80-140-2] is designed

N-22205 to open and release the A/C charge if the pressure
reaches 535 PSI (3689 kPa).
The pressure relief valve (Item 1) [Figure 80-140-1] is This will cause the A/C system to shut down, saving the
located on the receiver drier assembly. compressor.
The Pressure Relief Valve is a secondary protection

device in the A/C system, with the Pressure Switch
shutting down the system at 384 PSI (2648 kPa).
NOTE: If a Pressure Relief Valve is found open, check

the A/C system for problems. Replace the
complete receiver/drier unit.

PRESSURE SWITCH

WARNING
Figure 80-150-1
a toxic gas.
W-2371-0500
Remove the pressure switch (Item 1) [Figure 80-150-2]

from the A/C high pressure hose.
1 Remove the pressure switch from the loader.
Schraeder Valve Removal And Installation
Figure 80-150-3
P-24299
on Page 10-20-1.)

on Page 10-30-1.)
1
Disconnect the loader wire harness (Item 1) [Figure 80-
150-1] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
N-22166
Figure 80-150-2
The schraeder valve (Item 1) [Figure 80-150-3] is
located in the A/C high pressure hose and is located
under the pressure switch.
on Page 10-20-1.)
1
on Page 10-30-1.)
Remove the refrigerant from the A/C system. (See

SYSTEM CHARGING AND RECLAMATION on Page
80-100-1.)
P-24298
Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.

EVAPORATOR/HEATER UNIT Figure 80-160-3
Figure 80-160-1
N-22129
Disconnect the blower fan wiring connector (Item 1)

N-22122 [Figure 80-160-3] from the loader wiring harness.
Figure 80-160-4
on Page 10-20-1.)

on Page 10-30-1.)
Evacuate the A/C system.(See SYSTEM CHARGING

AND RECLAMATION on Page 80-100-1.)
1
At the rear of the cab, disconnect the thermostat wiring
Figure 80-160-2
N-22119
Remove the two mounting nuts (Item 1) [Figure 80-160-

2 4].
N-22130
Remove the mount bolt (Item 1) [Figure 80-160-2] from

the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-160-2]

from the loader.

EVAPORATOR/HEATER UNIT (CONT'D) Figure 80-160-7
Figure 80-160-5
1
N-22128
Remove the two A/C hoses (Item 1) [Figure 80-160-6]

N-22120 from the expansion valve.
Installation: Tighten the A/C hoses to 22 ft.-lb. (29,8

Remove the two mounting nuts (Item 1) [Figure 80-160- Nm) torque.
5].
Cap and plug the hoses and the expansion valve fittings
Figure 80-160-6 with the proper A/C caps and plugs.
Remove the heater hoses (Item 1) [Figure 80-160-7]

from the heater coil.
Installation: Tighten the Heater hoses to 22 ft.-lb. (29,8

Nm) torque.
1
Remove the evaporator/heater unit from the loader.
N-22126
Remove the Evaporator/Heater Unit from the rear of the

cab. Place it on the fenders of the loader supported by
2X4's (blocking) [Figure 80-160-6].
WARNING
a toxic gas.
W-2371-0500

EVAPORATOR/HEATER UNIT (CONT'D)
Figure 80-160-8
1
1
N-22065
Remove the six mount bolts (Item 1) [Figure 80-160-8]

from the Evaporator/Heater Unit rear cover.
Remove the rear cover from the unit.

THERMOSTAT Figure 80-170-3
Figure 80-170-1
N-22072
Remove the thermostat from the unit [Figure 80-170-3].

N-22069
Figure 80-170-4
NOTE: The thermostat can be changed without A

evacuating the A/C system, or removing the
evaporator/heater unit from the loader. B
Remove the rear cover from the evaporator/heater unit.

(See EVAPORATOR/HEATER UNIT on Page 80-160- C
1.))
1
Remove the two thermostat mount bolts (Item 1), and
remove the wiring harness and grommet (Item 2) [Figure
80-170-1] from the evaporator/heater housing.
Figure 80-170-2
N-22072

changed. The wiring position and color in the connector
is:
A Blue
1 B White
C Black
N-22071
Remove the thermostat probe (Item 1) [Figure 80-170-2]

from the A/C evaporator coil.

EXPANSION VALVE Figure 80-180-2
Figure 80-180-1
N-22073
Remove the two evaporator fittings (Item 1) [Figure 80-

N-22150 180-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 22 ft.-

NOTE: The expansion valve can be changed without lb. (29,8 Nm) torque.
removing the evaporator/heater unit from the
loader. Remove the two mount bolts (Item 2) [Figure 80-180-2].
Raise the lift arms and install an approved lift arm Remove the expansion valve from the loader.
on Page 10-20-1.) Figure 80-180-3

on Page 10-30-1.)
(See SYSTEM CHARGING AND RECLAMATION on

Page 80-100-1.)
1
WARNING
N-22074
a toxic gas.
W-2371-0500
Cap and plug the evaporator tubelines (Item 1) [Figure

Remove the two A/C hoses (Item 1) [Figure 80-180-1] 80-180-3] and the expansion valve fittings with the
from the expansion valve. proper A/C caps and plugs.
Installation: Tighten the two A/C hose fittings to 22 ft.-lb.

(29,8 Nm) torque.
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.

EXPANSION VALVE (CONT'D)
Figure 80-180-4
1
1
N-22074

from the expansion valve mount.
Remove the expansion valve mount from the unit.
Figure 80-180-5
N-22085
The expansion valve [Figure 80-180-5] is replaced as a

complete unit.

EVAPORATOR Remove the expansion valve mount bracket (Item 1)
[Figure 80-190-2] from the unit.
Figure 80-190-3
Figure 80-190-1
1 N-22075
N-22073
Remove the two mount bolts (Item 1) from the mount

Raise the lift arms and install an approved lift arm plate (Item 2) [Figure 80-190-3].
on Page 10-20-1.) Remove the mount plate from the unit.
Raise the operator cab.(See Raising The Operator Cab Figure 80-190-4
on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-100-1.)
Remove the evaporator/heater unit from the back of the

cab. (See EVAPORATOR/HEATER UNIT on Page 80-
160-1.)
Remove the expansion valve (Item 1) [Figure 80-190-1]

from the unit. (See EXPANSION VALVE on Page 80-
180-1.)
Figure 80-190-2 1
N-22076
Remove the two retaining clips (Item 1) [Figure 80-190-

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074

EVAPORATOR (CONT'D)
Figure 80-190-5
N-22078
Inspect the evaporator coil [Figure 80-190-5] for leaks,

Clean with low water or air pressure.

HEATER COIL Remove the rear cover from the evaporator/heater unit.
(See EVAPORATOR/HEATER UNIT on Page 80-160-1.)
Removal And Installation With A/C
Figure 80-200-1 from the heater coil at the expansion valve end of the
unit.
Figure 80-200-3
1
N-22128

N-22087
on Page 10-20-1.)
Remove the two retaining clips (Item 1) [Figure 80-200-
on Page 10-30-1.) 3] that connect the evaporator coil, to the heater coil.
Remove the evaporator/heater unit from the back of the Figure 80-200-4
cab.(See EVAPORATOR/HEATER UNIT on Page 80-
160-1.)
Mark the heater hoses (Item 1) [Figure 80-200-1] for

1 1
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system. 2
Installation: Tighten the two heater hose fittings to 22 ft.- 2

lb. (29,8 Nm) torque.
Figure 80-200-2
N-22089
1 Remove the three mount bolts (Item 1) [Figure 80-200-4]

and remove the mount plate from the end of the unit.

that support the heater coil tubelines to the unit.
Remove the heater coil from the unit.
1
N-22086

HEATER COIL (CONT'D) Mark the heater hoses (Item 1) [Figure 80-200-6] for
Removal And Installation With A/C (Cont'd)
Remove the two heater hoses from the heater coil.
Figure 80-200-5
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.-

lb. (29,8 Nm) torque.
Figure 80-200-7
1 1
N-22090
2
The heater coil [Figure 80-200-5] can be cleaned with

low air or water pressure. 2
If the heater coil needs replacement it must be replaced
as complete unit.
N-22093
Removal And Installation Without A/C

Remove the rear cover from the evaporator/heater unit.
Figure 80-200-6 (See EVAPORATOR/HEATER UNIT on Page 80-160-1.)
Remove the three mount bolts (Item 1) [Figure 80-200-7]

and remove the mount plate from the end of the unit.

that support the heater coil tubelines to the unit.
Figure 80-200-8
1
1
N-22128

Page 10-20-1.)

N-22094
on Page 10-30-1.)
Remove the heater unit from the back of the cab. (See Remove the two mount bolts (Item 1) [Figure 80-200-8]
EVAPORATOR/HEATER UNIT on Page 80-160-1.) from the heater coil.
Remove the heater coil from the unit.

HEATER/AC FAN Figure 80-210-3
Figure 80-210-1
N-22099
Remove the blower fan wiring harness and grommet

N-22096 (Item 1) [Figure 80-210-3] from the unit
Figure 80-210-4
on Page 10-20-1.)
1
on Page 10-30-1.)
Remove the evaporator/heater unit from the back of the

cab. (See EVAPORATOR/HEATER UNIT on Page 80-
160-1.)
NOTE: The heater/AC fan assembly can be removed

from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is removed here for photo clarity. N-22100
Remove the grommet (Item 1) [Figure 80-210-1] from

the side of the evaporator/heater unit. Remove the three mount bolts (Item 1) [Figure 80-210-4]
from the blower fan housing.
Figure 80-210-2
Remove the blower fan housing from the evaporator/
heater unit.
N-22097

HEATER/AC FAN (CONT'D) Figure 80-210-6
Figure 80-210-5
1
2
1 1
N-22107
Check the blower housing (Item 1) and fan motor mount

2
N-22102 (Item 2) [Figure 80-210-6] for wear and replace as
needed.
Remove the eight mount bolts (Item 1) [Figure 80-210-5] Figure 80-210-7
from the blower wheel cover.
Remove the blower wheel cover from the fan housings. 1

from the fan motor mount. 1
Remove the fan motor mount.
Remove the fan motor assembly from the housing.
2
N-22108
Remove the outside rings (Item 1) and fan wheel covers

(Item 2) [Figure 80-210-7] from the fan motor and blower
wheels.

HEATER/AC FAN (CONT'D) Figure 80-210-10
Figure 80-210-8
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

N-22109 80-210-9] & [Figure 80-210-10] from the blower wheel.
Figure 80-210-11
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-8].
Figure 80-210-9
1 N-22111
Remove the inside blower wheel clamp (Item 1) [Figure

N-22110 80-210-11] from the blower wheel.

HEATER/AC FAN (CONT'D) Wire Connector Removal and Installation
Disassembly And Assembly (Cont'd) Figure 80-210-13
Figure 80-210-12
1
1
2
N-22103
N-22116
Figure 80-210-14
Note: Before removing blower wheels, mark their

orientation to ensure they are assembled
back on the correct side and the fins are
facing the same direction.
Remove the blower wheel (Item 1) and inside ring (Item

2) [Figure 80-210-12] from the blower fan motor shaft. 1
Repeat the procedure for the other blower wheel.
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-13] &

[Figure 80-210-14] from the center of the blower fan
motor wiring connector.

HEATER/AC FAN (CONT'D)
Wire Connector Removal and Installation (Cont'd)
Figure 80-210-15
1 1 1
N-22105
With a pointed screw driver lightly press in on the tabs

(Item 1) [Figure 80-210-15] and remove the individual
wires from the connector.
Figure 80-210-16
N-22106
The wiring code for the blower fan connectors [Figure

80-210-16]i:
Number on Connector Wire Color

1 Orange
2 Red
3 Yellow
4 Black
5 Open
6 Open

HEATER VALVE Disassembly And Assembly
Removal And Installation Figure 80-220-2
Figure 80-220-1
1
3
N-22155
P-48009
Remove the three mount bolts (Item 1) [Figure 80-220-2]
from the heater valve actuator.
Disconnect the loader wiring harness (Item 1) [Figure
80-220-1]. Figure 80-220-3
Remove the two coolant hoses (Item 2) [Figure 80-220-

1] from the heater valve.
NOTE: Cap the hoses and the heater valve to prevent

contamination and coolant loss from the system.
Remove the two heater valve mounting bolts (Item 3) 1

2
[Figure 80-220-1].
Remove the heater valve from the loader.
N-22156
Remove the actuator (Item 1) and the three mounting

spacers (Item 2) [Figure 80-220-3] from the heater valve
mount plate.

HEATER VALVE (CONT'D) Figure 80-220-6
Figure 80-220-4
1
N-22159

N-22157 6] from the heater valve.
Figure 80-220-7
Remove the three mounting bolts (Item 1) [Figure 80-
220-4] from the heater valve mount plate.
Figure 80-220-5
1
1
N-22160
Remove the heater valve mount bracket (Item 1) [Figure

N-22158 80-220-7] from the heater valve.
Replace the parts as needed.

Remove the mount plate (Item 1) [Figure 80-220-5] from
the heater valve bracket.

SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) . . . . SPEC-21-1
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 DRIVE
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 SYSTEM
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 ELECTRICAL
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 SYSTEM &
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 ANALYSIS
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI . . . . . . . . . . . . . . . SPEC-20-1 ENGINE

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 SERVICE
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 SPECIFICATIONS
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2

SPEC-01 Service Manual
SPECIFICATIONS (CONTD)
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-40-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-40-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-40-2
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS SPEC-50-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS. . . . . . . . . . . . SPEC-30-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-30-2
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . SPEC-30-1

SPEC-02 Service Manual
LOADER SPECIFICATIONS
Machine Dimensions
Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
B-17328
TIRE DESCRIPTION WIDTH (OVER TIRES) WHEEL TREAD BUCKET WIDTH WIDTH (OVER BUCKET)
10-16.5 TIRES 66.0in. (1676mm) or 54.5in. (1385mm) or 62 62.0in. (1575mm)
60.0in (1524mm) 48.5in. (1232mm) 68 68.0in. (1727mm)
31-15x15 TIRES 74 74.0in. (1880mm)
72.0in. (1829mm) 55.9in. (1420mm)
* 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.
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 Service Manual
LOADER SPECIFICATIONS (CONTD)
Performance
S175 S185
Rated Operating Capacity (ISO) 1750 lb. (794kg) 1850 lb. (839kg)
Tipping Load (SAE Rating) 3900 lb. (1769 kg)
Operating Weight 5808 lb. ( 2635 kg)
SAE Breakout Force-Lift 3400 lb. (15123 N) 3600 lb. (16013 N)
-Tilt 3240 lb. (14412 N) 3550 lb. (15791 N)
Axle Torque 4900 ft.- lb. (6644 Nm)
Travel Speed 0-7.3 MPH (11,7 km/hr.)
Controls
Vehicle Steering Direction and Speed controlled by two hand levers.

Loader Hydraulics Lift and Tilt Controlled by separate foot pedals or optional hand controls.
Front Auxiliary Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option) Controlled by electrical switch on LH steering lever.
Engine Hand lever throttle: Key-type starter switch and shutdown.
Keyless start and shutdown with deluxe instrumentation.
Starting Aid Glow Plugs
Automatically activated by standard or deluxe instrumentation.
Service Brake Two independent hydrostatic systems controlled by two hand opertated steering
levers.
Secondary Brake One of the hydrostatic transmissions.
Parking Brake Mechanical Disc, switch in control panel.
Engine
Make/Model Kubota V2203-M-DI Kubota V2003-M-DI-T

Fuel/Cooling Diesel/Liquid Diesel/Liquid
Horsepower (SAE Net) 46 HP (34kW) 56 HP (42kW)
Maximum Governed RPM 2800 RPM 2800 RPM
Torque (SAE Net) 103.5 ft.-lb. (140 Nm) @ 1700 RPM 120.8 ft.-lb. (164 Nm) @ 1825 RPM
Number of Cylinders Four Four
Displacement 134 cu.in. (2,2L) 122 cu.in. (2,0L)
Bore/Stroke 3.425/3.638 (87.0/92.4) 3.268/3.638 (83.0/92.4)
Lubrication Pressure System W/Filter Pressure System W/Filter
Crankcase Ventilation Closed Breathing Open Breathing
Air Induction Naturally aspirated Turbocharged
Air Cleaner Dry replaceable cartridge w/safety Dry replaceable cartridge w/safety
element element
Ignition Diesel-Compression Diesel-Compression
Maximum Governed RPM 2800 RPM 2800 RPM
High Idle RPM 2860-3000 2860-3000
Low Idle RPM 1075-1225 1195-1245

Hydraulic System
S175 S185
Pump Engine Driven, Gear Type
Pump Capacity 16.9 GPM (64 L/min.) at High Idle
Charge Pump Capcity (SJC) 12.8 GPM (48,5 L/min.) at High Idle
High Flow (Option) 26.4 GPM (99,9 L/min.) at High Idle
System Relief at Quick Couplers 3300 PSI (206 Bar)
Filter Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders Doubleacting;
Tilt cylinders have cushioning feature on dump
Bore Diameter: Lift Cylinder (2) 2.50 (63,5)
Tilt Cylinder (2) 2.75 (69,9)
Rod Diameter: Lift Cylinder (2) 1.50 (38,1)
Tilt Cylinder (2) 1.375 (34,9)
Stroke: Lift Cylinder (2) 23.67 (601,2)
Tilt Cylinder (2) 13.19 (335,0)
Control Valve 3-spool, open center type w/float detent on lift and electrically controlled auxiliary
spool.
Fluid Lines SAE standard tubelines, hoses & fittings
Fluid Type BOBCAT FLUID, Hydraulic/Hydrostatic
6903117 - (Two - 2.5 gal. containers)
6903118 - (5 gal.)
6903119 - (55 gal.)
Hydraulic Function Time:
Raise Lift Arms 3.49 Seconds
Lower Lift Arms 2.54 Seconds
Bucket Dump 2.28 Seconds
Bucket Rollback 1.78 Seconds
Electrical
Alternator Belt driven, 90 amp., open

Battery 12 volt, 600 cold cranking amps. @ 0F. (-18C);
115 minute reserve capacity at 25 amps.
Starter 12 volt, Gear reduction type, 3.62 HP (2,7Kw)
Instrumentation Gauges: Hourmeter, Fuel, Engine Coolant Temperature.
Warning lights: Fuel Level, Glow Plugs, System Voltage, Seat Belt, Engine
Coolant Temperature, Engine Oil Pressure, Hydrostatic Charge Pressure,
Hydraulic Oil Temperature, Engine Air Filter & Hydraulic Filter.
Other: Audible Alarm, BICS Function, Lights, Opt./Accessory Switches.
Optional Deluxe 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 Incl.: Keyless Start, Clock, Job Clock, Help Screens,
Diagnostic Capability, Automatic Shutdown Function.

Drive System
S175 S185
Main Drive Hydrostatic 4 wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors.
Final Drive #80 HSOC endless roller chain & sprockets in sealed chaincase with oil
lubrication.
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 (50,8)
Wheel Bolts (8) 9/16
Capacities
Cooling System W/Heater (Includes 12 qts. (11,4 L)

Recovery Bottle)
Cooling System W/O Heater (Includes 11 qts. (10,4 L)
Recovery Bottle)
Fuel 23.0 gals. (87,1 L)
Engine Oil W/Filter 9.5 qts. (9,0 L)
Hydraulic/Hydro. System W/Reservoir 8.5 gals. (32,2 L)
Chaincase Reservoir 9 gals. (34,1 L)
Tires
Flotation 10-16.5, 8 Ply Rating

Ultra Grip 31 x 15.5-15, 8 Ply Rating
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.

ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles
Opening Pressure 2702-2916 PSI (18600-20100 kPa)

Fuel Tightness Nozzle Seat Dry Nozzle at 2418 PSI (16672 kPa) for 10 seconds
Fuel Injection Pump
Injection Timing 6.2-8.2 degrees B.T.D.C.

High Idle 2860-3000 RPM
Low Idle 1195-1245 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 (2940-3240 kPa)
Allowable Limit 341 PSI (2350 kPa)
Difference Between Cylinders 10%
Valves
Valve Seat Width (Intake & Exhaust) 0.084 (2,12)

Valve Seat Angle Intake 60 degrees, Exhaust 45 degrees
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 0.004 (0,1)
Valve Clearance (Cold) 0.0071-0.0087 (0,18-0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.006 (0,15)

(CONTD)
parentheses.
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)
Valve Timing
Intake Valve (Open) 9 degrees B.T.D.C.

(Close) 45 degrees A.T.D.C.
Exhaust Valve (Open) 50 degrees B.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 0.5501-0.5506 (13,973-13,984)

I.D. of Rocker Arm Bushings 0.5512-0.5519 (14,0-14,018)
Clearance Between Rocker Arm & Bushing 0.0006-0.0018 (0,016-0,045)
Camshaft
Journal O.D. 1.5722-1.5728 (39,934-39,95)

Bearing I.D. 1.5748-1.5758 (40,0-40,025)
Oil Clearance 0.002-0.0036 (0,05-0,091)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height 1.3346 (33,90)
End Clearance 0.0028-0.0087 (0,07-0,22)
Tappet
Clearance Between Tappet & Guide 0.0071-0.0087 (0,18-0,22)

Tappet O.D. 0.9433-0.9441 (23,959-23,98)
Tappet Guide I.D. 0.9449-0.9457 (24,0-24,021)

(CONTD)
parentheses.
Cylinders
Cylinder Bore I.D. 3.4252-3.4261 (87,00-87,022)

Allowable Limit +0.0059 (+0,15)
Piston Rings
Ring Gap (Top Ring) 0.0079-0.0138 (0,20-0,35)

Limit Permitted 0.0492 (1,25)
Ring Gap (2nd Ring) 0.0138-0.0197 (0,35-0,50)
Ring Gap (Oil Ring) 0.079-0.0157 (0,20-0,40)
Side Clearance of Ring Groove:
Top Ring 0.0037-0.0047 (0,093-0,12)
Second Ring 0.0037-0.0047 (0,094-0,12)
Oil Ring 0.0008-0.002 (0,02-0,052)
Pistons
Piston Pin Bore 0.9843-0.9848 (25,0-25.013)

Connecting Rod
Piston Pin O.D. 0.9843-0.9847 (25,002-25,011)

Small End Bushing I.D. 0.9852-0.9858 (25,025-25,04)
Clearance Between Piston Pin & Small End Bushing 0.0006-0.0015 (0,014-0,038)
Allowable Limit 0.0059 (0,15 mm)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)
Oil Pump
Oil Pressure Rated RPM 43-64 PSI (294-441 kPa)

Limit Permitted 36 PSI (248 kPa)
Idle Speed 14 PSI (98 kPa)
Limit Permitted 7 PSI (49 kPa)
Clearance Between Inner Rotor & Outer Rotor 0.0012-0.0055 (0,03-0,14)
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)

(CONTD)
parentheses.
Crankshaft
Crankshaft Alignment Limit Permitted 0.00079 (0,02)

Oil Clearance Between Journal & Bearing #1 0.0016-0.0046 (0,04-0,118)
Journal O.D. #1 2.3591-2.3598 (59,921-59,940)
Bearing I.D. #1 2.3614-2.3637 (59,98-60,039)
Journal O.D. #2 2.3591-2.3598 (59,921-59,940)
Bearing I.D. #2 2.3614-2.3632 (59,98-60,025)
Oil Clearance Between Crank Pin & Bearing 0.0010-0.0034 (0,025-0,087)
Crank Pin O.D. 1.8488-1.8494 (46,96-46,97)
Crank Pin Bearing I.D. 1.8504-1.8522 (47,0-47,046)
Crankshaft Side Clearance 0.0059-0.0138 (0,15-0,35)
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)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.001-0.0026 (0,025-0,066)
Idle Gear Side Clearance Idle Gear 0.005-0.019 (0,12-0,48)
Thermostat
Valve Opening Temperature 176.9-182.3F (80.5-83.5C)

Valve Fully Open 203F (95C)

ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO)
parentheses.
Fuel Injection Nozzles
Opening Pressure 2702-2916 PSI (18.6-20.1 MPa)

Fuel Tightness Nozzle Seat Dry Nozzle at 2418 PSI (16.67 MPA)
Fuel Injection Pump
Injection Timing 8.5-10 degrees B.T.D.C.

High Idle 2860-3000 RPM
Low Idle 1075-1225 RPM
Cylinder Bore
I.D. of Bore 3.2677-3.2686 (83,0-83,022)
Cylinder Head
Cylinder Head Surface Distortion 0.002 (0,05) Max.

Top Clearance (Piston to Head) 0.0236-0.0276 (0,60-0,70)
Compression 427-469 PSI (2944,1 - 3233,6 kPa)
Allowable Limit 341 PSI (2351,1 kPa)
Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake & Exhaust) 0.0835 (2,12)

Valve Seat Angle Intake 60 degrees, exhaust 45 degrees
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)
Valve Clearance (Cold) 0.0071-0.0087 (0,18-0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.0059 (0,15)

ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONTD)
parentheses.
Valve Springs
Free Length 1.6417-1.6614 (41,7-42,2)

Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.4 lb. (117,6 N)
Tilt 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.
Rocker Arms
O.D. of Rocker Arm Shaft 0.5501-0.5506 (13,973-13,984)

I.D. of Rocker Arm Bushings 0.5512-0.5519 (14,0-14,018)
Clearnace Between Rocker Arm & Bushing 0.0006-0.0018 (0,016-0,045)
Camshaft
Journal O.D. 1.5722-1.5728 (39.934-39,95)

Bearing I.D. 1.5748-1.5758 (40,0-40,025)
Oil Clearance 0.002-0.0036 (0,05-0,091)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height (Intake) 1.3346 (33,90)
Allowable Limit (Intake) 1.3327 (33,85)
Cam Lobe Height (Exhaust) 1.3346 (33,90)
Allowable Limit (Exhaust) 1.3327 (33,85)
Side 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. 0.9433-0.9441 (23,959-23,98)
Tappet Guide I.D. 0.9449-0.9457 (24,0-24,021)

ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT'D)
parentheses.
Cylinder Liner
Cylinder Bore I.D. 3.2677-3.2686 (83,0-83,022)

Oversized Cylinder Liner (Bore) I.D. 3.2776-3.2784 (83,25-83,27)
Piston Rings
Ring Gap (Top Ring) 0.0079-0.0138 (0,2-0,35)

Ring Gap (2nd Ring) 0.0157-0.0217 (0,4-0,55)
Ring Gap (Oil Ring) 0.0098-0.0177 (0,25-0,45)
Side Clearance of Ring Groove:
Second Ring 0.0037-0.0050 (0,093-0,128)
Oil Ring 0.0008-0.0021 (0,02-0,060)
Pistons
Piston Pin Bore 0.9843-0.9848 (25,0-25,013)

Connecting Rod
Piston Pin O.D. 0.9843-0.9847 (25,002-25,011)

Small End Bushing I.D. 0.9852-0.9858 (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 Rated RPM 43-64 PSI (294-441 kPa)

Allowable Limit 36 PSI (245 kPa)
Idle Speed Allowable Limit 7 PSI (49 kPa)
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)

ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT'D)
parentheses.
Crankshaft
Crankshaft Alignment Limit Permitted 0.00079 (0,02)

Journal O.D. #1 2.3591-2.3598 (59,921-59,940)
Bearing I.D. #1 2.3614-2.3637 (59,98-60,039)
Journal O.D. #2 2.3591-2.3598 (59,921-59,940)
Bearing I.D. #2 2.3614-2.3632 (59,98-60,025)
Oil Clearance Between Crank Pin & Bearing 0.0010-0.0034 (0,025-0,087)
Crank Pin O.D. 1.8488-1.8494 (46,96-46,97)
Crank Pin Bearing I.D. 1.8504-1.8522 (47,0-47,046)
Crankshaft Side Clearance 0.0059-0.0138 (0,15-0,35)
Timing Gear
Timing Gear Backlash:

Crank Gear-Idle Gear 0.0016-0.0044 (0,0415-0,1122)
Idle Gear-Cam Gear 0.0016-0.0045 (0,0415-0,1154)
Idle Gear-Injection Pump Gear 0.0016-0.0045 (0,0415-0,1154)
Crank Gear-Oil Pump Gear 0.0016-0.0043 (0,0415-0,109)
Clearance Between Idle Gear Shaft & Idle Gear Bushing:
Idle Gear 0.001-0.0026 (0,025-0,066)
Idle Gear Bushing I.D. 1.4961-1.4970 (38,0-38,025)
Idle Gear Shaft O.D. 1.4944-1.4951 (37,959-37,975)
Idle Gear Side Clearance Idle Gear 0.0079-0.020 (0,2-0,51)
Thermostat
Valve Opening Temperature 176.9-182.3F (80.5-83.5C)

Valve Fully Open 203F (95C)

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
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(Nm) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
.750 220-245 300-330
(300-330) (410-450)
.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)

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 Nm)
M 6 x 1.0 6-7 ft.-lb. 6-9 ft.-lb.
(8-9 Nm) (8-12 Nm)
M 8 x 1.25 6-9 ft.-lb. 11-16 ft.-lb. 18-25 ft.-lb.
(8-12 Nm) (15-22 Nm) (24-34 Nm)
M 10 x 1.25 13-18 ft.-lb. 22-30 ft.-lb. 36-50 ft.-lb.
(18-24 Nm) (30-41 Nm) (49-68 Nm)
M 12 x 1.25 22-30 ft.-lb. 40-54 ft.-lb. 69-87 ft.-lb.
(30-41 Nm) (54-73 Nm) (94-118 Nm)
M 14 x 1.25 36-50 ft.-lb. 58-80 ft.-lb. 116-137 ft.-lb.
(49-68 Nm) (79-108 Nm) (157-186 Nm)

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x Ft.-lb.
IMPORTANT Diameter
1/4
Thread Size
9/16 - 18
(Nm)
13 (18)
When repairing hydrostatic and hydraulic systems, 3/8 11/16 - 16 22 (30)
clean the work area before disassembly and keep all 1/2 13/16 - 16 40 (54)
5/8 1 - 14 60 (81)
damage the system. 3/4 1-3/16 - 12 84 (114)
I-2003-0888 7/8 1-3/16 - 12 98 (133)
1 1-7/16 - 12 118 (160)
Figure SPEC-40-1
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-40-1].

HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONTD)
Figure SPEC-40-4
Straight Thread O-ring Fitting
Figure SPEC-40-3
Nut Nut
Washer
Washer 2
O-ring
O-ring
TS-1619
A-1852 Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-40-4]
the washer is tight against the surface [Figure SPEC-40-
3]. Use the chart [Figure SPEC-40-5 on Page 3] to find the
correct tightness needed (Item 2) [Figure SPEC-40-4]. If
Tubelines And Hoses the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.

(CONTD)
Hex Flat Tightening Method
Flare Fitting (Contd)
Figure SPEC-40-5
1
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x Ft.-lb.
Diameter Thread Size (Nm)
1/4 7/16 - 20 13 (18)
2
5/16 1/2 - 20 17 (23)
3/8 9/16 - 18 22 (30)
1/2 3/4 - 16 40 (54)
TS-1619
5/8 7/8 - 14 60 (81)
3/4 1-1/16 - 12 84 (114)
Tighten the nut until it contacts with the seat. Make a
7/8 1-3/16 - 12 98 (133) mark across the flats of both the male and female parts of
1 1-5/16 - 12 118 (160) the connection (Item 1) [Figure SPEC-40-7].
1-1/4 1-5/8 - 12 154 (209)
Use the chart [Figure SPEC-40-8 on Page 4] to find the
1-1/2 1-7/8 - 12 163 (221) correct tightness needed (Item 2) [Figure SPEC-40-7]. If
2 2-1/2 - 12 252 (342) the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
O-ring Flare Fitting
Figure SPEC-40-6
Primary O-ring Flare

Seal
Secondary
Seal
P13009
The flare is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-6].
If necessary, the O-ring-flare fitting can be used without

an O-ring.
Use the following procedure to tighten the O-ring flare

fitting.

(CONTD)
O-ring Flare Fitting (Contd)

Copper Bonnet Orifice
Figure SPEC-40-8
O-ring Flare Fitting Tightening Torque

x x *
Tubeline x TORQUE
Outside x Ft.-lb.
1
Diameter Thread Size (Nm)
1/4 7/1 - 20 13 (18)
5/16 1/2 - 20 17 (23)
3/8 9/16 - 18 22 (30) P13572
1/2 3/4 - 16 40 (54)

5/8 7/8 - 14 60 (81) NOTE: O-ring flare fittings are not recommended in
all applications. Use the standard flare fittings
3/4 1-1/16 - 12 84 (114)
in these applications.
7/8 1-3/16 - 12 98 (133)
1 1-5/16 - 12 118 (160) Do not use a O-ring flare fitting when a copper bonnet
orifice is used. When tightened the connection at the
1-1/4 1-5/8 - 12 154 (209)
bonnet may distort the flare face and prevent it from
1-1/2 1-7/8 - 12 163 (221) sealing.
2 2-1/2 - 12 252 (342)
Use a standard flare fitting (Item 1) [Figure SPEC-40-9]
* If a torque wrench is used to tighten a new fitting to a as shown.
used hose/tubeline.
When a O-ring flare fitting is used as a straight thread
* If a toque wrench is used to tighten a used fittng to a port adapter the O-ring flare face is not used to seal. The
new hose/tubeline. O-ring may come off the fitting and enter the system.
* If a torque wrench is used to tighten a new fitting to a Figure SPEC-40-10

new hose/tubeline.
** If using the hex flat tightening method to tighten a new
fitting to a new hose/tubeline.
2
** If using the hex flate tighening method to tighten a
new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a

used fitting to a new hose/tubeline.
1
P13573
NOTE: Always remove the O-ring (Item 1) [Figure

SPEC-40-10] from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-40-10] is added to the

flat boss of the fitting to seal the connection in this
application.

(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting
Tightening Torque
Figure SPEC-40-11 x TORQUE
x Ft.-lb.
Thread Size (Nm)
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)
Nut Seals
To Fitting 1-3/16 - 12 98 (133)
1-5/16 - 12 118 (160)
1-7/16 - 12 154 (209)
Nut Seals
1-5/8 - 12 163 (221)
To Port
Use the following procedure to tighten the port seal

fitting:
Secondary O-ring Seal P-13008
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at If a torque wrench cannot be used, use the following
the connection [Figure SPEC-40-11]. method.
The hex portion of the nut does not contact the surface of Tighten the nut until it just makes metal to metal contact,
the component when the nut is tight. 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.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.

HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
Use Bobcat hydraulic/hydrostatic transmission fluid During cold weather (32F [0C] and below), do not
(P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.), operate machine until the engine has run for at least
(P/N 6903119 - 55 Gal.). five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
Hydraulic Fluid Chart stopping. Do not operate controls during warm-up
period.
When temperatures are below -20F (-30C), 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 0F (-18C) if possible.
W-2027-1285
DO NOT use automatic transmission fluids in the loader

or permanent damage to the transmission will result.
WARNING
W-2072-0496
When temperatures below zero degree F (-18C) 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.

CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

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: S175, S185-1

Date: 8 January, 2004
Product: Bobcat Loader
Model: S175, S185
Manual No: 6902732 (11-03)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:
TAKE OUT PUT IN REVISION DESCRIPTION
10-170-1 thru 10-170-2 10-170-1 thru 10-170-2 Revised Text
50-101-1 thru 50-101-20 Added CONTROL PANEL (ADJUSTABLE PINTLES)
Printed in U.S.A.
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 20 April, 2004
Model: S175, S185
Manual No: 6902732 (11-03)

20-01 thru 20-04 20-01 thru 20-04 Revised Text
HYD./HYDO SCHEMATIC HYD./HYDO SCHEMATIC Revised Text

WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION
S175 (S/N 525211001 AND ABOVE) S175 (S/N 525211001 AND ABOVE)
(S/N 525311001 AND ABOVE) (S/N 525311001 AND ABOVE)
(PRINTED NOVEMBER 2002) (PRINTED APRIL 2002)
V-0444 title & legend V-0444 title & legend
HYD./HYDO SCHEMATIC HYD./HYDO SCHEMATIC Revised Text

(PRINTED NOVEMBER 2002) (PRINTED APRIL 2002)
V-0445 title & legend V-0445 title & legend
TAKE OUT PUT IN REVISION DECRIPTION

20-42-1 thru 20-42-34 Added Hyd. Control Valve (1 piece casting)

(Foot Control)
Added Hyd. Control Valve (1 piece casting)
20-43-1 thru 20-43-30
(Advanced Hand Control) (ACS)

50-31-1 hru 50-31-6 50-31-1 hru 50-31-6 Revised Text



SPEC-10-1 thru SPEC-10-4 SPEC-10-1 thru SPEC-10-4 Revised Text

ROUTE TO
ATTENTION
PARTS MANAGER

Date: 10 May, 2004
Model: S175, S185
Manual No: 6902732 (11-03)


HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC Revised Text
S175 (S/N 525211001 AND ABOVE) S175 (S/N 525211001 -525214999)
(S/N 525311001 AND ABOVE) (S/N 525311001 - 525314999)
S185 (S/N 525011001 AND ABOVE) S185 (S/N 525011001 - 525014999)
(S/N 525111001 AND ABOVE) (S/N 525111001 - 525114999)
(PRINTED APRIL 2004) (PRINTED MAY 2004)
V-0444 tilte & legend V-0444 tilte & legend

S175 (S/N 525211001 AND ABOVE) S175 (S/N 525211001 -525214999)
(S/N 525311001 AND ABOVE) (S/N 525311001 - 525314999)
S185 (S/N 525011001 AND ABOVE) S185 (S/N 525011001 - 525014999)
(S/N 525111001 AND ABOVE) (S/N 525111001 - 525114999)
V-0444 V-0444

S175 (S/N 525211001 AND ABOVE) S175 (S/N 525211001 -525214999)
(S/N 525311001 AND ABOVE) (S/N 525311001 - 525314999)
S185 (S/N 525011001 AND ABOVE) S185 (S/N 525011001 - 525014999)
(S/N 525111001 AND ABOVE) (S/N 525111001 - 525114999)
V-0445 tilte & legend V-0445 tilte & legend
Printed in U.S.A.
S175 (S/N 525211001 AND ABOVE) S175 (S/N 525211001 -525214999)
(S/N 525311001 AND ABOVE) (S/N 525311001 - 525314999)
S185 (S/N 525011001 AND ABOVE) S185 (S/N 525011001 - 525014999)
(S/N 525111001 AND ABOVE) (S/N 525111001 - 525114999)
V-0445 V-0445
HYD./HYDRO. SCHEMATIC Added

S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED MAY 2004)
V-0565 tilte & legend

S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED MAY 2004)
V-0565

S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED MAY 2004)
V-0566 tilte & Legend

S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED MAY 2004)
V-0566

WIRING SCHEMATICS WIRING SCHEMATICS Revised
OPTIONS OPTIONS
(PRINTED NOVEMBER 2003) (PRINTED MAY 2004)
V-0442 V-0442
SPEC-21-1 thru SPEC-21-6 SPEC-21-1 thru SPEC-21-6 Revised Text
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 14 April, 2005
Model: S175, S185
Manual No: 6902732 (11-03)
The following Sections are a revision to the above Service Manual.
Take out existing Sections and put in the new Sections as listed below:
Section 10-50 Section 10-50 Revised Text


S175 (S/N 525211001 -525214999) S175 (S/N 525211001 -525214999)
(S/N 525311001 - 525314999) (S/N 525311001 - 525314999)
S185 (S/N 525011001 - 525014999) S185 (S/N 525011001 - 525014999)
(S/N 525111001 - 525114999) (S/N 525111001 - 525114999)
(PRINTED MAY 2004) (PRINTED APRIL 2005)
V-0444 V-0444

S175 (S/N 525211001 -525214999) S175 (S/N 525211001 -525214999)
(S/N 525311001 - 525314999) (S/N 525311001 - 525314999)
S185 (S/N 525011001 - 525014999) S185 (S/N 525011001 - 525014999)
(S/N 525111001 - 525114999) (S/N 525111001 - 525114999)
V-0445 V-0445

(PRINTED APRIL 2005)
(PRINTED MAY 2004)
V-0565
V-0565
Printed in U.S.A.
V-0566 V-0566

30-01, 30-02 30-01, 30-02 Revised Text

40-01, 40-02 40-01, 40-02 Revised Text



Section SPEC-10 Section SPEC-10 Revised Text

ROUTE TO
ATTENTION
PARTS MANAGER

Date: 5 July 2005
Model: S175, S185
Manual No: 6902732 (11-03)
The following Sections are a revision to the above Service Manual.
Take out existing Sections and put in the new Sections as listed below:

Maintenance Safety Maintenance Safety Revised
ALPHABETICAL INDEX ALPHABETICAL INDEX Revised Text
Foreword i-x Foreword i-x Updated Safety pages
20-01 20-01 Revised Text

HYD/HYDRO SCHEMATIC HYD/HYDRO SCHEMATIC Revised
(PRINTED APRIL 2005) (PRINTED JULY 2005)
V-0565 V-0565
HYD/HYDRO SCHEMATIC HYD/HYDRO SCHEMATIC Revised

(PRINTED APRIL 2005) (PRINTED JULY 2005)
V-0566 V-0566
HYD/HYDRO SCHEMATIC Added

WITH SJC OPTION
S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED JULY 2005)
V 0715
Printed in U.S.A.
HYD/HYDRO SCHEMATIC Added
S175 (S/N 525215000 AND ABOVE)
S185 (S/N 525015000 AND ABOVE)
(PRINTED JULY 2005)
V-0716
Section 20-62 Added Hydraulic Pump (SJC)

Section 20-63 Added Hydraulic Pump (High
Flow) (SJC)

Section 30-21 Added Hydrostatic Motor Carrier
Section 30-22 Added Hydrostatic Motor Carrier
(SJC)
Section 30-41 Added Hydrostatic Pump (SJC)

Section 50-102 Added Control Panel (SJC)
Section 50-112 Added Control Handle (SJC)
ALL WIRING SCHEMATICS ALL WIRING SCHEMATICS Revised

(PRINTED NOVEMBER 2003) (PRINTED JULY 2005)

Section 60-71 Added Controller (Selectable
Joystick Control) (SJC)
Section 60-131 Added Electrical/Hydraulic
Controls Reference (Selectable
Joystick Control) (SJC)
Section 60-150 Added Service PC (Laptop
Comuter)
Section 60-160 Added Calibration
Section 60-170 Added Speed Sensor

ROUTE TO
ATTENTION
PARTS MANAGER

Date: 23 March 2006
Model: S175, S185
Manual No: 6902732 (11-03)
S175, S185 Service Manual (P/N 6902732) Dated (2-06) contains updated service information which replaces the
previous S175, S185 Service Manual (P/N 6902732) Dated (11-03).
Printed in U.S.A.

Service Manual: S/N 525011001 & Above S/N 525111001 & Above S/N 525211001 & Above S/N 525311001 & Above

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Service Manual: S/N 525011001 & Above S/N 525111001 & Above S/N 525211001 & Above S/N 525311001 & Above

Загружено:

Авторское право:

Доступные форматы

Service

S/N 525011001 & Above

CORRECT CORRECT CORRECT

B-10731a B-15535 B-15524

B-15734 B-15732 B-15525

B-15733 B-15523 B-6589

ADVANCED CONTROL SYSTEM (ACS) FAN GEARBOX.......................................................10-01

RADIATOR ............................................................. 70-01

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

S175, S185 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

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

6. Machine signs must be 14. Check hydraulic fluid level,

7. Steering levers and foot 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

S175, S185 Bobcat Loader

21. Inspect for loose or broken

S175, S185 Bobcat Loader

The Skid-Steer Loader Operator Training Course is

The Skid-Steer Loader Safety Video is available from

S175, S185 Bobcat Loader

The dealer and owner/operator review the recommended

Call Before You Dig

S175, S185 Bobcat Loader

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

Do not use the machine where exhaust, arcs, sparks

The operator cab, engine compartment, and engine

Check all electrical wiring and connections for

Check fuel and hydraulic tubes, hoses and fittings for

Do not use ether or starting fluids on any engine

Always clean the machine, disconnect the battery,

Stop the engine and let it cool before adding fuel. NO

S175, S185 Bobcat Loader

Always use the serial number of the loader when Figure 3

Loader Serial Number

The engine serial number is in the location shown

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module

2. The five digit Production Sequence Number identifies

S175, S185 Bobcat Loader

The Delivery Report must be filled out by the dealer and

S175, S185 Bobcat Loader

FRONT LIGHTS OPERATOR SEAT

BUCKET STEPS SAFETY TREAD

LIFT ARM LINK

TAIL LIGHT LIFT CYLINDER

S175, S185 Bobcat Loader

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

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

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

LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . 10-160-1

Continued On Next Page

S175, S185 Bobcat Loader