T35100 - T35120 6986766 enUS SM 08-12

Service Manual
T35100, T35100S, T35100L,

T35100SL, T35120L, T35120SL
Telescopic Handler
T35100: S/N A8HD11001 & Above
T35100L: S/N A8GW11001 & Above
T35100SL: S/N A8GT11001 & Above
T35120L: S/N A8GV11001 & Above
Dealer Copy -- Not for Resale

T35120SL: S/N A8GJ11001 & Above
6986766-EN (11-07) Revised (08-12) Printed in Belgium © Bobcat Company 2012
1 of 1040
2 of 1040
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
CORRECT
Safety Alert Symbol: This symbol with a warning statement,

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

B-16082 B-16080 B-16079
Cleaning and maintenance are Disconnecting or loosening any Never work on VersaHANDLER
required daily. hydraulic tubeline, hose, fitting, with boom up unless boom is
component or a part failure can held by an approved boom stop.
cause boom to drop. Do not go Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.
WRONG WRONG WRONG
B-16081 B-16078 B-6589
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW12-0409
3 of 1040
4 of 1040
CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01
5 of 1040 1-3 T35100(S)(L), T35120(S)L Service Manual


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Telescopic Handler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11


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

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

correctly installed, functional condition.
and in good condition.

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

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

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

function correctly. battery and cables.

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

parts or connections. that all necessary corrections
be made before the machine
is returned to service.

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

operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Telescopic Handler Operator Training Course is
DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Telescopic Handler.
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury. • The Telescopic Handler Safety Video is available from
D-1002-1107 your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
The dealer and owner / operator review the
WARNING 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
The signal word WARNING on the machine and in the recommendations on the new use.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI VH EMEA-0409 SM

SAFETY INSTRUCTIONS (CONT’D) FIRE PREVENTION
Maintenance
The machine and some attachments have components

that are at high temperatures under normal operating
Cutting or drilling concrete containing sand or rock conditions. The primary source of high temperatures is
containing quartz may result in exposure to silica dust. the engine and exhaust system. The electrical system, if
Use a respirator, water spray or other means to control damaged or incorrectly maintained, can be a source of
dust. arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
The operator’s area, engine compartment and engine

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

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

hot components can contact flammable material,
explosive dust or gases.
Electrical
Check all electrical wiring and connections for damage.

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

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI VH EMEA-0409 SM

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

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

smoking! Do not refuel a machine near open flames or

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

glow plugs. These starting aids can cause explosion and Know where fire extinguishers and first aid kits are
injure you or bystanders. located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Use the procedure in the Operation & Maintenance Obey the recommendations on the instructions plate.
Manual for connecting the battery and for jump starting.
Spark Arrestor Exhaust System
The spark arrestor exhaust system 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.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
SI VH EMEA-0409 SM

SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the telescopic handler Figure 2

when requesting service information or when ordering
parts.
Telescopic Handler Serial Number
Figure 1
S6813
P-24121

The front, on the right side of the frame [Figure 1].
S6801
The engine serial number can be found on the water

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

use these serial numbers when requesting parts.

DELIVERY REPORT
Figure 3
B-16315
The Delivery Report must be completed by the dealer

and signed by the owner or operator when the telescopic
handler is delivered. An explanation of the form must be
given to the owner. Make sure it is complete [Figure 3].

BOBCAT TELESCOPIC HANDLER IDENTIFICATION
OPERATOR HANDBOOK AND
LOAD CAPACITY CHARTS
BOOM MIRROR
OPERATOR
CAB
(ROPS/FOPS)
TELESCOPING
BOOM
BOOM
STOP
SEAT
BELT
PARKING BRAKE
(Right Instrument Panel)
TIRES (use only approved tires
PALLET FORK at correct pressure)
ATTACHMENT
SAFETY TREAD MIRROR

LIGHTS
(under boom, on top of frame)
LIGHT
ENGINE
COVER
S6921
S3505

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
OPERATOR CAB (ROPS / FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

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

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

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

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

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

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Primary Fuel Filter (Pre-Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-100-3
Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Removing And Replacing Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Checking And Adding Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing And Replacing Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Checking And Adding Oil (Front Drop Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-5
Removing And Replacing Oil (Front Drop Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-5
LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

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

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

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Checking And Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Extend / Retract Chain Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-2
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-180-1

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER
Procedure
Always park the machine on a level surface.
WARNING
The seat bar system must deactivate the lift, and tilt
control functions when the seat bar is up. See your
Bobcat dealer for service if joysticks do not
deactivate.
S7423
W-2461-1210
Figure 10-10-1 Put the floor jack under the center of the rear axle. Lift the
telescopic handler and install jackstands [Figure 10-10-
2].

P-23829
STOP the engine. Put the floor jack under the center of
the front axle. Lift the telescopic handler and install
jackstands [Figure 10-10-1].
19 of 1040 10-10-1 T35100(S)(L), T35120(S)L Service Manual


OPERATOR CAB (ROPS / FOPS)
Figure 10-20-1
S3527
The telescopic handler has an operator cab (ROPS and

FOPS) (Item 1) [Figure 10-20-1] to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. Never operate

without right window. 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 (FOPS Level II).
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or
death.
W-2906-0211

OPERATOR CAB (ROPS / FOPS) (CONT’D)
Cab Door Cab Door Window
Figure 10-20-2 Figure 10-20-4
1
2
P-47350 P-47202
Figure 10-20-3 Turn the handle (Item 1) [Figure 10-20-4]. Push open the
window fully until it latches against the cab.

Figure 10-20-5
1
1
P-47201
The cab door can be opened from the outside of the cab P-47203
using the latch (Item 1) [Figure 10-20-2] and open from
the inside of the cab when you squeeze the latch (Item 1)
[Figure 10-20-3]. Pull the lever (Item 1) [Figure 10-20-5] inside the cab to
disengage the latch and close the window.
The cab door can be locked (Item 2) [Figure 10-20-2]
with the start key.

TRANSPORTING THE TELESCOPIC HANDLER ON A
TRAILER
Fastening
Loading And Unloading
Figure 10-30-2
Figure 10-30-1
3
2
4
1 1
1 S3519
P-97038
Fasten the telescopic handler to the transport vehicle to

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

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


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

such as removing it from mud or loading onto a transport
vehicle.
1
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
SERIOUS INJURY OR DEATH
S1394
• Block wheels to prevent roll away before
adjusting screws to bypass the park brake
At each end of the central part of the front axle are two
system.
bolts (see (Item 1) [Figure 10-40-1] and (Item 1) [Figure
• Return adjustment screws to the operating
10-40-2]). When screwed in, these bolts will remove the
position before operating the machine.
W-2808-0909
spring pressure that engages the brake discs.
[Figure 10-40-2] shows the function of such a bolt inside
Block the wheels to prevent the machine from rolling. the axle.
The work will first be carried out on the two bolts on one
Releasing The Parking Brake Discs side of the front axle then the two bolts on the other side:

The brakes are engaged by spring pressure and released Loosen the locking nuts (Item 2) [Figure 10-40-1] of the
by hydraulic pressure. The park brake must be released bolts and create some clearance for the bolts.
manually before towing. Only the front axle has brakes. Turn the two bolts (Item 1) [Figure 10-40-1] IN, 90° at a
The following procedure describes how to release the time, alternating between the two bolts until the bolts are
brakes: firmly seated.
Figure 10-40-1 Repeat this on the two opposite side bolts on the front
axle.
2 The brakes are now released for towing the machine.
2
Please note that the machine will not be able to brake
until the bolts are returned to their original position.
1
1
S2722

TOWING THE TELESCOPIC HANDLER (CONT’D) Engaging Brake Discs
Procedure (Cont’d)
Releasing The Parking Brake Discs (Cont’d)

WARNING
Figure 10-40-3
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
SERIOUS INJURY OR DEATH
• Block wheels to prevent roll away before
1 adjusting screws to bypass the park brake
Operating system.
Position
• Return adjustment screws to the operating
position before operating the machine.
W-2808-0909
Block the wheels to prevent the machine from rolling.

Towing
After towing is completed, turn the tow valve (Item 1)
Position
[Figure 10-40-3] clockwise 90° to the OPERATING
POSITION.
S6802 Figure 10-40-4
Raise the engine cover. 2

2
Turn the tow valve (Item 1) [Figure 10-40-3]
counterclockwise 90° to TOWING POSITION.
Tow the telescopic handler at a slow speed.
1
1
S2722
To reactivate the park brake, release the 4 bolts (see

(Item 1) [Figure 10-40-4] on the front axle to their
original position (turn the two bolts out, 90° turn at a time,
until no resistance can be felt. Repeat this procedure for
the opposite side two bolts).
Make sure that all 4 bolts have been turned out until they
can easily be loosened by hand. Tighten the locking nuts
(Item 2) [Figure 10-40-4].
This will allow the park brake piston to be active again.

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 telescopic handler.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals when making repairs, adjustments
WARNING or servicing. Check for correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions can cause injury or death.
W-2003-EN-0903
SERVICE SCHEDULE HOURS

[5]
ITEM SERVICE REQUIRED 10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Hydraulic Fluid Check fluid level and add as needed.
Articulation Pins Lubricate with lithium based multipurpose grease.
Safety Signs, Safety Tread and Check for damaged signs (decals), safety tread and mirrors. Replace if
Mirrors damaged or worn.
Fuel Filter Clean the sediment bowl / water trap.
Nuts and Bolts Check for loose nuts and bolts. Tighten as needed.
Seat Belt Check the condition of the seat belt.
Brakes Check for function. Service as necessary.

Back-up Alarm (if equipped) Check for function. Replace as necessary.
Tires Check for wear or damage. Inflate to correct pressure. Be sure all tires are
inflated to the same pressure. Use only approved tires.
Engine Air Filter And Air System Check condition indicator, replace element when required and empty dust cup
as needed. Check air system for leaks.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser. check
coolant level cold in reservoir. Add premixed coolant as needed. (See
ENGINE COOLING SYSTEM.) Check cooling system for leaks.
King Pins, Axle Oscillation (Front/ Lubricate with lithium based multipurpose grease.
Rear), Attach. Frame Pivot(s), Tilt /
Lift Cyl., Boom Pivot, Leveling Cyl.
Telescopic Boom Slide Lubricate with lithium based multipurpose grease. Check wear blocks for
adjustment or replacement.
Hydraulic Hoses, Tubelines and Check condition of hoses, tubelines and connectors. Repair or replace as
Connections needed.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed (300 N•m [221 ft-lb]). [1]
Boom Chain Check and apply chain lubricant as needed. Check chain tension and wear.
Adjust or replace as necessary.
Alt. and Air Cond. Belt (if equipped) Check belt tension and adjust as needed. [2]
Door hinges Lubricate door hinges with lithium based multipurpose grease.
Engine Oil and Filter Replace the engine oil and filter. See SPECIFICATIONS for correct capacity.
Use a genuine Bobcat filter. [2]
Engine Air Filter Replace the outer filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, secondary Replace the secondary fuel filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, primary Replace the primary fuel filter (pre-filter) element. Use a genuine Bobcat filter. [2]
Hydraulic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. [2]
Hydraulic Tank Breather Replace the hydraulic tank breather.
Hydraulic Fluid and Filter Replace the hydraulic fluid and filter element. See SPECIFICATIONS.
Front and Rear Axle Fluid Replace the axle fluid. See SPECIFICATIONS. [3] [4]
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace as necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.
Engine valve lash Check and adjust as needed.
Stabilizers (If Equipped): Cylinders Lubricate with lithium based multipurpose grease.
and pivots
Engine Coolant Check freeze protection of antifreeze -30°C (-34°F). Flush cooling system and
replace with premixed coolant Every 2 years
[1]Check wheel nut torque every 8 hours for the first 24 hours.
[2]Perform service first time, then as indicated in chart.
[3]Check level.
[4]Replace fluid first time, then as indicated in chart.
[5]Or every 12 months.


AIR CLEANER SERVICE Outer Filter
Replacing Filter Element(s) Figure 10-60-2
Figure 10-60-1
1
1
2 1 S6803
S3571
Loosen the filter housing clamps (Item 1) [Figure 10-60-
2].
Replace the large (outer) filter element only when the red
ring shows in the window of the condition indicator Release the fastener and remove the cover (Item 2)

(Item 1) [Figure 10-60-1]. [Figure 10-60-2].
NOTE: Before replacing the filter element, push the Figure 10-60-3
button on the condition indicator (Item 2)
[Figure 10-60-1]. Start the engine. If the red
ring does not show, do not replace the filter
element.
Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.
S6804
Pull the element straight out [Figure 10-60-3].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install a new outer element.
Install the dust cover and fasten [Figure 10-60-2].
Connect the filter housing clamps.

AIR CLEANER SERVICE (CONT’D)
Replacing Filter Element (Cont’d)
Inner Filter
Remove the outer element.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Figure 10-60-4

S6805
Remove the inner filter (Item 1) [Figure 10-60-4] and

install a new element.
Install the outer element.
Install the dust cover and fasten [Figure 10-60-2].
Connect the filter housing clamp (Item 1) [Figure 10-60-

2].

ENGINE COOLING SYSTEM Removing And Replacing The Coolant
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
WARNING
WARNING AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
AVOID INJURY OR DEATH W-2070-1203
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure. Open the engine cover.
• Flying debris or loose material is present.
• Engine is running. Figure 10-70-3
• Tools are being used.
W-2019-0907
1
Cleaning
Figure 10-70-1
2
MAX

MIN
S3528
Remove the cap (Item 1) [Figure 10-70-3] from the

coolant reservoir.
Remove the fan shield.

S3527
Open the engine cover (Item 1) [Figure 10-70-1].
Figure 10-70-2
S6815
Use low air pressure or water pressure to clean the

radiator, oil cooler and intercooler [Figure 10-70-2].

ENGINE COOLING SYSTEM (CONT’D) Run the engine until it is at operating temperature.
Removing And Replacing The Coolant (Cont’d) Stop the engine.
Figure 10-70-4 Check the coolant level (COLD) in the reservoir when
cool.
Add coolant to the reservoir as needed.
IMPORTANT
AVOID ENGINE DAMAGE
1 Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

2 efficiency and may cause serious premature engine
S6817 damage.
Too little antifreeze reduces the additives which

Remove the engine block drain plug (Item 1) [Figure 10- protect the internal engine components; reduces the
70-4]. boiling point and freeze protection of the system.

Open the drain valve (Item 2) [Figure 10-70-4] and drain Always add a premixed solution. Adding full strength
all of the coolant into a container. Dispose of used concentrated coolant can cause serious premature
coolant in an environmentally safe manner. engine damage.
I-2124-0497
Close the drain valves.
NOTE: The cooling system is factory filled with

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

is low.
Use a refractometer to check the condition of ethylene

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

radiator cap.
Add coolant to the reservoir. The coolant level must be

between the MIN and MAX marks (Item 2) [Figure 10-
70-3] on the coolant reservoir.
Follow the following steps when using concentrated

coolant instead of a ready-to-use premix:
• mix the coolant in a separate container: 4,3 L (one

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

glycol to the coolant tank until the coolant level
reaches the MIN marker on the tank (Item 1) [Figure
10-70-3].

ENGINE COOLING SYSTEM (CONT’D)
Checking Level
Open the engine cover.
Check the coolant level in the coolant reservoir.
Figure 10-70-5
1
MAX
MIN
S3528

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

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

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

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


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

used:
• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low
• Ensure the fuel tank is as full as possible at all times
sulfur petroleum based diesel. This is commonly
to prevent moisture from collecting in the fuel tank.
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or • Ensure that the fuel tank cap is securely tightened.
EN590 (EU Standard) specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term
stability and should not be stored for more
than 3 months.

FUEL SYSTEM (CONT’D) Secondary Fuel Filter
Filling The Fuel Tank See the SERVICE SCHEDULE for the service interval
when to replace the secondary fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Figure 10-80-2
WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
1
Figure 10-80-1
S6824

Remove the filter element (Item 1) [Figure 10-80-2].
Clean the area around the filter housing.
Install the new filter element with a new seal, and hand
tighten.
S3524 Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)
Remove the fuel fill cap (Item 1) [Figure 10-80-1].
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
WARNING
SMOKING!
Always clean up spilled fuel or oil. Keep heat, flames,
Install and tighten the fuel fill cap [Figure 10-80-1].
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

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

1
See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
2
Replacing Element
Figure 10-80-3
S36232
Remove the filter element (Item 1), bowl (Item 2) and

bottom cover (Item 3) [Figure 10-80-5] from the filter
housing.
Clean the area around the filter housing and reinstall

1 using a new filter element (Item 1) [Figure 10-80-5].

S36232 Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)
Open the drain valve (Item 1) [Figure 10-80-3] on the Removing Water
bottom cover of the fuel primary filter and allow the fluid
to drain into a container. Figure 10-80-6
Tighten the drain valve (Item 1) [Figure 10-80-3] by hand
pressure.
Figure 10-80-4
1
1 S36232
Open the drain valve (Item 1) [Figure 10-80-6] on the

fuel pre-filter bottom cover to remove water from the filter.
S36233
When clean fuel drains from the water separator, tighten

the drain valve (Item 1) [Figure 10-80-6] by hand
Hold the filter assembly (Item 1) and remove the screw pressure.
(Item 2) [Figure 10-80-4].

FUEL SYSTEM (CONT’D)
Removing Air From The Fuel System
Figure 10-80-7
2
WARNING
1
explosion or fire.
W-2103-0508
WARNING
S36409
Diesel fuel or hydraulic fluid under pressure can
After replacing the filter element or when the fuel tank penetrate skin or eyes, causing serious injury or
has run out of fuel, the air must be removed from the fuel death. Fluid leaks under pressure may not be visible.

system before starting the engine. Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
Turn the Start key to the Preheat position (Item 1) enters skin or eyes, get immediate medical attention
[Figure 10-80-7] (this will activate the electrical pump from a physician familiar with this injury.
relay). W-2072-0807
Leave the Start key in the Run position (Item 2) [Figure

10-80-7] for 3 minutes.
Crank the engine with the accelerator pedal released

(low idle position) until the engine starts.
Run the engine at low idle for approximately 5 seconds

then cycle the accelerator pedal rapidly from the low idle
position to the high idle position three times. The time
taken to cycle the accelerator pedal to be typically one to
3 seconds. This will assist in displacing any residual
trapped air in the fuel injection pump.
Check for fuel leaks in the fuel system.

ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-90-1 CRANKCASE)
S6807

Open the engine cover and remove the dipstick (Item 1) TEMPERATURE RANGE ANTICIPATED BEFORE
[Figure 10-90-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick [1] Synthetic Oil - Use recommendation from Synthetic
(Inset) [Figure 10-90-1]. Oil Manufacturer.
Use a good quality motor oil that meets API Service Use good quality engine oil that meets API Service
Classification of CI-4 or better. (See Oil Chart, [Figure Classification of CI-4 or better. (See Oil Chart, [Figure
10-90-2].) 10-90-2].)

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

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

1
the engine.
Figure 10-90-3
S6814
1
Open the engine cover. (See Opening And Closing on

Page 10-160-1.)
Remove the oil filter (Item 1) [Figure 10-90-4].
Clean the filter housing surface.

Put clean oil on the new oil filter gasket. Install the filter
and hand tighten.
S3525
Figure 10-90-5
Remove the access panel at the rear of the engine

compartment. Route the hose (Item 1) [Figure 10-90-3] 1
out through the access hole. Remove the cap.
Drain the oil into a container and recycle or dispose of 2

used oil in an environmentally safe manner.
Install cap and put the drain hose into the engine
compartment, install the access cover.
WARNING S6809

Always clean up spilled fuel or oil. Keep heat, flames, Remove the filler cap (Item 1) [Figure 10-90-5].
Failure to use care around combustibles can cause Put oil in the engine. For capacity, (See Fluid Capacities
explosion or fire. on Page SPEC-10-4.)
W-2103-0508
Install fill cap, start the engine and let it run for several
minutes.
Stop the engine, and check for leaks at the oil filter.
Remove the dipstick (Item 2) [Figure 10-90-5] and check

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

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-100-3
Use only recommended fluid in the hydraulic system. HYDRAULIC / HYDROSTATIC FLUID
(See Hydraulic / Hydrostatic Fluid Chart on Page 10-100- RECOMMENDED ISO VISCOSITY GRADE (VG)
1.) AND VISCOSITY INDEX (VI)
Stop the machine on a level surface. Lower the boom all

the way.
Stop the engine.
Figure 10-100-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 120

[2] VG 46; Minimum VI 140
[3] Synthetic Fluid; VG 46; Minimum VI 150
1 [4] BOBCAT Hydraulic / Hydrostatic Fluid
P-97034
Use only recommended fluid in the hydraulic system
[Figure 10-100-3]. (See Specifications on Page SPEC-
Check the fluid level at the sight gauge (Item 1) [Figure 50-1.)
10-100-1].
Figure 10-100-2
P-97033
Remove the fill / breather cap (Item 1) [Figure 10-100-2]

and add hydraulic fluid.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-5
Removing And Replacing Hydraulic Fluid
WARNING
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
enters skin or eyes, get immediate medical attention P-52179
from a physician familiar with this injury.
W-2072-0807
Remove the reservoir drain plug (Item 1) [Figure 10-100-
5] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner. Reinstall the drain plug and
WARNING tighten.

Add fluid until it is at the center of the sight gauge (Item 1)
AVOID INJURY OR DEATH [Figure 10-100-5].
sparks or lighted tobacco away from fuel and oil. Install the fill cap.
explosion or fire.
W-2103-0508
Figure 10-100-4
P-97033
Remove the fill / breather cap (Item 1) [Figure 10-100-4].

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Hydraulic Tank Breather
Removing And Replacing Hydraulic / Hydrostatic See the SERVICE SCHEDULE for the correct
Filter replacement interval. (See SERVICE SCHEDULE on
Page 10-50-1.)
See the SERVICE SCHEDULE for the correct service
intervals. (See SERVICE SCHEDULE on Page 10-50-1.) Open the engine cover. (See Opening And Closing on
Page 10-160-1.)
Figure 10-100-6
Figure 10-100-8
1
P-97034

P-97033
Unscrew the plug (Item 1) [Figure 10-100-6] by hand.

Remove and discard the breather (Item 1) [Figure 10-
Figure 10-100-7 100-8].
Install the new breather.
1
S6819
Remove the cartridge (Item 1) [Figure 10-100-7] from

the oil filter.
NOTE: Be careful to keep impurities from getting into

the hydraulic / hydrostatic system.
Put the new cartridge in the oil filter.

Top up the oil if necessary.
Inspect the seal and replace if necessary.
Replace the plug.


AXLES (FRONT AND REAR) Removing And Replacing Oil (Planetary Carrier)
Checking And Adding Oil (Planetary Carrier) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-110-1
Figure 10-110-2
S3297
S3296
Put the machine on a level surface with the plugs (Item 1)

[Figure 10-110-1] positioned as shown.
Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-2] positioned as shown.

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

AXLES (FRONT AND REAR) (CONT’D)
Checking And Adding Oil (Rear Differential) Removing And Replacing Oil (Rear Differential)
See the SERVICE SCHEDULE for the correct service See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.) interval. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-110-3 Figure 10-110-4
S1841
S1842

Put the machine on a level surface.
With the machine on a level surface remove the plug
Remove the plug (Item 1) [Figure 10-110-3]. The oil level (item 1) [Figure 10-110-4] and drain into a container.
should be at the bottom edge of the plug hole. Recycle or dispose of the used lubricant in an
environmentally safe manner.
Add oil through the hole if the oil level is below the hole.
For capacity, (See Fluid Capacities on Page SPEC-10-4.) Add oil through the hole (Item 1) [Figure 10-110-3] if the
For type, (See Specifications on Page SPEC-50-1.) oil level is below the hole. For capacity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See
Install and tighten the plug. Specifications on Page SPEC-50-1.)

Checking And Adding Oil (Front Differential)

Figure 10-110-5
S1843

Figure 10-110-6
S1851
Remove the plugs (Item 1) [Figure 10-110-5] and

[Figure 10-110-6]. The oil level should be at the bottom
edge of the plug hole.
Add oil through the hole if the oil level is below the hole.
For capacity, (See Fluid Capacities on Page SPEC-10-4.)
For type, (See Specifications on Page SPEC-50-1.)

Removing And Replacing Oil (Front Differential) Figure 10-110-8
Figure 10-110-7 V723
V723
1
1
1
S1842
S1844
1
S1842
S1845
V723
V723

1
1
1
S1842
S1843
1
S1842
S1846
With the machine on a level surface remove the plug(s)

(Item 1) [Figure 10-110-7] and [Figure 10-110-8] and
drain into a container. Recycle or dispose of the used
lubricant in an environmentally safe manner.
Add oil through the hole (Item 1) [Figure 10-110-5] and

[Figure 10-110-6] if the oil level is below the hole. For
capacity, (See Fluid Capacities on Page SPEC-10-4.) For
type, (See Specifications on Page SPEC-50-1.)

Checking And Adding Oil (Front Drop Box) Removing And Replacing Oil (Front Drop Box)
Figure 10-110-9 Figure 10-110-10
S1851 S1844
Remove the plug (Item 1) [Figure 10-110-9]. The oil level With the machine on a level surface, remove the plug
should be at the bottom edge of the plug hole. (item 1) [Figure 10-110-10] and drain into a container.

Recycle or dispose of the used lubricant in an
Add oil through the hole if the oil level is below the hole environmentally safe manner.
(Item 1) [Figure 10-110-9]. For capacity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See Add oil through the hole if the oil level is below the hole
Specifications on Page SPEC-50-1.) (Item 1) [Figure 10-110-9]. For capacity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See
Install and tighten the plug. Specifications on Page SPEC-50-1.)


LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-3
Lubrication Locations
Lubricate as specified, to obtain the best performance of

the machine. (See SERVICE SCHEDULE on Page 10-
50-1.)
Record the operating hours each time you lubricate so

that it is performed at the correct interval.
Always use a good quality lithium based multipurpose

grease. Apply lubricant until extra grease shows.
Lubricate the following locations on the telescopic 1

handler: S3538
Figure 10-120-1
3. Axle Oscillation - Front Axle (Item 1) [Figure 10-120-
3].
Figure 10-120-4

1
P-24167
1. Axle Pivots - Top and bottom (Item 1) [Figure 10-120-

1] all four wheels. S2003
Figure 10-120-2
4. Frame Leveling Cylinder - Rod End (Item 1) [Figure
10-120-4].
1 1
S2000 S1998
2. Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-

2].

(CONT’D)
Lubrication Locations (Cont’d)
Figure 10-120-5
1 1
1
S3542
7. Tilt Cylinder Rod End (Item 1) [Figure 10-120-7].
S3539 Figure 10-120-8
5. Attachment Frame Pivot (Item 1) [Figure 10-120-5]

(Both Sides).
Figure 10-120-6
1
1
S3541
8. Tilt Cylinder pivot (Item 1) [Figure 10-120-8] (both

sides).
S3540
6. Tilt Cylinder Base End (Item 1) [Figure 10-120-6].

(CONT’D)

2
Figure 10-120-9
S3522
NOTE: Raise the boom and install the approved

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

1
[Figure 10-120-9].
3
S3543
10. Lift Cylinder Base End (Item 1), Slave Cylinder Rod
End (Item 2), Slave Cylinder Base End (Item 3)
[Figure 10-120-10].
Figure 10-120-11
1 1
S3544
11. Boom Pivot (Item 1) [Figure 10-120-11] (Four

Places).

(CONT’D)
Figure 10-120-12
S3546
1
14. Boom Slide [Figure 10-120-14] (Eight Places), Front
Chain Pulley Pivot (Item 1) [Figure 10-120-14].
P-52183
Figure 10-120-15
12. Cab Door Hinges (Item 1) [Figure 10-120-12]

(Upper).
Figure 10-120-13
1
1 1
1 S3572
15. Rear Chain Pulley Pivot (Item1) [Figure 10-120-15].
S3545
13. Cab Door Hinges (Item 1) [Figure 10-120-13]

(Lower).

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

P-23854 [Figure 10-130-3] must move freely. The pins must not
be bent or the ends deformed.
The telescopic handler mounting hooks (Item 1) [Figure Figure 10-130-4

10-130-1] must not be damaged. Check for cracked or

broken hooks.
Figure 10-130-2
S3547
1
The pins must extend through the holes in the

P-23858 attachment mounting frame (Item 1) [Figure 10-130-4].
Lubricate the attachment carrier. (See SERVICE

The stop blocks (Item 1) [Figure 10-130-2] must not be SCHEDULE on Page 10-50-1.)
damaged. Check for bent or broken stop blocks.


TIRE MAINTENANCE Mounting
Wheel Nuts
Figure 10-140-1
WARNING
When the engine is running during service, the Travel
Direction Lever must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2397-0301
Tires are to be repaired only by an authorized person

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

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
S2004 bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.
(See SERVICE SCHEDULE on Page 10-50-1.) [Figure Avoid excessive pressure which can rupture the tire and
10-140-1] for the service interval to check the wheel nuts. cause serious injury or death.

The correct torque is 360 N•m (266 ft-lb) torque.
During inflation of the tire, check the tire pressure
Rotating frequently to avoid over inflation.
Check the tires regularly for wear, damage and pressure.

(See Traction on Page SPEC-10-3.) for the correct tire
pressure.)
Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires
to the front.
It is important to keep the same size tires on each side of

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

excessive tire wear and loss of stability and handling
capacity. Check for the correct pressure before operating
the telescopic handler.


APPROVED BOOM STOP Removing The Approved Boom Stop
If the boom is raised for service or maintenance, use the • Start the engine and raise the boom. Stop the engine.
following procedure to install and remove the approved
boom stop. • Remove the fasteners, pins and boom stop.
Installing The Approved Boom Stop
• Put the telescopic handler on a flat, solid and level

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

Travel Direction Control in neutral and the parking
brake engaged, start the engine and raise the boom
and stop the engine.
Figure 10-150-1

1
S3521
• Remove the boom stop (Item 1) [Figure 10-150-1]

from the storage position.
Figure 10-150-2
S3522
• Install the pins and secure with fasteners [Figure 10-

150-2].
• Start the engine and lower the boom slowly [Figure

10-150-2] so that the boom stop is held securely.


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

rotate counterclockwise. Raise the engine cover to

provide access for maintenance.


CHAIN
Checking And Adjustment Procedure Extend Chains Tightness
Retract Chains Tightness Figure 10-170-2
Figure 10-170-1 1
2 3
1
4
2
3
S3574
4
S3573
Loosen the two lock nuts (Item 1) [Figure 10-170-2].

Loosen the lock nuts (Item 1) [Figure 10-170-1]. Check the tightness of the adjustment nuts (located
behind the lock nuts). The correct torque value is 18 N•m
Check the tightness of the adjustment screw (Item 2) (13.5 ft-lb).
[Figure 10-170-1]. The correct torque value is 30 N•m
(22.1 ft-lb). Tighten the adjustment nuts as required.
Tighten the adjustment screws as required. Tighten the adjustment nuts alternately and evenly as
required to achieve the desired torque value. Distance
The chain anchor (Item 3) must be perpendicular to the between the mounting surface on the top of the outer
bottom of the intermediate boom section. Re-position the boom section (Item 2) and the chain anchors (Item 3)
chain anchor as required using screw (Item 4) [Figure MUST be even. DO NOT tighten one chain (Item 4)
10-170-1] and lock nut to position the anchor correctly. [Figure 10-170-2] more than the other.
Re-tighten the lock-nuts. Re-tighten the lock-nuts.
Start the engine and operate the extend / retract function

through several cycles to check for proper operation.
Repair as required.

CHAIN (CONT’D)
Extend / Retract Chain Wear Check
Figure 10-170-3
S0581
Start the engine.

Extend the boom completely in the horizontal position.
Shut off the engine. Use a Vernier caliper to measure the
length “L” of 11 links of the extend chain. Measure from
the outside edge of link pin 1 to outside edge of link pin
11 [Figure 10-170-3].
The wear is considered normal as long as “L” is less than

169,50 mm (6.68 in).
If “L” is equal to or longer than 169,50 mm (6.68 in), the

chains, pins, rollers, tension rods and attachment screws
MUST be replaced.
Each time the chain wear is checked, record the date,

machines hours and measurement “L” for future
reference.

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

a few minutes to circulate the stabilizer to the pump • Remove cover from exhaust pipe opening.
and fuel injectors.
• Start the engine and let run for a few minutes while
If biodiesel blend fuel has been used, perform the observing the instrument panels and systems for
following: correct operation.
Drain the fuel tank, refill with 100% petroleum diesel • Operate machine, check for correct function.
fuel, add fuel stabilizer and run the engine for at least
30 minutes. • Stop the engine and check for leaks. Repair as
needed.
• Drain and flush the cooling system. Refill with
premixed coolant.
• Replace all fluids and filters (engine, hydraulic /

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

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

condition.


STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER
Procedure
• Stop the telescopic handler on solid, flat and level

ground.
• Put the Travel Direction Control Lever and Joystick in

neutral.
• Engage the parking brake. (See Operation &

Maintenance Manual for correct procedure.)
Figure 10-190-1

S3518
• Retract and lower the boom and attachment flat on

the ground [Figure 10-190-1].
• Turn the key switch to STOP and unfasten the seat

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

getting off.
DO NOT JUMP
WARNING
Before you leave the operator’s position:
• Put the travel Direction Control Lever and the
Joystick in neutral.
• Engage the parking brake.
• Retract and lower the boom and attachment flat
on the ground.
• Stop the engine. Raise the restraint bar (if
equipped).
SEE THE MACHINE OPERATION & MAINTENANCE
MANUAL FOR MORE INFORMATION.
W-2637-0607


EMERGENCY EXIT
Rear Window
Figure 10-200-1
S3520
Turn the handle (see picture inset) [Figure 10-200-1] and

push the rear window open. Exit through the rear window

opening.


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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

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

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-9
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
STEERING CYLINDER (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Removing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Installing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
STEERING CYLINDER (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Removing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Installing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Disassembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Assembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Testing And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
QUICK-TACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-7
FRAME LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-9
STEERING MODE VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6

BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Troubleshooting Chart (Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Telescoping Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-2
Auxiliary Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-6

Troubleshooting Chart (Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-15
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-17
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-170-18
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-170-23
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-170-28
Auxiliary / Frame Leveling Valve Section Disassembly And Assembly . . . . . . . . . 20-170-40
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-170-50
PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1

Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1

Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Pressure Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-3
Parking Brake Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-4
Parking Brake Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-5
Parking Brake Valve Disassembly And Assembly (Cont’d) . . . . . . . . . . . . . . . . . . . 20-210-6
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1
TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1

STABILIZER CYLINDER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-9
STABILIZER CONTROL VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-3


HYDRAULIC SCHEMATIC
TL35100 (S/N A8HD11001 - A8HD12025)
TL35100L (S/N A8GW11001 - A8GW12044)
TL35100SL (S/N A8GT11001 - A8GT12063)
Printable Version Click Here
(Printed FEBRUARY 2012)
6927503-legend
LEGEND
1 RESERVOIR: 19 CHECK VALVE 38 MOTOR DISPLACEMENT CONTROL 57 TELESCOPIC CYLINDER LOAD HOLDING
Reservoir Capacity 76 L (20 U.S. U.S. gal) SPOOL VALVE – rod end: 25000 kPa (250 bar) (3625 psi)
System Capacity 120 L (31.7 U.S. U.S. gal) 20 ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL
39 SHUTTLE VALVE - Drain
2 FILTER - Hydraulic VALVE – Boom: 21000 kPa (210 bar) (3045 psi) CONTROL VALVE – LLMC Over Ride
21 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT 59 PROPORTIONAL REDUCER VALVE –
3 SPRING LOADED FILTER BYPASS BIDIRECTIONAL HYDROSTATIC MOTOR
VALVE: 250 kPa (2,5 bar) (36 psi) VALVE – Boom: 27500 kPa (275 bar) (3988 psi) LLMC Valve
41 SERVO PISTON - Swash Plate 60
4 CHECK VALVE CHECK VALVE – LLMC (3)
22 ANTICAVITATION/WORK PORT RELIEF
VALVE – Tilt: 21000 kPa (210 bar) (3045 psi) 42 FLUSHING VALVE: 16 L/min (4.2 U.S. gpm)
5 CHECK VALVE - With 50 kPa (0,5 bar) 61 ANTICAVITATION/WORK PORT RELIEF
(7 psi) Spring 43
43 TOW VALVE VALVE: 25000 kPa (250 bar) (3626 psi)
6 BOOM CYLINDER LOCK VALVE - Lock VALVE – Tilt: 25000 kPa (250 bar) (3625 psi) 44 NOT ANTICAVITATION/WORK PORT RELIEF
NOT USED
USED FOR
FOR THIS
THIS MODEL
MODEL 62
Pressure: 37500 kPa (375 bar) (5439 psi) VALVE: 25000 kPa (250 bar) (3626 psi)
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE
7 ACCUMULATOR (If Equipped): 0,75 L 63 NOT USED FOR THIS MODEL
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 46 NOT USED FOR THIS MODEL
8 TILT CYLINDER LOCK VALVE: 64 LOCK VALVES- Stabilser Cylinder:
26 RELIEF VALVE: 24500 kPa (245 bar) (3553 psi)
28000 kPa (280 bar) (4061 psi) 28000 kPa (280 bar) (4061 psi)
CopyCHECK
Dealer 47 -- NotVALVE - With 350 kPa (3,5 bar)
for Resale
9 SOLENOID - Reverse Drive 27 BLEED CARTRIDGE (50 psi) Spring 65 LOCK VALVES- Stabilser Cylinder:
21000 kPa (210 bar) (3045 psi)
10 SOLENOID - Forward Drive 28 SELF LEVELING CYLINDER LOCK 48 PRIORITY VALVE: 400 kPa (4,0 bar) (58 psi)
VALVE: 25000 kPa (250 bar) (3625 psi) 66 CHECK VALVE with Orifice
11 RELIEF VALVE – Charge 49 RELIEF VALVE: 20000 kPa (200 bar) (2900 psi)
30000 kPa (30 bar) (435 psi) 29 JOYSTICK LOCKOUT VALVE 67
SOLENOID ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL
50
12 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FRAME LEVEL - CONTROL VALVE – Stabiliser Cylinder)
30 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE (2): 45000 kPa (450 bar) (6527 psi) REDUCED SPEED
CONTROL VALVE – Boom Lift Stop 68 SOLENOID ACTIVATED DIRECTIONAL
51 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Stabiliser Cylinder)
13 VARIABLE CAPACITY DISPLACEMENT 31 ACCUMULATOR: 1.4 L (0.37 U.S. gal.) CONTROL VALVE - FRAME LEVEL -
BIDIRECTIONAL HYDROSTATIC PUMP
1500 kPa (15 bar) (217 psi) LEFT/RIGHT DIRECTION CONTROL 69 ORIFICE: 1,0 mm (0.039 in)
14 CHARGE PUMP: 32 L/min (8.5 U.S. gpm) @ 32 PRESSURE SWITCH- Brake:
52 SHUTTLE VALVE 70 SOLENOID ACTIVATED DIRECTIONAL CONTROL
High Engine Idle 1600 kPa (16 bar) 232 psi
VALVE – Two Speed Fan Motor (OPTIONAL)
53 LOCK VALVES- FRAME LEVELING:
15 SERVO PISTON - Swash Plate 33 PARK BRAKE VALVE – Lever Actuated
21000 kPa (210 bar) (3045 psi) 71 SOLENOID ACTIVATED DIRECTIONAL CONTROL
34 VALVE – FAN Inverter Block (OPTIONAL)
16 HYDRAULIC PUMP - Gear type BRAKE VALVE: 6000 kPa (60 bar) (870 psi) 54 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
96 L/min (25.4 U.S. gpm) @ High Engine Idle 72
35 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi) RELIEF VALVE (OPTIONAL):
55 CHECK VALVE - Anti-cavitation 20000 kPa (200 bar) (2900 psi)
17 HYDRAULIC PUMP - Gear Type
37 L/min (9.8 U.S. gpm) @ High Engine Idle 36 RELIEF VALVE (2): 22000 kPa (220 bar) (3190 psi) 56 TELESCOPIC CYLINDER LOAD HOLDING
18 PRIORITY VALVE VALVE – base end: 25000 kPa (250 bar) (3625 psi) NOTE: Unless otherwise specified, springs have
37 SHUTTLE VALVE - Drive Pressure NO significant pressure value.
6927503 (1-23-12)
Printed in Belgium
75 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
7 EV51
FEMALE
COUPLER
10 FORWARD
BOOM CYLINDER HYDRAULIC CONTROL VALVE HYDROSTATIC PUMP
2ND AUX
24 VALVE M2 M5 M4 M1
20 FLOW
OUT A
28
A
C2
2 13
A1
COOLER 15
B 9 REVERSE
21 EV74 3 CW
B1
B2 S
V2 A
17 cc 11
B1
a1
BOOM LIFT 30 55 WITH 2 SPEED FAN
STOP VALVE MOTOR (OPTIONAL) 14 M3
b1 B C
19 22 5
24 EV58 T
SELF LEVELLING CYLINDER 4 HYDRAULIC

L1
FILTER
A 1
A2
71
FAN MOTOR 70 L2
23 HYDRAULIC
B2 B A 54 RESERVOIR
47
8 12
EV52 B A
a2 FAN INVERSION
BLOCK
(OPTIONAL)
18 GEAR PUMP
b2 C1 C2 C3 C4 16
19
C9 C10
CF
24 IN
EF
C8 C7 C6 C5 T P
TILT CYLINDER
A3
61 DRAIN 72 IN
BLOCK
B3
EVP3
OUT LS
57 17
62
19
44 24
M2 M4 L1 L2
56 A4 B
44 M3
B4
EVP4 FRONT AXLE REAR AXLE
40 41
EXTENSION CYLINDER
EV8
pst Vg min 42 38
19
Y Dealer Copy -- Not for Resale TOW
VALVE
STEERING MODE
VALVE
26 37 EV7
66
P2
T1 43 A
39
P1
P
XB XA
P1
T
A
27 M1 B
P2
EV6
TRAVEL MOTOR
P LS M 25 T
65 64
STABILIZER CYLINDER
58
M2 M1 M
66
P 67 69 T LS
EV14
B T
STEERING UNIT
A
EV21 EV22
60 36
P2 P1 P
59 R L
AMA VALVE
B
64
65 A
4 3 2 1
EV18 EV17
B
EV85
STABILIZER CYLINDER SERVICE
BRAKE
68 STABILISERS BLOCK VALVE
34
F A
45 AUX RELEASE
VALVE
V T P
FRAME LEVELLING CYLINDER
T P
32 P T T LS P
JOYSTICK
50 53
53 PARK BRAKE
VALVE
35
48 EV73 C 29
T
JOYSTICK
EV3
LOCK
49 VALVE X 31
P
P T
EV71 EV72
33
51
CHARGE C6 C1
B A BLOCK C2
FRAME LEVELLING
C5
HYDRAULIC SCHEMATIC
BLOCK 52
C4 C3
C7
TL35100 (S/N A8HD11001 - A8HD12025)
TL35100L (S/N A8GW11001 - A8GW12044)
TL35100SL (S/N A8GT11001 - A8GT12063)
76 of 1040
(PRINTED FEBRUARY 2011)
Printed in Belgium 6927503
375 b
HYDRAULIC SCHEMATIC
TL35100 (S/N A8HD12026 AND ABOVE)
TL35100L (S/N A8GW12045 AND ABOVE)
TL35100SL (S/N A8GT12064 AND ABOVE)
TL35100L (S/N A8GZ11001 AND ABOVE)
TL35100SL (S/N A8GU11001 AND ABOVE)
6927503-A-legend
LEGEND
(7 psi) Spring 43 TOW VALVE VALVE: 25000 kPa (250 bar) (3626 psi)
6 BOOM CYLINDER LOCK VALVE - Lock VALVE – Tilt: 25000 kPa (250 bar) (3625 psi) 44 NOT USED FOR THIS MODEL 62 ANTICAVITATION/WORK PORT RELIEF
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE 63 PRESSURE SWITCH- Brake:
7 ACCUMULATOR (If Equipped): 0,75 L
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 10000 kPa (100 bar) 1450 psi
46 ACCUMULATOR: 0,5 L (0.13 U.S. gal)
8 TILT CYLINDER LOCK VALVE: (7200 kPa (72 bar) (1044 psi) 64 LOCK VALVES- Stabilser Cylinder:
CopyCHECK
for Resale
21000 kPa (210 bar) (3045 psi)
50
96 L/min (25.4 U.S. gpm) @ High Engine Idle 72 RELIEF VALVE (OPTIONAL):
35 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi) 55 CHECK VALVE - Anti-cavitation 20000 kPa (200 bar) (2900 psi)
6927503-A (1-19-12)
Printed in Belgium
77 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
EV51
7 FEMALE
COUPLER
ENGINE
6
10 FORWARD
HYDROSTATIC
BOOM CYLINDER HYDRAULIC CONTROL VALVE PUMP
2ND AUX VALVE
M2 M5 M4 M1
(OPTIONAL)
24 HYDRAULIC FLOW
20 FILTER OUT A
28 A 2
13
C2
A1
COOLER 15 9 REVERSE
3 CW
21
PIL B1
BOOM LIFT
B2 S
STOP VALVE 11
V2 55 WITH 2 SPEED FAN
B1
MOTOR (OPTIONAL)
a1
A B
B C 14 M3
b1 EV58
5
19 22
T
24 4 L1
A
SELF LEVELLING CYLINDER EV74
1
71 FAN MOTOR
A2
54 70 HYDRAULIC L2
B A RESERVOIR
23 30
B2
EV52 47 12
8 FAN B A
INVERSION
BLOCK
a2 DRAIN (OPTIONAL) GEAR
BLOCK 16 18 PUMP
b2 C1 C2 C3 C4
19 C9 C10 IN
CF
T P
24 EF
C8 C7 C6 C5
TILT CYLINDER
A3
72 IN
61
B3 OUT LS
EVP3
17
57
62
44
44
19
24 M2 M4 L1 L2
B
A4
56 M3
FRONT AXLE
B4
EVP4 40 41
EV8
EXTENSION CYLINDER 42
38
pst
Y
Dealer Copy -- Not for Resale T3
TOW
VALVE
19 37
26
P2
43
66 T1 39
P1
REAR AXLE
XB XA
P1
65 A
M1
STEERING
27
P2
64 TRAVEL MOTOR MODE VALVE
EV7
P LS M 25 T
A
STABILIZER CYLINDER B
EV6
B4 B3 B1
66 69 58
P 67 T LS LS
EV16
EV20
65 B
STEERING UNIT
T
A B
64
EV21 EV22 36 EV85
R L
60 59
B A4 A3 A2 A
LLMC VALVE 45 AUX

A
RELEASE
EV18 EV17 VALVE

4 3 2 1 BRAKE
68 VALVE 34
ACCUMULATOR
F
CHARGING VALVE
P LS T 63
V T P
S
53 53 P T T LS P
50 P T
32 MA
A
16 b 35
JOYSTICK PARK
BRAKE 1.4 l 46
15 b
VALVE
48 EV73
49 C 29 T
C6 C1 EV3 31
EV71 EV71 C2
X
P Printable Version Click Here
C5 JOYSTICK
P T LOCK VALVE 33
51
C4 C3
C7
HYDRAULIC SCHEMATIC
B A
CHARGE TL35100 (S/N A8HD12026 AND ABOVE)
BLOCK
FRAME
LEVELLING WORKING CIRCUITS TL35100L (S/N A8GW12045 AND ABOVE)
PILOT CIRCUITS
BLOCK
DRAIN CIRCUITS TL35100SL (S/N A8GT12064 AND ABOVE)
COMPONENTS
52 TL35100L (S/N A8GZ11001 AND ABOVE)
78 of 1040 TL35100SL (S/N A8GU11001 AND ABOVE)
Printed in Belgium 6927503-A
HYDRAULIC SCHEMATIC
T35120SL (S/N A8GJ11001 - A8GJ12029)
T35120L (S/N A8GV11001 - A8GV12111)

6927503-legend
LEGEND
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE
7 ACCUMULATOR (If Equipped): 0,75 L 63 NOT USED FOR THIS MODEL
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 46 NOT USED FOR THIS MODEL
8 TILT CYLINDER LOCK VALVE: 64 LOCK VALVES- Stabilser Cylinder:
CopyCHECK
for Resale
21000 kPa (210 bar) (3045 psi)
50
6927503 (1-23-12)
Printed in Belgium
79 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
7 EV51
FEMALE
COUPLER
10 FORWARD
BOOM CYLINDER HYDRAULIC CONTROL VALVE HYDROSTATIC PUMP
2ND AUX
24 VALVE M2 M5 M4 M1
20 FLOW
OUT A
28
A
C2
2 13
A1
COOLER 15
B 9 REVERSE
21 EV74 3 CW
B1
B2 S
V2 A
17 cc 11
B1
a1
BOOM LIFT 30 55 WITH 2 SPEED FAN
STOP VALVE MOTOR (OPTIONAL) 14 M3
b1 B C
19 22 5
24 EV58 T
SELF LEVELLING CYLINDER 4 HYDRAULIC

L1
FILTER
A 1
A2
71
FAN MOTOR 70 L2
23 HYDRAULIC
B2 B A 54 RESERVOIR
47
8 12
EV52 B A
a2 FAN INVERSION
BLOCK
(OPTIONAL)
18 GEAR PUMP
b2 C1 C2 C3 C4 16
19
C9 C10
CF
24 IN
EF
C8 C7 C6 C5 T P
TILT CYLINDER
A3
61 DRAIN 72 IN
BLOCK
B3
EVP3
OUT LS
57 17
62
19
44 24
M2 M4 L1 L2
56 A4 B
44 M3
B4
EVP4 FRONT AXLE REAR AXLE
40 41
EXTENSION CYLINDER
EV8
pst Vg min 42 38 TOW STEERING MODE
19
Y
Dealer Copy -- Not for Resale VALVE VALVE
26 37 EV7
66
P2
T1 43 A
39
P1
P
XB XA
P1
T
A
27 M1 B
P2
EV6
TRAVEL MOTOR
P LS M 25 T
65 64
STABILIZER CYLINDER
58
M2 M1 M
66
P 67 69 T LS
EV14
B T
STEERING UNIT
A
EV21 EV22
60 36
P2 P1 P
59 R L
AMA VALVE
B
64
65 A
4 3 2 1
EV18 EV17
B
EV85
BRAKE
68 STABILISERS BLOCK VALVE
34
F A
45 AUX RELEASE
VALVE
V T P
T P
32 P T T LS P
JOYSTICK
50 53
53 PARK BRAKE
VALVE
35
48 EV73 C 29
T
JOYSTICK
EV3
LOCK
49 VALVE X 31
P
P T
EV71 EV72
33
51
B A
CHARGE
BLOCK
C6 C1
C2
C5
FRAME LEVELLING
BLOCK 52 C7
HYDRAULIC SCHEMATIC
C4 C3
T35120SL (S/N A8GJ11001 - A8GJ12029)
T35120L (S/N A8GV11001 - A8GV12111)
80 of 1040
Printed in Belgium 6927503
HYDRAULIC SCHEMATIC
T35120SL (S/N A8GJ12030 AND ABOVE)
T35120L (S/N A8GV12112 AND ABOVE)
T35120SL (S/N A8GE11001 AND ABOVE)
T35120L (S/N A8GG11001 AND ABOVE)
6927503-A-legend
LEGEND
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE 63 PRESSURE SWITCH- Brake:
7 ACCUMULATOR (If Equipped): 0,75 L
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 10000 kPa (100 bar) 1450 psi
46 ACCUMULATOR: 0,5 L (0.13 U.S. gal)
8 TILT CYLINDER LOCK VALVE: (7200 kPa (72 bar) (1044 psi) 64 LOCK VALVES- Stabilser Cylinder:
CopyCHECK
for Resale
21000 kPa (210 bar) (3045 psi)
50
6927503-A (1-19-12)
Printed in Belgium
81 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
EV51
7 FEMALE
COUPLER
ENGINE
6
10 FORWARD
HYDROSTATIC
BOOM CYLINDER HYDRAULIC CONTROL VALVE PUMP
2ND AUX VALVE
M2 M5 M4 M1
(OPTIONAL)
24 HYDRAULIC FLOW
20 FILTER OUT A
28 A 2
13
C2
A1
COOLER 15 9 REVERSE
3 CW
21
PIL B1
BOOM LIFT
B2 S
STOP VALVE 11
V2 55 WITH 2 SPEED FAN
B1
MOTOR (OPTIONAL)
a1
A B
B C 14 M3
b1 EV58
5
19 22
T
24 4 L1
A
SELF LEVELLING CYLINDER EV74
1
71 FAN MOTOR
A2
54 70 HYDRAULIC L2
B A RESERVOIR
23 30
B2
EV52 47 12
8 FAN B A
INVERSION
BLOCK
a2 DRAIN (OPTIONAL) GEAR
BLOCK 16 18 PUMP
b2 C1 C2 C3 C4
19 C9 C10 IN
CF
T P
24 EF
C8 C7 C6 C5
TILT CYLINDER
A3
72 IN
61
B3 OUT LS
EVP3
17
57
62
44
44
19
24 M2 M4 L1 L2
B
A4
56 M3
FRONT AXLE
B4
EVP4 40 41
EV8
EXTENSION CYLINDER 42
pst 38 TOW
Y
Dealer Copy -- Not for Resale T3 VALVE
19 37
26
P2
43
66 T1 39
P1
REAR AXLE
XB XA
P1
65 A
M1
STEERING
27
P2
64 TRAVEL MOTOR MODE VALVE
EV7
P LS M 25 T
A
STABILIZER CYLINDER B
EV6
B4 B3 B1
66 69 58
P 67 T LS LS
EV16
EV20
65 B
STEERING UNIT
T
A B
64
EV21 EV22 36 EV85
R L
60 59
B A4 A3 A2 A
LLMC VALVE 45 AUX

A
RELEASE
EV18 EV17 VALVE

4 3 2 1 BRAKE
68 VALVE 34
ACCUMULATOR
F
CHARGING VALVE
P LS T 63
V T P
S
53 53 P T T LS P
50 P T
32 MA
A
16 b 35
JOYSTICK PARK
BRAKE 1.4 l 46
15 b
VALVE
48 EV73
49 C 29 T
C6 C1 EV3
X
31
EV71 EV71
C5
C2
JOYSTICK
P
P T LOCK VALVE 33
51 C7
B A
C4 C3
HYDRAULIC SCHEMATIC
CHARGE
FRAME
BLOCK T35120SL (S/N A8GJ12030 AND ABOVE)
LEVELLING
BLOCK
WORKING CIRCUITS
PILOT CIRCUITS T35120L (S/N A8GV12112 AND ABOVE)
DRAIN CIRCUITS
52 COMPONENTS T35120SL (S/N A8GE11001 AND ABOVE)
T35120L (S/N A8GG11001 AND ABOVE)
82 of 1040
Printed in Belgium 6927503-A
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
mc-2340

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340
2

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340-3

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

1. The fluid level is not correct

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

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

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

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


LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1 3
2
2
S3563
1
Support the lift cylinder using a cinch strap (Item 1).
S2885 Remove the upper pivot pin snap ring (Item 2) and the
upper pivot pin washer (Item 3) [Figure 20-20-3] at both
sides of the pivot.
Raise the boom and install on adequate stands (Item 1)
[Figure 20-20-1]. Figure 20-20-4
Figure 20-20-2

2
S3622
S3556
Remove the upper pivot pin (Item 1) [Figure 20-20-4].
Remove the bolts (Item 1) and remove the rear cover Using the lifting chain (Item 2) [Figure 20-20-1], lower
(Item 2) [Figure 20-20-2] from the machine. the boom onto 0 degrees. Lower the lift cylinder onto a
block and remove the cinch strap.

LIFT CYLINDER (CONT’D) Installation: Tighten the bolt to 345 N•m (255 ft-lb)
torque.
Removal And Installation (Cont’d)
Figure 20-20-7
Figure 20-20-5
P-50975
P-29774
Lift and support the base end of the cylinder [Figure 20-
20-7].
Remove the two hoses (Item 1) [Figure 20-20-5] from
the lift lock on the lift cylinder. Figure 20-20-8

NOTE: Mark all hoses for correct installation.
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
I-2003-0888
S3559
Figure 20-20-6
Remove the lower pivot pin snap ring (Item 1) [Figure 20-
20-8] at both sides of the pivot pin.
S3562
Remove the bolt (Item 1) (both sides) and remove the

cross brace (Item 2) [Figure 20-20-6].

LIFT CYLINDER (CONT’D) Figure 20-20-11
Figure 20-20-9
1
P-29779A
Lift and remove the cylinder [Figure 20-20-11].

S3560
Remove the lower pivot pin washer (Item 1) [Figure 20-

Figure 20-20-10

1
S3561
Remove the base end pivot pin (Item 1) [Figure 20-20-

10].

LIFT CYLINDER (CONT'D)
Parts Identification
1. Housing
2. Bushing
3. Spacer
4. Grease Fitting
5. Wiper
6. Wear Ring
7. Seal
8. O-ring
9. Rod
10. Head
11. Piston
12. Lock Washer
13. Nut
B-19851

LIFT CYLINDER (CONT'D) Figure 20-20-14
Disassembly
Figure 20-20-12
P-29905
Carefully peen the lock ring from the head gland [Figure
P-29903 20-20-14].
Figure 20-20-15
Use the following tools to disassemble the cylinders:

MEL1354-Spanner Wrench
MEL1076-Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-12].
Figure 20-20-13
1
2
P-29906
Use a spanner wrench to loosen the head gland [Figure

20-20-15].
P-29904
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-13].

Disassembly (Cont'd)
Figure 20-20-16
P-29910
Support the cylinder rod on a wood block [Figure 20-20-

P-29907 18].
Figure 20-20-19
Remove the rod assembly (Item 1) [Figure 20-20-16]
from the housing.

Figure 20-20-17
P-29923
Carefully peen the lock ring tab (Item 1) [Figure 20-20-

P-29909 19] up and out of the lock nut groove.
Put the rod end of the cylinder in a vise [Figure 20-20-

17].

Figure 20-20-20
1
P-29914
Remove the piston (Item 1) [Figure 20-20-22] from the

P-29912 rod.
Figure 20-20-23
Remove the lock nut from the cylinder rod [Figure 20-20-
20] using a cylinder wrench. 1

Figure 20-20-21
2
P-29915
Remove the two wear rings (Item 1) and seal (Item 2)

P-29913 [Figure 20-20-23] from the piston.
Remove the lock ring (Item 1) [Figure 20-20-21].

Figure 20-20-24 1
P-29918
1
Remove the head gland (Item 1) [Figure 20-20-26] from
P-29916 the rod.
Figure 20-20-27
Remove the O-ring (Item 1) [Figure 20-20-24].

Figure 20-20-25
P-29919
P-29917 Remove the two O-rings (Item 1) [Figure 20-20-27] from

the head gland.
Remove the O-ring (Item 1) [Figure 20-20-25] from the

piston.

Figure 20-20-28
P-29920
Remove the wear ring (Item 1) [Figure 20-20-28].

Figure 20-20-29
2 3
P-29921
Remove seal (Item 1), wear ring (Item 2) and wiper (Item
3) [Figure 20-20-29] from the head gland.

Assembly
Use the following tools to assemble the cylinders:
MEL1354-Spanner Wrench 1
MEL1033-Rod Seal Installation Tool
Wash the cylinder parts in solvent and dry with

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

damage. Replace any damaged parts.
P-29885
Lubricate all O-rings and seals with hydraulic fluid during
installation. Always use new O-rings and seals.
Install the center seal (Item 1) [Figure 20-20-32].
Figure 20-20-30
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-20-30].
1
Figure 20-20-33

1
2
P-29884
Install the wiper (Item 1) and wear ring (Item 2) [Figure

20-20-30] in the head gland. P-29919
Figure 20-20-31
Install the two O-rings (Item 1) [Figure 20-20-33].
P-29883
Install the wear ring (Item 1) [Figure 20-20-31].

Assembly (Cont'd)
Figure 20-20-34
1
P-29916
Install the expander O-ring (Item 1) [Figure 20-20-36] on

P-29918 the piston.
Figure 20-20-37
Install the head gland (Item 1) [Figure 20-20-34] onto the
rod.
1

Figure 20-20-35
2
P-29915
Install the two wear rings (Item 1) and seal (Item 2)

P-29917 [Figure 20-20-37] onto the piston.
Install the O-ring (Item 1) [Figure 20-20-35] in the piston.

Assembly (Cont'd)
Figure 20-20-38
P-29913
Install the lock ring (Item 1) [Figure 20-20-40].

P-32047
Figure 20-20-41
Clean off any old residue, and apply Loctite® #242 or

equivalent to the threads on the rod [Figure 20-20-38].

Figure 20-20-39
1
1
P-29922
Use the cylinder wrench to install the lock nut (Item 1)

[Figure 20-20-41] and tighten.
P-29914
Install the piston (Item 1) [Figure 20-20-39] on the rod.

Assembly (Cont'd)
Figure 20-20-42
P-29925
Use the spanner wrench to tighten the head gland

P-29924
[Figure 20-20-44].
Figure 20-20-45
Peen the lock ring tab (Item 1) [Figure 20-20-42] into the
groove in the lock nut.

Figure 20-20-43
P-29926
Peen the lock ring into the groove in the head gland
[Figure 20-20-45].
P-29907
Install the rod assembly (Item 1) [Figure 20-20-43] into

the housing.

Assembly (Cont'd)
Figure 20-20-46
2
1
P-29904
Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-46].

BUCKET POSITIONING CYLINDER Figure 20-30-3
Figure 20-30-1 3
2
1
P-58090
Remove the upper hose (Item 1), tubeline (Item 2) and

S3211
fitting (Item 3) [Figure 20-30-3] from the cylinder.
Lower the boom onto adequate stands or blocks as NOTE: Mark all hoses for correct installation.
shown (Item 1) [Figure 20-30-1].
Figure 20-30-2

IMPORTANT
1 damage the system.
I-2003-0888
Figure 20-30-4
S3556
Remove the rear cover (Item 1) [Figure 20-30-2] from

the machine.
2
P-58091
Remove the lower hose (Item 1), tubeline (Item 2) and

load lock (Item 3) [Figure 20-30-4] from the cylinder.

BUCKET POSITIONING CYLINDER (CONT’D) Figure 20-30-7
Figure 20-30-5 2
1
1
S3562
Remove the bolt (Item 1) (both sides) and remove the

cross brace (Item 2) [Figure 20-30-7].
S3557
Installation: Tighten the bolt to 345 N•m (255 ft-lb)

Remove the nut (Item 1) [Figure 20-30-5] from the upper torque.
retainer bolt.
Figure 20-30-8
Figure 20-30-6

1
S3559
S3558
Remove the lower pivot pin snap ring (Item 1) [Figure 20-
Remove the upper pivot pin using a pin removal tool 30-8] at both sides of the pivot pin.
[Figure 20-30-6].
NOTE: Secure the top of the cylinder from falling

forward and causing damage to the cylinder
rod when the pivot pin is removed.

BUCKET POSITIONING CYLINDER (CONT’D) Figure 20-30-11
Figure 20-30-9
1
P-29762A
Have an assistant tilt the cylinder forward while removing

the cylinder out the back [Figure 20-30-11].
S3560
Remove the lower pivot pin washer (Item 1) [Figure 20-

Figure 20-30-10

1
S3561
Remove the base end pivot pin (Item 1) [Figure 20-30-

10].

BUCKET POSITIONING CYLINDER (CONT’D)
1. Bushing
2. Housing
3. Wear Ring
4. Seal
5. O-ring
6. Set Screw
7. Piston
8. Rod
9. Head Gland
10. Wiper
11. Grease Fitting
B-19852

BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-14
Disassembly
Use the following tools to disassemble the cylinder:
Figure 20-30-12
P-29869
Use a spanner wrench to remove the head gland [Figure

20-30-14].
Figure 20-30-15
P-29871

1
Figure 20-30-13
P-29872

from the housing.
P-29868
Carefully peen the lock ring from the head gland [Figure
20-30-13].

Figure 20-30-16 1
P-29874
Remove the piston assembly (Item 1) [Figure 20-30-18]

P-29873 from the rod.
Figure 20-30-19
16].

1
Figure 20-30-17
1
P-29877

P-29875 [Figure 20-30-19] from the piston.
Support the cylinder rod on a wood block and remove the

set screw (Item 1) [Figure 20-30-17] from the piston.

Figure 20-30-20
P-29881
1
P-29879 the rod.
Figure 20-30-23

Figure 20-30-21
1
1
P-29883
P-29880 Remove the center seal (Item 1) and outer wear ring
(Item 2) [Figure 20-30-23].

piston.

Figure 20-30-24
P-29878
Remove any residue from the threads on the cylinder rod

P-29884 [Figure 20-30-26].
Remove the outer wear ring (Item 1) and wiper (Item 2)

[Figure 20-30-24].

Figure 20-30-25
P-29882
Remove the two O-rings (Item 1) [Figure 20-30-25].

Assembly
Use the following tools to assemble the cylinder: 1
MEL1033-Rod Seal Installation Tool

compressed air.


P-29883
installation.
Always use new O-rings and seals.

Figure 20-30-27
Figure 20-30-30

1
P-29882
P-29885
Install the two O-rings (Item 1) [Figure 20-30-27] onto
the head gland.
Figure 20-30-28
1
P-29884
Install the wiper (Item 1) and wear ring (Item 2) [Figure

20-30-28].

Assembly (Cont'd)
Figure 20-30-31
P-29879
Install the O-ring (Item 1) [Figure 20-30-33] onto the

P-29881 piston.
Figure 20-30-34
rod.

1
Figure 20-30-32
1
P-29877

P-29880 [Figure 20-30-34].
Install the O-ring (Item 1) [Figure 20-30-32] in the piston.

Assembly (Cont'd)
Figure 20-30-35
P-29888
Align the hole (Item 1) [Figure 20-30-37] in the piston

P-29886 with the hole in the end of the cylinder rod.
Figure 20-30-38
Apply Loctite® #242 or equivalent to the threads on the
rod [Figure 20-30-35].

Figure 20-30-36
P-29887
Apply Loctite® #242 or equivalent to the set screw (Item

P-29874 1) [Figure 20-30-38].
Install the piston (Item 1) [Figure 20-30-36] onto the rod.

Assembly (Cont'd)
Figure 20-30-39
1
P-29869
Use the spanner wrench to tighten the head gland

P-29875 [Figure 20-30-41].
Figure 20-30-42
Install the set screw (Item 1) [Figure 20-30-39] into the
piston and tighten.

Figure 20-30-40
P-29868
Carefully peen the lock ring over and into the nut [Figure
P-29874
20-30-42].

the housing.

EXTENSION CYLINDER Figure 20-40-3
Cylinder Group Removal And Installation
Figure 20-40-1
S3565
Remove the attachment screws (Item 1) [Figure 20-40-3]

from both sides of the cylinder head.
S3211
Figure 20-40-4
Start the engine and raise the boom until the boom is in
the horizontal position (Item 1) [Figure 20-40-1]. Make
sure that the booms are retracted.

Figure 20-40-2
S3566
Remove the support blocks. [Figure 20-40-4].
S3556

the machine.

EXTENSION CYLINDER (CONT’D)
Cylinder Group Removal And Installation (Cont’d)

IMPORTANT
Figure 20-40-5
damage the system.
I-2003-0888
Figure 20-40-7
1
S3567A
1
Start the engine and move the cylinder (Item 1) [Figure
20-40-5] a few centimeters toward the rear.

WARNING S3568

Wear safety glasses to prevent eye injury when any Remove the four attachment screws (Item 1) [Figure 20-
of the following conditions exist: 40-7] from the cylinder body.
• When fluids are under pressure.
• Flying debris or loose material is present. Figure 20-40-8
• Engine is running.
W-2019-0907
Figure 20-40-6
1 S3569
Lift and remove the cylinder out of the boom [Figure 20-
40-8].
S3570
Remove the two tubelines (Item 1) [Figure 20-40-6] from

the bulkhead fittings.

EXTENSION CYLINDER (CONT’D)
Cylinder Group Removal And Installation (Cont’d)
Figure 20-40-9
S3571A
Remove the skid that enables the telescoping cylinder

shaft to be held on the caisson by removing the two bolts
(Item 1) [Figure 20-40-9].

EXTENSION CYLINDER (CONT'D)
S2886

EXTENSION CYLINDER (CONT'D) Figure 20-40-12
Disassembly
Spanner Wrench
Cylinder Wrench
Figure 20-40-10
1 S3650
Use the spanner wrench to loosen the head gland (Item

1) [Figure 20-40-12].
Figure 20-40-13
1

S3652
Put the cylinder in a vise.
Remove the cylinder lock (Item 1) [Figure 20-40-10].
Figure 20-40-11
1
S3651

from the housing.
1
S3658
Carefully peen the lock ring (Item 1) [Figure 20-40-11]

up and out of the lock groove.

Disassembly (Cont’d) 2
Figure 20-40-14
1 S3654
1 Remove the two wear rings (Item 1) and seal (Item 2)

[Figure 20-40-16].
S3656
Figure 20-40-17
Remove the lock screws (Item 1) [Figure 20-40-14] from
the piston. 1
Figure 20-40-15

S3653
2
Remove the two O-rings (Item 1) [Figure 20-40-17] from
1 the piston.
S3657
Put the other side of the rod assembly in a vise. Use the
cylinder wrench to remove the piston (Item 1) from the
rod (Item 2) [Figure 20-40-15].

1
Figure 20-40-18
S3660
Remove the three O-rings (Item 1) [Figure 20-40-20]

from the head gland.
S3662
Remove the ring (Item 1) [Figure 20-40-18] from the rod.
Figure 20-40-19

1
S3661
Remove the stop ring (Item 1) [Figure 20-40-19] from the

rod.

Figure 20-40-21
S3659

the rod.
Figure 20-40-22

3 1
P-29921
Remove the wiper seal (Item 1), two wear rings (Item 2),
and seal (Item 3) [Figure 20-40-22] from the head gland.

Assembly
Spanner Wrench
1
Cylinder Wrench
Rod Seal Installation Tool

compressed air.
S3659
Install the head gland (Item 1) [Figure 20-40-24] on the
rod.
Figure 20-40-25
Figure 20-40-23
1

3 1
S3660
P-29921
Install the three O-rings (Item 1) [Figure 20-40-25] on
Install the wiper seal (Item 1) and two wear rings (Item 2) the head gland.
[Figure 20-40-23] into the head gland.
Install the seal (Item 3) [Figure 20-40-23] using the seal

installation tool.

the wiper seal

Assembly (Cont’d) 1
Figure 20-40-26
1 S3653
Install the two O-rings (Item 1) [Figure 20-40-28] on the

piston.
S3661
Figure 20-40-29
Install the stop ring (Item 1) [Figure 20-40-26] on the rod.
2
Figure 20-40-27

1
1 S3654

S3662
[Figure 20-40-29] on the piston.
Install the ring (Item 1) [Figure 20-40-27] on the rod.

Assembly (Cont’d)
Figure 20-40-30
1
S3651
1

the housing.
S3657
Figure 20-40-33
Clean off any old residue, and apply Loctite® 242 or
equivalent to the threads on the piston.
Use the cylinder wrench to install the piston (Item 1)

[Figure 20-40-30] on the cylinder rod.
Figure 20-40-31
1 S3650
Use the spanner wrench to tighten the head gland (Item

1) [Figure 20-40-33].
1
S3656
Install the lock screws (Item 1) [Figure 20-40-31] on the

piston.

Assembly (Cont’d)
Figure 20-40-34
S3664
Carefully peen the lock ring into the groove in the head
gland (Item 1) [Figure 20-40-34].
Figure 20-40-35

1
S3652
Install the cylinder lock (Item 1), install the two fittings
(Item 2) and two relief cartridges (Item 3) [Figure 20-40-
35].

TILT CYLINDER Figure 20-50-3
Figure 20-50-1
2
1
1
S3625
Install a lifting eye (Item 1) on the top of the tilt cylinder,

then connect the eye with a lifting chain (Item 2) [Figure
S3577
20-50-3].
Disconnect the four hydraulic hoses (Item 1) [Figure 20- Figure 20-50-4
50-1] at the front of the boom.
NOTE: Mark the hoses for correct installation.

IMPORTANT
1
damage the system. S3626
I-2003-0888
Remove the upper pivot pin snap ring (Item 1) [Figure

Figure 20-50-2
20-50-4] at both sides of the pivot pin.
1
S3624
Disconnect the two connectors (Item 1) [Figure 20-50-2]

at the front of the boom (If Equipped).

TILT CYLINDER (CONT’D) Figure 20-50-7
Figure 20-50-5
1 1
S3629
Remove the pivot pin retainer bolt (Item 1) [Figure 20-50-

7].
S3627
Figure 20-50-8
Remove the upper pivot pin washer (Item 1) [Figure 20-
Figure 20-50-6

1
S3630
1
Remove the lower pivot pin (Item 1) [Figure 20-50-8].
S3628

TILT CYLINDER (CONT’D)
Figure 20-50-9
S3631
Carefully lift and remove the tilt cylinder (Item 1) [Figure

20-50-9].

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

7
B-19854

TILT CYLINDER (CONT'D) Figure 20-50-12
Disassembly
Use the following tool to disassemble the cylinder:
MEL1075-Adjustable Gland Wrench
Figure 20-50-10
P-32032
Remove the relief cartridge (Item 1) [Figure 20-50-12].
Figure 20-50-13
P-32030

1
Figure 20-50-11
S3632
Loosen the head gland (Item 1) [Figure 20-50-13].
1
1
P-32031

the cylinder.

Disassembly (Cont’d)
Figure 20-50-14
S3635
1
Support the cylinder rod on a wood block [Figure 20-50-
S3634 16].
Figure 20-50-17
Remove the rod assembly (Item 1) [Figure 20-50-14].
Figure 20-50-15

1
P-32039
S32036 Remove the lock ring (Item 1) [Figure 20-50-17].

15].

Figure 20-50-18
1
P-32041
S3635
Figure 20-50-21
Remove the piston (Item 1) [Figure 20-50-18] from the
rod.
Figure 20-50-19

1 1
P-32042

2 inside of the piston.
P-32040

[Figure 20-50-19] from the piston.

Figure 20-50-22 1
3
S3639
Remove the wiper seal (Item 1), wear rings (Item 2) and
S3637
seal (Item 3) [Figure 20-50-24].

the rod.
Figure 20-50-23

S3638

head gland.

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

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

damaged parts.
Lubricate all O-rings and seals with hydraulic fluid during S3637
Figure 20-50-25
rod.
Figure 20-50-28
1
3

2
S3639
Install the wiper seal (Item 1), wear rings (Item 2), and
seal (Item 3) [Figure 20-50-25]. P-32042

Install the O-ring (Item 1) [Figure 20-50-28] on the inside
of the piston.
Figure 20-50-26
S3638

head gland.

Assembly (Cont'd)
Figure 20-50-29
P-32047

1 equivalent to the threads on the rod [Figure 20-50-31].
P-32041
Figure 20-50-32
piston.
1

Figure 20-50-30
S3635
Install the piston (Item 1) [Figure 20-50-32] onto the rod

1 1 and tighten.
2 P-32040

[Figure 20-50-30].

Assembly (Cont'd)
Figure 20-50-33
S3632
Tighten the head gland (Item 1) [Figure 20-50-35].

P-32039
Figure 20-50-36
Install the lock ring (Item 1) [Figure 20-50-33].
Figure 20-50-34
1

1
P-32050

S3634
1) [Figure 20-50-36].
Install the piston / rod assembly (Item 1) [Figure 20-50-

34] into the housing.

TILT CYLINDER (CONT'D)
Assembly (Cont'd)
Figure 20-50-37
P-32032
Screw in the relief cartridge (Item 1) [Figure 20-50-37]
Figure 20-50-38

1
1
P-32031
Install the two hoses (Item 1) [Figure 20-50-38].

STEERING CYLINDER (FRONT) Figure 20-60-3
Removing The Steering Cylinder
Remove the front axle. (See Removal on Page 40-30-1.) 2

Figure 20-60-1 1
2
S2515
3
Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-60-3].
1
S2649 Figure 20-60-4
Remove the two bolts (Item 1) and remove the centering

sensor (Item 2) from the front steering cylinder (Item
3) [Figure 20-60-1]. 1
Figure 20-60-2
S2516
Remove the nut (Item 1) [Figure 20-60-4].
S2515
Remove the cotter pin (Item 1) [Figure 20-60-2].

STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-7
Removing The Steering Cylinder (Cont’d)
Figure 20-60-5
2
S2651
Remove the ball joints (Item 1) from the steering cylinder

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

Figure 20-60-6
1 2
S2652
Extract the cylinder (Item 1) [Figure 20-60-8] using a

S2650 plastic hammer.
NOTE: For cylinder disassembly (See Disassembling

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

Installing The Steering Cylinder
Figure 20-60-9
S2650
Apply Loctite® #242 to the thread and connect the

S2653 steering bars by screwing the terminals onto the piston
stem [Figure 20-60-11], apply a torque of 240 - 270 N•m
(177 - 199 ft-Ib).
Lubricate the seats of the seals and install the steering
cylinder (Item 1) [Figure 20-60-9] into its seat. Figure 20-60-12

Figure 20-60-10
1
1
S2524
S2654
Insert the pins (Item 1) in the steering case (Item 2)
[Figure 20-60-12] and lock into position using a torque
Tighten the bolts (Item 1) [Figure 20-60-10] to 116 - 128 wrench setting of 260 - 290 N•m (192 - 214 ft-Ib).
N•m (85 - 94,6 ft-Ib) torque.
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (Item 3) [Figure 20-
60-12] further.
NOTE: Check that the rubber guards [Figure 20-60-

12] are intact.

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

bend the safety stems.

NOTE: Use new cotter pins.
Figure 20-60-14
1
2
S2526
Install the centering sensor (Item 1) for checking piston

centering.
Tighten the bolts (Item 2) [Figure 20-60-14] to 5 - 6 N•m

(44.3 - 53.1 in-Ib) torque.

Disassembling The Steering Cylinder
Figure 20-60-15 2
2
S1518
With the help of a drift, apply pressure to the stop ring

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

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

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

the head then the piston (Item 3) [Figure 20-60-19].
NOTE: Mark the assembly side of the piston (Item 3).

The bevelled part “A” of the piston is oriented
toward the head (Item 2) [Figure 20-60-19].
Remove all seals, anti-extrusion rings and scraper rings

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

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

Assembling The Steering Cylinder

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

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

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

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

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

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

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

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

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

[Figure 20-60-25] for 100 mm (4.00 in) using a plastic
hammer.

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

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

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

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

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


STEERING CYLINDER (REAR) Figure 20-61-3
Removing The Steering Cylinder
Remove the rear axle. (See Removal on Page 40-90-1.) 2

1
Figure 20-61-1
2
3
S2515
Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-61-3].
1
S2513 Figure 20-61-4
Remove the two bolts (Item 1) and remove the centering

sensor (Item 2) from the steering cylinder 1
(Item 3) [Figure 20-61-1].
Figure 20-61-2
S2516
1
S2514
Remove the cotter pin (Item 1) [Figure 20-61-2].

STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-7
Removing The Steering Cylinder (Cont’d)
Figure 20-61-5 2
1
1
S2519
Remove the bolts (Item 1) from the steering cylinder

S2517 (Item 2) [Figure 20-61-7].
Figure 20-61-8
Remove the tie rod end (Item 1) [Figure 20-61-5] by
means of a puller.

Figure 20-61-6 1
2
1
S2520
Extract the cylinder (Item 1) [Figure 20-61-8] using a

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

Disconnect the left and right steering bars (Item 1) from The Steering Cylinder on Page 20-61-5.).
the piston (Item 2) [Figure 20-61-6].

Installing The Steering Cylinder
Figure 20-61-9
S2523
Apply Loctite® #242 to the thread and install the two tie
S2521 rods [Figure 20-61-11]. Tighten the tie rods to 240 - 270
N•m (177 - 199 ft-Ib) torque.
Lubricate the seats of the seals and install the steering Figure 20-61-12
cylinder (Item 1) [Figure 20-61-9] into its seat.

Figure 20-61-10
2
1
S2524
S2522 Insert the tie rods (Item 1) in the steering case

(Item 2) [Figure 20-61-12]. Tighten the nuts to 260 - 290
N•m (192 - 214 ft-Ib) torque.
Tighten the bolts (Item 1) [Figure 20-61-10] to 116 - 128
N•m (85 - 95 ft-lb) torque. Tighten the nut (Item 3) [Figure 20-61-12] until the
cotter pin hole is visible.
NOTE: Check that the rubber guards [Figure 20-61-

12] are intact.

STEERING CYLINDER (REAR) (CONT’D)
Installing The Steering Cylinder (Cont’d)
Figure 20-61-13
S2525
Insert the cotter pins (Item 1) [Figure 20-61-13] and

bend the ends.

NOTE: Use new cotter pins.
Figure 20-61-14
S2526
Install the centering sensor for checking piston centering.
Tighten the bolt (Item 1) [Figure 20-61-14] to 5 - 6 N•m

(44.3 - 53.1 in-Ib) torque.

Disassembling The Steering Cylinder
Figure 20-61-15 2
2
S1518
With the help of a drift, apply pressure to the stop ring

S1516 (Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-61-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-61-15]. Figure 20-61-18

Figure 20-61-16
2
S1519
S1517
Push the piston shaft (Item 1) out of the cylinder until the
head (Item 2) [Figure 20-61-18] can be removed.
With the help of a plastic hammer, push the head
(Item 1) inside the cylinder (Item 2) [Figure 20-61-16].
NOTE: The head should line up with the edge of the

cylinder.

STEERING CYLINDER (REAR) (CONT’D) Assembling The Steering Cylinder
Disassembling The Steering Cylinder (Cont’d) Figure 20-61-20
Figure 20-61-19
1 2 3
1
S1521
S1520
After applying grease, install the sealing ring (Item 1), the
anti-extrusion ring (Item 2) and the scraper ring
NOTE: Mark the piston (Item 1) and the end of the (Item 3) [Figure 20-61-20] inside the end of the cylinder.
cylinder housing (Item 2) [Figure 20-61-19]
for ease of assembly. NOTE: Make sure the anti-extrusion ring

(Item 2) [Figure 20-61-20] is installed as
Remove the piston (Item 1) from the cylinder (Item 2) shown.
[Figure 20-61-19].
Remove all seals, anti-extrusion rings and scraper rings

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

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


5 3 2
Figure 20-61-21
1
3 2 1 4
S1524
Prepare the piston (Item 1) by installing the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring
S1522
(Item 4) and the seal (Item 5) [Figure 20-61-23].
NOTE: Apply grease to the outer diameter of the

After applying grease, install the sealing ring (Item 1), the piston.
anti-extrusion ring (Item 2) and the scraper ring
(Item 3) [Figure 20-61-21] in the head.

NOTE: Make sure the anti-extrusion ring
(Item 2) [Figure 20-61-21] is installed as
shown.
Figure 20-61-22
S1523
Install the seal (Item 1) [Figure 20-61-22] onto the

outside of the head.
NOTE: In order to facilitate assembly, apply grease to

the outer surface of the piston.
Do not roll the seal (Item 1) [Figure 20-61-22].

Figure 20-61-24 1
T18
T18
2
1
S1527
Remove tool T18 and install it to the opposite side of the

S1525 piston shaft (Item 1) [Figure 20-61-26].
Figure 20-61-27
NOTE: Make sure the piston assembly orientation is
correct per the marks added in [Figure 20-61-
19]

1
Install tool T18 to the piston shaft (Item 2) and install it in
the cylinder (Item 1) [Figure 20-61-24]. T18
NOTE: Apply a little grease to seals and cylinder.
Figure 20-61-25
3
2
S1528
1
Apply grease to the head seals (Item 1), install the head
onto the piston shaft (Item 2) and push it onto the cylinder
(Item 3) [Figure 20-61-27].
S1526
Push the piston (Item 1) into the cylinder (Item 2)

[Figure 20-61-25] for 100 mm (4.00 in) using a plastic
hammer.

Assembling The Steering Cylinder (Cont’d) 2
Figure 20-61-28
S1531
2 Install the snap ring (Item 1) on the head (Item 2)

S1529 [Figure 20-61-30].
NOTE: Make sure that the snap ring (Item 1)

Insert the stop ring (Item 1) ensuring that it fits into the [Figure 20-61-30] is securely fastened in its
seat of the cylinder (Item 2) [Figure 20-61-28]. seat.
If necessary, force it into its seat using a drift

Figure 20-61-29 and a hammer.
S1530
Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-61-29].


DRIVE BOX
1. Gear
2. Snap ring
3. Ball bearing
4. Snap ring
5. Vent
6. Ring nut
7. Bearing
8. Ring
9. Plug
10. Seal
11. Ball bearing

12. Gear
13. Snap ring

14. Ball bearing
15. Seal
16. Plug
17. Spring washer
18. Hexagon bolt
19. Magnet plug
20. Dowel
21. Plug
22. Flange
23. O-ring
24. Screw
25. Cover
26. Shim
27. Bearing
S2500

DRIVE BOX (CONT’D) Figure 20-70-3
Disassembly 1
Remove the front axle. (See Removal on Page 40-30-1.)
Remove the drive motor. (See Removal And Installation

on Page 30-30-1.)
Figure 20-70-1
1
S2463
Take of the drive side flange cover (Item 1) [Figure 20-

70-3] by alternatively forcing a screwdriver into the
appropriate slots.
1 NOTE: Look out not to damage the surfaces.
Figure 20-70-4
S2603

Loosen the securing bolts (Item 1) [Figure 20-70-1] only
so that later when you pry the drive side flange cover
loose, it does not fall.
Figure 20-70-2 1
S2463
1 Remove the securing bolts and lift off the cover (Item 1)
[Figure 20-70-4].
S2604
Loosen the drive side flange cover (Item 1) [Figure 20-

70-2] using a plastic hammer.

Figure 20-70-5
1
S2488
Using a lever, remove the flange sealing ring (Item 1)

S2663 [Figure 20-70-7].
To remove the drive side shaft (Item 1), hook off the snap Figure 20-70-8
ring (Item 2) [Figure 20-70-5].
1
Figure 20-70-6

1
S2432
S2463 Remove the snap ring (Item 1) [Figure 20-70-8].
Using two levers, remove the drive side shaft (Item 1)

[Figure 20-70-6].

Figure 20-70-9
2
2
1
S2489
With a puller, remove the bearing (Item 1) from the flange

1
shaft (Item 2) [Figure 20-70-11].
S2433
Figure 20-70-12
With a puller, remove the bearing (Item 1) from the input
shaft (Item 2) [Figure 20-70-9].
1

Figure 20-70-10
2 S2490
Remove the secondary gear wheel (Item 1) [Figure 20-

70-12].
S2434
Remove the bearing (Item 1) and the snap ring (Item 2)

[Figure 20-70-10].

Figure 20-70-13
S2492
1
Remove the internal bearing (Item 1) [Figure 20-70-15].
S2435 Figure 20-70-16
Remove the snap ring (Item 1) [Figure 20-70-13].
Figure 20-70-14

2
S2493
1 Pull out the cup of the sealing ring (Item 1) by using drift
(Item 2) [Figure 20-70-16].
S2491
Remove the flange (Item 1) [Figure 20-70-14] by means

of a plastic hammer.

Assembly
Figure 20-70-17
S2494
T27
Install the flange (Item 1) [Figure 20-70-19] and fasten it.
S2665
For keying the flange (Item 1) [Figure 20-70-19], use a
Insert the sealing ring using tool T27 [Figure 20-70-17]. plastic hammer if necessary.
NOTE: Bring the sealing ring just to the end stop, Figure 20-70-20
apply grease to the sealing lips.

Figure 20-70-18
1
S2495
Insert the bearing (Item 1) [Figure 20-70-20].

S2436
Insert the sealing ring (Item 1) [Figure 20-70-18] with a

normal tool.
NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

Assembly (Cont’d)
Figure 20-70-21
1 S2437 / S2438
Using a normal tool insert the bearing (Item 1) [Figure

20-70-23].
S2496
Figure 20-70-24
Using a normal tool insert the bearing (Item 1) [Figure
20-70-21] and snap ring.

Figure 20-70-22
2
1
S2439 / S2440
Insert the snap ring (Item 1) and using a normal tool

S2497 insert the bearing (Item 2) [Figure 20-70-24].
Install the secondary gear wheel (Item 1) [Figure 20-70-

22] with a plastic hammer.

Assembly (Cont’d)
Figure 20-70-25
1
1
S2606
Install drive side flange cover (Item 1) [Figure 20-70-27],

apply Loctite® #510 to the short screws.
S2441
Figure 20-70-28
Secure the bearing with the snap ring (Item 1) [Figure

20-70-25].

Figure 20-70-26
S2666
Tighten the bolts to 80 - 90 N•m torque [Figure 20-70-

28].
S2498
Install the drive side shaft (Item 1) [Figure 20-70-26] with

a plastic hammer.

DRIVE BOX (CONT’D)
Special Tools
TOOL IMAGE DESCRIPTION BOBCAT PN

T27 Pinion tail seal 6912202


MAIN RELIEF VALVE Figure 20-80-3
S/N A8HD12999 & BELOW
Testing And Adjustment S/N A8GW12999 & BELOW
S/N A8GT12999 & BELOW
The following tool will be needed to do the following S/N A8GV12999 & BELOW
procedure: S/N A8GJ12999 & BELOW
MEL10003-Hydraulic Tester
Figure 20-80-1
3
4

1 P-44328 2 1
Connect the inlet hose (Item 1) from the tester (Item 5) to S3507
the front coupler (Item 2) [Figure 20-80-1].
Connect the outlet hose (Item 3) from the tester (Item 5) Start the engine, lower the restraint bar (if equipped) and
to the rear coupler (Item 4) [Figure 20-80-1]. run at low idle RPM. Push the detent rocker switch (Item
1) and front auxiliary rocker switch (Item 2) [Figure 20-
80-2] and [Figure 20-80-3]. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
IMPORTANT the hoses are connected wrong. with the hoses
connected correctly, increase the engine speed to 2200
RPM.
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284 Warm the fluid to 60°C (140°F) by turning the restrictor
control (Item 5) [Figure 20-80-1] on the tester to about
6,9 MPa (69 bar) (1000 psi). DO NOT exceed system
Figure 20-80-2 relief pressure. Open the restrictor control knob and
S/N A8HD13000 & ABOVE record the free flow (U.S. gpm) at 2200 RPM.
S/N A8GW13000 & ABOVE
S/N A8GT13000 & ABOVE There should be 55 L/min (13 U.S. gpm) free flow. Turn
S/N A8GV13000 & ABOVE the restrictor control (Item 5) [Figure 20-80-1] on the
S/N A8GJ13000 & ABOVE
tester until the main relief opens. The correct pressure
should be 26,5 MPa (265 bar) (3844 psi).
If adjustment is needed, (See [Figure 20-80-4].)
2 1
P-97008

MAIN RELIEF VALVE (CONT’D) Removal And Installation
Testing And Adjustment (Cont’d)
Remove the rear cover.

IMPORTANT
Figure 20-80-4
damage the system.
1 I-2003-0888
Remove the rear cover.
Figure 20-80-6
1
P-50980

Locate the main relief valve (Item 1) on the front right
side of the control valve [Figure 20-80-4].
Figure 20-80-5
P-50980
1
Locate the main relief valve (Item 1) [Figure 20-80-6] on

the front right side of the control valve.
2
Clean the area around the control valve.
Remove the main relief valve (Item 1) [Figure 20-80-6].
Installation: Tighten the main relief valve to 45 N•m

P-44331 (33 ft-lb) torque.
Loosen the lock nut (Item 1) and turn the adjustment

screw (Item 2) [Figure 20-80-5] clockwise to increase the
pressure or counterclockwise to decrease the pressure.
NOTE: A 90° turn = 1 MPa (10 bar) (150 psi).
Retest the main relief valve after adjustment.

QUICK-TACH CYLINDER Figure 20-90-3
Figure 20-90-1
S3645
Remove the end bushing (Item 1) [Figure 20-90-3] (Both

sides).
S3643
Figure 20-90-4
the cylinder.

IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly S3646
damage the system.
I-2003-0888
Remove the roll pin (Item 1) [Figure 20-90-4] (Both
sides).
Figure 20-90-2
S3644
Remove the bolt (Item 1) [Figure 20-90-2] from each

side of the cylinder.

QUICK-TACH CYLINDER (CONT'D)
Removal And Installation (Cont'd)
Figure 20-90-5
2 1
S3647
Remove the washer (Item 1) and spring (Item 2)

[Figure 20-90-5] from the cylinder rod extension (Both
sides).

Figure 20-90-6
S3648
Remove the roll pin (Item 1) and remove the extension

rod (Item 2) [Figure 20-90-6] from the cylinder rod (Both
sides).
Remove the cylinder.

QUICK-TACH CYLINDER (CONT'D)
1. Housing
2. Extension
3. Wiper
4. Seal
5. O-ring
6. Head Gland
7. Rod
8. Piston
9. Wear Ring
S4890

QUICK-TACH CYLINDER (CONT'D) Figure 20-90-9
Disassembly
Use the following tool to disassemble the cylinder:
Figure 20-90-7
P-32173
Use the cylinder wrench to loosen the head gland

[Figure 20-90-9].
Figure 20-90-10
P-32169

Place the cylinder in a vise [Figure 20-90-7].
Figure 20-90-8
1
P-32172
1
from the housing.
P-32170
Remove the two fittings (Item 1) [Figure 20-90-8].

1
Figure 20-90-11
P-32175
1

each rod.
P-32173
Figure 20-90-14
Use the cylinder wrench to loosen the second head gland
(Item 1) [Figure 20-90-11] on the opposite side.
Figure 20-90-12

1
1
P-32176
Remove the O-rings (Item 1) [Figure 20-90-14] from

each head gland.
P-32174

from the housing.

Figure 20-90-15
1
P-32179
2
Remove the O-ring (Item 1) [Figure 20-90-17] from each
piston.
P-32177
Remove the wiper seal (Item 1) and seal (Item 2)

[Figure 20-90-15] from each head gland.
Figure 20-90-16

2 1
P-32178
Remove the wear ring (Item 1) and seal (Item 2)

[Figure 20-90-16] from each piston.

Assembly
1

compressed air.
Inspect the cylinder parts for nicks, scratches or other 2

Lubricate all O-rings and seals with hydraulic fluid during P-32177
installation.
Install the wiper (Item 1) and seal (Item 2) [Figure 20-90-
Always use new O-rings and seals.
20] in each head gland.
Figure 20-90-18
Figure 20-90-21

1
P-32179 1
Install a new O-ring (Item 1) [Figure 20-90-18] on each

piston. P-32176
Figure 20-90-19
Install the two O-rings (Item 1) [Figure 20-90-21] on
each head gland.
2 1
P-32178
Install a new wear ring (Item 1) and seal (Item 2)

[Figure 20-90-19] on each piston.

Assembly (Cont'd)
Figure 20-90-22
P-32180
Use the cylinder wrench to tighten both head glands

[Figure 20-90-24].
P-32175
Figure 20-90-25
Install each head gland (Item 1) [Figure 20-90-22] onto
the rod.
Figure 20-90-23

1
1
1
P-32170
Install the two fittings (Item 1) [Figure 20-90-25].

P-32174
Install each rod assembly (Item 1) [Figure 20-90-23] into

the housing.

FRAME LEVELING CYLINDER Figure 20-100-2
Figure 20-100-1
1 1
P-40479
Remove the two hoses (Item 1) [Figure 20-100-2].

S2050
Install caps and plugs.
Install jack stands under the frame to prevent the frame Figure 20-100-3
from tilting during cylinder removal [Figure 20-100-1].

Relieve hydraulic pressure.
WARNING 1

immediately.
W-2145-0290 S2049
Remove the snap ring (Item 1) and washer (Item 2)

[Figure 20-100-3].
IMPORTANT
damage the system.
I-2003-0888

FRAME LEVELING CYLINDER (CONT’D)
Figure 20-100-4
S2034
Remove the pivot pin (Item 1) [Figure 20-100-4].

Figure 20-100-5
1 1
P-40483
Remove the four mounting bolts (Item 1) [Figure 20-100-

5].
Remove the frame leveling cylinder.

1. Relief Cartridge
2. Housing
3. Wear Ring
4. Seal
5. Set Screw
6. Piston
7. O-ring
8. Sleeve
9. Head Gland
10. Wiper
11. Bushing
12. Rod
13. Grease Fitting

4
5
1
3
6
7
1 8
7
4
10
13
7
9
3
11
12
B-19814

FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-8
Disassembly
2
1
MEL1353 - Cylinder Gland Nut Wrench
Figure 20-100-6
2
P-40486
1 Remove the two relief cartridges (Item 1) and two fittings

1 (Item 2) [Figure 20-100-8].
Figure 20-100-9
P-40484

Remove the mounting blocks (Item 1) [Figure 20-100-6].
Figure 20-100-7
P-40487
P-40485
Remove the bushing (Item 1) [Figure 20-100-7] from

both mounting blocks.

Figure 20-100-10 1
P-40492

P-29868 from the housing.
Figure 20-100-13
Carefully peen the lock ring from the head gland
[Figure 20-100-10].

Figure 20-100-11
P-40493

P-40489 13].
Remove the head gland using a wrench [Figure 20-100-

11].

Figure 20-100-14
1
P-29879
Remove the expander O-ring (Item 1) [Figure 20-100-

P-40494 16].
Figure 20-100-17
Remove the set screw (Item 1) [Figure 20-100-14] from
the piston.

from the rod.
Figure 20-100-15
1
1
1 P-29880

piston.
2
P-29877

[Figure 20-100-15] from the piston.

Figure 20-100-18 1
P-40497
Remove the head gland (Item 1) [Figure 20-100-20]

P-40496 from the rod.
Figure 20-100-21
Remove the sleeve (Item 1) [Figure 20-100-18] from the
rod.

Figure 20-100-19
1 2
P-29883
Remove the center seal (Item 1) and outer wear ring

P-40501 (Item 2) [Figure 20-100-21] from the head gland.

sleeve.

Figure 20-100-22
1
P-40509
Remove the bushing (Item 1) [Figure 20-100-24] from

P-29884 the rod end.
Remove the outer wear ring (Item 1) and wiper seal (Item
2) [Figure 20-100-22]

Figure 20-100-23
P-29882
Remove the rod from the vise.

Assembly
1
Use the following tools to assemble the cylinder:
MEL1353 - Cylinder Gland Nut Wrench

compressed air.
2
Always use new O-rings and seals. Lubricate all O-rings

and seals with hydraulic fluid during installation. P-29884
Figure 20-100-25
Install the wiper seal (Item 1) and wear ring (Item 2)
[Figure 20-100-27].
1
Figure 20-100-28

1
P-40509
Install the bushing (Item 1) [Figure 20-100-25] in the rod

end. P-29883
Figure 20-100-26
P-29882

the head gland.

Assembly (Cont’d)
Figure 20-100-29
1
P-40501
Install the O-ring (Item 1) [Figure 20-100-31] in the

P-29885 sleeve.
Figure 20-100-32

1
Figure 20-100-30
P-40496
Install the sleeve (Item 1) [Figure 20-100-32] on the rod.
P-40497
Put the rod end in a vise. Use care not to damage the
rod.
Install the head gland (Item 1) [Figure 20-100-30] onto

the rod.

Assembly (Cont’d)
Figure 20-100-33
1 1
1 2
P-29877

P-29880 [Figure 20-100-35].
Figure 20-100-36
piston.

Figure 20-100-34
P-40508
1
Clean the threads and apply Loctite® #242 or equivalent
P-29879 to the threads on the rod [Figure 20-100-36].
Install the expander O-ring (Item 1) [Figure 20-100-34]

onto the piston.

Assembly (Cont’d)
Figure 20-100-37
P-29887

P-40493 1) [Figure 20-100-39].
Figure 20-100-40
Install the piston (Item 1) [Figure 20-100-37] on the rod.

Figure 20-100-38
1
P-40494
P-29888 Install the set screw (Item 1) [Figure 20-100-40] into the
piston and tighten.
Align the hole (Item 1) [Figure 20-100-38] in the piston

with the hole in the end of the cylinder rod.

Assembly (Cont’d)
Figure 20-100-41
P-40491
Carefully peen the lock ring over and into the nut (Item 1)
P-40492 [Figure 20-100-43].
Remove the cylinder from the vise.

Put the housing in a vise. Use care not to damage the
housing. Figure 20-100-44

the housing. 2
Figure 20-100-42 1
2
P-40486
Install the two relief valve cartridges (Item 1) and two

fittings (Item 2) [Figure 20-100-44].
P-40490
Tighten the head gland using a wrench [Figure 20-100-

42].

Assembly (Cont’d)
Figure 20-100-45
P-40485
Install the bushing (Item 1) [Figure 20-100-45] on both

mounting blocks.

Figure 20-100-46
P-40484
Install the two mounting blocks (Item 1) [Figure 20-100-

46].

STEERING MODE VALVE BLOCK Figure 20-110-2

1
WARNING 2

and possible death if proper medical treatment by a 1
immediately.
W-2145-0290
P-50932
Figure 20-110-1
2].
NOTE: Mark the location of the valve on the block.

1
Remove the valve (Item 2) [Figure 20-110-2] from the

block.
IMPORTANT
1 When repairing hydrostatic and hydraulic systems,
P-50931 clean the work area before disassembly and keep all
Relieve hydraulic pressure. damage the system.
I-2003-0888
Remove the retainer screw (Item 1) [Figure 20-110-1]
from the two solenoids.
Remove the wire connectors from the two solenoids.
NOTE: Mark the location of the wire connectors for

correct installation.

STEERING MODE VALVE BLOCK (CONT’D)
Figure 20-110-3
1
1
P-50934
Remove the four hoses (Item 1) [Figure 20-110-3].

NOTE: Mark the location of the hoses.
Figure 20-110-4
P-50936

4] and remove the block.

STEERING MODE VALVE BLOCK (CONT’D)
1
1. Nut
2. O-Ring
3. Solenoid
4. Shaft 2
5. Pin
6. Spring
7. Retainer 3
8. Spool
9. Housing
10. Bolt 4
11. Washer 2
12. Elbow 5
13. Adapter
14. Housing 6
7

10
11
8
9
3
2
2
1
12 13
*
* 10
* * 12
14
13
* Supplied with fitting. S4891

STEERING MODE VALVE BLOCK (CONT'D)
Disassembly
IMPORTANT
Mark the location of the solenoids to the housing for
correct assembly. When repairing hydrostatic and hydraulic systems,
Figure 20-110-5 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1
Figure 20-110-7
1 1
P-42291

Remove the four O-rings (Item 1) [Figure 20-110-5] from
the housing.
P-42294
Figure 20-110-6
Remove the solenoids (Item 1) [Figure 20-110-7] from

the solenoid shafts.
Figure 20-110-8
1
1 1
P-42292
Remove the nut (Item 1) [Figure 20-110-6] from each

solenoid.
P-42295
NOTE: Mark the location of the solenoids.
Remove the O-ring (Item 1) [Figure 20-110-8] from both

shafts.

STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-11
Figure 20-110-9
1 1
P-42299
Remove the O-ring (Item 1) [Figure 20-110-11] from

P-42296 each shaft.
Figure 20-110-12
Loosen the shafts (Item 1) [Figure 20-110-9].

Figure 20-110-10
5
1
4
2
1
3
P-42300
P-42297 Carefully remove the spool (Item 1) [Figure 20-110-12]

from the housing.
Remove the shaft (Item 1), pin (Item 2), spring (Item 3)
and spring retainer (Item 4) from the housing (Item 5)
[Figure 20-110-10] (Both Sides).

Solenoid Testing
Figure 20-110-13
P-42299
Install a new O-ring (Item 1) [Figure 20-110-15] on each

P-42301 shaft.
Figure 20-110-16
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-13], there

must be continuity. If there is no continuity, replace the
solenoid. 5
2
Assembly
Clean all components with solvent and dry with

compressed air.
Check all components for wear or damage. Replace any 1

3
worn or damaged components.
4
Always use new O-rings.
P-42297
Lightly oil all parts.
Figure 20-110-14 Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) and shaft (Item 4) in the housing (Item 5)
[Figure 20-110-16] (Both Sides).
P-42300
Carefully install the spool (Item 1) [Figure 20-110-14].

Assembly (Cont'd)
Figure 20-110-17
1 1
P-42293
Install the O-ring (Item 1) [Figure 20-110-19] on the two

P-42296 solenoids.
Figure 20-110-20
Tighten each shaft (Item 1) [Figure 20-110-17].

Figure 20-110-18 1
2
1 1
P-42294
P-42295 Install the solenoids (Item 1) on the shafts (Item 2)

[Figure 20-110-20].
Install an O-ring (Item 1) [Figure 20-110-18] on each

shaft.

STEERING MODE VALVE BLOCK (CONT'D)
Assembly (Cont'd)
Figure 20-110-21
1 1
P-42292
Install the nuts (Item 1) [Figure 20-110-21] on each shaft

and hand tighten.

NOTE: Do not overtighten the nuts.
Figure 20-110-22
P-42291
Install the four O-rings (Item 1) [Figure 20-110-22] on

the housing.

BRAKE VALVE Figure 20-120-3
Figure 20-120-1
1 P-25249
Remove the accelerator cable (Item 1) from the pedal

P-52341 and mounting bracket (Item 2) [Figure 20-120-3].
Figure 20-120-4
Remove the dash cover / column cover. (See Removal
And Installation on Page 50-140-1.)

Disconnect the connector (Item 1) [Figure 20-120-1]
from the brake light switch.
Figure 20-120-2
P-25638
Remove the three hoses (Item 1) [Figure 20-120-4] from

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

P-42865

from the inching switch. IMPORTANT
damage the system.
I-2003-0888

BRAKE VALVE (CONT’D) Figure 20-120-7
Figure 20-120-5
1 1
1
P-42870
Remove the roll pin (Item 1) and pedal (Item 2)

1 P-25637 [Figure 20-120-7].
Figure 20-120-8
Remove the mounting bolts (Item 1) [Figure 20-120-5].

Remove the pedal assembly.
Disassembly And Assembly 2
Figure 20-120-6
1
1 2
P-42871
Assembly: Align the hole (Item 1) in the pedal with the

hole (Item 2) [Figure 20-120-8] in the shaft.
P-42869
Remove the bolt (Item 1) and spring (Item 2) [Figure 20-

120-6].

Disassembly And Assembly (Cont’d)
Figure 20-120-9
P-42875
Remove the shaft and bearing assembly [Figure 20-120-

P-42872 11].
Figure 20-120-12
Loosen the two set screws (Item 1) [Figure 20-120-9] on
the two bearings. 1

Figure 20-120-10
1 2
2
1 P-42876
1
Remove the flanges (Item 1) and bearings (Item 2)
P-42874 [Figure 20-120-12].
Remove the three bolts (Item 1) [Figure 20-120-10] from

both bearing flanges.

Figure 20-120-13
P-42879
Remove the brake valve (Item 1) [Figure 20-120-15]

P-42878
Remove the three fittings (Item 1) [Figure 20-120-13]

from the brake valve.

Figure 20-120-14
2
P-42877
Remove the four bolts (Item 1), spacers (Item 2)

[Figure 20-120-14] and nuts from the brake valve.

GEAR PUMP Figure 20-130-2
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Stop the engine.
Relieve the hydraulic pressure. Drain the hydraulic 1

reservoir. (See Removing And Replacing Hydraulic Fluid 2
on Page 10-100-2.)
WARNING P-56477
Hydraulic fluid escaping under pressure can have Remove the four bolts (Item 1) and remove the hose
sufficient force to enter a person’s body by (Item 2) [Figure 20-130-2] from the hydrostatic pump.
and possible death if proper medical treatment by a Figure 20-130-3
immediately.

W-2145-0290
IMPORTANT
damage the system.
I-2003-0888
P-56478
Figure 20-130-1
Remove the hose (Item 1) [Figure 20-130-3] from the
backside of the gear pump.
1
1
1
P-56463

the backside of the pump.

GEAR PUMP (CONT'D) Figure 20-130-6
Figure 20-130-4
1 P-56470
Loosen the hose clamp (Item 1) and remove the hose

P-56464 (Item 2) [Figure 20-130-6].
Figure 20-130-7
Remove the hose (Item 1) [Figure 20-130-4].

Figure 20-130-5
1
1 1
P-56482
P-56468 Install a chain hoist and lifting strap to lift and support the
gear pump [Figure 20-130-7].
Loosen the hose clamp (Item 1) [Figure 20-130-5] and Remove the two mounting bolts (Item 1) [Figure 20-130-
remove the hose. 7] from the gear pump.
Installation: Tighten the mounting bolts to 50 - 80 N•m

(52 - 59 ft-lb) torque.

GEAR PUMP (CONT'D)
Figure 20-130-8
P-56483
Remove the gear pump [Figure 20-130-8].

NOTE: It can be necessary to reposition any hose or
wires.

GEAR PUMP (CONT’D)
1. Fitting
2. O-ring 1
3. Spring
4. Spring Seat 2
5. Spool 3
6. Screen 8
4
7. Orifice Spool
8. Bolt 5
9. Housing 6
10. Plug 7
11. Bolt 14
12. Washer
13. Cover 9 16
14. Seal Ring 17
15. Housing
16. Back-up Ring 18
19
17. Seal Ring

18. Holder 2 18
10
19. Gear 17
20. Drive Shaft 16
21. Mount Plate
22. Thrust Plate 13
15
23. Mount Plate
24. Seal 14
25. Snap ring 14
12
11
15
14
21 19
22
17
16
20
25 2
24
23
8 17
16
22
S4892

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
P-56449
Figure 20-130-9
Remove the flow divider from the housing [Figure 20-

1 130-11].
Figure 20-130-12
1
6

1
5 4 3 2
1
1
P-56447
Mark the pump housing for correct assembly and remove

the fittings (Item 1) [Figure 20-130-9].
P-25293
Figure 20-130-10
Remove the fitting (Item 1), O-ring (Item 2), spring (Item
1 1 3), spring seat (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-130-12].
NOTE: Always use new O-rings.
1 1
P-56448
Remove the four bolts (Item 1) [Figure 20-130-10].
Assembly: Tighten the bolts to 33 N•m (25 ft-lb) torque.

Disassembly And Assembly (Cont'd)
Figure 20-130-13
2
1
P-25296
To remove the orifice assembly (Item 1) [Figure 20-130-

P-25294 15] from the spool, make a holding fixture from a 19 mm
thick x 38 mm wide x 50 mm (0.750 in thick x 1.500 in
wide x 2.0 in long) long piece of hardwood. Drill a 14 mm
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- (0.550 in) hole in the center of the hardwood block. Cut
130-13] from the housing. the block lengthwise [Figure 20-130-14].

Figure 20-130-14 Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-130-15].
Cut
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.
Figure 20-130-16
14 mm
(0.550”) dia. 50 mm (2.0”)
1 2
38 mm (1.500”)
B-14674
P-25295
Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-130-16] and clean.

Figure 20-130-17 1
2 1 3
1
2
1 1
P-56451
Remove the housing (Item 1) from the gear assembly

P-56450 (Item 2) [Figure 20-130-19].
Assembly: The position of the small opening (Item 3) on

Remove the four bolts (Item 1) and cover (Item 2) the gear holders will point toward the large port (Item 4)
[Figure 20-130-17]. [Figure 20-130-19] on the housing.

Figure 20-130-18 Figure 20-130-20
1
1
P-56454 P-56452
Remove the housing / gear assembly (Item 1) Remove both O-rings (Item 1) [Figure 20-130-20] from
[Figure 20-130-18] from the main housing. the housing.

Figure 20-130-21 1 1
1 1
2
P-25304
1
Remove the four bolts (Item 1) and drive shaft (Item 2)

P-56453 [Figure 20-130-23].
Assembly: Tighten the bolts to 33 N•m (25 ft-lb) torque.

Remove the back-up ring (Item 1) and seal ring (Item 2)
[Figure 20-130-21] from the gear holder. Figure 20-130-24

Assembly: The seal ring (Item 2) [Figure 20-130-21] is
installed onto the gear holder first followed by the back-
up ring.
Figure 20-130-22
P-25305
Turn the housing over and remove the mount plate

[Figure 20-130-24].
P-25322
Remove and discard the O-ring (Item 1) [Figure 20-130-

22] from the flange.


2
Figure 20-130-25
1
1
3
4
P-25310
Remove the O-ring (Item 1) and gear assembly (Item 2)

P-25306 [Figure 20-130-27] from the housing.
Assembly: The position of the V portion (Item 3) on the

Remove the snap ring (Item 1) [Figure 20-130-25]. thrust plate must point toward the larger port (Item 4)
[Figure 20-130-27] on the housing.

Figure 20-130-26
Figure 20-130-28
1 2 2
3 1 3
1
P-25307
P-25313
Remove the shaft seal (Item 1) [Figure 20-130-26].

Remove the two thrust plates (Item 1), seal ring (Item 2)
and back-up ring (Item 3) [Figure 20-130-28] from the
gears.
Assembly: The seal ring (Item 2) will be installed on the

thrust plate (Item 1) first followed by the back-up ring
(Item 3) [Figure 20-130-28].


FAN MOTOR Figure 20-140-2
Removal And Installation 4 4
IMPORTANT 5

damage the system.
I-2003-0888
2 1
S6837
Drain the radiator. (See Removing And Replacing The
Coolant on Page 10-70-1.)
Remove the mounting bolt (Item 1) and nut (Item 2).
Figure 20-140-1 Remove the radiator support (Item 3) [Figure 20-140-2].
Loosen the two hose clamps (Item 4) and remove the

1 intercooler hose (Item 5) [Figure 20-140-2].
2

1 Figure 20-140-3
2
S6834
Loosen the two hose clamps (Item 1) and remove the

radiator hose (Item 2) [Figure 20-140-1].
S6835
Mark the location of the hood latch (Item 1). Remove the
two mounting bolts (Item 2) [Figure 20-140-3]. Remove
the hood latch.

FAN MOTOR (CONT’D) Figure 20-140-6
Figure 20-140-4 2
1
P-53264
Loosen the screw (Item 1) and disconnect the connector

S6836 (Item 2) [Figure 20-140-6].
Figure 20-140-7
Remove the top hose (Item 1) [Figure 20-140-4] from the
fan motor. 1

Figure 20-140-5
1 S6845
Remove the two bolts (Item 1) [Figure 20-140-7] (both

S6848 sides) from the fan guard.
Tilt the cooler forward and carefully remove the fan

Remove the three hoses (Item 1) [Figure 20-140-5] from assembly.
the bottom of the fan motor.

Figure 20-140-8 2
1 2
1
1
1
1 P-53270
Remove the four fan guard mount bolts (Item 1) and

P-53269 remove the fan guard (Item 2) [Figure 20-140-10].
Figure 20-140-11
Remove the four bolts (Item 1) and remove the blade
assembly (Item 2) [Figure 20-140-8] from the fan motor.

NOTE: Mark the direction of the fan for correct
assembly.
1
Figure 20-140-9
1 P-53272
Remove the nut and lock washer (Item 1) [Figure 20-

140-11].
P-53271
Mark the location of the fan motor to the fan guard for
correct assembly (Item 1) [Figure 20-140-9].

FAN MOTOR (CONT’D)
Figure 20-140-12
P-53273
Remove the fan blade mounting flange (Item 1) [Figure

20-140-12] from the fan motor.

FAN MOTOR (CONT’D)

3
1. Seal
2. Check valve
3. Housing
4. Gear assembly
S2754

IMPORTANT
parts clean. Always use caps and plugs on hoses, 4
3
damage the system. 2
I-2003-0888
1
P-53276
Figure 20-140-13
Remove the plug (Item 1), spring (Item 2) and check

2 1 valve (Item 3) from the housing (Item 4) [Figure 20-140-
15].
Figure 20-140-16

P-53274
1
Remove the nut (Item 1) and solenoid (Item 2) [Figure
20-140-13].
Mark the housing for correct assembly. P-53277
Figure 20-140-14
plug. Replace as needed.
2
1
P-53275
Remove the solenoid stem (Item 1) and three fittings

(Item 2) [Figure 20-140-14].

Figure 20-140-17
1
1
1 1 P-53281
Remove the quad ring (Item 1) [Figure 20-140-19] from

P-53278 the housing.
Figure 20-140-20
Remove the four bolts (Item 1) [Figure 20-140-17] from
the end. 2

Assembly: Tighten bolts to 43 - 47 N•m (32 - 35 ft-lb) 1
torque.
Figure 20-140-18
P-53282
Remove the gear assembly (Item 1) from the housing

(Item 2) [Figure 20-140-20].
P-53279
Remove the end cover (Item 1) from the main housing

(Item 2) [Figure 20-140-18].

Figure 20-140-21
P-53285
1
Inspect the gears (Item 1) [Figure 20-140-23] for
P-53283 damage or wear.
Remove the back-up ring / seal (Item 1) [Figure 20-140-

21] from the gear holder.

Figure 20-140-22
P-53256
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-140-22].
Assembly: The open part of the seal goes into the

housing first.

HYDRAULIC FLUID RESERVOIR Figure 20-150-3
Removal And Installation 2
Remove the engine / hydrostat assembly. (See Removal

Figure 20-150-1
1 S6856

tubeline.
Remove the mounting bolt (Item 2) [Figure 20-150-3].

P-56462
Figure 20-150-4

Remove the two bolts (Item 1) [Figure 20-150-1]. 1
Figure 20-150-2
1
2
S6857
Loosen the nut (Item 1) [Figure 20-150-4] on the

S6855 tubeline.
Remove the tubeline.

Remove the bolt (Item 1) and shield (Item 2) [Figure 20-
150-2]. Remove the two hoses (Item 2) [Figure 20-150-4] from
the filter.

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-150-6
Figure 20-150-5
P-55220
Figure 20-150-7
P-55217

tank.

1
S6858
Remove the two tank mounting bolts (Item 1) [Figure 20-

150-6] and [Figure 20-150-7].
Remove the hydraulic reservoir.

STEERING VALVE
Removal And Installation Figure 20-160-2
S/N A8HD12999 & Below, S/N A8GW12999 & Below,

S/N A8GT12999 & BELOW, S/N A8GV12999 & Below, 1
S/N A8GJ12999 & Below: 1
S/N A8HD13000 & Above, S/N A8GW13000 & Above,

S/N A8GT13000 & Above, S/N A8GV13000 & Above, 1
S/N A8GJ13000 & Above:
1
P-27156
Figure 20-160-1
Remove the four bolts (Item 1) [Figure 20-160-2] and
remove the steering valve.
1

1
P-42863
Remove the five hoses (Item 1) [Figure 20-160-1] from

the steering valve.
NOTE: Mark hoses for correct installation.
IMPORTANT
damage the system.
I-2003-0888

STEERING VALVE (CONT'D)
1. Bolt 13. Drive Pin

2. End Cap 14. Pin
3. Spacer 15. Check Ball (.250”)
4. O-ring 16. Spring
5. Wear Ring 17. Pin
6. Gerotor assembly 18. Check Ball (.187”)
7. Drive Shaft 19. O-ring
8. O-ring 20. Housing
1
2 9. Spacer Plate 21. Thrust Washer
10. Spool 22. Thrust Bearing
3 11. Sleeve 23. Seal
12. Springs 24. Gland Bushing
4 25. Seal
5
7
8

13
14
15
10
19
11 20
21
22
21
23
24
25
26
16 27
17 12
18
S4721

STEERING VALVE (CONT'D) Figure 20-160-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888
S0200
Remove the hydraulic fittings from the steering valve.

Remove the gerotor assembly (Item 1) [Figure 20-160-5]
Figure 20-160-3
and the O-ring beneath.
Figure 20-160-6

1
S4962
Remove the seven end cap bolts [Figure 20-160-3]. S0202
Figure 20-160-4
Remove the spacer plate (Item 1) [Figure 20-160-6].
1 2
S0198
Remove the O-ring (Item 1), spacer (Item 2) and wear

ring (Item 3) [Figure 20-160-4].

1
Figure 20-160-7
1 2
S4728
Tip the housing onto the port face and remove the spool
S0203
and sleeve assembly (Item 1) [Figure 20-160-9].
NOTE: Do not bind spool and sleeve in housing.

Remove the O-ring (Item 1) [Figure 20-160-7]. Rotate spool and sleeve assembly slowly
when removing it from housing.
Remove the drive shaft (Item 2) [Figure 20-160-7], while

holding the steering valve upright. Figure 20-160-10
Figure 20-160-8
4
3
1
4
2
1 2
S4726
S4722
Remove the two bearing washers (Item 1) and thrust
bearing (Item 2) [Figure 20-160-10].
Carefully remove the two springs (Item 1), two pins (Item
2), pin (Item 3) and balls (Item 4) [Figure 20-160-8] from
each port.

Figure 20-160-11 1
2 1
S4731
1
The housing valves (Item 1) [Figure 20-160-13] are
factory adjusted and are not to be changed. The housing
S5361
with specified valve pressure settings, the mating spool
and sleeve are not practical replacement parts.
Remove the pin (Item 1), then remove the six springs
(Item 2) by partially sliding out the spool. [Figure 20-160- Figure 20-160-14
11].

Figure 20-160-12
S4731
2
Remove the seals (Items 1 and 2) [Figure 20-160-14]
S5360
from the gland bushing.
Remove the control spool (Item 1) from the sleeve NOTE: Gland bushing removal requires a special 4-
(Item 2) [Figure 20-160-12]. pin tool. Do not attempt to remove without
this tool as damage to the bushing could
occur.
It is not required to remove the bushing for
seal replacement.

STEERING VALVE (CONT'D) Assembly
Inspection Figure 20-160-17
Figure 20-160-15
2
S4738
2
S4738
Assemble the spool (Item 1) and sleeve (Item 2)
[Figure 20-160-17] carefully so that spring slots line up
Inspect the spool (Item 1) and sleeve (Item 2) [Figure 20- at the same end. Rotate the spool while sliding parts
160-15] for any damage or wear. Replace as needed. together.

Figure 20-160-16 NOTE: Test for free rotation. The spool should rotate
smoothly in the sleeve with fingertip force
applied at splined end.
Figure 20-160-18
S4737
1
Inspect the drive shaft (Item 1) [Figure 20-160-16] for

any damage or wear. Replace as needed.
S5360
Install the six springs (Item 1) [Figure 20-160-18] onto

the spool and sleeve.
Center spring set in spring slots. Seat springs down
evenly and flush with upper surface of spool and sleeve.
NOTE: There are six springs and should be

positioned three per side and back to back.

Assembly (Cont’d)
Figure 20-160-19
S4731
1 Install the seal (Item 1) [Figure 20-160-21] in the gland

bushing, with smooth side of the seal facing toward
S5361
bushing.
Insert pin (Item 1) [Figure 20-160-19] through the spool Figure 20-160-22
and sleeve assembly until the pin is flush at both sides of
the sleeve.

Figure 20-160-20
1
3
S4731
Install the seal (Item 1) [Figure 20-160-22] in the gland

2 bushing.
S4726
Install the big diameter bearing washer (Item 1)

[Figure 20-160-20] with the chamfered side toward the
sleeve.
Install the thrust bearing (Item 2) [Figure 20-160-20].
Install the small diameter bearing washer (Item 3)

[Figure 20-160-20] with the chamfered side facing the
outside of the bearing assembly.

STEERING VALVE (CONT'D) Assembly (Cont’d)
Assembly (Cont’d) Figure 20-160-25
Figure 20-160-23
5
4 6
1
3
S4728
Insert the spool and sleeve assembly (Item 1)

[Figure 20-160-23] so that the splined end of the spool
enters the 14 hole end of the housing first. Mind the

correct position of the bearing and washers inside the S4732
housing.
NOTE: To prevent the cross pin from dropping into Install the two 4,74 mm (0.187 in) balls (Item 1), 6,35 mm
the discharge groove of the housing, do not (0.250) ball (Item 2), pin (Item 3), two pins (Item 4) and
pull the spool assembly beyond this point. springs (Item 5) [Figure 20-160-25] in the holes as
With the spool assembly in this flush position, shown.
check for free rotation within housing by
turning assembly with fingertip force at the Install the spacer plate (Item 6) [Figure 20-160-25]. Align
splined end. the bolt holes in the spacer plate with tapped holes in the
housing.
Figure 20-160-24
Figure 20-160-26
2
1
S4742
S4733
Install the O-ring (Item 1) [Figure 20-160-24] into the

Rotate the spool and sleeve assembly until the pin (Item
housing.
1) is parallel with the port face (Item 2) [Figure 20-160-
26].
Install the drive (Item 3) [Figure 20-160-26] making sure
the drive is engaged with the pin.
Mark the drive according to the parallel line.

Assembly (Cont’d)
Figure 20-160-27 1
2 3
1 S0198
Install the O-ring (Item 1), spacer (Item 2) and wear ring
S4734 (Item 3) [Figure 20-160-29].
Figure 20-160-30
gerotor (on the spacer plate side).

Figure 20-160-28
S4962
2 Install the seven end cap bolts [Figure 20-160-30].
Pretighten to 17 N•m (12.5 ft-lb), then tighten screws to

26 - 30 N•m (19.2 - 22.1 ft-lb) torque.
S4735
Align the star valleys (Items 1) (Reference A) to the

marked drive (Item 2) (Reference B) [Figure 20-160-28].
This way the valleys are aligned with the pin.
NOTE: Keep in mind the parallel relationship of

reference lines A, B, C, and D in [Figure 20-
160-28].


HYDRAULIC CONTROL VALVE
Troubleshooting Chart (Controllers)

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.
W-2004-1285
PROBLEM CAUSE CORRECTION

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

in one direction valve in the controller
Controller creeps Neutral position incorrect Adjust neutral adjustment
Oil leakage between control valve Faulty seals Replace seal
and controller
Oil leakage between controllers Faulty controller couplers Replace controller couplers

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-2
S/N A8HD13000 & ABOVE
Telescoping Valve Section Troubleshooting
S/N A8GT13000 & ABOVE
Record the serial number of the machine, control valve S/N A8GV13000 & ABOVE
and control module. S/N A8GJ13000 & ABOVE
The following procedure must be done with the control

valve in the machine. The control valve is removed for
photo clarity. 1
With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure.
Remove the rear cover from machine. P-97008
Figure 20-170-1
The hydraulic control function switch (Item 1) [Figure 20-
170-1] and [Figure 20-170-2] must be ON (light is on) for
all testing procedures.
1 Figure 20-170-3

1
P-50943
1. Locate the telescoping valve section (Item 1)

[Figure 20-170-3] on the control valve.
S/N A8GW12999 & BELOW
S/N A8GV12999 & BELOW
S/N A8GJ12999 & BELOW P-50797

HYDRAULIC CONTROL VALVE (CONT’D) (Item 1) [Figure 20-170-4] (pin 3, brown wire) is 0.9
volt. If the voltage drops below 0.9 volt the controller
Telescoping Valve Section Troubleshooting (Cont’d) will interpret this as a failure.
Figure 20-170-4 5. With the telescopic function switch (Item 1)

[Figure 20-170-5] in the neutral (middle) position
1 check that the voltage on the controller connector
(Item 1) [Figure 20-170-4] (pin 3, brown wire) is 2.5
volt.
6. With the telescopic function switch (Item 1)

[Figure 20-170-5] in the maximum (forward) position
check that the voltage on the controller connector
(Item 1) [Figure 20-170-4] (pin 3, brown wire) is 4.1
volt.
If one of the three voltage readings in Steps 4, 5 and 6 is

not correct, replace the joystick handle. (See Removal
P-47793
If all voltage readings in Steps 4, 5 and 6 are correct go
to step 7.
2. With the engine OFF, the key in the run position,
check that the battery voltage on the controller

connector (Item 1) [Figure 20-170-4] (pin 1, blue
wire) is at least 12 volt or higher.

check the regulated voltage on the controller
connector (Item 1) [Figure 20-170-4] (pin 4, black
wire) is 5 volt. If 5 volt is not seen, replace the
controller.
Figure 20-170-5
m
Maximu
l
Neutra
1
m
Minimu
S7486
4. With the telescopic function switch (Item 1)

[Figure 20-170-5] in the minimum (back) position
check that the voltage on the controller connector

HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure
Telescoping Valve Section Troubleshooting (Cont’d) Figure 20-170-8
Checking Pilot Pressure
Figure 20-170-6
1
1
P-42977
11. Remove the hose (Item 1) [Figure 20-170-8] from the

control valve, and install a tee fitting.
Figure 20-170-9

P-44343
7. Locate the test fitting (Item 1) [Figure 20-170-6] and

remove the cap.
Figure 20-170-7
P-52913
12. Install a 3,5 MPa (35 bar) (508 psi) gauge on the tee
fitting [Figure 20-170-9].
13. Start the engine, lower the restraint bar (if equipped)
P-44342 and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 150
kPa (1,5 bar) (22 psi) maximum.
8. Install a 7 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-170-7]. 14. Remove the gauge.

and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 3,5
MPa (35 bar) (508 psi) maximum.
10. Remove the gauge.

Telescoping Valve Section Troubleshooting (Cont’d)
Figure 20-170-10
1 2
P-52901
17. If the telescopic function does not work, remove the

P-52155 two screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-12].
15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.

the engine at 2200 RPM. Move the telescopic control
switch (Item 1) [Figure 20-170-10] forward and back Figure 20-170-13
to see if this function works. Stop the engine.
Figure 20-170-11
P-61126
P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-13] to test the movement of the telescopic
function in both directions.
16. If the telescopic function does not work, with the
engine running disconnect the controller connector NOTE: If by manually operating the spool, and the
(Item 1) [Figure 20-170-11] and reconnect it back in. telescopic function is working the controller
must be replaced.

Auxiliary Valve Section Troubleshooting S/N A8GW13000 & ABOVE
Record the serial number of the machine, control valve S/N A8GV13000 & ABOVE
and control module. S/N A8GJ13000 & ABOVE
The following procedure must be done with the control

valve in the machine. The control valve is removed for
photo clarity. 1
With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure. 2
Figure 20-170-14 P-97008

The hydraulic control function switch (Item 1) must be ON
S/N A8GV12999 & BELOW (light is on) and the front auxiliary hydraulics ON/OFF
S/N A8GJ12999 & BELOW 1 switch (Item 2) [Figure 20-170-14] and [Figure 20-170-
15] must be ON (top position).
Figure 20-170-16

1
P-50943
1. Locate the auxiliary valve section (Item 1) [Figure 20-

170-16] on the control valve.
P-50797

Auxiliary Valve Section Troubleshooting (Cont’d)
Figure 20-170-17
m
Maximu
1
l
Neutra
m
Minimu
1
P-47793
P-52155

check that the battery voltage on the controller 4. With the auxiliary function switch (Item 1) [Figure 20-

connector (Item 1) [Figure 20-170-17] (pin 1, blue 170-18] in the minimum (back) position check that the
wire) is at least 12 volt or higher. voltage on the controller connector (Item 1)
[Figure 20-170-17] (pin 3, brown wire) is 0.9 volt. If
3. With the engine OFF, they key switch in the run the voltage drops below 0.9 volt the controller will
position, check the regulated voltage on the controller interpret this as a failure.
connector (Item 1) [Figure 20-170-17] (pin 4, black
wire) is 5 volt. If 5 volt is not seen, replace the 5. With the auxiliary function switch (Item 1) [Figure 20-
controller. 170-18] in the neutral (middle) position check that the
voltage on the controller connector (Item 1)
[Figure 20-170-17] (pin 3, brown wire) is 2.5 volt.
6. With the auxiliary function switch (Item 1) [Figure 20-

170-18] in the maximum (forward) position check that
the voltage on the controller connector (Item 1)
[Figure 20-170-17] (pin 3, brown wire) is 4.1 volt.
If one of the three voltage readings in Steps 4, 5 and 6 is

not correct, replace the joystick handle. (See Removal
If all voltage readings in Steps 4, 5 and 6 are correct go

to step 7.

HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure
Auxiliary Valve Section Troubleshooting (Cont’d) Figure 20-170-21
Checking Pilot Pressure
Figure 20-170-19
1
1
P-42977
11. Remove the hose (Item 1) [Figure 20-170-21] from

the control valve, and install a tee fitting.
Figure 20-170-22

P-44343
7. Locate the test fitting (Item 1) [Figure 20-170-19] and

remove the cap.
Figure 20-170-20
P-52913
12. Install a 3,5 MPa (35 bar) (500 psi) gauge on the tee
P-44342 and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 150
kPa (1,5 bar) (22 psi) maximum.
8. Install a 7 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-170-20]. 14. Remove the gauge.

and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 3,5
MPa (35 bar) (500 psi) maximum.
10. Remove the gauge.

Auxiliary Valve Section Troubleshooting (Cont’d)
Figure 20-170-23
1 2
P-52901
17. If the auxiliary function does not work, remove the two
P-52155 screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-25].
15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.

the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-23] forward and back Figure 20-170-26
to see if this function works. Stop the engine.
Figure 20-170-24
P-61228
P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-26] to test the movement of the auxiliary function
in both directions.
16. If the auxiliary function does not work, with the engine
running disconnect the controller connector (Item 1) NOTE: If by manually operating the spool, and the
[Figure 20-170-24] and reconnect it back in. auxiliary function is working the controller
must be replaced.

HYDRAULIC CONTROL VALVE (CONT’D)
Troubleshooting Chart (Control Valve)

WARNING
W-2004-1285
PROBLEM CAUSE CORRECTION

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

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

Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See Removing And Replacing Hydraulic Fluid on Page
10-100-2.)
WARNING 1
Hydraulic fluid escaping under pressure can have 1
P-50942
immediately. Remove the two tie-straps (Item 1) [Figure 20-170-28]
W-2145-0290
and reposition the harness.
Figure 20-170-29
IMPORTANT

damage the system.
I-2003-0888
1
Figure 20-170-27
P-50943
1
NOTE: Mark all hoses and tubelines for correct

installation.
S7421
Remove the rear cover (Item 1) [Figure 20-170-27].


1
1
Figure 20-170-30
P-50946
1 Remove the six hoses (Item 1) [Figure 20-170-32] from

P-50944 the control valve.
Figure 20-170-33

Figure 20-170-31
1
1 P-50947
P-50945 Remove the two hoses (Item 1) [Figure 20-170-33] from

the control valve.
Remove the five hoses (Item 1) [Figure 20-170-31] from

the control valve.

Figure 20-170-34
P-50950
Remove the mounting bolt (Item 1) [Figure 20-170-36]

P-50948 from the front of the control valve.
Figure 20-170-37
Disconnect the two wire connectors (Item 1) [Figure 20-
170-34] from the main wire harness.

NOTE: Mark the location of the connectors for
Figure 20-170-35
1 1
1
1 P-50951
Remove the two mounting bolts (Item 1) [Figure 20-170-

37] from the control valve.
Installation: Tighten the mounting bolts to 24 - 26 N•m

P-50949 (18 - 19 ft-lb) torque.

Figure 20-170-38
P-50952
Install a hoist and lifting strap (Item 1) [Figure 20-170-

38] on the control valve.

Remove the hydraulic control valve.
Use care not to damage the tubelines or fittings.

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

1
4 5
2 3 6
P-47794

IMPORTANT
damage the system.
I-2003-0888
P-47794
Figure 20-170-39
Remove all hydraulic fittings. Mark the valve sections for

proper assembly [Figure 20-170-40].
Figure 20-170-41

6 1
5 4 3 2
P-50956
Mark the valve sections for ease of assembly Inlet-Outlet

Valve Section (Item 1), Auxiliary / Frame Leveling Valve 1
Section (Item 2), Telescoping Valve Section (Item 3), P-47795
Tilting Valve Section (Item 4), Lifting Valve Section (Item
5) and End Housing Valve Section (Item 6) [Figure 20-
170-39]. Remove the three nuts (Item 1) [Figure 20-170-41] from
the tie rod bolts.
Assembly: Tighten the nuts to 35 N•m (26 ft-lb) torque.

End Housing Disassembly And Assembly
Figure 20-170-42
P-42985
1 Remove the O-ring (Item 1) [Figure 20-170-44] from the

P-47796 plug.
Remove the end housing (Item 1) [Figure 20-170-42].

Figure 20-170-43
1
2
P-42984
Remove the dust cap (Item 1) and plug (Item 2)

[Figure 20-170-43] from the end housing.

Lifting Valve Section Disassembly And Assembly
Figure 20-170-45
1
1
P-42989
Remove the plug (Item 1) [Figure 20-170-47] from the

P-47797 valve section.
Figure 20-170-48
Remove the lifting valve section (Item 1) [Figure 20-170-
45].

Figure 20-170-46
1
2
1
P-42990
1 Remove the two O-rings (Item 1) and back-up ring (Item

P-42987 2) [Figure 20-170-48] from the plug.
Remove the four O-rings (Item 1) [Figure 20-170-46]

from the valve section.


(Cont’d)
Figure 20-170-49
P-42993

1 cover.
P-42991
Figure 20-170-52
Loosen the four screws (Item 1) [Figure 20-170-49].

Assembly: Tighten the screws to 10 N•m (88.5 in-lb)
torque.
Figure 20-170-50
2 2
1 1
P-42995
Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-170-52] from the spool.
P-42992
Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-50].


(Cont’d)
Figure 20-170-53
1
1
P-42997
P-42996 Assembly: Tighten the screws to 10 N•m (88.5 in-lb)

torque.
Remove the relief valve (Item 1) [Figure 20-170-53] from Figure 20-170-56

the valve section.
Assembly: Tighten the relief valve to 45 N•m (33 ft-lb)

torque.
Figure 20-170-54 2
1
2
1
P-42998

[Figure 20-170-56] from the valve section.
P-42988
Remove the two O-rings (Item 1) and back-up ring (Item

2) [Figure 20-170-54] from the relief valve.


(Cont’d)
Figure 20-170-57
P-44000
Remove the spool (Item 1) [Figure 20-170-59] from the

valve section.
P-42993
Figure 20-170-60

cover.
Figure 20-170-58
1
2
1
P-44275
Remove the two plugs (Item 1) [Figure 20-170-60] from

the valve section.
P-42999
Assembly: Tighten the plugs to 27 - 33 N•m (20 - 24 ft-
lb) torque.


(Cont’d)
Figure 20-170-61
1
2
1
P-44278
Loosen the plug (Item 1) [Figure 20-170-63].
P-44276 Assembly: Tighten the plug to 54 - 66 N•m (40 - 49 ft-lb)

torque.
Remove the spring (Item 1) and poppet (Item 2) Figure 20-170-64

[Figure 20-170-61] from the plugs.
Figure 20-170-62
1
3
P-44279
P-44277 Remove the individual pressure compensator plug (Item

1), poppet (Item 2) and guide (Item 3) [Figure 20-170-
64] from the valve section.
plugs.

HYDRAULIC CONTROL VALVE (CONT’D) Tilting Valve Section Disassembly And Assembly
Lifting Valve Section Disassembly And Assembly Figure 20-170-66

(Cont’d)
Figure 20-170-65 1
P-44001
P-44280 Remove the tilting valve section (Item 1) [Figure 20-170-

66]
Remove the O-ring (Item 1) [Figure 20-170-65] from the Figure 20-170-67

plug.
P-44002


Tilting Valve Section Disassembly And Assembly

(Cont’d)
Figure 20-170-68
1 1
P-44004
Loosen the four screws (Item 1) [Figure 20-170-70] on

the cover.
P-44003
torque.
Remove the relief valve (Item 1) [Figure 20-170-68] from

the valve section. Figure 20-170-71

torque.
Figure 20-170-69
1
1
P-44005

P-42988



(Cont’d)
Figure 20-170-72
1
P-44007
Remove the relief valve (Item 1) [Figure 20-170-74] from

the valve section.
P-42993
torque.

cover. Figure 20-170-75
Figure 20-170-73
1
2
1
2
1
P-42988
P-44006


(Cont’d)
Figure 20-170-76
2
1
P-44010
1

P-44008
Figure 20-170-79

the cover.

torque.
1
Figure 20-170-77
2
P-44011
1

valve section.
P-44009



(Cont’d)
Figure 20-170-80 1
P-44277
1

plugs.
P-44275
Figure 20-170-83

the valve section.

lb) torque. 1
Figure 20-170-81
2
1
P-44278
Assembly: Tighten the plug to 54 - 66 N•m (40 - 49 ft-lb)

torque.
P-44276
Remove the spring (Item 1) and poppet (Item 2)


HYDRAULIC CONTROL VALVE (CONT’D) Telescoping Valve Section Disassembly And
Assembly
(Cont’d) Figure 20-170-86
Figure 20-170-84
1
1 P-47799
P-44279
Remove the telescoping valve section (Item 1)
[Figure 20-170-86].
Remove the individual pressure compensator plug (Item

1), poppet (Item 2) and guide (Item 3) [Figure 20-170- Figure 20-170-87
Figure 20-170-85
1 1
P-44013
P-44280 Remove the four O-rings (Item 1) [Figure 20-170-87]


plug.

Telescoping Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-170-88
P-44016
1
controller assembly.
P-44014
Figure 20-170-91
Remove the two screws (Item 1) [Figure 20-170-88] from

the controller assembly.
Assembly: Tighten the screws to 14 - 16 N•m (10 - 12 ft-

lb) torque.
Figure 20-170-89
1
P-44017
Remove the two couplers (Item 1) [Figure 20-170-91]

from the controller assembly.
1
P-44015
Remove the controller assembly (Item 1) [Figure 20-170-



Assembly (Cont’d)
Figure 20-170-92
2
1
P-44020

[Figure 20-170-94] from the controller assembly.
P-44018
Figure 20-170-95
Remove the two O-rings (Item 1) [Figure 20-170-92]

from the couplers.
Figure 20-170-93
1 P-44021
Remove the seal (Item 1) [Figure 20-170-95] from the

cover.
P-44019

Assembly: Tighten the screws to 3 - 3,5 N•m (26.6 - 31

in-lb) torque.


Assembly (Cont’d)
Figure 20-170-96
1
2
P-44024
1
Remove the port block (Item 1) from the controller (Item

2) [Figure 20-170-98].
P-44022
Figure 20-170-99

cover.
Figure 20-170-97
3
1
2
1
4
P-47808
Remove the two valve cartridges (Item 1) and plunger

(Item 2) [Figure 20-170-99] from the controller.
P-44023
NOTE: The upper valve cartridge (Item 3) is for
extending the boom and the lower valve
Remove the O-ring (Item 1) [Figure 20-170-97] from the cartridge (Item 4) [Figure 20-170-99] is for
plug. retracting the boom.


Assembly (Cont’d)
Figure 20-170-100 1
1
P-44028
2
5
4 from the port valve.
3
P-47810
Figure 20-170-103
Remove the cover (Item 1), poppet (Item 2), spool (Item

3) and spacer (Item 4) from the valve (Item 5) [Figure 20-
170-100].
Figure 20-170-101
1
2
1
P-47811

from the valve.
P-44027
Remove the spool (Item 1) and spring (Item 2)

[Figure 20-170-101] from the port valve.
Assembly: The port valve, spool and spring must be

thoroughly cleaned before assembly.


Assembly (Cont’d)
Figure 20-170-104
1 1
P-44037
Loosen the screw (Item 1) [Figure 20-170-106] on the

piston.
P-44036
Assembly: Tighten the screw to 10 N•m (88.5 in-lb)
torque.
Remove the relief valve (Item 1) [Figure 20-170-104]

from the valve section. Figure 20-170-107
Assembly: Tighten the valve to 45 N•m (33 ft-lb) torque.
Figure 20-170-105
1
2
1
2
1
P-44038
Remove the screw (Item 1) and piston (Item 2)

P-42988 [Figure 20-170-107] from the adapter.



Assembly (Cont’d)
1
Figure 20-170-108
P-42990
1 Remove the two O-rings (Item 1) and back-up ring (Item

2) [Figure 20-170-110] from the plug.
P-44039
Figure 20-170-111

from the piston.
Figure 20-170-109
1
1
P-44041
Loosen the two screws (Item 1) [Figure 20-170-111] on

the cover.
P-44040
torque.
valve section.


Assembly (Cont’d)
Figure 20-170-112
1
P-44045
Loosen the adapter (Item 1) [Figure 20-170-114].
P-44042 Assembly: Tighten the adapter to 9 - 11 N•m (79.7 - 97.4

in-lb) torque.
Remove the two screws (Item 1) and cover (Item 2) Figure 20-170-115

Figure 20-170-113
P-44046
1
P-44044 Remove the adapter (Item 1) [Figure 20-170-115] from
the spool.
Install a hex wrench in the screw (Item 1) [Figure 20-

170-113] on the end of the spool.


Assembly (Cont’d)
Figure 20-170-116
P-44049
Assembly: Install the countersunk side of the washer

(Item 1) [Figure 20-170-118] into the valve section.
P-44047
Figure 20-170-119

the adapter.
Figure 20-170-117
P-44050

valve section.
P-44048
NOTE: When the spool is removed, use care not to
scratch the spool surface and do not
Remove the washer (Item 1) [Figure 20-170-117] from interchange spools and valve blocks.
the valve section.


Cut
Assembly (Cont’d)
Figure 20-170-120
3 18 mm 51 mm (2.0”)
2 (0.710”)
38 mm
(1.500”) 19 mm (0.750”)
B-14674
To remove the spring assembly from the spool, make a

holding fixture from a 19 mm thick x 38 mm wide x 51 mm
P-44051 long (0.750 in thick x 1.500 in wide x 2.0 in long) piece of
hardwood. Drill a 18 mm (0.710 in) hole in the center of
the hardwood block. Cut the block lengthwise [Figure 20-
Remove the O-ring (Item 1) seal (Item 2) and retainer 170-122].

(Item 3) [Figure 20-170-120] from the spool.
Figure 20-170-123
Figure 20-170-121
P-33886
P-44053
Using the wood blocks clamp the spool (Item 1)

Assembly: The lip on the seal (Item 1) [Figure 20-170- [Figure 20-170-123] in a vise.
121] fits inside the retainer (Item 3) [Figure 20-170-120].
damaged.
Loosen the screw (Item 2) [Figure 20-170-123].

torque.


Assembly (Cont’d)
2
Figure 20-170-124
1
1 P-44276
4
3
2 [Figure 20-170-126] from the plugs.
P-44052
Figure 20-170-127
Remove the screw (Item 1), spring retainer (Item 2),

spring (Item 3) and spring retainer (Item 4) [Figure 20-
170-124] from the spool.
1
Figure 20-170-125
P-44277
1
the plugs.
P-44275

the valve section.

lb) torque.


Assembly (Cont’d)
Figure 20-170-128
P-44280

the plug.
P-44278

torque.
Figure 20-170-129
1
P-44279

1), poppet (Item 2) and guide (Item 3) [Figure 20-170-

Auxiliary / Frame Leveling Valve Section

Figure 20-170-131
P-44081
Remove the two screws (Item 1) [Figure 20-170-133]

from the controller assembly.
P-44079
Assembly: Tighten the screws to 14 - 16 N•m (10 - 12 ft-
lb) torque.
Remove the frame leveling valve section (Item 1)

[Figure 20-170-131]. Figure 20-170-134
Figure 20-170-132
1 1
P-44082
P-44080
Remove the controller assembly (Item 1) [Figure 20-170-


Figure 20-170-135
2
1
P-44085
1 Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-137] from the controller assembly.
P-44083
Figure 20-170-138

1
Figure 20-170-136
P-44021
1 Remove the seal (Item 1) [Figure 20-170-138] from the

cover.
P-44084
Assembly: Tighten the screws to 3 - 3,5 N•m (26.6 - 31

in-lb) torque.


Figure 20-170-139
2
1
P-44086
1
Remove the controller (Item 1) from the port block (Item

2) [Figure 20-170-141].
P-44022
Figure 20-170-142

cover.
Figure 20-170-140
1
P-47808
Remove the two valve cartridges (Item 1) and plunger

(Item 2) [Figure 20-170-142] from the controller.
P-44023

the plug.


Figure 20-170-143 1
2
5
3
4 P-44028

from the port valve.
P-47810
Figure 20-170-146
Remove the cover (Item 1), poppet (Item 2), spool (Item

3) and spacer (Item 4) from the valves (Item 5)
[Figure 20-170-143].
Figure 20-170-144
1
2
1
P-47811

from the valve.
P-44027
Remove the spool (Item 1) and spring (Item 2)

[Figure 20-170-144] from the port valve.
Assembly: The port valve, spool and spring must be

thoroughly cleaned before assembly.


Figure 20-170-147
1 2 P-44093

from the connecting flange.
P-44091

the connecting flange.
Assembly: Tighten the screws to 9 - 11 N•m (79.7 - 97.4

in-lb) torque.
Controller Filter Removal And Installation
Remove the filter (Item 2) [Figure 20-170-147] from the

port.
NOTE: The valve assembly does not have to be

removed for this procedure.
Figure 20-170-148
P-44092
Remove the two screws (Item 1) and connecting flange

(Item 2) [Figure 20-170-148].


Figure 20-170-150
P-44097
1
the cover.
P-44094
torque.
Loosen the screw (Item 1) [Figure 20-170-150] on the

piston. Figure 20-170-153

torque.
Figure 20-170-151
2
1
P-44098
Remove the two screws (Item 1) and cover (Item 2)

P-44096
Remove the screw (Item 1) and piston (Item 2)

[Figure 20-170-151] from the adapter.


Figure 20-170-154
P-44101
1 Remove the adapter (Item 1) [Figure 20-170-156] from

the spool.
P-44099
Figure 20-170-157
Install a hex wrench in the screw (Item 1) [Figure 20-

170-154].
Figure 20-170-155
1
P-44047

the adapter.
P-44100
Loosen the adapter (Item 1) [Figure 20-170-155].
Assembly: Tighten the adapter to 9 - 11 N•m (79.7 - 97.4

in-lb) torque.


Figure 20-170-158
P-44103

valve section.
P-44102
NOTE: When the spool is removed, use care not to
scratch the spool surface and do not
Remove the washer (Item 1) [Figure 20-170-158] from interchange spools and valve blocks.

the valve section.
Figure 20-170-161
Figure 20-170-159
3
2
P-44051
P-44049
Remove the O-ring (Item 1), seal (Item 2) and retainer

Assembly: Install the countersunk side of the washer (Item 3) [Figure 20-170-161] from the spool.
(Item 1) [Figure 20-170-159] into the valve section.


Figure 20-170-162
1
2
P-33886
Using the wood blocks clamp the spool (Item 1)

[Figure 20-170-164] in a vise.
P-44053
Assembly: The lip on the seal (Item 1) [Figure 20-170- damaged.

162] fits inside the retainer.
Loosen the screw (Item 2) [Figure 20-170-164].
Figure 20-170-163
Assembly: Tighten the screw to 10 N•m (88.5 ft-lb)
Cut torque.
Figure 20-170-165
18 mm 51 mm (2.0”)
(0.710”)
38 mm
(1.500”) 19 mm (0.750”)
4
B-14674 1
3
To remove the spring assembly from the spool, make a 2

holding fixture from a 19 mm thick x 38 mm wide x 51 mm
P-44052
long (0.750 in thick x 1.500 in wide x 2.0 in long) piece of
hardwood. Drill a 18 mm (0.710 in) hole in the center of
the hardwood block. Cut the block lengthwise [Figure 20- Remove the screw (Item 1), spring retainer (Item 2),
170-163]. spring (Item 3) and spring retainer (Item 4) [Figure 20-


Figure 20-170-166
1
P-44277
1
the plugs.
P-44281
Figure 20-170-169

the valve section.
1
lb) torque.
Figure 20-170-167
2
1
P-44282

torque.
P-44276


HYDRAULIC CONTROL VALVE (CONT’D) Inlet-Outlet Valve Section Disassembly And
Assembly
Disassembly And Assembly (Cont’d) Figure 20-170-172
Figure 20-170-170
3
2
P-44104
1
P-44283

1), poppet (Item 2) and guide (Item 3) [Figure 20-170- Figure 20-170-173
Figure 20-170-171
P-44105
P-44280 Remove the flushing valve plug (Item 1) [Figure 20-170-

Remove the O-ring (Item 1) [Figure 20-170-171] from Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque.
the plug.

Inlet-Outlet Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-170-174 1
P-44108

valve section.
P-44106
Assembly: Tighten the plug to 20 N•m (15 ft-lb) torque.
Remove the O-ring (Item 1) [Figure 20-170-174] from Figure 20-170-177

the plug.
Figure 20-170-175
P-44109
P-44107 Remove the O-ring (Item 1) [Figure 20-170-177] from

the plug.
Remove the spring, shims and piston (Item 1)



Assembly (Cont’d)
Figure 20-170-178
1
1
P-44112
Remove the flow regulator valve (Item 1) [Figure 20-170-

P-44110
Assembly: Tighten the flow regulator valve to 20 N•m
(15 ft-lb) torque.
Remove the relief valve (Item 1) [Figure 20-170-178]

from the valve section. Figure 20-170-181

torque.
Figure 20-170-179
4
3
2 1
2
1
P-44265
1 Remove the plug (Item 1), shim (Item 2), spring (Item 3)
and spool (Item 4) [Figure 20-170-181] from the valve.
P-44111



Assembly (Cont’d)
Figure 20-170-182 1
1
1 2
P-44267

2) [Figure 20-170-184] from the flow regulator valve.
P-44268
Figure 20-170-185

the plug.
Figure 20-170-183
1
P-44114
Remove the test fitting (Item 1) [Figure 20-170-185] from

the valve section.
P-44269
Remove the screen (Item 1) [Figure 20-170-183] from

the valve.


Assembly (Cont’d)
Figure 20-170-186
1
P-44117

the test fitting.
P-44115

the test fitting.
Figure 20-170-187
P-44116
Remove the cap (Item 1) [Figure 20-170-187] from the

test fitting.

PORT RELIEF VALVES Figure 20-180-2
Adjustment Procedure
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888
P-50958
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat Loosen the lock nut (Item 1) [Figure 20-180-2].
hydraulic fluid.
Turn the adjusting screw (Item 2) [Figure 20-180-2]
NOTE: The valve is shown removed from the clockwise to increase the pressure and counterclockwise
machine for photo clarity. to reduce the pressure.

Figure 20-180-1 NOTE: A 90° turn is approximately 2758 kPa (27,58
bar) (400 psi). When the correct pressure
setting is obtained, tighten the locknut while
holding the adjustment screw from turning.
Adjust the port relief valve until the correct setting is

obtained.
P-50955
Install the hand pump, hose and a pressure gauge

(minimum of 34,4 MPa [344 bar] [5000 psi]) into the valve
section work port in which the port relief valve is located
[Figure 20-180-1]. Pressurize this section with the hand
pump until the port relief valve opens and record the
pressure reading.
If the port relief pressure setting needs to be adjusted,

release the hand pump pressure valve.


FLOW CONTROL VALVE Figure 20-190-3
Figure 20-190-1
1
1
P-44263
Remove and clean the filter (Item 1) [Figure 20-190-3].

S7421
NOTE: Check the filter for any damage. Replace the
filter if required.

Figure 20-190-2
P-44331
Remove the flow control valve (Item 1) [Figure 20-190-2]

from the right front of the hydraulic control valve.
Installation: Tighten the flow control valve to 20 N•m (15

ft-lb) torque.


JOYSTICK Remove the joystick panel. (See Removal And
Installation on Page 50-131-1.)
Figure 20-200-3
S/N A8GT12999 & Below, S/N A8GV12999 & Below,
S/N A8GJ12999 & Below:
Remove the dash cover / steering column cover. (See

Removal And Installation on Page 50-140-1.)
Remove the joystick panel. (See Removal And

Figure 20-200-1
1
S36357
Disconnect the electrical connector (Item 1) [Figure 20-

200-3].

For All Models:
1
NOTE: The joystick is not serviceable and must be
replaced as a complete unit.
P-61622 Figure 20-200-4

200-1].

S/N A8GT13000 & Above, S/N A8GV13000 & Above,
S/N A8GJ13000 & Above: 1
Figure 20-200-2
1
P-61623
Raise the dust boot (Item 1) [Figure 20-200-4].
P-97028
Remove the fuse box cover (Item 1) [Figure 20-200-2].

JOYSTICK (CONT’D) Figure 20-200-6
Figure 20-200-5
2
1
1
1
2 P-61624
Remove the six hoses (Item 1) [Figure 20-200-6] from

P-61640 the joystick.
Mark the hoses for correct assembly.

Remove the four mounting bolts and spacers (Item 1)
[Figure 20-200-5]. Figure 20-200-7

Installation: The joystick harness (Item 2) [Figure 20-
200-5] must be positioned around the swivel joint as
shown.
WARNING
P-61623
immediately.
W-2145-0290
Remove the joystick assembly (Item 1) [Figure 20-200-

7].
IMPORTANT
damage the system.
I-2003-0888

PARKING BRAKE Figure 20-210-2
Parking Brake Valve Removal And Installation
Figure 20-210-1
2
2
1
S4519
Remove the three hoses (Item 1). Unplug the electrical

P-50821
connector (Item 2) [Figure 20-210-2].
Relieve the hydraulic pressure. Figure 20-210-3

Remove the three screws (Item 1) from the access panel
1
(Item 2) [Figure 20-210-1].
Remove the access panel (Item 2) [Figure 20-210-1].
WARNING
S4519
immediately.
W-2145-0290 Remove the two screws (Item 1) [Figure 20-210-3] in
order to loosen the parking brake lever.
IMPORTANT
damage the system.
I-2003-0888
Mark all hoses and electrical connectors for correct

installation.

PARKING BRAKE (CONT’D) Parking Brake Valve Disassembly And Assembly
Parking Brake Valve Removal And Installation Figure 20-210-5

(Cont’d)
Figure 20-210-4
1
S2756
S4519 Remove the fittings (Item 1) [Figure 20-210-5].
Figure 20-210-6
Lift the parking brake lever and valve (Item 1) [Figure 20-

210-4] out the frame.
P-44439
Loosen the collar (Item 1) [Figure 20-210-6].
NOTE: Use care removing the collar. The collar is

under spring pressure.

PARKING BRAKE (CONT’D) Figure 20-210-9
Parking Brake Valve Disassembly And Assembly

(Cont’d)
Figure 20-210-7
1
P-44442
Remove the electrical connector (Item 1) [Figure 20-210-

9] from the housing.
P-44440
Remove the collar (Item 1), spring (Item 2) and shaft

(Item 3) [Figure 20-210-7] from the housing.
Figure 20-210-8
P-44441
Remove the washer (Item 1) [Figure 20-210-8] from the

housing


PRESSURE REDUCING VALVE Figure 20-220-3
Testing
Figure 20-220-1
1
P-50928
Install a 7 MPa (70 bar) (1000 psi) gauge on the test

Start the engine, lower the restraint bar (if equipped) and
S7421 run engine at 2200 RPM.

Record the pressure. The pressure at the gauge should
Remove the rear cover (Item 1) [Figure 20-220-1]. be 3,31 MPa (33,10 bar) (480 psi).
Figure 20-220-2 The pressure reducing valve is not adjustable. If the

pressure is incorrect, replace the pressure reducing
valve. (See Removal And Installation on Page 20-220-2.)
P-50930
Locate the test fitting (Item 1) [Figure 20-220-2] below

the control valve and remove the cap.

PRESSURE REDUCING VALVE (CONT’D)

WARNING
Relieve hydraulic pressure. Drain the hydraulic reservoir.
(See Removing And Replacing Hydraulic Fluid on Page Hydraulic fluid escaping under pressure can have
10-100-2.) sufficient force to enter a person’s body by
Figure 20-220-4 and possible death if proper medical treatment by a
immediately.
W-2145-0290
1
IMPORTANT
damage the system.
I-2003-0888
S7421

Figure 20-220-6
Mark the hoses and electrical connectors for correct

installation.
Figure 20-220-5
2 1
P-50938
1
Remove the top hose (Item 1) [Figure 20-220-6].
P-50937
Remove the screw (Item 1) and disconnect the electrical


PRESSURE REDUCING VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-220-9
Figure 20-220-7
1
P-44338
1
P-50939
Remove the nut (Item 1) and coil (Item 2) [Figure 20-
Figure 20-220-10

Figure 20-220-8
1
1
P-44337
P-50940
Remove the spool (Item 1) [Figure 20-220-10].

Remove the two mounting bolts (Item 1) and remove the
pressure reducing valve (Item 2) [Figure 20-220-8].

PRESSURE REDUCING VALVE (CONT’D) Figure 20-220-12
Figure 20-220-11
2 1
1
P-44341
1 2
1
2 Remove the fittings (Item 1) [Figure 20-220-12].
P-44340
Wash the valve in clean solvent and dry with compressed
air. Check the components for wear or damage. Replace
Remove the three O-rings (Item 1) and four back-up rings any worn or damaged components. Always use new O-
(Item 2) [Figure 20-220-11] from the spool. rings and back-up rings.

Apply clean hydraulic fluid to the components during
assembly.

ACCUMULATOR Figure 20-230-2
The accumulator is located below the control valve, and S/N A8GV12999 & BELOW
can be seen through an access hole on the bottom of the S/N A8GJ12999 & BELOW
machine.
WARNING
immediately.
W-2145-0290
WARNING

Load, unload and turn on flat level ground. Do not
exceed Rated Operating Capacity (ROC) shown on P-50796
sign (decal) in cab. Failure to obey warnings can
cause the machine to tip or roll over and cause injury
or death. With the engine off, relieve the hydraulic pressure by
W-2056-0903
pressing the bottom of the button (Item 1) [Figure 20-
230-1] and [Figure 20-230-2].
Figure 20-230-1
Figure 20-230-3
S/N A8GV13000 & ABOVE
2 1
1
P-97008
P-50941
Remove the accumulator (Item 1) from the manifold (Item

2) [Figure 20-230-3].


TOW VALVE Figure 20-240-2

Page 10-160-1.)
Figure 20-240-1
1
S6839
Mark the hoses for correct installation. Remove the two

hoses (Item 1) [Figure 20-240-2].
Figure 20-240-3
S6838

Position the tow valve to towing position to relieve
hydraulic pressure [Figure 20-240-1].
2
WARNING 3
Hydraulic fluid escaping under pressure can have 1

S6892
immediately.
W-2145-0290
Remove the two bolts, nuts (Item 1) and strap (Item 2).
Remove the tow valve (Item 3) [Figure 20-240-3].
IMPORTANT
damage the system.
I-2003-0888

TOW VALVE (CONT’D) Figure 20-240-6
Clean the outside of the tow valve before disassembly.
Mark the outside of the tow valve for ease of assembly.
Figure 20-240-4
1
P-46750
Remove the retainer (Item 1) and stop plate (Item 2)

2 [Figure 20-240-6].
NOTE: Record the position of the stop plate for

1 proper assembly.
P-46747

Figure 20-240-7
Remove the screw (Item 1) and washer (Item 2) [Figure

20-240-4].
Figure 20-240-5
1
1 1
P-46752
Remove the two fittings (Item 1) [Figure 20-240-7].
P-46749
Remove the handle (Item 1) [Figure 20-240-5].

Figure 20-240-8 1
P-46755
1

P-46753 adapters.

fittings.

Figure 20-240-9
1 1
P-46754
Remove the two adapters (Item 1) [Figure 20-240-9].

Figure 20-240-11
1
P-46759
Figure 20-240-14
P-46756
Figure 20-240-12
1

2
1
P-46760
Assembly: Align the slot (Item 1) [Figure 20-240-13]

P-46758 with the notch (Item 1) [Figure 20-240-14] in the shaft.

valve (Both sides).
Assembly: The concave side of the seal (Item 1) [Figure

20-240-11] fits over the ball (Item 2) [Figure 20-240-12].
Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-240-12] are in the position shown. Remove
the ball.
Assembly: Record the position of the shaft and ball for

proper assembly.

Figure 20-240-15
1
1
P-46762

P-46763 housing.
Clean all parts in solvent and dry with compressed air.

Remove the shaft (Item 1) [Figure 20-240-15] by
pressing the shaft into the housing. Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Figure 20-240-16
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.
P-46761

shaft.


STABILIZER CYLINDER (IF EQUIPPED) Figure 20-250-3
Removal
Figure 20-250-1
1 1
S3220
Disconnect both hoses (Item 1) [Figure 20-250-3] and

S3217 put caps on the connections to prevent bleeding the
hydraulic tank.
Extend and support the boom on adequate stands Figure 20-250-4

[Figure 20-250-1].

Figure 20-250-2
S3218
S3215 Remove the bolt and washer (Item 1) [Figure 20-250-4]

on one side of the rod end articulation pin.
Position the stabilizer horizontally and place blocks to

support the stabilizer when being disassembled [Figure
20-250-2].
IMPORTANT
damage the system.
I-2003-0888

STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-7
Removal (Cont’d)
Figure 20-250-5 1
S3221
1
Remove the pivot pin retainer bolt (Item 1) [Figure 20-
S3224 250-7].
Figure 20-250-8
Remove the pin (Item 1) [Figure 20-250-5].
Figure 20-250-6

1
S3227
S3226 Remove the pivot pin (Item 1) [Figure 20-250-8] and

remove the cylinder using the lifting strap.
Support the cylinder by using a lifting strap (Item 1)

[Figure 20-250-6].

STABILIZER CYLINDER (IF EQUIPPED) (CONT’D)
Figure 20-250-9
1 7
10
12
5
8
1. Cylinder Ref. 2 to 14
2. Rod
3. Piston Torque: 900 ± 180 N•m
(664 ± 133 ft-lb)
4. Screw Torque: 20 N•m (14.7 ft-lb)

5. Bushing
6. Grease nipple
7. Cap
8. Inner ring
9. Cylinder 9
13
10. Grease nipple 8
11. Cylinder head Torque: 450 - 500 N•m 5
(332 - 369 ft-lb)
12. Valve Torque: 45 - 50 N•m
(33 - 37 ft-lb)
13. Valve
14. Seal kit
3
14
7
6
11
5
8 4
8
5
S2821

Disassembly
Figure 20-250-10
1
S3230
Carefully peen the lock ring (Item 1) [Figure 20-250-12]

S3229 from the head gland.
Figure 20-250-13
Put the cylinder (Item 1) [Figure 20-250-10] in a vise.
Figure 20-250-11

1
1 S2819
S3222 Loosen the head gland using a wrench (Item 1) [Figure

20-250-13].
Remove both relief cartridges (Item 1) [Figure 20-250-

11] from the cylinder.

Figure 20-250-14
S3235

S2820
from the rod.
Figure 20-250-17
from the housing.

Figure 20-250-15 2
4 3
1
1 3
2
S3228
Remove the seal (Item 1), two wear rings (Item 2), two
S3234 rings (Item 3) and the O-ring (Item 4) [Figure 20-250-17]
from the piston.
Remove the set screw (Item 1) [Figure 20-250-15] from

the piston.

Figure 20-250-18
1
S2839

S2836 inside of the head gland.
Remove the head gland (Item 1) [Figure 20-250-18]

from the rod.

Figure 20-250-19
S2837
Remove the O-ring (Item 1) and wiper seal (Item 2)

[Figure 20-250-19] from the head gland.

Assembly

MEL1075-Adjustable Gland Nut Wrench

compressed air.
1
Inspect the cylinder parts for damage. Replace any
damaged parts.

installation. Always use new O-rings and seals. S2836
Figure 20-250-21
Install the head gland (Item 1) [Figure 20-250-23] onto
the rod.
2
Figure 20-250-24

2
4 3
1 1
3
S2837
2
Install the O-ring (Item 1) and wiper seal (Item 2) [Figure

20-250-21] onto the head gland. S3228
Figure 20-250-22
Install the seal (Item 1), two wear rings (Item 2), two rings
(Item 3) and the O-ring (Item 4) [Figure 20-250-24] onto
the piston.
S2839
Install the seal (Item 1) [Figure 20-250-22] into the head

gland.

Assembly (Cont’d)
Figure 20-250-25
2
S2820
1
Install the rod assembly (Item 1) [Figure 20-250-27] onto
S3235
the housing.
Figure 20-250-28
equivalent to the threads on the rod (Item 1). Install the
piston (Item 2) [Figure 20-250-25] onto the rod and

tighten.
Figure 20-250-26
1
S2819
Tighten the head gland (Item 1) using a wrench [Figure

20-250-28].
S3234
Apply Loctite® #242 or equivalent to the set screw

(Item 1) [Figure 20-250-26]. Install the set screw into the
piston and tighten.

STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Installation
Assembly (Cont’d) Figure 20-250-31
Figure 20-250-29
1 1
S3226
S3230
Install the pivot pin (Item 1) [Figure 20-250-31].
Using a punch, seat the lock ring to keep the head gland Figure 20-250-32
from turning [Figure 20-250-29].

Figure 20-250-30
1
1 S3221
S3222 Install the pivot pin retainer bolt (Item 1) [Figure 20-250-
32].
Install both relief cartridges (Item 1) [Figure 20-250-30]

onto the cylinder.

STABILIZER CYLINDER (IF EQUIPPED) (CONT’D)
Installation (Cont’d)
Figure 20-250-33
S3218
Install the rod end pivot pin and secure with the bolt and
washer (Item 1) [Figure 20-250-33].

Figure 20-250-34
1 1
S3220
Remove caps and connect the two hoses (Item 1)

[Figure 20-250-34].

STABILIZER CONTROL VALVE (IF EQUIPPED)
Figure 20-260-1
1. Hydraulic block
2. Set of plugs 6
3. Screw
4. Washer
5. Nut 1
6. Control valve
7. Adapter
8. Adapter 7
9. Fitting
3
10. Elbow fitting
11. Adapter 1
12. No return valve
13. Elbow fitting
14. Hose

15. Adapter 4
2
16. Pipe 5
17. Pipe
18. Support
19. Elbow fitting
20. Screw
21. Washer
22. Nut
14
10
12
11 8
9
10
22
17 13
21
20
13 11
14
12
19 15
16
18
S3214

STABILIZER CONTROL VALVE (IF EQUIPPED) Figure 20-260-4
(CONT’D)
Removal
Figure 20-260-2
2 2 2 2
2 1
1
1 S3247
2
Pull the connections plate forward, mark the tube

positions, disconnect the four hoses / tubes (Item 2) and
S3217 remove the plate (Item 1) [Figure 20-260-4].
Figure 20-260-5
Remove the nuts and bolts (Item 1) and the two hoses for
oil flow from and to the machine (Item 2) [Figure 20-260-
2].

1
IMPORTANT
damage the system. S2818
I-2003-0888
Figure 20-260-3 Mark and remove the remaining hoses (Item 1) [Figure
20-260-5] from the block.
2 2
1 1
S3220
Mark and disconnect the four hoses (Item 1) and remove

both bolts (Item 2) [Figure 20-260-3].

STABILIZER CONTROL VALVE (IF EQUIPPED) Installation
(CONT’D)
Figure 20-260-8
Removal (Cont’d)
Figure 20-260-6 1
1
1
1
3 3
2 2 2
2
2
3 S3249
3
1
S3248 Install the bolts (Item 1) to install the valve (Item 2)
[Figure 20-260-8].
Carefully remove the stabilizer control valve block Figure 20-260-9

(Item 1) [Figure 20-260-6] and put it on a stand, without
damaging the electric cables.

Mark and remove the four nuts (Item 2) and coils (Item 3) 2
[Figure 20-260-6] from the spools. 2
Figure 20-260-7 3 3
3
1 3
1
2
1 2
1
1
S3248
2
Put the stabilizer control valve block (Item 1) on a stand
in such a way that the electrical coils can be connected to
the spools. Install the coils (Item 2) and the four nuts
(Item 3) [Figure 20-260-9] on the spools.
S3249
Remove the bolts (Item 1) to uninstall the valve (Item 2)

[Figure 20-260-7].

STABILIZER CONTROL VALVE (IF EQUIPPED) Figure 20-260-12
(CONT’D)
1 1
Figure 20-260-10
2 2
1
S3220
Install both bolts (Item 1) and connect the four hoses

(Item 2) [Figure 20-260-12].
S2818
Figure 20-260-13
Place the valve block in its position in the stabilizer frame,

but do not yet secure the valve block to the frame.
2 1

Install the hoses (Item 1) [Figure 20-260-10].
Figure 20-260-11
1
2
2 2 2 2
S3217
Secure the valve block to the frame with two bolts

(Item 1) and connect the hoses (Item 2) [Figure 20-260-
1 13].
S3247
Pull the valve block a bit forward in order to be able to

connect the four hoses / tubes (Item 2) [Figure 20-260-
11].

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

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

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

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-22
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-25


HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
WARNING
only. W-2004-1285
PROBLEM CAUSE
The telescopic handler does not move 1, 2
The telescopic handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

1. The hydrostatic pump has damage.
2. The hydrostatic motor has damage.
3. The tires do not have the correct tire pressure.

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

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Replenishing Valve Function

IMPORTANT
Figure 30-10-1
damage the system.
I-2003-0888
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
Valve Moves For
Function 1 flow to the oil cooler for cooling; Function 1
Charge Oil [Figure 30-10-1].
Replacement
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2
[Figure 30-10-1].

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2 B-2804

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

COOLER / RADIATOR on Page 70-50-1.)


HYDROSTATIC DRIVE MOTOR
Remove the front axle. (See Removal on Page 40-30-1.)
Figure 30-30-1
1 1
P-22325

Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-1].

1] from the drive motor.
Installation: Tighten the mounting bolts to 190 - 210

N•m (140 - 155 ft-lb) torque.
Remove the hydrostatic drive motor from the axle

housing.

HYDROSTATIC DRIVE MOTOR (CONT'D)
1. Bolt
2. End Cap
3. Plug
4. O-ring
5. Seal
6. Servo Piston
7. Feed Back Lug
8. Nut
9. Adjuster
10. Rod
11. Set Screw
12. Spring seat
13. Spring
14. Spool
15. Orifice
16. Housing
17. Solenoid
B-18528

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

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


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

HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4
Disassembly 1
IMPORTANT
damage the system.
I-2003-0888
P-29653
Figure 30-30-2
Remove the solenoid nut (Item 1) [Figure 30-30-4].
Figure 30-30-5

P-29652
Place the hydrostatic drive motor on a work surface, mark

the sections for correct assembly [Figure 30-30-2]. P-29654
Figure 30-30-3
Remove the solenoid (Item 1) [Figure 30-30-5] from the
shaft.
P-29651

remove the solenoid housing.

Disassembly (Cont'd) 1
Figure 30-30-6
2
1
P-29657
Remove the solenoid shaft (Item 1) and O-ring (Item 2

P-29655 [Figure 30-30-8] from the housing.
Figure 30-30-9
Remove and discard the O-ring (Item 1) [Figure 30-30-6]
from the solenoid.

Figure 30-30-7 3
1
1
2
P-29659
Remove the O-ring (Item 1) and pin (Item 2) from the

P-29656 solenoid shaft (Item 3) [Figure 30-30-9].

housing.

Figure 30-30-10
P-29661
Remove the pin (Item 1) [Figure 30-30-12] from the

P-29660 housing.
Figure 30-30-13
housing.

Figure 30-30-11
1 1
P-29663
Remove the fitting (Item 1) [Figure 30-30-13].

P-29662

11] from the plug.

Figure 30-30-14
1 1
1 1
P-22345
Remove the eight bolts (Item 1) [Figure 30-30-16] from

P-29664 the end cap.
Figure 30-30-17
housing.

Figure 30-30-15
1
1
1
P-29667
1
Lift and remove the end cap (Item 1) [Figure 30-30-17]
P-29666 from the housing.
Remove and discard the seven O-rings (Item 1)

[Figure 30-30-15] from the housing.

Figure 30-30-18
1
P-29670
Remove the orifice (Item 1) [Figure 30-30-20].

P-29688
NOTE: Mark the orifice location for correct assembly.
Remove the gasket (Item 1) [Figure 30-30-18] from the Figure 30-30-21
end cap.

Figure 30-30-19
P-29671
P-29669 Remove the spool (Item 1) [Figure 30-30-21].
Remove the plug (Item 1) [Figure 30-30-19].

Figure 30-30-22
1
P-29674
Remove the two orifices (Item 1) [Figure 30-30-24] from

P-29672 the spool.
NOTE: Mark the orifice location for correct assembly.

Remove the servo control spool (Item 1) [Figure 30-30-
22] from the housing. Figure 30-30-25

Figure 30-30-23
P-29675
P-29673
Remove the two spring seats and spring (Item 1) from the
servo spool hole (Item 2) [Figure 30-30-25].
Remove the two O-rings (Item 1) [Figure 30-30-23] from
the servo control spool.

Figure 30-30-26
P-29678

P-29676 28].
Figure 30-30-29
Loosen the large nut (Item 1) [Figure 30-30-26] on the
adjustment screw.

2
NOTE: Do not change the adjustment.
Figure 30-30-27
1
1
P-29679
Remove the four bolts (Item 1) and remove the end cap
(Item 2) [Figure 30-30-29].
P-29677
Remove the adjustment screw (Item 1) [Figure 30-30-

27] from the housing.

Figure 30-30-30
1
P-29682
Remove the inner set screw from the servo piston

P-29680 [Figure 30-30-32].
Figure 30-30-33

Figure 30-30-31
P-29683
P-29681 Remove the feedback lug (Item 1) [Figure 30-30-33]

from the servo piston.
Remove the outer set screw from the servo piston

[Figure 30-30-31].

Figure 30-30-34
1
1
P-29686

P-29684 the housing.
Figure 30-30-37
Remove the servo piston (Item 1) [Figure 30-30-34].

Figure 30-30-35
P-29687
P-29685 Remove the relief valve (Item 1) [Figure 30-30-37] from

the housing by loosening the larger nut.
Remove the two seals (Item 1) [Figure 30-30-35] from

the servo piston.

Figure 30-30-38
4
5 2 3
1 2 3 4 2
1
P-29690
Remove the plug (Item 1), spring (Item 2), spring seat
P-22501 (Item 3) and spool (Item 4) [Figure 30-30-40] from the
housing.
Remove the plug (Item 1), O-rings (Item 2), spring (Item Figure 30-30-41
3) and poppet (Item 4) from the relief valve housing (Item

5) [Figure 30-30-38].
Figure 30-30-39
1 P-29692

P-29689

Figure 30-30-42
3
2
1
P-29696

P-29693
Figure 30-30-45
Remove the plug (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-42] from the housing.

Figure 30-30-43
1
P-29697
P-29691 NOTE: Mark the location of the orifice for correct

assembly.

43] from the plug.

Figure 30-30-46
1
1
P-29698
Remove the valve segment (Item 1) [Figure 30-30-48]

P-29694 from the cylinder.
Figure 30-30-49

Figure 30-30-47 2 2
1 1
2
P-22386
P-29695 Remove and discard the O-ring (Item 1). Remove the
eight mounting bolts (Item 2) [Figure 30-30-49] from the
mounting plate.
NOTE: Mark the location of the orifice for correct

assembly.

Figure 30-30-50
2 1
P-22503
Remove the cylinder block (Item 1) and synchronizing

P-22504 shaft assembly (Item 2) [Figure 30-30-52] from the
housing.
Remove the mounting plate [Figure 30-30-50] using a NOTE: It is not important that the pistons are
suitable puller. installed in their original position.

Figure 30-30-51 Figure 30-30-53
P-22449 P-22459
Remove and discard the seal (Item 1) [Figure 30-30-51] Remove the bearing plate (Item 1) [Figure 30-30-53]
from the mounting plate. from the cylinder block.

Figure 30-30-54
P-22390
Press the piston / shaft assembly from the housing

P-22458 [Figure 30-30-56].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-54]. Figure 30-30-57

DO NOT damage the bearing plate surface of the
cylinder block.
Figure 30-30-55
1
P-22505
Pry up the peened notch (Item 1) [Figure 30-30-57] in

the ring nut.
P-22388

housing.

Figure 30-30-58
P-22446
Using a clamp, compress the spring seat and spring, and

P-22506 drive the pin (Item 1) [Figure 30-30-60] inwards. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-58] from the Figure 30-30-61
shaft.

Figure 30-30-59
2 3
1
3
1
P-22447
P-22507 Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-61] from the shaft assembly.
Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3)
[Figure 30-30-59] from the shaft.

1
Figure 30-30-62
P-22462
Inspect the cylinder block assembly for wear or damage.

P-22508 The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-64]
must not be worn.
Remove the piston rings (Item 1) [Figure 30-30-62] from
the pistons. If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.
NOTE: If any portion of the shaft assembly, bearings
or races must be replaced, the complete shaft/
bearing assembly must be ordered. The only
serviceable part is the piston rings (Item 1)
[Figure 30-30-62].
Inspection
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of
material can get into the system and cause damage.
Figure 30-30-63
2 1
P-22461
Inspect the running (bronze) surface of the bearing plate

(Item 1) and locating pin holes (Item 2) [Figure 30-30-63]
for wear. Replace if damaged or worn.

Inspection (Cont'd)
Figure 30-30-65
1
B-15936
Inspect the valve segment for damage or wear on the

P-29685 sealing surface (Item 1) [Figure 30-30-67].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-65] for wear or segment by measuring distance "A" [Figure 30-30-67]. If
damage. this dimension is not within 34,5 to 34,7 mm (1.36 to 1.37

in) the assembly must be replaced.
Figure 30-30-66
P-29349
Inspect the swash plate running surface (Item 1)

[Figure 30-30-66] in the end cap for wear or damage.

Assembly
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
P-22441
Clean and lightly oil all parts prior to assembly.
Figure 30-30-68 Install the pin (Item 1) [Figure 30-30-70] as shown.
NOTE: Clamp is removed for photo clarity.

3
Figure 30-30-71
1 2

3
2
P-22447
Install the spring (Item 1) and spring seat (Item 2) into the 1
shaft assembly (Item 3) [Figure 30-30-68]. P-22453
Figure 30-30-69
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-71] into the shaft assembly.
NOTE: Be sure not to over press the bearings, they

should be able to roll freely.
P-22446
Using a clamp, compress the spring and spring seat

[Figure 30-30-69].

Assembly (Cont'd)
Figure 30-30-72
P-22455
Press the piston / shaft assembly into the housing

P-22505 [Figure 30-30-74].
DO NOT DAMAGE THE PISTONS.

Install the ring nut (Item 1) [Figure 30-30-72] onto the
shaft. Figure 30-30-75

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
Figure 30-30-73
1
P-22450
Install a new seal (Item 1) [Figure 30-30-75] into the

mounting plate until it is fully seated.
P-22509
Using a punch seat the ring nut into the groove in the
shaft. [Figure 30-30-73].

Assembly (Cont'd)
Figure 30-30-76 1
P-22386
Install a new O-ring (Item 1) [Figure 30-30-78] onto the

P-22388 mounting plate.
Figure 30-30-79
housing.

Figure 30-30-77
13,5 - 14 mm
(0.53 - 0.55”)
1 1
B-15933
1 1
Press a new bearing into the cylinder block until it is
P-22387 located 13,5 - 14,0 mm (0.53 - 0.55 in) below the bearing
plate surface [Figure 30-30-79].
Install the mounting plate onto the housing, install the

eight mounting bolts (Item 1) [Figure 30-30-77] and
tighten to 63 N•m (46 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-80
1
2
P-22459
Install the bearing plate (Item 1) [Figure 30-30-82] with

P-22440 the bronze surface facing up onto the cylinder block.
Figure 30-30-83
Figure 30-30-81

Piston End
2
1
P-22464
B-15935
Position the housing on end, tip the three pistons (Item 1)

Install new piston rings (Item 1) [Figure 30-30-80] onto [Figure 30-30-83] closest to the minimum angle stop out
the pistons, make sure the spherical surface (Item 1) toward the housing.
[Figure 30-30-81] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-80] and

[Figure 30-30-81] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.

Assembly (Cont'd)
1
Figure 30-30-84
B-15934
NOTE: The recess (Item 1) [Figure 30-30-86] on each

P-22511 roller MUST face the synchronizing shaft.
Figure 30-30-87
Install the synchronizing shaft support pin (Item 1)
[Figure 30-30-84] into the cylinder block and retain with

grease.
Figure 30-30-85
1
1
P-22512
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-87] into the motor shaft assembly and
P-22499 retain with grease.
Install the six synchronizing shaft rollers (Item 1)

[Figure 30-30-85] onto the synchronizing shaft and
retain with grease.

HYDROSTATIC DRIVE MOTOR (CONT'D) Lift the cylinder block slightly and guide the three
remaining pistons in position.
Assembly (Cont'd)
Figure 30-30-90
Figure 30-30-88
3
2
P-22500
P-22513
If the cylinder block (Item 1) [Figure 30-30-90] is properly

Install the synchronizing shaft and rollers (Item 1) installed, there should be very little rotational free-play
[Figure 30-30-88] into the motor shaft races. When between the block and the motor shaft.
properly installed the synchronizing shaft should move

freely in all directions. NOTE: A brass rod can be used to guide the pistons
into their bores.
NOTE: The motor shaft end of the synchronizing shaft
is smaller than the cylinder end. Lubricate the pistons and cylinder block bores with
hydraulic fluid.
Figure 30-30-89
Figure 30-30-91
2
1
4
1
3
3
2
1
1
P-22511
P-29698
When installing the cylinder block, the races (Item 1)
[Figure 30-30-89] in the cylinder block must be
positioned so the synchronizing shaft rollers (Item 2) Install a new gasket (Item 1) [Figure 30-30-91] onto the
[Figure 30-30-88] and pistons (Item 3) [Figure 30-30- housing.
88] and their bores (Item 2) [Figure 30-30-89] are
aligned. Install the valve segment (Item 2) [Figure 30-30-91] onto
the cylinder block and retain with heavy grease.
Install the six pistons (Item 3) [Figure 30-30-88] into the
cylinder bores, tilt the block so the synchronizing shaft NOTE: The hole (Item 3) in the valve segment should
rollers enter their races in the block and the support pin be next to the minimum displacement
(Item 3) [Figure 30-30-89] enter the recess. adjustment screw (Item 4) [Figure 30-30-91].

Assembly (Cont'd)
Figure 30-30-92
1
1
P-29697
Install the orifice (Item 1) [Figure 30-30-94] and tighten

P-29695 to 5 N•m (44.3 in-lb) torque.
Figure 30-30-95
Install the orifice (Item 1) [Figure 30-30-92] and tighten
to 5 N•m (44.3 in-lb) torque.

Figure 30-30-93
1
1
P-29696
Install the plug (Item 1) [Figure 30-30-95] and tighten to

P-29694 5 N•m (44.3 in-lb) torque.

5 N•m (44.3 in-lb) torque.

Assembly (Cont'd)
Figure 30-30-96
1
P-29691
Install a new O-ring (Item 1) [Figure 30-30-98] on the

P-29691 plug.
Figure 30-30-99
plug.

Figure 30-30-97
1
2
1 3
2
3
4
P-29693
Install the spring seat (Item 1), spring (Item 2) and plug
P-29690 (Item 3) [Figure 30-30-99] into the housing and tighten to
41 N•m (30 ft-lb) torque.
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3) and plug (Item 4) [Figure 30-30-97] into the
housing and tighten to 41 N•m (30 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-100
1
1
3 4
5 4 2 1
P-29686
Install the two plugs (Item 1) [Figure 30-30-102] and

P-22501 tighten to 41 N•m (30 ft-lb) torque.
Figure 30-30-103
Assemble the poppet (Item 1) and spring (Item 2) into the
relief valve housing (Item 3) using new O-rings (Item 4)

and plug (Item 5) [Figure 30-30-100].
Figure 30-30-101
P-29685
Install the two seals (Item 1) [Figure 30-30-103] onto the

servo piston.
P-29687
Install the relief valve (Item 1) [Figure 30-30-101] into the

housing and tighten to 52 N•m (38 ft-lb) torque.

Assembly (Cont'd)
Figure 30-30-104
P-29682
While holding the feedback lug, install the pointed set

P-29684 screw into the groove in the feedback lug [Figure 30-30-
106].
Install the servo piston (Item 1) into the housing, make Do not tighten at this time.
sure the hole (Item 2) [Figure 30-30-104] is in the

position shown when the piston is fully installed. Figure 30-30-107
Figure 30-30-105
2 1
P-29680
P-29683
Install the two O-rings (Item 1) [Figure 30-30-107].
Install the feed back lug (Item 1) [Figure 30-30-105] into

the servo piston.
NOTE: The position of the flat side of the feed back

lug (Item 2) [Figure 30-30-105].

Assembly (Cont'd)
Figure 30-30-108
1
1
P-29677
Install the adjustment rod (Item 1) [Figure 30-30-110]

P-29679 into the housing and through the feed back lug. Tighten
the large nut to 20 N•m (15 ft-lb) torque.
Install the end cap and tighten the four bolts (Item 1) Figure 30-30-111
[Figure 30-30-108] to 78 N•m (58 ft-lb) torque.

Figure 30-30-109
P-29682
P-29678 Tighten the pointed set screw at this time [Figure 30-30-
111].

adjustment rod.

Assembly (Cont'd)
Figure 30-30-112
1
P-29674
Install the two orifices (Item 1) [Figure 30-30-114] into

P-29681 the spool and tighten to 2 N•m (18 in-lb) torque.
Figure 30-30-115
Install the second set screw and tighten [Figure 30-30-
112].

Figure 30-30-113
1
1
P-29673

P-29675 the spool.
Install the two spring seats and spring (Item 1) into the
servo piston hole (Item 2) [Figure 30-30-113].
NOTE: Apply assembly lube to help hold into correct

position.

Assembly (Cont'd)
Figure 30-30-116 1
P-29670
Install the orifice (Item 1) [Figure 30-30-118] into the

P-29672 housing and tighten to 5 N•m (44.3 in-lb) torque.
Figure 30-30-119
Install the servo control spool (Item 1) [Figure 30-30-
116] into the housing.

Figure 30-30-117
1
P-29669

P-29671 5 N•m (44.3 in-lb) torque.
Install the inner spool (Item 1) [Figure 30-30-117].

Assembly (Cont'd)
Figure 30-30-120
1 1
1 1
P-22345
Install the end cap housing and tighten the eight bolts
P-29688 (Item 1) [Figure 30-30-122] to 115 N•m (85 ft-lb) torque.
Figure 30-30-123
Install a new gasket (Item 1) [Figure 30-30-120] onto the
end cap.

Figure 30-30-121 1
1
1
2 P-29666
Install the seven O-rings (Item 1) [Figure 30-30-123].

P-29667
Align the feed back lug (Item 1) and the valve segment
(Item 2) [Figure 30-30-121].

Assembly (Cont'd)
Figure 30-30-124
1
2
P-29661
Install the pin into the housing as shown [Figure 30-30-

P-29664 126].
Figure 30-30-127
Install the spool (Item 1) [Figure 30-30-124] into the
housing.

NOTE: The position of the groove (Item 2) [Figure 30-
1
30-124].
Figure 30-30-125
1 P-29662

plug.
P-29663
Install the fitting (Item 1) [Figure 30-30-125].

Assembly (Cont'd) 2
Figure 30-30-128
P-29657
Install a new O-ring (Item 1) and solenoid shaft assembly

P-29660 (Item 2) [Figure 30-30-130] into the housing.
Figure 30-30-131
5 N•m (44.3 in-lb) torque.

Figure 30-30-129 1
P-29656
Install the spool (Item 1) [Figure 30-30-131] into the

P-29659 housing.

solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-129] and

install into the solenoid shaft.

Assembly (Cont'd) 1
Figure 30-30-132
P-29653
Install the solenoid nut (Item 1) [Figure 30-30-134] and

P-29655 hand tighten.
Figure 30-30-135
solenoid.

1
Figure 30-30-133 2
P-29651
Install the solenoid housing assembly (Item 1). Tighten

P-29654 the bolts (Item 2) [Figure 30-30-135] to 78 N•m (58 ft-lb)
torque.
Install the solenoid (Item 1) [Figure 30-30-133].

HYDROSTATIC PUMP Figure 30-40-2
Remove the gear pump. (See Removal And Installation

on Page 20-130-1.)
1
IMPORTANT 1

P-56485
damage the system.
I-2003-0888
Figure 30-40-1
Figure 30-40-3

1
1
P-56484
P-56486
Remove the hose (Item 1) [Figure 30-40-1] from the top

of the hydrostatic pump. Remove the tubeline (Item 1) [Figure 30-40-3].

HYDROSTATIC PUMP (CONT’D) Figure 30-40-6
Figure 30-40-4
P-56490
Remove the four bolt flange hose (Item 1) [Figure 30-40-

P-56488 6] from the front of the pump.
Figure 30-40-7
Remove the two wires (Item 1) [Figure 30-40-4] from the
solenoids.

Figure 30-40-5
1
1
P-56491

P-56489

tubeline.

HYDROSTATIC PUMP (CONT’D) Figure 30-40-10
Figure 30-40-8
1
P-56494
Lift and remove the hydrostatic pump [Figure 30-40-10].

P-56493
NOTE: It can be necessary to remove fittings from
the pump for complete removal.

Figure 30-40-9
P-56492
Install a chain hoist and lifting strap to lift and support the
pump.

9].

HYDROSTATIC PUMP (CONT'D)
1. Multi-Function Valve Assembly

2. O-Ring
3. Plug
4. Plug
5. Nut
6. Charge Relief
7. O-Ring
8. Spring
9. Poppet
10. Plug
11. Control Filter Screen
12. Bolt
13. Lip Seal
14. Cover
15. O-Ring
16. Retainer Plate
B-15899

1. Bolt
2. Bolt
3. Bolt
4. Solenoid
5. Gasket
6. Plug
B-15900

1
2
3
4
5

8
6
1. Key
2. Charge Pump Shaft 7
12
3. Pin 13
4. Wear Plate
5. Gears 14
6. Coupling
7. Seal
11
8. Charge Pump Cover
9. Retaining Plate 9
10. Bolt
15
11. O-Ring
10
12. Flange Adapter
13. Washer
14. Bolt
15. O-Ring
B-23195

HYDROSTATIC PUMP (CONT’D)
1. Valve Plate
2. Retaining Ring
3. Spring Retainer
4. Spring
5. Spring Seat
6. Cylinder
7. Bolt
8. Slipper Guide Bearing
9. Spacer
10. Slipper Guide
11. Piston
12. Bolt
13. Bolt
14. Block
15. Spring
16. Servo Arm
17. Pin

18. Washer
19. Swash Plate Guide
20. Pin
21. Housing
22. Swash Plate
23. Bearing Assembly
24. Pin
25. Housing
B-19856

HYDROSTATIC PUMP (CONT’D)
1. Snap Ring
2. Spring Guide
3. Spring
4. Spring Guide

5. Bolt
6. Bolt
7. Servo Spring Housing
8. Nut
9. Screw
10. Servo Cylinder
11. O-Ring
12. O-Ring
13. Nut
14. Nut
15. Bearing
16. Spacer
17. Snap Ring
18. Shaft
19. Piston Ring
20. O-Ring
21. Block
22. Servo Piston
23. O-Ring
24. O-Ring
25. Bolt
26. End Cap
27. Shim
28. Spring
29. Spring Seat
30. Guide Post
31. Leveler
32. O-ring
33. Inserts
34. Side Cover
35. Bolt
36. Nut
37. Plug
B-19857

HYDROSTATIC PUMP (CONT'D) Figure 30-40-13
Disassembly
1
IMPORTANT
damage the system.
I-2003-0888
P-18566
Figure 30-40-11
Remove the shaft and bearing assembly (Item 1) from

the housing [Figure 30-40-13].
1 NOTE: If the shaft or bearing assembly become stuck

in the housing, lightly tap on the shaft.

Figure 30-40-14
2
P-18550
Remove the retainer bolt (Item 1). Remove the coupler

gear (Item 2) [Figure 30-40-11] from the shaft.
Figure 30-40-12
P-18567
Remove the shaft seal (Item 1) [Figure 30-40-14] from

2 the shaft.
1
P-18565
Remove the three screws (Item 1) and remove the

retainer plate (Item 2) [Figure 30-40-12] from the pump
housing

Figure 30-40-15
1 1
P-18721
Remove the relief valve lock nut (Item 1) and the plug
P-18570 (Item 2) [Figure 30-40-17].
Figure 30-40-18
Remove the snap ring (Item 1) and spacer washer (Item
2) [Figure 30-40-15] from the shaft.

Figure 30-40-16
P-18722
Remove the spring and relief poppet from the charge

P-18572 pump housing [Figure 30-40-18].
Remove the bearing (Item 1) [Figure 30-40-16] from the

shaft.
Place the pump on the work surface with the charge

pump up.
Mark the pump housings for correct assembly.
Before removing the relief valve mark the plug, lock nut
and housing for approximate assembly adjustment.

Figure 30-40-19
P-18584
2
Lift and remove the charge pump (Item 1) [Figure 30-40-
P-18723 21] from the pump housing.
Figure 30-40-22
19].

1
NOTE: Remove the lifting bracket (Item 2) [Figure 30-
40-19] from the pump.
1
Figure 30-40-20
2
1 1
2
1 1
P-18726
Remove the six bolts (Item 1) and remove the retaining

plate (Item 2) [Figure 30-40-22] from the charge pump.
P-18724

20] from the flange adapter.
Remove the flange adapter (Item 2) [Figure 30-40-20].

Figure 30-40-23 1
P-18728
Remove the coupler (Item 1) [Figure 30-40-25].

P-18726
Figure 30-40-26
Remove the charge pump cover (Item 1) [Figure 30-40-

23].

1
Figure 30-40-24
1
2
2
P-18729
Remove the charge pump shaft (Item 1) and key (Item 2)

[Figure 30-40-26] from the pump.
P-18558
Only if wear marks are present, remove the bushing (Item

1) from the charge pump cover (Item 2) [Figure 30-40-
24].

Figure 30-40-27
1
P-18732
Remove the charge pump wear plate (Item 1)

P-18730 [Figure 30-40-29].

Remove the charge pump gears (Item 1) [Figure 30-40-
27]. Figure 30-40-30

Figure 30-40-28
2 1
1
2 1
P-18585
P-18731
Remove the swash plate leveler spring shims (Item 1)
[Figure 30-40-30] from the spring pockets.
Remove the excentric ring (Item 1) and alignment pin
(Item 2) [Figure 30-40-28] from the pump. Inspect the journal bearing (Item 2) [Figure 30-40-30].
Replace as needed.
Note the position of the alignment pin.

3 1
Figure 30-40-31
2 2
2
1 3
P-18586
Remove the gasket (Item 1) and the valve plate (Item 2)

P-18734 from the housing. Note the direction of the arrows (Item
3) [Figure 30-40-33] on the valve plate for proper
assembly.
For proper operation, if the plugs (Item 1) and (Item 2)
[Figure 30-40-31] are removed from the housing they Figure 30-40-34

must be returned to their original position.
Installation: Tighten the servo relief valve plug (Item 1) 1

to 12 N•m (9 ft-lb) torque. Tighten the rotation pipe plugs
(Item 2) [Figure 30-40-31] to 5,4 N•m (47.8 in-lb) torque.
Figure 30-40-32 1
P-18588
1
Remove the two leveler springs (Item 1) [Figure 30-40-
34].
1
P-18735
Remove the multifunction valve assemblies (Item 1)


Figure 30-40-35
1
1 1
1
P-18596
Remove the six bolts (Item 1) [Figure 30-40-37] from the

P-18589 side cover.
Figure 30-40-38
Remove both spring seats (Item 1) [Figure 30-40-35]
from the swash plate leveler.

Figure 30-40-36
P-18597
Remove the side cover / swash plate leveler assembly

P-18590 from the housing [Figure 30-40-38].
Remove the swash plate hold down spring (Item 1)

[Figure 30-40-36].
Mark the position of the side cover.

Figure 30-40-39 2
2
1
1 1
P-18601
1
Remove the six solenoid manifold mounting screws (Item
P-18598 1). Remove the manifold (Item 2) [Figure 30-40-41].
Figure 30-40-42
Remove and discard the O-ring (Item 1). Loosen and
remove both guide posts (Item 2) [Figure 30-40-39].

Figure 30-40-40
1
P-18602
Remove the gasket (Item 1) [Figure 30-40-42] from the

P-18599 manifold.
Remove the leveler (Item 1) and slide inserts (Item 2)

[Figure 30-40-40] from the side cover.
Inspect the slide inserts for wear or damage.
Replace if needed.

Figure 30-40-43
1
1
1
1 P-18605
Remove and discard the three O-rings (Item 1)

P-18603 [Figure 30-40-45] from the solenoid.
Figure 30-40-46
Remove the four solenoid mounting screws (Item 1)
[Figure 30-40-43].

Figure 30-40-44
1 1
P-18606
Remove the anchor pin (Item 1) [Figure 30-40-46].

P-18604
Remove the solenoids (Item 1) [Figure 30-40-44] from

the manifold.

Figure 30-40-47
1
P-18610
Remove the swash plate / piston assembly (Item 1)

P-18607 [Figure 30-40-49] from the pump housing.
Figure 30-40-50
Remove the cage locator link (Item 1) [Figure 30-40-47]
from the swash plate.

1
Figure 30-40-48
P-18611
Remove the four slipper guide bearing retainer bolts

P-18609 (Item 1) [Figure 30-40-50].
Remove the cylinder block (Item 1) [Figure 30-40-48]

through the housing end opening. The swash plate and
piston assembly will remain in the housing.

Figure 30-40-51
P-18617
1
Remove the bronze slider block (Item 1) [Figure 30-40-

P-18615 53] from the servo piston.
Mark the position of the servo end covers.

Remove the swash plate bearings (Item 1) [Figure 30-
40-51] from the housing. Figure 30-40-54

Figure 30-40-52
1
P-18777
P-18616
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-
Remove the swash plate bearing races (Item 1) 40-54].

Figure 30-40-55 3 2
1
P-18622
Remove the servo piston (Item 1) from the housing (Item

P-18778 2) [Figure 30-40-57].

Remove the three screws (Item 1) [Figure 30-40-55] and 57].
remove the servo adjustment cover.

Figure 30-40-56
P-18620
Measure and record the adjustment setting for

approximate installation adjustment [Figure 30-40-56].

Inspection
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of 1 1
material can get into the system and cause damage.
Figure 30-40-58
1 2
P-18628
Inspect the servo piston and seal rings (Item 1)

[Figure 30-40-60] for wear. If worn, remove the seal
rings and expander O-rings from the piston.
Install new expander O-rings into the grooves in the

P-18769 servo piston. Carefully install the piston seal rings over

the expander rings. Do not overstretch the piston seal
rings.
Check the wear plate (Item 1) and charge pump gears
(Item 2) [Figure 30-40-58] for damage or wear. Figure 30-40-61
Figure 30-40-59
1
P-18622
P-187670
Lubricate the seal rings and carefully slide the servo
piston (Item 1) into the cylinder (Item 2) [Figure 30-40-
Check the valve plate [Figure 30-40-59], the surface 61]. Allow the assembly to set for 5 minutes to allow the
must be smooth and free of scratches. If scratches can seal rings to return to their original size.
be felt with a finger nail, replace the part.

Inspection (Cont'd)
Figure 30-40-62
1
P-18739
Servo arm (Item 1) [Figure 30-40-64] alignment is critical

P-18736 for proper pump operation. For this reason, removal of
the servo arm from the swash plate is not recommended.
Check the swash plate assembly surface, it must be If the servo arm must be removed from the swash plate.
smooth and free of scratches [Figure 30-40-62]. Remove the swash plate guide bolt (Item 2) and the

servo arm mounting bolt (Item 3) [Figure 30-40-64].
Figure 30-40-63
Installation: The servo arm (Item 1) [Figure 30-40-64]
must be carefully aligned with the slot and threaded holes
in the swash plate while installing, and must be pressed
completely into the swash plate slot.
Tighten the swash plate guide bolt and servo arm bolt to
Figure 30-40-65
1
P-18737
Inspect the swash plate guide (Item 1) [Figure 30-40-63]

for wear. Replace as needed.
Installation: Tighten the bolt to 32 N•m (24 ft-lb) torque.
P-18738
The threaded holes [Figure 30-40-65] in the swash plate

must be cleaned prior to assembly.

Inspection (Cont'd)
Figure 30-40-66
P-18773
1
Check the swash plate bearings [Figure 30-40-68] for
P-18739 wear and damage. Replace as needed.
Figure 30-40-69
Figure 30-40-67

2 1
P-18771
EM9353
Check each piston (Item 1) and piston shoe (Item 2)

If the headed roll pin and flat washer (Item 1) [Figure 30- [Figure 30-40-69] for wear or scratches.
40-66] must be installed in the swash plate, the distance
between the washer and the side of the swash plate must
be 5,33 mm (0.21 in) [Figure 30-40-67].

Inspection (Cont'd)
Figure 30-40-70 1
P-18568
Inspect the shaft seal (Item 1) [Figure 30-40-72].

P-18772 Replace if needed.

Check the cylinder block bores for wear or scratches 72].
[Figure 30-40-70].

Figure 30-40-73
If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.
Figure 30-40-71
P-18741
Inspect the multifunction valve cartridge for damage to

P-18712 parts or O-rings.
Replace O-rings as needed [Figure 30-40-73].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-71].
Check the bearing for correct operation. Remove the race

(Item 1) [Figure 30-40-71] from the shaft only if it is
necessary to replace the bearing.

Assembly
1
2
1
IMPORTANT
clean the work area before disassembly and keep all 3
damage the system. 3 1
I-2003-0888
2
1
P-18611
Clean and lightly oil all parts prior to assembly.
Figure 30-40-74 Apply Loctite® #242 to four NEW retainer bolts (Item 1).
Install the slipper guide bearings (Item 2) and spacers
(Item 3) and bolts (Item 1) [Figure 30-40-76].
Tighten the four bolts to 13,5 N•m (10 ft-lb) torque.

NOTE: Always use NEW retainer bolts with proper
locking compound.
NOTE: The slipper guides and piston slippers must

slide freely on the swash plate.
Figure 30-40-77
P-18754
Put the piston assemblies into the slipper guide

[Figure 30-40-74].
Figure 30-40-75
P-18756
Lubricate the pistons and cylinder block bores. Install the

assembled swash plate and pistons into the cylinder
block [Figure 30-40-77].
NOTE: The pistons and bores are not selectively

installed.
P-18755
Lubricate the slipper running surface on the swash plate,

center the piston and guide on the swash plate
[Figure 30-40-75].

Assembly (Cont'd)
Figure 30-40-78
1 P-18757
Install the bronze slider block (Item 1) [Figure 30-40-80]

on the swash plate servo arm.
P-18616
Figure 30-40-81
Install the swash plate bearing races (Item 1) [Figure 30-
40-78] into the housing. Note the locating pins are offset
in the housing to assure proper assembly.

Figure 30-40-79
P-18758
1
Carefully lower the cylinder block and swash plate

assembly into the housing [Figure 30-40-81].
P-18615
Assemble and lubricate the bearing cage (Item 1)

[Figure 30-40-79] and install it on the bearing races.

Assembly (Cont'd)
Figure 30-40-82
1
1
2
1
P-18595
Install new O-rings (Item 1) [Figure 30-40-84] on the

servo end cap.
P-18759
Lightly lubricate the O-rings and the inner surface of the

Holding the cylinder block and swash plate assembly end cap.
approximately 12 mm (0.5 in) above the bearings.
Position the servo piston (Item 1) on the bronze slider

Figure 30-40-85
block (Item 2) [Figure 30-40-82]. Take care not to wedge
the block, the parts should slide freely.
Figure 30-40-83
P-18594
Hold the servo piston in position and install the servo end
cap [Figure 30-40-85].
P-18760
Lower the cylinder block and swash plate assembly until

the swash plate is properly located on the bearings
[Figure 30-40-83].

Assembly (Cont'd)
Figure 30-40-86
3
1
1 1
P-18763
Align the slot in the swash plate bearing cage (Item 1)

with the pin (Item 2) in the swash plate and the pin hole
P-18761
(Item 3) [Figure 30-40-88] in the housing.
Install the three end cap mounting bolts (Item 1) Figure 30-40-89
[Figure 30-40-86]. Tighten to 13,5 N•m (10 ft-lb) torque.

Lightly lubricate the O-rings and inner surface of the
adjustment cover.
Figure 30-40-87
2
3
1
P-18606
Hook the cage locator link (Item 1) over the pin (Item 2)
[Figure 30-40-89] between the swash plate and washer.
Rotate the link into the slot in the bearing cage.
P-18762
Install the anchor pin (Item 3) [Figure 30-40-89] through
the locator link and into the housing.
Install the servo adjustment cover over the servo piston
until the piston adjustment screw touches the cover.
Using a hex wrench, turn the adjustment screw
counterclockwise while holding the cover until it is in
position [Figure 30-40-87].
NOTE: Do not install the bolts at this time.

Assembly (Cont'd)
Figure 30-40-90 1
P-18598
Install the two guide post bolts (Item 1) [Figure 30-40-92]

through the leveler and inserts. Install the sealing nuts
P-18764
and tighten to 23 N•m (17 ft-lb) torque.
Push the swash plate assembly toward the servo piston Install a new O-ring (Item 2) [Figure 30-40-92] on the
until the swash plate guide contacts the bearing races. cover.
Check for clearance between the servo arm and the

slider block [Figure 30-40-90]. If no clearance is present, Figure 30-40-93
recheck the assembly of the bearing cage and races.
Figure 30-40-91
2
P-18742
1 Lift the swash plate leveler and install the side cover
P-18765
[Figure 30-40-93].
Position the two side cover inserts (Item 1) and swash

plate leveler (Item 2) on the side cover. Note the
orientation of the leveler and the notch (Item 3)
[Figure 30-40-91] in the cover.

Assembly (Cont'd)
Figure 30-40-94
1 1
P-18745
Rotate the side cover [Figure 30-40-96] (which will also

rotate the leveler and swash plate) until the zero angle
P-18743
position is established, as determined by a second depth
measurement.
Install the two side cover bolts (Item 1) [Figure 30-40-94]
finger tight. Figure 30-40-97

Apply a force of 22 - 44 N (5 - 10 lbf) to the swash plate
leveler to make sure both lever arms contact the swash
plate.
Make sure the swash plate assembly is seated correctly

on the bearings.
Figure 30-40-95 1 1
P-18743
1
After the zero angle position has been established,
tighten the two side cover bolts (Item 1) [Figure 30-40-
97].
P18744
Use a depth micrometer to measure the distance from

the end cap to the swash plate surface. Take a second
measurement at a point 90° (Item 1) [Figure 30-40-95]
from the first point of measurement. These
measurements must not vary more than 0,025 mm
(0.001 in).

Assembly (Cont'd)
Figure 30-40-98
1 1
2 2
P-18747
Turn the adjustment screw on the servo, which will rotate

the swash plate assembly until a zero angle position is
P-18596
established [Figure 30-40-100].
Install the four remaining side cover bolts, apply Loctite® Figure 30-40-101
#242 to the threads of the "thru" bolts (Item 1)
[Figure 30-40-98].

First tighten the four side cover bolts (Item 2) to 32,5 N•m
(24 ft-lb) torque. Tighten the two remaining side cover
bolts (Item 1) [Figure 30-40-98] to 25 N•m (18.5 ft-lb)
torque.
Figure 30-40-99
P-18748
1
1
Use a depth micrometer to measure the distance from
the end cap to the swash plate surface [Figure 30-40-
101]. Take a second measurement at a point 180° from
the first point of measurement. These measurements
must not vary more than 0,025 mm (0.001 in).
P-18746
Install the three servo adjustment cover mounting screws

(Item 1) [Figure 30-40-99]. Tighten to 13,5 N•m (10 ft-lb)
torque.

Assembly (Cont'd)
Figure 30-40-102
1
1
P-18603
1
Lightly lubricate both solenoid spools and install into the

manifold housing and retain with the four screws (Item 1)
P-18749
[Figure 30-40-104].
Without turning the servo adjustment screw, install the Figure 30-40-105
sealed nut (Item 1) [Figure 30-40-102] and tighten.

Figure 30-40-103
P-18602
Apply assembly lube on the gasket (Item 1) [Figure 30-

P-18605
40-105] and install on the manifold housing.
Install new O-rings (Item 1) [Figure 30-40-103] on the

solenoid spool.

Assembly (Cont'd)
Figure 30-40-106
1
1
1
2
2 P-18589
2
Install the spring seats (Item 1) [Figure 30-40-108] on
the leveler arms.
P-18601
Figure 30-40-109
Install the manifold assembly (Item 1) on the pump with
the six screws (Item 2) [Figure 30-40-106].

1
Figure 30-40-107
2
1
1
P-18588
Install both springs (Item 1) [Figure 30-40-109] on the

leveler spring seats.
P-18590
Lubricate the running surface of the cylinder (Item 2)

Install the spring (Item 1) [Figure 30-40-107] on the [Figure 30-40-109].
servo arm link.

Assembly (Cont'd)
Figure 30-40-110 2
2 1
1 2
P-18585
Lubricate the end cap journal bearing (Item 1). Install the
hardened shims (Item 2) [Figure 30-40-112] in the
P-18587
charge pump pockets for the swash plate leveler springs.
Retain the shims with assembly lube.
Install the valve plate (Item 1) [Figure 30-40-110] on the
alignment pins. Turn the charge pump housing over.

NOTE: Ensure the direction of the arrow cut outs Figure 30-40-113
(Item 2) [Figure 30-40-110] in the valve plate
are positioned as shown.
Figure 30-40-111
1
1
P-18750
Lightly lubricate the alignment pin (Item 1) [Figure 30-

40-113] and install into the charge pump housing, in the
P-18586
position marked at time of disassembly. This will properly
align the wear plate and eccentric ring.
Install a new gasket (Item 1) [Figure 30-40-111] on the
housing. Install a new O-ring (Item 2) [Figure 30-40-113].

Assembly (Cont'd)
Figure 30-40-114
2
1
2
1
3
P-18729
Apply assembly lube and install the charge pump gears

(Item 1), charge pump shaft (Item 2) and key (Item 3)
P-18751
[Figure 30-40-116] into the pump.
Lubricate both sides of the wear plate (Item 1) and install Figure 30-40-117
in the charge pump. Align the wear plate with the
alignment pin (Item 2) [Figure 30-40-114].

Figure 30-40-115
1
2 1
P-18728
Install the coupler (Item 1) [Figure 30-40-117].

P-18731
Install the eccentric ring (Item 1) in the charge pump and

align with the alignment pin (Item 2) [Figure 30-40-115].

Assembly (Cont'd)
Figure 30-40-118
P-18752
Lower the charge pump onto the pump housing while

positioning the three springs in their pockets [Figure 30-
P-18727
40-120].
Install the charge pump cover (Item 1) [Figure 30-40- When properly installed, the charge pump will engage
118]. the alignment pins, but the springs will hold the charge

pump housing 3 - 8 mm (0.125 - 0.250 in) away from the
Rotate until pin hole in cover aligns with the pin. pump housing.
Figure 30-40-119 Figure 30-40-121
1
2 2 2
2
2 2
P-18726 P-18724
Install the retaining plate cover (Item 1) and six bolts Install the flange adapter (Item 1) and four bolts (Item 2)
(Item 2) [Figure 30-40-119]. Tighten the bolts to 13,5 [Figure 30-40-121]. Tighten the bolts to 122 N•m (90 ft-
N•m (10 ft-lb) torque. lb) torque.

Assembly (Cont'd)
Figure 30-40-122
1
P-18721
2
Install the plug with lock nut (Item 1) [Figure 30-40-124],

align the marks made at disassembly. Tighten the lock
P-18723
nut to 52 N•m (38 ft-lb) torque.
Install the two mounting bolts (Item 1) [Figure 30-40- Figure 30-40-125
122] and tighten to 38 N•m (28 ft-lb) torque.

NOTE: Install the lifting bracket (Item 2) [Figure 30-
40-122].
1 1
Figure 30-40-123
P-18753
Lightly lubricate and install both multifunction valve

assemblies (Item 1) [Figure 30-40-125] in the charge
pump. Tighten to 89 N•m (66 ft-lb) torque.
P-18722
Install the spring and relief poppet into the charge pump
[Figure 30-40-123].

Assembly (Cont'd)
Figure 30-40-126
3
1
2
P-18767
Install a new O-ring (Item 1) [Figure 30-40-128].

P-18570
Lubricate the seal with assembly lube and install the seal
assembly on the drive shaft and in the housing
Install the bearing (Item 1), the spacer washer (Item 2) [Figure 30-40-127].
and the snap ring (Item 3) [Figure 30-40-126] on the
drive shaft.

Figure 30-40-129
Position the pump on the charge pump end.
Figure 30-40-127
2 2
P-18768
Install the retainer plate (Item 1) and three screws (Item

2) [Figure 30-40-129]. Tighten the screws in a
P-18766
sequenced pattern to 16 N•m (12 ft-lb) torque.
Install the shaft and bearing assembly, aligning the shaft

spline with the cylinder block spline. Continue to lower
the shaft and align with the charge pump journal bearing
and charge pump coupler [Figure 30-40-127].

Assembly (Cont'd)
Figure 30-40-130
1
2
1,59 mm
(0.0625”)
B-15045
1,59 mm NOTE: When installing the coupler, maintain a 8,56

(0.0625”) mm (0.337 in) gap from the pump mount
P-18550
flange to the coupler [Figure 30-40-130] and
[Figure 30-40-131].
Install the coupler gear (Item 1) on the shaft and install
the bolt (Item 2) [Figure 30-40-130]. Remove the case plug (Item 3) [Figure 30-40-130] and

fill with clean hydraulic fluid prior to start up.
Rotate the pump shaft with a torque wrench to assure

correct assembly. The torque required to turn the shaft
(after "break away") should be within:
Minimum Maximum
5,4 N•m (47.8 in-lb) 12,2 N•m (9 ft-lb)


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

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-10
Brake System Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake System Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-17
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-18
Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-23
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-24
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-27
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-36
Brake System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-41

Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-47
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-49
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-52
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-56
AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Differential And Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-11
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-15
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-18
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-26
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-31
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-38
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-8
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2

STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-4

TROUBLESHOOTING
Chart
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Machine intensively operated or overloaded
20. Wheel loose
21. Beam housing bent


AXLE AND DIFFERENTIAL (FRONT)
General Information
For photo clarity, the following axle procedures are done • Front Axle removal. (See Removal on Page 40-30-1.),
with the complete axle assembly removed from the Front steering cylinder removal. (See Removing The
machine, although the planetary carrier, wheel hub, Steering Cylinder on Page 20-60-1.)
steering knuckle and drive axle procedures can be done
with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear

8. Ring gear support
9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Snap ring
19. Stud
S2668

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) Figure 40-20-3
Planetary Carrier Disassembly
Figure 40-20-1 1
1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-20-3].
Figure 40-20-4
so that later when you pry the planet gear carrier loose, is
does not fall.

1
Figure 40-20-2
1 2
S2466
S2464A
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-20-2] by alternatively forcing a
screwdriver into the appropriate slots.

Planetary Carrier Disassembly (Cont’d)
Figure 40-20-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-20-7] by acting on the stud bolts.
Figure 40-20-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-20-5].

Figure 40-20-6 1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-20-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-20-6].
points.

Figure 40-20-9
1
1
1 1
S2473A
Remove the snap rings (Item 1) [Figure 40-20-11].

S2470A
Figure 40-20-12
Remove the external bearing (Item 1) [Figure 40-20-9].
Figure 40-20-10

1
S2474A
With the help of a puller, remove the planet wheel gears

S2471A
(Item 1) [Figure 40-20-12].
NOTE: Mark the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-20-
10] by hand.


1
Figure 40-20-13
1 S2477A
Remove the sealing ring Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-20-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-20-16
[Figure 40-20-13].
1
Figure 40-20-14

1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-20-16].
Remove the ring gear support (Item 1) [Figure 40-20-

14].

AXLE AND DIFFERENTIAL (FRONT) (CONT’D)
Figure 40-20-17
S2479A
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-20-17].

NOTE: Hammer in an alternate way so as to avoid
crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Joint
8. Thrust bushing
9. Thrust bushing
10. Plug
15. Cover
17. Pivot pin
18. Grease fitting
19. Grease fitting
20. Plug

21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Articulation
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S2671

Steering Knuckle Disassembly
Figure 40-20-18 1 2
1
3
S2429B
2
1
Using two levers, remove the top tie rod (Item 1)
complete with front sealing ring (Item 2) and shims
S2591
(Item 3) [Figure 40-20-20].
Figure 40-20-21
Loosen and remove the bolts (Item 1) from the tie rod
(Item 2) [Figure 40-20-18].

Figure 40-20-19 2
1
3
2
UPPER TIE ROD BOTTOM TIE ROD

S1393
1 Configuration of the upper (Item 1) tie rod with shims

(Item 2) and the bottom tie rod (Item 3) [Figure 40-20-
S2427
21].
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-20-
19].

Steering Knuckle Disassembly (Cont’d)
Figure 40-20-22
S2539
Remove the complete steering case (Item 1) [Figure 40-

20-22].
Figure 40-20-23

1
3
4
S1387
Use a puller to remove the centering ring (Item 1), the

sealing ring (Item 2) and the bearing (Item 3) from the
steering case (Item 4) [Figure 40-20-23].
NOTE: Mark the orientation of both centering and

sealing ring.

Drive Axle Disassembly
Figure 40-20-24
1
2
1 S1402
Remove the snap ring (Item 1) from the bushing unit

S2592 (Item 2) [Figure 40-20-26].
Figure 40-20-27
Loosen and remove the top and bottom check nuts
(Item 1) from the dowels (Item 2) [Figure 40-20-24].
1

Figure 40-20-25
S1403
Position the entire drive axle (Item 1) under a press and

remove the complete bush (Item 2) [Figure 40-20-27].
S2593
Remove the entire drive axle (Item 1) [Figure 40-20-25].
NOTE: To remove the drive axle use, if necessary, a

plastic hammer or a lever.

Drive Axle Disassembly (Cont’d)
Figure 40-20-28
2 1
S3567
Remove the snap ring (Item 1) from the bearing (Item 2)

[Figure 40-20-28].

Figure 40-20-29
2
1
S1404
Use a puller to remove the bearing (Item 1), the sealing

ring (Item 2) [Figure 40-20-29] and the O-ring.

Brake System Parts Identification
1. Spacer
2. Spring
3. Piston
4. O-ring
5. O-ring
6. Back-up ring
7. Plug
8. Bleed fitting
9. Bolt
10. Seal washer
11. Cover
12. O-ring
13. Back-up ring

14. Piston
15. Intermediate brake
disc
16. Spring
17. Adjusting bolt
18. Adjusting bolt
19. Spring
20. Bolt
21. Nut
22. Lock washer
23. Shim
24. Spacer
25. Intermediate brake
disc
26. Brake disc
S2672

Brake System Disassembly 2
Figure 40-20-30
S2615
1
Remove the adjusting bolts (Item 1) from the

S2595 intermediate brake disc (Item 2) [Figure 40-20-32].
Figure 40-20-33
Sling the arms to be removed and connect it to a hoist.
Loosen and remove the bolts (Item 1) that secure the
arm (Item 2) to the central body (Item 3) [Figure 40-20-

30].
Figure 40-20-31 2
1
1
S2616
Remove the pin bolts (Item 1) guiding the intermediate

brake disc (Item 2) [Figure 40-20-33].
2
S2596 If the bolts are to be replaced, mark down the different
colors for the different brake gaps.
Remove arm (Item 1) together with the pack of the

braking discs (Item 2) [Figure 40-20-31]. Place the arm
on a bench.

Brake System Disassembly (Cont’d)
Figure 40-20-34
S2620
1 Remove the cover (Item 1) [Figure 40-20-36].

S2617
Figure 40-20-37
Remove the intermediate brake disc (Item 1) [Figure 40-
20-34].

Figure 40-20-35
1
1
S2621
1
Remove the Belleville washers (Item 1) [Figure 40-20-
37] and note down direction of assembly.
S2618
Loose the four studs (Item 1) [Figure 40-20-35].

Figure 40-20-38
1 S2624
Slowly introduce low-pressure compressed air through

S2622 the connection member for the service brake, in order to
extract the piston (Item 1) [Figure 40-20-40].
Slowly introduce low-pressure compressed air through Figure 40-20-41

the connection member for the service brake, in order to
extract the piston (Item 1) [Figure 40-20-38].

Figure 40-20-39
S2625
Remove the braking discs (Item 1) [Figure 40-20-41],

S2623 noting down direction of assembly.
NOTE: If discs are not to be replaced, avoid changing

Mark down the order of assembly and remove negative their position
piston. Mark the position [Figure 40-20-39].

Figure 40-20-42
S2626
Remove the braking discs, noting down direction of

assembly (Item 1) [Figure 40-20-42].

NOTE: If discs are not to be replaced, avoid changing
their position.

Differential Parts Identification
1. Lock nut
2. Cylinder bolt
3. Taper roller bearing
4. Cylinder bolt
5. Bolt
6. Pin
7. Snap ring
8. Snap ring
9. Friction washer
10. Differential pinion
11. Ring and Pinion
Gear Set
12. Differential side
gear

13. Differential carrier
14. Limited slip discs
S2673

Differential Disassembly
Figure 40-20-43
T13
2
1
S1409
Apply tool T13 and remove the ring nuts [Figure 40-20-
S2597 45].
Figure 40-20-46
Mark the position of the ring nut (Item 1). Remove the
cylinder bolts (Item 2) [Figure 40-20-43] from the ring
nut. 1 2

Figure 40-20-44
S2600
Remove the bolts (Item 1) from the middle cover (Item 2)

[Figure 40-20-46].
S2598
Uniformly heat the ring nuts (Item 1) [Figure 40-20-44]

up to a temperature of 80°C (176°F).

Differential Disassembly (Cont’d)
Figure 40-20-47
2 1
S2675

S2601
Figure 40-20-50
Insert a screwdriver in the opposing slots then force and

remove the middle cover (Item 1) and the complete
differential unit (Item 2) [Figure 40-20-47].

Figure 40-20-48
4
2
1
S2676
3 1
5 Remove the plug (Item 1) [Figure 40-20-50].
S1412
If the bearings need replacing, extract the bearing race

(Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-20-48].
NOTE: Check for damaged O-rings (Item 5) [Figure

40-20-48].


1
Figure 40-20-51
2
S1416
Remove the shim washer (Item 1) and the planetary gear

S1414 (Item 2) [Figure 40-20-53].
Figure 40-20-54
Remove the bolts (Item 1) from the crown (Item 2)
[Figure 40-20-51].

Figure 40-20-52
1
1
2
S1417
If the bearing needs to be replaced, extract the bearing

S1415 (Item 1) from the differential carrier (Item 2) [Figure 40-
20-54].

(Item 1) and remove the crown (Item 2) [Figure 40-20-
52].

Differential Disassembly (Cont’d) 3

2
Figure 40-20-55
3
1
2
1
S1421
2
Place the differential carrier (Item 1) under a press,

S1418 position a bushing (Item 2) and insert a pin (Item 3)
[Figure 40-20-57]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-20-56].
Remove the snap rings (Item 1) from the four pins
(Item 2) [Figure 40-20-55] of the planet wheel gears. Figure 40-20-58

Figure 40-20-56
T
2 1 2
1
S1422
S1419
Remove pinion and bush [Figure 40-20-58].
Insert a tool T between two planet wheel gears (Item 1) NOTE: In this condition the tool contains the pin.
[Figure 40-20-56].
NOTE: Make sure that the tool is perfectly lined up

with the pins (Item 2) [Figure 40-20-56] when
locked.


1
Figure 40-20-59
2
S1425
Remove the tool T and remove the planet wheel gears

S1423 (Item 1) and the relative shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-20-61].
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-20-59].

Figure 40-20-60
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

40-20-60] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

second planet wheel gear (Item 2) [Figure 40-20-60].
Repeat the operations for the two remaining pins.

Bevel Pinion Parts Identification
1. Cover
2. Gear
3. Snap ring
4. Ball bearing
5. Snap ring
6. Ring and Pinion
Gear Set
8. Shim
9. Shim
10. Spacer
11. Lock nut
12. Seal

13. Ball bearing
14. Gear
15. Snap ring
16. Ball bearing
17. Seal
18. Plug
19. Spring washer
20. Hexagon bolt
21. Magnet plug
22. Dowel
23. Plug
24. Flange
25. O-ring
26. Cylinder bolt
S1568

Bevel Pinion Disassembly
Figure 40-20-62
S2605
Place two levers into the appropriate slots [Figure 40-20-

S2603 64].
NOTE: Look out not to damage the surfaces.

Remove cylinder bolts (Item 1) [Figure 40-20-62] of the
drive side flange cover. Figure 40-20-65

Figure 40-20-63
S2606
2604
Lift off the cover (Item 1) [Figure 40-20-65].
Make the drive side flange cover loose using a plastic

hammer [Figure 40-20-63].

Bevel Pinion Disassembly (Cont’d)
Figure 40-20-66
1 1
S2733
Extract the pinion (Item 1) [Figure 40-20-68] complete

S2607 with the internal bearing, the distance piece and shims.
NOTE: The bearing races of the bearings remain in

Remove the sealing ring (Item 1) [Figure 40-20-66]. the central body (Item 2) [Figure 40-20-68].
Figure 40-20-67 Figure 40-20-69

T20
S2602 S2473
Position tool T20A (or T20B), so as to avoid pinion Remove the pinion, shims and distance piece [Figure
rotation. Loosen and remove the nut. Also remove the O- 40-20-69].
ring [Figure 40-20-67].

Figure 40-20-70
1 1
S2575
Insert a drift in the appropriate holes and remove the

S1565 bearing race (Item 1) as well as the shim
washers (Item 2) [Figure 40-20-72].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-20-70].

Figure 40-20-71
S2574
Remove the bearing race (Item 1) [Figure 40-20-71].

Bevel Pinion Assembly
Figure 40-20-73
T25C
DG
T24 1
T25A
S2576
Partially insert the bearing race (Item 1) [Figure 40-20-

S1569 75].
Figure 40-20-76
Using a surface plate, reset a magnetic based dial
indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.89 in]).

T25B T24 T25C T25A
Preset the indicator to approximately 2 mm (0.078 in).
Figure 40-20-74
1
2
S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race (Item 1) [Figure 40-
20-76].
1
S1570
Bring the internal bearing (Item 1), complete with its

bearing race, under the indicator (Item 2) [Figure 40-20-
74].
Determine overall thickness “D” of the bearing checking
the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the center and take

several measurements while rotating the
bearing race.

Bevel Pinion Assembly (Cont’d)
Figure 40-20-77 1
GB
GB
S1575
1
Install a depth gauge with long stem into a perfectly flat
S2577 bar (Item 1) [Figure 40-20-79]; when the bar rests on
two gauge blocks “GB” of 57 mm (2.24 in) size, reset the
indicator.
Connect the tension rod to the press and move the
bearing race (Item 1) [Figure 40-20-77] into its seat. Preset the indicator to approximately 2 mm (0.079 in).
Disconnect the press and remove the tension rod.

Figure 40-20-80
NOTE: Before starting the next stage, make sure that
the bearing race has been completely inserted
into its seat.
Figure 40-20-78
T26 (2)
T26 (2) T26 (1)

T24 1
1
S2579
Lay the bar (Item 1) [Figure 40-20-80] on tool T26 and

take the size “A” at about 57 mm (2.24 in) corresponding
S2578 to the maximum diameter of arms centring.
Assemble the different parts of tool T26 complete with See [Figure 40-20-81] for a sectional view.
external bearing (Item 1) [Figure 40-20-78],
measurement ring T24.
Tighten manually.

Figure 40-20-81
T24 T26 (2)
T26 (1)
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
under the bearing race [Figure 40-20-83].
Calculate size “B” which will be the first useful value for Figure 40-20-84
calculating the size of the shims that are to be inserted
1

Figure 40-20-82
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-20-
84] that will go under the bearing race.
Check the nominal size (X) marked on the pinion

(Item 1) [Figure 40-20-82] and add or subtract the
indicated variation (Y) so as to obtion size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-20-85
T26 (2)
1 2 T26 (1)
S2582
2 Position tool T26 complete with tapered bearings

S2580 (Items 1 and 2) [Figure 40-20-87]; manually tighten until
a rolling torque has been obtained.
Insert shim “S” (Item 1) and the bearing race of the Figure 40-20-88
internal bearing (Item 2) [Figure 40-20-85] in the central
body.

1
Figure 40-20-86
S2583
T25C
Insert the stem of a depth gauge (Item 1) [Figure 40-20-
S2581 88] in either side hole of tool T26(1); reset the indicator
with a presetting of approximately 3 mm.
Connect the tension rod to the press, fasten the bearing

race and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the bearing race has been completely
inserted.


1 S1
Figure 40-20-89
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12 -

S1585 0,13 mm [0.0047 - 0.0051 in], so as to obtain the size of
shim “S1” (Item 1) [Figure 40-20-91] which will be
inserted between the external bearing (Item 1) [Figure
Remove the indicator and release tools and bearings 40-20-90] and the distance piece (Item 1) [Figure 40-
from the central body. 20-89] and subsequently, to determine the preload for the
bearings.

Re-install all and insert the distance piece (Item 1)
between both bearings (Items 2 and 3) [Figure 40-20- Figure 40-20-92
89]; manually tighten the whole pack.
Figure 40-20-90
H
DDG
T26 (2)
2
1
1
T26 (1)
S1588
S1586 Position the internal bearing (Item 1) and the pinion

(Item 2) [Figure 40-20-92] under a press. Force the
bearing onto the pinion.
Insert depth gauge into tool T26 and measure variation
“H” in relation to the zero setting performed in [Figure 40-
20-90].

Figure 40-20-93
1
4 1 3
S2585
Connect the pinion (Item 1) [Figure 40-20-95] to the tie

S2584 rod T28A and T28B. Connect the tie rod T28C to the
press and block.
Install the pinion (Item 1), shim “S1” (Item 2) and the Figure 40-20-96
distance piece (Item 3) in the main body
(Item 4) [Figure 40-20-93].

NOTE: If multiple shims are used, always position the
thinner shims in between the thicker shims. 1
Figure 40-20-94
1
S1592
Apply Loctite® #242 to the thread of the ring nut

(Item 1) [Figure 40-20-96] and screw the nut onto the
pinion.
S1590
Insert the external bearing (Item 1) [Figure 40-20-94] in

the central body in order to complete the pack arranged
as in the figure.

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) NOTE: If torque does not reach the minimum value,
then the size of shim “S1” needs to be
Bevel Pinion Assembly (Cont’d) reduced.
Figure 40-20-97 NOTE: When calculating the increase or decrease in

size of shim “S1”, bear in mind that a variation
of shim of 0.01 mm corresponds to a variation
of 60 N•m (44 ft-lb) in the torque of the pinion.
Figure 40-20-99
T21
T22 1
S2608
Apply special wrench T22 to the ring nut and bar-hold T27
T21 to the pinion [Figure 40-20-97]. 2
S2610

Lock the wrench T22 and tighten the pinion to minimum
Lubricate the outer surface of the new sealing ring
Figure 40-20-98 (Item 1) and install it onto the central body
(Item 2) [Figure 40-20-99] using tool T27.
NOTE: Check that it is properly oriented.
T19
S2609
The rolling torque of the pinion shaft must be checked.

Using a dial indicator torque wrench, measure the rolling
torque. The correct torque is 1,20 - 1,70 N•m (10.6 - 15
in-lb) [Figure 40-20-98].
NOTE: If torque exceeds the maximum value, then

the size of shim “S1” between the bearing and
the distance piece needs to be increased.
NOTE: If torque does not reach the set value,

increase the torque setting of the ring nut in
different stages to obtain a maximum value of
570 N•m (420 ft-lb) (see the step under [Figure
40-20-97]).


2
Figure 40-20-100
1
1
S1532
Insert the thrust washer (Item 1) and the planetary gear

S2606 (Item 2) in the differential carrier (Item 3) [Figure 40-20-
102].
Install the drive side flange cover (Item 1) [Figure 40-20- Figure 40-20-103
100].
2

Figure 40-20-101
1
3
S1533
S2461 Position the thrust washer (Item 1) and the first planet
wheel gear (Item 2). Temporarily hold them in position
using a bar (Item 3) [Figure 40-20-103].
Tighten the bolts (Item 1) [Figure 40-20-101] of the drive
side flange cover.

Figure 40-20-104
2
1
1
S1535
Insert a tool between the two planetary gears and line up

S1534 the entire unit by pushing the bar (Item 1) [Figure 40-20-
105] all the way down until it is ejected.
With the help of a bar, position the second planet wheel

gear (Item 1) and the relative thrust washer
(Item 2) [Figure 40-20-104].

Differential Assembly 2
1
Figure 40-20-106
2
1
1
S1538
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-20-108].
Lock tool (Item 2) behind the planet wheel gears Figure 40-20-109
(Item 1) [Figure 40-20-106].

Figure 40-20-107
2
1
S1539
S1537 Put a tool pin on top of the planet wheel pin

(Item 1) [Figure 40-20-109].
Install the snap rings (Item 1) onto the pins

(Item 2) [Figure 40-20-107].

Differential Assembly (Cont’d)
Figure 40-20-110
1
1
S1542
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-20-112].
Figure 40-20-113
Press the pin all the way down (Item 1) [Figure 40-20-
110]

Figure 40-20-111 1
2
S1543
Position the thrust washer (Item 1) on the crown

S1541 (Item 2) [Figure 40-20-113].
NOTE: In order to hold the shim washer in position,

Remove the tool pin, bushing and install the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-20-111].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-20-114
1
3
1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races in the middle cover (Item 1) [Figure 40-20-116]
and in the central body.
Position the crown (Item 1) on the differential carrier Figure 40-20-117

(Item 2) and lock the bolts (Item 3) [Figure 40-20-114]
with Loctite® #242.
3

Tighten the bolts to 128 - 142 N•m (95 - 105 ft-lb) torque. 1
2
NOTE: Secure the bolts using the cross tightening
method.
Figure 40-20-115
S1547
T17
2
T17
1 Position the differential unit in the central body
(Item 1) with the help of a bar and install the middle
cover (Item 2) [Figure 40-20-117].
NOTE: Thoroughly check the state of the O-ring

(Item 3) [Figure 40-20-117] and make sure
S1545 that the cover is installted with the hole (see
arrow on [Figure 40-20-117]) in the lower
position.
Install the bearing races (Items 1 and 2) [Figure 40-20-
115] using tool T17.

Figure 40-20-118
T19
S1550
Pre-set the bearings by means of the ring nut situated on

S2613 the opposite side of the crown, so as to increase pinion
torque up to 1,40 - 2,10 N•m (12.4 - 18.6 in-lb) [Figure
40-20-120].
Lock the middle cover (Item 1) with bolts
(Item 2) [Figure 40-20-118]. NOTE: If bearings are not new, check the static
torque. If bearings are new, check the

continuous torque.
Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.5 ft-lb)
torque. Figure 40-20-121
Figure 40-20-119
A
2
T13
S2667
S2614
Introduce a dial indicator with rotary key “A” through the
plug hole (Item 1). Position the indicator on the center of
NOTE: If the ring nuts [Figure 40-20-119] are one of the teeth of the crown (Item 2) [Figure 40-20-
removed, apply some Loctite® #242 to them. 121] and pre-set it to 1 mm and reset it.
Tighten ring nuts on the crown side until
clearance between pinion and crown is zero,
then lock the crown. Go back 90 to 180°.

Figure 40-20-122
1
A
1
S2682
Apply Loctite® #242 to the bolts (Item 1) [Figure 40-20-

S2667 124], install them into one of the two holes and tighten.
Tighten the bolts to 23,8 - 26,2 N•m (17.5 - 19.3 ft-lb)

Manually move the crown (Item 1) [Figure 40-20-122] in torque.
both directions in order to check the existing backlash
between the pinion and the crown. Install the plug in the hole (Item 1) [Figure 40-20-121 on

Page 39] after applying flexible gasket compound for
Figure 40-20-123 seals to the rims.
T13
S2614
Adjust the backlash between the pinion and the crown by

unloosing one of the ring nuts [Figure 40-20-123] and
tightening the opposite to compensate.
Normal backlash: see table
CLEARANCE
RATIO
MIN. MAX.
14 – 32 0.18 mm 0.23 mm
(0.007 in) (0.009 in)
NOTE: Difference between MIN and MAX clearance

for whole circumference should not exceed
0,09 mm (0.0035 in).

Brake System Assembly
Figure 40-20-125

Y = Brake gap
Y = 0,75 mm (0.029 in)
S40033

Brake System Assembly (Cont’d)
Figure 40-20-126
1
S2629
Install O-rings (Item 1) [Figure 40-20-128] onto the

S2627 piston. Lubricate the piston and the O-rings and install
the unit into the cylinder.
Install O-rings (Item 1) [Figure 40-20-126] onto the Figure 40-20-129

piston. Lubricate the piston and the O-rings and install
the unit into the cylinder.

Figure 40-20-127
2
1
1 S2631
Using a plastic hammer, tap the piston (Item 1) into the

S2628 cylinder (Item 2) [Figure 40-20-129].
NOTE: Lightly hammer all around the edge in an

Using a plastic hammer, tap the piston (Item 1) into the alternate sequence.
cylinder (Item 2) [Figure 40-20-127].
NOTE: Lightly hammer all around the edge in an

alternate sequence.

Figure 40-20-130
S2634
1
Install the O-ring (Item 1) [Figure 40-20-132].
S2632
Figure 40-20-133
Clean and grease the surface, position one Belleville

washer (Item 1) [Figure 40-20-130] with the concave
side onto the cylinder. See [Figure 40-20-125 on Page

41] for a sectional view.
Figure 40-20-131
S2620
1
Engage the cylinder while holding the Belleville washers
into their position (Item 1) [Figure 40-20-133].
NOTE: Check the relative centering of the washers.

S2633
Position the second Belleville washer (Item 1) [Figure

40-20-131] with the concave side onto the other cylinder.
See [Figure 40-20-125 on Page 41] for a sectional view.

Figure 40-20-134
1
1
1
S2636
Insert the stroke automatic regulation springs (Item 1)

S2619 [Figure 40-20-136], place them in line with the piston.
Figure 40-20-137
Tighten the studs (Item 1) [Figure 40-20-134] to 30 - 45

Figure 40-20-135
1
S2612
1
Insert the intermediate disc (Item 1) [Figure 40-20-137].
S2635
Connect an external pump to the negative brake (Item 1)

[Figure 40-20-135] and introduce pressure to 1,5 - 3
MPa (15 - 30 bar) (217 - 435 psi). Always use Bobcat
hydraulic fluid.

Figure 40-20-138
S2638 / S2639
2 3
Take measure from the surface of the intermediate disk
S2637 to the cover sealing surface with 3 MPa (30 bar) (435 psi)
of pressure introduced. (example: 25,4 mm [1 in])
[Figure 40-20-140].
Install the six springs (Item 1) and the bolts (Item 2) into
the piston (Item 3) [Figure 40-20-138]. Figure 40-20-141

Figure 40-20-139
S2640
S2615
Put the brake disc pack including the shim under a press,
load with 100 kg (220 lb) and take the measure “V”.
Install the pin bolts making sure that they are all of the (example: 40 mm [1.57 in]) [Figure 40-20-141].
same color [Figure 40-20-139].
Apply Loctite® #270 to the thread.
Tighten the bolts to 5 - 7 N•m (44.3 - 62 in-lb) torque.

Figure 40-20-142
S2596
Check integrity and position of the arms’ O-ring (Item 1)

S2642 [Figure 40-20-144], install the complete arm.
NOTE: To assist axle shaft centring, slightly move

S = 68 mm (2.67 in) - (x + y + v) = Thickness of shims to the wheel hub.
insert under the shim washer.
Figure 40-20-145

See [Figure 40-20-125 on Page 41] for a sectional view
showing these dimensions.
Figure 40-20-143
1
3
1
1 4
2
S2645
Install the four washer (Item 1) and nuts (Item 2), tighten
S2643 nuts to 200 N•m (150 ft-lb) torque. Install the twelve
washer (Item 3) and bolts (Item 4) [Figure 40-20-145],
tighten the bolts to 283 N•m (209 ft-lb).
Slightly lubricate the braking disks with Bobcat hydraulic
fluid and install them in the arm following the correct NOTE: Tighten using the criss-cross method.
sequence. Orient them so that the oil circulation holes
and the holes (Item 1) [Figure 40-20-143] are perfectly
lined up.

Drive Axle Assembly
Figure 40-20-146
1
T5 T6
1 2 S1399
3
3 Heat the bush in oil at an approx. temperature of 100°C
S1397 (212°F) and install the entire bush (Item 1) on the drive
axle (Item 2) [Figure 40-20-148].
Using tools T5 and T6, insert the sealing ring (Item 1) Figure 40-20-149
and the bearing (Item 2) in the bush (Item 3) [Figure 40-
20-146].

NOTE: Carefully check the assembly side of the
sealing ring. 3
Figure 40-20-147
2
1
S1400
2 1
Install the snap ring (Item 1) on the axle shaft (Item 2).
After the bearing has cooled, install the O-ring
(Item 3) [Figure 40-20-149].
S1398
Install the snap ring (Item 1) on the bearing

(Item 2) [Figure 40-20-147].

Drive Axle Assembly (Cont’d)

1
Figure 40-20-150 2 1
2
S1507
Screw the check nuts (Item 1) of the dowels

S2592 (Item 2) [Figure 40-20-151] and lock them using a
torque wrench: 122 N•m (90 ft-lb) .
Insert the drive axle and tighten the top and bottom
dowels (Item 1) [Figure 40-20-150]. Tighten to
maximum 15 N•m (11 ft-lb) torque.

NOTE: Center the point of the check dowels in the
slot.

Steering Knuckle Assembly
Figure 40-20-152
T7
1
1
S1496
Lubricate the terminal of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-20-154].
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-20-152], using tool T7. Figure 40-20-155

Figure 40-20-153
2
1 2
1
T8
S40021
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).
To be assembled under the upper pin (Item 2) [Figure
Lubricate the outer surface of the sealing ring (Item 1) 40-20-155].
and centering ring (Item 2) [Figure 40-20-153]. Install
them into their seat using tool T8.

Steering Knuckle Assembly (Cont’d)
Figure 40-20-156
1
3
3
2
2 1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
S40022 orientated as shown in the inset. Lubricate the pivot pin
(Item 3) and the seal (Item 1). Install the pivot pin (Item 3)
and the six bolts (Item 2) [Figure 40-20-158]. (Bolts not
Install the seal (Item 1). Make sure the seal (Item 1) is shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
orientated as shown in the inset. Lubricate the pivot pin torque.
(Item 3) and the seal (Item 1). Install the pivot pin (Item 3)

and the six bolts (Item 2) [Figure 40-20-156]. (Bolts not Figure 40-20-159
shown in photo.) Tighten the bolts to 140 N•m (103 ft-lb)
torque.
Figure 40-20-157
S40023
Tighten the bolts (Item 1) [Figure 40-20-159] of the

S1499 bottom tie rod in sequence using the cross tightening
method, to 140 N•m (103 ft-lb) torque.
Lubricate the group with grease and mount it in the


Figure 40-20-160
S40024
Check the torque of the pins, which has to be between 30

S2568 and 60 N•m (22 - 44 ft-lb). If the preliminary measured
value is too high, the shims have to be increased
[Figure 40-20-161].
Install a magnetic based dial indicator on the steering
housing. Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the

width and reduce it by removing shims [Figure 40-20-
160].

Planetary Carrier Assembly
Figure 40-20-162
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-20-164] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-20-165
of the external bearing (Item 1) [Figure 40-20-162]
under the press.

Figure 40-20-163
2
1
S2587
T9A Install the bearing (Item 1) [Figure 40-20-165] into the

S2586 bearing race.
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-20-163] (wide side up).
NOTE: Check that the bearing race is correctly

oriented.

Planetary Carrier Assembly (Cont’d)
Figure 40-20-166
1
T10
3
S1456
1
Insert the snap ring (Item 1) in order to secure the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-20-168].
NOTE: Make sure the snap ring is firmly seated in the

Position tool T10 and press the sealing ring groove.
(Item 1) [Figure 40-20-166] into its seat.
Figure 40-20-169

Figure 40-20-167
DOWN
T11
1
1
2 2
S1457
S1455
With the help of tool T11, insert the planet wheel gears
Insert the flange (Item 1) in the crown (Item 2) [Figure (Item 1) into the cover (Item 2) [Figure 40-20-169].
40-20-167].
Accurately check the orientation.

Figure 40-20-170
S2470A
Install the external bearing (Item 1) [Figure 40-20-172].

S2473A
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-20-170]. edge.
Figure 40-20-171 Figure 40-20-173

1 1
S2471A S2646
Install the hub (Item 1) [Figure 40-20-171]. Install the complete crown flange (Item 1) [Figure 40-20-
173].
NOTE: In order to fasten the flange, use a plastic

hammer and alternatively hammer on several
equidistant points.

Figure 40-20-174 2
3
1
2
1
S2465A
Install the planetary carrier cover (Item 1) onto the hub

S2467 (Item 2) [Figure 40-20-176].
NOTE: Check that the O-ring (Item 3) [Figure 40-20-

Apply silicone-based grease to the surface of the flange 176] is in good condition and in position.
(Item 1) which touches the crown flange (Item 2) [Figure
40-20-174]. Figure 40-20-177

Install the flange (Item 1) [Figure 40-20-174].
Figure 40-20-175 1
2 2
S2648
Lock the planetary carrier cover (Item 1) by tightening the

S2647 bolts (Item 2) [Figure 40-20-177]. Tighten the bolts to 40
- 50 N•m (30 - 37 ft-lb) torque.
Apply silicone based grease to the surface of the flange

(Item 1) which touches the crown flange (Item 2) [Figure
40-20-175].
Cross tighten the nuts (Item 1) [Figure 40-20-175] in two

stages.
Initial torque: 120 N•m (89 ft-lb)

Final torque: 255 - 285 N•m (188 - 210 ft-lb)

Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS

6912197 PINION RING NUT T19
T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

AXLE AND DIFFERENTIAL (REAR)
General Information with the axle assembly installed in the machine. For
complete axle repair, the following must be done.
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the • Rear Axle removal. (See Removal on Page 40-90-1.)
machine, although the planetary carrier, wheel hub, Rear steering cylinder removal. (See Removing The
steering knuckle and drive axle procedures can be done Steering Cylinder on Page 20-60-1.)
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support

9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Snap ring
19. Stud
S2668

AXLE AND DIFFERENTIAL (REAR) (CONT’D) Figure 40-21-3
Figure 40-21-1 1
1
S2465X
S2465A
Remove the securing bolts and lift the planet gear carrier
S2463A (Item 1) [Figure 40-21-3].
Figure 40-21-4
so that later when you pry the planet gear carrier loose, is
does not fall.

1
Figure 40-21-2
2
1
S2466
S2464A
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-21-2] by alternatively forcing a
screwdriver into the appropriate slots.

Figure 40-21-5 1
1 2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-21-7] by acting on the stud bolts.
Figure 40-21-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-21-5].

Figure 40-21-6 1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-21-8]

S2467
using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-21-6]
points.

Figure 40-21-9
1
1
1
1
1
S2473A
Remove the snap rings (Item 1) [Figure 40-21-11].

S2470A
Figure 40-21-12
Remove the external bearing (Item 1) [Figure 40-21-9].
Figure 40-21-10

1
S2474A
With the help of a puller, remove the planet wheel gears

S2471A
(Item 1) [Figure 40-21-12].
NOTE: Note the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-21-
10] by hand.

Figure 40-21-13 1
1 S2477A
Remove the sealing ring (Item 1) from the wheel hub

S2475 (Item 2) [Figure 40-21-15].
Remove the snap ring (Item 1) from the ring gear (Item 2) Figure 40-21-16
[Figure 40-21-13].
Figure 40-21-14

1
S2478A
S2476 Remove the internal bearing (Item 1) [Figure 40-21-16].
Remove the ring gear support (Item 1) [Figure 40-21-

14].

AXLE AND DIFFERENTIAL (REAR) (CONT’D)
Figure 40-21-17
S2479A
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub
(Item 1) [Figure 40-21-17].

NOTE: Hammer in an alternate way so as to avoid
crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1. Snap ring
2. Snap ring
3. Ball bearing
4. Seal
5. Reduction bushing
6. O-ring
7. Joint
8. Thrust bushing
9. Thrust bushing
10. Plug
15. Cover
17. Pivot pin
18. Grease fitting
19. Grease fitting
20. Plug

21. Shim
22. Seal
23. Bushing
24. Nut
25. Washer
26. Stud
27. Steering case
28. Steering case
29. Articulation
30. Pivot pin
31. Bolt
32. Articulated tie rod
33. Bushing
34. Nut
35. Cylinder
36. Bolt
37. Bushing assembly
S2671

Steering Knuckle Disassembly
Figure 40-21-18 2
1
1
3
S2429B
2
1
Using two levers, remove the top tie rod (Item 1)
complete with front seal (Item 2) and shims (Item 3)
S2591
[Figure 40-21-20].
Figure 40-21-21
Loosen and remove the bolts (Item 1) from the tie rod
(Item 2) [Figure 40-21-18].

Figure 40-21-19
2
1
3
2
UPPER TIE ROD BOTTOM TIE ROD

S1393
Configuration of the upper (Item 1) tie rod with shims

1 (Item 2) and the lower tie rod (Item 3) [Figure 40-21-21].
S2427A
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-21-
19].

Steering Knuckle Disassembly (Cont’d)
Figure 40-21-22
1 1
S2540
Remove the entire drive axle (Item 1) [Figure 40-21-24].

S2539
NOTE: To remove the drive axle use, if necessary, a

Remove the complete steering case (Item 1) [Figure 40- plastic hammer or a lever.
21-22].
Figure 40-21-23

1
3
1 2 3
4
S1387
Use a puller to remove the centering ring (Item 1), the

sealing ring (Item 2) and the bearing (Item 3) from the
NOTE: Mark the orientation of both centring and

sealing ring.

Differential And Bevel Pinion Parts Identification

1. Cylinder bolt
2. Shim
3. Taper roller bearing 10. Differential pinion
4. Bolt 11. Washer
5. Bevel gear set 12. Differential side
gear
6. Circlip
13. Differential carrier
7. Friction washer
14. Differential
8. Snap ring
9. Pin
16. Shim
18. Shim
19. Shim
20. Spacer
21. Ring nut
22. Seal
23. Gear assembly
24. Flange
25. O-ring
26. Pinion
S2670

Differential Disassembly
Figure 40-21-25
S2543
Pull out the differential (Item 1) [Figure 40-21-27].

S2541
Figure 40-21-28
Loose the nuts (Item 1) [Figure 40-21-25].
Figure 40-21-26

1
S2544

1 S2542
Remove the complete arm (Item 1) [Figure 40-21-26].

Figure 40-21-29
1
1
2
S1415

S2545 (Item 1) and remove the crown (Item 2) [Figure 40-21-
31].
Remove the top plug (Item 1) [Figure 40-21-29]. Figure 40-21-32
Figure 40-21-30

1
S1416
S1414
Remove the shim washer (Item 1) and the planetary gear
(Item 2) [Figure 40-21-32].
Remove the bolts (Item 1) from the crown (Item 2)
[Figure 40-21-30].

Figure 40-21-33 T
2 1 1 2
2
S1419
Insert a tool T between two planet wheel gears (Item 1)

S1417 [Figure 40-21-35].
NOTE: Make sure that the tool is perfectly lined up

If the bearing needs to be replaced, extract the bearing with the pins (Item 2) [Figure 40-21-35] when
(Item 1) from the differential carrier (Item 2) [Figure 40- locked.
21-33].

Figure 40-21-36
Figure 40-21-34
3
2
3
1
2
1
2
S1421
S1418
Place the differential carrier (Item 1) under a press,

Remove the snap rings (Item 1) from the four pins position a bushing (Item 2) and insert a pin (Item 3)
(Item 2) [Figure 40-21-34] of the planet wheel gears. [Figure 40-21-36]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-21-36].

Figure 40-21-37
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

S1422 40-21-39] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

Remove the pin and bushing [Figure 40-21-37]. second planet wheel gear (Item 2) [Figure 40-21-39].
NOTE: In this condition the tool contains the pin. Repeat the operations for the two remaining pins.

Figure 40-21-38 Figure 40-21-40
S1423 S1425
Remove the tool with inside the pin of the planet wheel Remove the tool T and remove the planet wheel gears
gear [Figure 40-21-38]. (Item 1) and the relative shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-21-40].

Bevel Pinion Disassembly
Figure 40-21-41
1
1
S2547
2
Remove the flange (Item 1) [Figure 40-21-43] complete
S2546 with guard by means of a puller.
Figure 40-21-44
If disassembly is awkward, heat the check nut (Item 1) of
the flange (Item 2) [Figure 40-21-41] at 80°C (176°F).

NOTE: Heating is meant to loosen the setting of
1
Loctite® on the nut. Always be careful with
hot parts.
Figure 40-21-42
S2548
1
Remove the swinging support (Item 1) [Figure 40-21-
44].
2
S2571
Remove the nut (Item 1) and remove the O-ring (Item 2)

[Figure 40-21-42].

Figure 40-21-45
2
1
S2551
Extract the pinion (Item 1) [Figure 40-21-47] complete

S2549 with the internal bearing, the distance piece and shims.
NOTE: The bearing races remain in the central body

Remove the sealing ring (Item 1) [Figure 40-21-45]. (Item 2) [Figure 40-21-47].
Figure 40-21-46 Figure 40-21-48

T21 1 1
T22
S2550 S1564
Position wrench T22 onto the ring nut (Item 1) [Figure Remove the pinion (Item 1) [Figure 40-21-48], shims
40-21-46] and apply bar hold T21 to the pinion (Item 1) and distance piece.
[Figure 40-21-47].
Stop wrench T22 and rotate the pinion so as to release

and remove the ring nut (Item 1) [Figure 40-21-46].
NOTE: If disassembly proves awkward, heat the ring

nut to approximately 80°C (176°F).

Figure 40-21-49
1 1
S1567
Insert a drift in the appropriate holes and remove the

S1565 bearing race (Item 1) as well as the shim washers
(Item 2) [Figure 40-21-51].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-21-49].

Figure 40-21-50
S1566
Remove the bearing race of the external bearing (Item 1)

[Figure 40-21-50].

Bevel Pinion Assembly
Figure 40-21-52
DG
T25C
T24
T25A S1571
Partially insert the bearing race (Item 1) [Figure 40-21-

S1569 54].
Figure 40-21-55
Using a surface plate, reset a magnetic based dial
indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm [1.19 in]) [Figure 40-21-52].

T25B T24 T25C T25A
Preset the indicator to approximately 2 mm (0.079 in).
Figure 40-21-53
1
DG
S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race of the external
bearing (Item 1) [Figure 40-21-55].
1
S1570
Bring the internal bearing (Item 1) [Figure 40-21-53],

complete with its bearing race, under the indicator.
Determine overall thickness “D” of the bearing checking

the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the center and take

several measurements while rotating the
bearing race.

Figure 40-21-56 DG1

1
GB
GB
S1575
Install a depth gauge with long stem into a perfectly flat

S2556 bar (Item 1) [Figure 40-21-58]; when the bar rests on two
size-blocks “GB” of 57 mm (2.24 in), reset the indicator.
Connect the tension rod to the press and move the Preset the indicator to approximately 2 mm (0.079 in) and
bearing race [Figure 40-21-56] into its seat. reset.

Disconnect the press and remove the tension rod. Figure 40-21-59
NOTE: Before starting the next stage, make sure that

the bearing race has been completely inserted
into its seat.
Figure 40-21-57 T26 (1)
T26 (2) T24 T26 (1)

S1576
1
Lay bar (Item 1) [Figure 40-21-59] on tool T26(1) and

take the size “A” at about 57 mm (2.24 in) corresponding
to the maximum diameter of arms centring.
S1574
Insert both parts of tool T26 complete with external

bearing (Item 1) [Figure 40-21-57], measurement ring
T24.
Tighten manually.

Figure 40-21-60
T26 (2)
T24
T26 (1)
S1579
Calculate size “C” which represents the second value for

S1577 calculating the size of the shims “S” that are to be placed
Calculate size “B” which will be the first useful value for Figure 40-21-63
calculating the size of the shims that are to be inserted
1

Figure 40-21-61
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-21-
63] that will go under the bearing race.
Check the nominal size (X) marked on the pinion

(Item 1) [Figure 40-21-61] and add or subtract the
indicated variation (Y) so as to obtion size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-21-64
T26 (2)
1 2
T26 (1)
S2561
Position tools T26C and T26B complete with tapered

2 S2559 bearings (Items 1 and 2) [Figure 40-21-66]; manually
tighten until a rolling has been obtained.
Insert shim “S” (Item 1) and the bearing race of the Figure 40-21-67
internal bearing (Item 2) [Figure 40-21-64] in the central
body.

Figure 40-21-65 DDG
S2562
T25A
Insert the stem of a depth dial indicator in either side hole
T25C S2560 of tool T26C; reset the indicator with a presetting of
approximately 3 mm (0.118 in) [Figure 40-21-67].
Position tool T25A and tension rod T25C [Figure 40-21-

65].
Connect the tension rod to the press, fasten the bearing

race and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the bearing race has been completely
inserted.


1 S1
Figure 40-21-68
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12-

S1585 0,13 mm (0.0047 - 0.0051 in), so as to obtain the size of
shim “S1” (Item 1) [Figure 40-21-70] which will be
inserted between the external bearing (Item 1) [Figure
Remove the indicator and release tools and bearings 40-21-69] and the distance piece (Item 1) [Figure 40-
from the central body. 21-68] and subsequently, to determine the preload for the
bearings.

Re-install all and insert the distance piece (Item 1)
between both bearings (Items 2 and 3) [Figure 40-21- Figure 40-21-71
68]; manually tighten the whole pack.
Figure 40-21-69
H
DDG
2
T26 (2)
1
1
T26 (1)
S1588
S1586 Position the internal bearing (Item 1) and the pinion

(Item 2) [Figure 40-21-71] under a press. Force the
bearing onto the pinion.
Insert depth dial indicator into tool T26B-T26C and
measure variation “H” in relation to the zero setting
performed in [Figure 40-21-69].

Figure 40-21-72
4
1 3
S2564
2 Connect the pinion (Item 1) [Figure 40-21-74] to the tie

S2563 rod T28A and T28B. Connect the tie rod T28C to the
press and block.
Install the pinion (Item 1), shim “S1” (Item 2) and the Figure 40-21-75
distance piece (Item 3) in the main body (Item 4) [Figure
40-21-72].

NOTE: The finer shims must be placed in between
the thicker ones.
Figure 40-21-73
2 1
1
S2570
Apply Loctite® #242 to the thread of the ring nut

(Item 1) and screw the nut onto the pinion
(Item 2) [Figure 40-21-75].
S1590
Insert the external bearing (Item 1) [Figure 40-21-73] in

the central body in order to complete the pack arranged
as in the figure.

Figure 40-21-76
T19
T19
T22
S2566
The rolling torque of the pinion shaft must be checked.

S2565 Using a dial indicator torque wrench, measure the rolling
torque [Figure 40-21-77]. The correct torque is 1,20-
1,70 N•m (10.6 - 15 in-lb).
Apply special wrench T22 to the ring nut and bar-hold
T19 to the pinion [Figure 40-21-76]. NOTE: If torque exceeds the maximum value, then
the size of shim “S1” between the bearing and

Lock the wrench T22 and rotate the pinion using a torque the distance piece needs to be increased.
wrench, up to a minimum required torque of 500 N•m
(370 ft-lb). NOTE: If torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
570 N•m (420 ft-lb).
NOTE: If torque does not reach the minimum value,

then the size of shim “S1” needs to be
reduced.
NOTE: When calculating the increase or decrease in

size of shim “S1”, bear in mind that a variation
of shim of 0,01 mm corresponds to a variation
of 60 N•m (44 ft-lb) in the torque of the pinion.

Figure 40-21-78
2
T27
1
S1597
Install the flange (Item 1) complete with the guard

S2567 (Item 2) [Figure 40-21-80] and fasten it. For aligning the
flange, use a plastic hammer if necessary.
Lubricate the outer surface of the new sealing ring and NOTE: Make sure that the guard is securely fastened
install it onto the central body (Item 1) [Figure 40-21-78] onto the flange and that it is not deformed.
using tool T27.

Figure 40-21-81
Figure 40-21-79
1
S2571
S2548
Apply Loctite® #242 to the threads on the pinion shaft.

Install the swinging support (Item 1) [Figure 40-21-79].
Install the O-ring (Item 1) and nut (Item 2) [Figure 40-21-
NOTE: Check that it is properly oriented. 81] on the pinion shaft.
Tighten the bolt to 280 - 310 N•m (207 - 229 ft-lb) torque.

Differential Assembly
2
Figure 40-21-82
1
2
S1534
With the help of a bar, position the second planet wheel

S1532 gear (Item 1) and the relative shim washer
(Item 2) [Figure 40-21-84].
Insert the shim washer (Item 1) and the planetary gear Figure 40-21-85
(Item 2) in the differential carrier (Item 3) [Figure 40-21-
82].

Figure 40-21-83
1
1
3
S1535
Insert a tool between the two planetary gears and. Line

S1533 up the entire unit by pushing the bar (Item 1) [Figure 40-
21-85] all the way down until it is ejected.
Position the shim washer (Item 1) and the first planet

wheel gear (Item 2). Hold them in position using a bar
(Item 3) [Figure 40-21-83].

Differential Assembly (Cont’d) 2

1
Figure 40-21-86
1
1
S1538
Place the differential carrier under the press, position

S1536 bushing (Item 1) and insert the planet wheel pin
(Item 2) [Figure 40-21-88].
Lock the tool behind the planet wheel gears Figure 40-21-89
(Item 1) [Figure 40-21-86]. After locking, remove bar
T16C.

Figure 40-21-87
2
1
S1539
Put a tool pin on top of the planet wheel pin

S1537 (Item 1) [Figure 40-21-89].
Install the snap rings (Item 1) onto the pins

(Item 2) [Figure 40-21-87].

Figure 40-21-90
1
S1542
1
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-21-92].
Figure 40-21-93
Press the pin all the way down (Item 1) [Figure 40-21-
90].

Figure 40-21-91 1
2
S1543
Position the shim washer (Item 1) on the crown

S1541 (Item 2) [Figure 40-21-93].
NOTE: In order to hold the shim washer in position,

Remove tool pin, bushing and install the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-21-91].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-21-94 1
3 1 2
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races (Item 1) in the central body (Item 2) [Figure 40-21-
96].
Position the crown (Item 1) on the differential carrier Figure 40-21-97

(Item 2) and lock the bolts (Item 3) [Figure 40-21-94]
with Loctite® #242.

Tighten the bolts to 128 - 142 N•m (94 - 105 ft-lb) torque. 1
A
NOTE: Secure the bolts using the cross tightening
method.
Figure 40-21-95 2
S1551
T17
2
T17
1 Introduce a dial indicator with rotary key “A” through the
top plug hole (Item 1). Position the indicator on the center
of one of the teeth of the crown (Item 2) [Figure 40-21-
97] and pre-set it to 1 mm (0.039 in) and reset it.
S1545
Install the bearing races (Item 1 and 2) [Figure 40-21-

95] using tool T17.

Figure 40-21-98
A 1
S2542
Re-install the complete arms (Item 1) [Figure 40-21-99].

S1552
Manually move the crown (Item 1) [Figure 40-21-98] in

both directions in order to check the existing backlash
between the pinion and the crown.

NOTE: Difference between MIN and MAX clearance
for whole circumference should not exceed
0.09 mm (0.038 in).

Steering Knuckle Assembly
Figure 40-21-100
T17
1
S1496
Lubricate the terminal of the drive axle and install the

S1447 steering case (Item 1) [Figure 40-21-102].
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-21-100], using tool T17. Figure 40-21-103

Figure 40-21-101
2
1 2
1
T8
S40021
S1448
Prepare a series of shims (Item 1) of 0,85 mm (0.033 in).
To be assembled under the upper pin (Item 2) [Figure
Lubricate the outer surface of the sealing ring 40-21-103].
(Item 1) and centering ring (Item 2) [Figure 40-21-101].
Install them into their seat using tool T8.

Figure 40-21-104
1
3
3
2
2 1
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the unit (Item 1) in the steering case

S40022 (Item 2) [Figure 40-21-106]. Position the new bolts and
tighten.
Install a new seal (Item 1) onto the top tie rod (Item 3). Check for the correct assembly side of the seal
Lubricate and install the unit in the steering case. Insert (Item 3) [Figure 40-21-106].
and tighten the 6 bolts (Item 2) [Figure 40-21-104] to

140 N•m (103 ft-lb) using the cross tightening method. Figure 40-21-107
Check the correct assembly side of the seal

(Item 1) [Figure 40-21-104].
Figure 40-21-105
S40023
Tighten the bolts (Item 1) [Figure 40-21-107] of the

bottom tie rod in sequence using the cross tightening
S1499 method, to 140 N•m (103 ft-lb).
Lubricate the group with grease and mount it in the


Figure 40-21-108
S2568
Install a magnetic based dial indicator on the steering

housing. Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the

width and reduce it by removing shims [Figure 40-21-
108].
Figure 40-21-109
S2569
Check the torque of the pins, which has to be between

30 - 60 N•m (22 - 44 ft-lb). If the preliminary measured
value is too high, the shims have to be increased [Figure
40-21-109].

Planetary Carrier Assembly
Figure 40-21-110
T10
T9B
S2588
Position tool T10 and press the sealing ring into its seat
S1451 [Figure 40-21-112].
Figure 40-21-113
Position the upper part of tool T9B and press the bearing
races into the hub (Item 1) [Figure 40-21-110] all the
way down.

Figure 40-21-111
1
1 2
S1455
Insert the flange (Item 1) in the crown (Item 2) [Figure

40-21-113].
S2587
Install the bearing (Item 1) [Figure 40-21-111] into the

internal bearing race (wide side up).

Figure 40-21-114
3 S2473A
Install the four snap rings (Item 1) [Figure 40-21-116].

S1456
Figure 40-21-117
Insert the snap ring (Item 1) in order to secure the flange

(Item 2) in the crown (Item 3) [Figure 40-21-114].
2

NOTE: Carefully check that the ring is properly
inserted in the slot of the crown.
Figure 40-21-115
DOWN 1
S2539
T11
1
Install the steering case (Item 1) onto the drive axle
2 (Item 2) [Figure 40-21-117] and install the tie rods.
Connect the steering bars.

S1457
With the help of tool T11, insert the planet wheel gears
(Item 1) into the cover (Item 2) [Figure 40-21-115].
Accurately check the orientation.

Figure 40-21-118
1
S2646
Install the complete crown flange (Item 1) [Figure 40-21-

S2471A 120].
NOTE: In order to fasten the flange, use a plastic

Install the hub (Item 1) [Figure 40-21-118]. hammer and alternatively hammer on several
equidistant points.
Figure 40-21-119

Figure 40-21-121
2
1
1
S2470A
S2467
Install the external bearing (Item 1) [Figure 40-21-119].

Apply silicone based grease to the surface of the flange
NOTE: Using a plastic hammer, drive the bearing to (Item 1) which touches the crown flange (Item 2). Install
the limit stop by lightly hammering around the the flange (Item 1) [Figure 40-21-121].
edge.

Figure 40-21-122
1
2
1
S1468
Lock the planetary carrier cover (Item 1) by tightening

S2647 the bolts (Item 2) [Figure 40-21-124]. Tighten the bolts
to 40 - 50 N•m (30 - 37 ft-lb).
Cross tighten the nuts (Item 1) [Figure 40-21-122] in two

stages.

Initial torque setting: 120 N•m (88 ft-lb).
The final torque setting is 255 - 285 N•m (188 - 210 ft-lb)
torque.
Figure 40-21-123
1
S2465
Install the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-21-123] and install the snap ring.
NOTE: Check that the O-ring is in good condition and

in position.

Special Tools
TOOL
BOBCAT PN IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS

6912197 PINION RING NUT T19
T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

FRONT AXLE Figure 40-30-2
Removal
Fully retract the telescoping boom. Raise the boom and

install the boom stop. (See Installing The Approved
Boom Stop on Page 10-150-1.) 1
Figure 40-30-1
1 1
P-29281
Remove the two bolts (Item 1) from the cover (Item 2)

[Figure 40-30-2]. Remove the cover.
S1978
IMPORTANT

Rotate the battery disconnect switch (Item 1) [Figure 40- When repairing hydrostatic and hydraulic systems,
30-1] to the right, to disconnect the power supply from clean the work area before disassembly and keep all
the battery. parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
WARNING Figure 40-30-3

immediately.
W-2145-0290
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-100-2.)
S2066
NOTE: On machines without frame leveling, the

frame leveling cylinder has been replaced by
a rigid connection [Figure 40-30-3]. Follow the
same procedure.

FRONT AXLE (CONT’D) Figure 40-30-6
Removal (Cont’d)
Figure 40-30-4
1
2
1
S1960
Remove the hose (Item 1) [Figure 40-30-6] from the right

S1986 side of the drive motor.
Figure 40-30-7
Remove the hose (Item 1) and disconnect the wire
harness (Item 2) [Figure 40-30-4] from the top of the

drive motor.
Figure 40-30-5
1
1
S1966
Remove the hose (Item 1) [Figure 40-30-7] from the left

side of the drive motor.
S1975
Remove the hose (Item 1) [Figure 40-30-5] from the top

right side of the drive motor.

Removal (Cont’d)
Figure 40-30-8
S1959
2 1
S1984 bottom of the drive motor.
Figure 40-30-11
Remove the nut (Item 1) and coil (Item 2) [Figure 40-30-
8] from the right side of the drive motor.

Figure 40-30-9
1
S1961

S1970 bottom right side of the drive motor.
Disconnect the wire harness (Item 1) [Figure 40-30-9]

coming from the headlights on the right side.

Removal (Cont’d)
Figure 40-30-12
1
1
1
S1981
Remove the hose (Item 1) [Figure 40-30-14] on the right

S1975 side of the steering cylinder.
Figure 40-30-15
Remove the two four bolt flange hoses (Item 1) [Figure
40-30-12].

Mark the location of the hoses for correct installation.
Figure 40-30-13
1 S2042
1
Lift the front of the machine and place jack stands (Item
1) [Figure 40-30-15] under the frame as shown.
S1983 Place a block in front and behind one of the rear wheels.
Remove the hose (Item 1) [Figure 40-30-13] on the left

side of the steering cylinder.

Removal (Cont’d)
Figure 40-30-16
1
2
1
S1951
Remove the four bolts (Item 1) from both front fender

S1850 mount brackets (Item 2) [Figure 40-30-18].
Remove the front fenders.

Remove the four driveshaft mounting bolts (Item 1)
[Figure 40-30-16] and nuts. Figure 40-30-19

Figure 40-30-17
S2037
S1954
Using a jack, apply upward pressure to lift and support
the front axle [Figure 40-30-19].
Remove the eight lug nuts and washers (Item 1) [Figure
40-30-17] from each front tire.
Remove both front wheels.

Removal (Cont’d)
Figure 40-30-20
2
2
1
S2035
Remove the bolt (Item 1) and nut from the pivot pin (Item
S2049 2) [Figure 40-30-22].
Figure 40-30-23
Remove the snap ring (Item 1) and washer (Item 2)
[Figure 40-30-20].

Figure 40-30-21
2
1
1
S2030
Use a pin removal tool (Item 1) to remove the pivot pin

S2034 (Item 2) [Figure 40-30-23].

Removal (Cont’d)
Figure 40-30-24
S1981
Remove the brake hose (Item 1) [Figure 40-30-26] from

S2017 the right side of the axle.
Figure 40-30-27
Gently lower the jack approximately 150 mm (6 in).

Figure 40-30-25
S2022
S1983 Have an assistant balance the axle on the jack and lower
the jack slowly while rolling the axle out from under the
frame [Figure 40-30-27].
Remove the brake hose (Item 1) [Figure 40-30-25] from
the left side of the axle.

Installation
Figure 40-30-28
S1981
Install the brake hose (Item 1) [Figure 40-30-30] from the

S2022 right side of the axle.
Figure 40-30-31
Have an assistant balance the axle on the jack and roll
the axle under the frame [Figure 40-30-28].

Figure 40-30-29
1
1
S2017
Install the pivot pin (Item 1) [Figure 40-30-31] using a

S1983 copper hammer.
Install the brake hose (Item 1) [Figure 40-30-29] from the

left side of the axle.

Figure 40-30-32
S2034
Install the pivot pin (Item 1) [Figure 40-30-34].

S2017
Figure 40-30-35
Gently raise the jack [Figure 40-30-32].

Figure 40-30-33
1
2
S2049
1
Install the washer (Item 1) and snap ring (Item 2) [Figure
S2017 40-30-35].
Install the bolt (Item 1) and nut on the pivot pin

(Item 2) [Figure 40-30-33].

Figure 40-30-36 1
S1954
Install both front wheels. Install the eight lug nuts and
S2037 washers (Item 1) [Figure 40-30-38] from each front tire.
Tighten the nuts to 360 N•m (266 ft-lb) torque.
Lower the jack and remove it [Figure 40-30-36]. Figure 40-30-39

Figure 40-30-37
1
1
2
S1850
S1951
Install the four driveshaft mounting bolts (Item 1) [Figure
40-30-39] and nuts. Tighten the bolts to 118 N•m (87 ft-
Install the front fenders. lb) torque.
Install the four bolts (Item 1) from both front fender mount
brackets (Item 2) [Figure 40-30-37].
Tighten the bolts to 125 - 140 N•m (90 - 100 ft-lb) torque.

Figure 40-30-40
S1983
Install the hose (Item 1) [Figure 40-30-42] on the left

1 S2042 side of the steering cylinder.
Figure 40-30-43
Lift the front of the machine and remove the jack stands
(Item 1) [Figure 40-30-40] from uhnder the frame.

Figure 40-30-41
1
S1975
Install the two four bolt flange hoses (Item 1) [Figure 40-
S1981 30-43].
Mark the location of the hoses for correct installation.

Install the hose (Item 1) [Figure 40-30-41] on the right
side of the steering cylinder.

Installation (Cont’d) 1
Figure 40-30-44
S1973
Connect the wire harness (Item 1) [Figure 40-30-46]

S1961 coming from the headlights on the left side.
Figure 40-30-47
Install the hose (Item 1) [Figure 40-30-44] from the
bottom right side of the drive motor.

Figure 40-30-45
S1970
1
Connect the wire harness (Item 1) [Figure 40-30-47]

S1959 coming from the headlights on the right side.
Install the hose (Item 1) [Figure 40-30-45] from the

bottom of the drive motor.

Figure 40-30-48
1
S1960
1 2
Install the hose (Item 1) [Figure 40-30-50] on the right
S1984 side of the drive motor.
Figure 40-30-51
Install the coil (Item 1) and nut (Item 2) [Figure 40-30-48]
from the right side of the drive motor.

Figure 40-30-49
1
S1975
Install the hose (Item 1) [Figure 40-30-51] on the top

S1966 right side of the drive motor.
Install the hose (Item 1) [Figure 40-30-49] on the left

side of the drive motor.

Figure 40-30-52
1 1
2
S1977
Rotate the battery switch (Item 1) [Figure 40-30-54] to

S1986 the left to reconnect the power supply from the battery.
Install the hose (Item 1) and connect the wire harness

(Item 2) [Figure 40-30-52] on the top of the drive motor.

Figure 40-30-53
2
P-29281
Install the cover (Item 1) with two bolts (Item 2) [Figure

40-30-53].
Fill the hydraulic fluid reservoir. (See Removing And


AXLE TOE-IN Figure 40-40-3
Adjustment
The axle is removed from the machine for photo clarity,

1 2
but this procedure can be completed with the axle
installed in the machine.
3
Turn the steering wheel until the steering cylinder rod is
positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-40-1
S2056
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-40-3] of both tie rods until the measurement
is the same.
1
Tighten the nut (Item 3) [Figure 40-40-3] to 360 N•m
(266 ft-lb) torque.

1
EM9354
Install two identical, straight bars (Item 1) [Figure 40-40-

1] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

ground.
Figure 40-40-2
S2057
Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.


PARKING BRAKE Figure 40-50-3
Releasing The Brake For Towing
Block all four wheels to prevent the machine from moving

1
once the parking brake is released.
Locate the six brake release bolts (three per side) on the
front axle.
Figure 40-50-1
Towing
Position
S6802
Locate the tow valve (Item 1) [Figure 40-50-3], turn

counterclockwise 90° to the towing position.
The machine is now ready to be towed.

S1394
Figure 40-50-2
S1395
Alternately turn the brake release bolts [Figure 40-50-1]

and [Figure 40-50-2] "IN" (clockwise) 180° each until you
feel resistance. Continue to turn each release bolt in
equally 180° for a total of approximately 5 complete
turns.

PARKING BRAKE (CONT'D) Figure 40-50-6
Re-Activating The Brake

Operating
Block all four wheels to prevent the machine from Position 1
moving.
Locate the six brake release bolts (three per side) on the
front axle.
Figure 40-50-4
S6802
Locate the tow valve (Item 1) [Figure 40-50-6] under the

hood, turn clockwise 90° to the operating position.
The parking brake is now re-activated.

S1394
Figure 40-50-5
S1395
Alternately turn the brake release bolts [Figure 40-50-4]

and [Figure 40-50-5] OUT (counterclockwise) 180° until
the torque drops off sharply. Continue to turn each
release bolt out equally 180° until the brake release bolt
presses against the bolt housing. After the brake release
bolt is touching the bolt housing turn each brake release
bolt IN (clockwise) 90°.

STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
1
The axle is removed from the machine for photo clarity,
but this procedure can be completed with the axle
installed in the machine.
Figure 40-60-1
S2061
Adjust the stop (Item 1) [Figure 40-60-3] as needed.

Tighten the lock nut to 150 N•m (110 ft-lb) torque.
Figure 40-60-4
2
S2059

Install a straight bar (Item 1) onto the wheel hub and
secure using lug nuts. Turn the steering wheel completely
to one side. Place a straight bar (Item 2) [Figure 40-60-
1] on the pinion shaft.
Figure 40-60-2
S2062
Turn the steering wheel completely to the other side

[Figure 40-60-4] and repeat above procedure.
32-35
Degrees
S2060
Use an angle gauge, to obtain a reading of 32 - 35

degrees [Figure 40-60-2].


DRIVE SHAFT Figure 40-70-2
Figure 40-70-1
1
S2047
S1850
Remove the drive shaft (Item 1) [Figure 40-70-2] out the
rear of the machine.
Remove the four drive shaft mounting bolts (Item 1)

[Figure 40-70-1] from each end of the drive shaft.


SERVICE BRAKE Figure 40-80-2
Description
There are two bleed screws located on each side of the

front axle differential housing.
1
Air trapped in the brake lines can cause a spongy feel
and / or delayed activation of the service brake. 2
Use the following procedure to remove air from the brake

circuit.
Bleeding The Brake Circuit

S2013
Lift and block the machine. (See Procedure on Page 10-
10-1.)
Figure 40-80-3
NOTE: Position the jack stands to allow starting the
machine and driving the wheels.
Figure 10-151-1 1
2

S2014
Remove the caps and loosen the four bleed screws

1 (Items 1 and 2) [Figure 40-80-2] and [Figure 40-80-3].
S2043
With the aid of an assistant, start the engine, lower the
restraint bar and apply the service brake until a
Figure 40-80-1
continuous stream of clean hydraulic fluid, with no air,
flows from the inside bleed screws (Item 1) [Figure 40-
80-2] and [Figure 40-80-3]. Stop the engine and tighten
the two inside bleed screws.
Start the machine, engage the hydro stat and turn the
wheels until a continuous stream of clean hydraulic fluid,
with no air, flows from the outside bleed screws (Item 2)
[Figure 40-80-2] and [Figure 40-80-3]. Stop the engine
and tighten the two outside bleed screws.
1
Lower the machine and test for proper brake operation.
S2048
On machines with frame leveling the bleed screws are

accessible from [Figure 10-151-1] and [Figure 40-80-1]
on each side of the pivot frame.


REAR AXLE Figure 40-90-2
Removal
Position the machine on the work surface.
WARNING
S7422
immediately. Lift the rear of the machine and place jack stands under
W-2145-0290
the frame as shown [Figure 40-90-2].
Figure 40-90-1 Place a block in front and behind the front wheel.
Figure 40-90-3

1
S1978
S1955
Rotate the battery disconnect switch (Item 1) [Figure 40-
90-1] to the right, to disconnect the power supply from
the battery. Remove the eight lug nuts and washers (Item 1)
[Figure 40-90-3] from each rear tire.
Drain the hydraulic fluid reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-100-2.) Remove both rear tires.

REAR AXLE (CONT’D)
Removal (Cont’d)
IMPORTANT
Figure 40-90-4
damage the system.
1 I-2003-0888
Figure 40-90-6
1
S1951

remove the rear fenders.

Figure 40-90-5
S1947

steering cylinder.
Figure 40-90-7
1
S1850
Remove the four bolts (Item 1) [Figure 40-90-5] and nuts

from the driveshaft.
S1949

steering cylinder.

REAR AXLE (CONT’D) Figure 40-90-10
Removal (Cont’d)
Figure 40-90-8
S1945
Remove the two bolts (Item 1) [Figure 40-90-10] from

S1950 the front mount bracket.
Figure 40-90-11
90-8].

Figure 40-90-9
1 1
1
S1943
Remove the two bolts (Item 1) [Figure 40-90-11] from

S1939 the rear mount bracket.
Install two jack stands (Item 1) [Figure 40-90-9] under

the axle.

Removal (Cont’d)
Figure 40-90-12
S1936
Raise the floor jack, lifting the axle upward and into
S1936 position [Figure 40-90-14].
Remove the jack stands from the axle.

Have an assistant balance the axle on the floor jack and
lower the floor jack slowly. Roll the axle out from under
the frame [Figure 40-90-12].
Installation
Figure 40-90-13
S1934
Have an assistant balance the axle on the floor jack and

roll the axle under the frame [Figure 40-90-13].

Figure 40-90-15
1
1 1
P-44945
S1945
Install the two bolts (Item 1) [Figure 40-90-17] in the

S1939 front mounting bracket.
Figure 40-90-18
Install jack stands (Item 1) [Figure 40-90-15] under the
axle.
1

Figure 40-90-16
S1950
1
Plug the wire connector (Item 1) [Figure 40-90-18] into
S1943 the wire harness.
Install the two bolts (Item 1) [Figure 40-90-16] in the rear

mount bracket.

Figure 40-90-19
S1850
Install the driveshaft (Item 1) with four bolts (Item 2)

S1949 [Figure 40-90-21]. Tighten the bolts to 118 N•m (87 ft-lb)
torque.
Install the hose (Item 1) [Figure 40-90-19] on the Figure 40-90-22

steering cylinder.

Figure 40-90-20
1
2
S1951
S1949 Install the rear fenders (Item 1) with four bolts (Item 2)
[Figure 40-90-22].
Install the hose (Item 1) [Figure 40-90-20] on the

steering cylinder

Figure 40-90-23
1
S1977

S1955 90-25] to the left, to restore the power supply from the
battery.
Install the rear tires with eight nuts (Item 1) [Figure 40-
90-23] and washers.

Tighten the nuts to 360 N•m (266 ft-lb) torque.
Figure 40-90-24
S7422
Raise the machine and remove the jack stands. Lower

the machine and remove the blocks from the front tire
[Figure 40-90-24].


MAINFRAME
OPERATOR CAB (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) . . . . . . . . . . . . . . . . 50-10-1
OPERATOR CAB (S/N A8HD13000 & ABOVE, S/N A8GW13000 & ABOVE, S/N A8GT13000 &
ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE) . . . . . . . . . . . . . . . . 50-11-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

FIXED BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
END BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3

WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51-2
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
AIR INTAKE COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

QUICK-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
REAR WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
PIVOT LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1


JOYSTICK PANEL (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999
& BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) . . . . . . . . . . . . . 50-130-1
JOYSTICK PANEL (S/N A8HD13000 & ABOVE, S/N A8GW13000 & ABOVE, S/N A8GT13000
& ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE) . . . . . . . . . . . . . . 50-131-1
DASH COVER / STEERING COLUMN COVER (S/N A8HD12999 & BELOW, S/N A8GW12999
& BELOW, S/N A8GT12999 & BELOW, S/NA8GV12999 & BELOW, S/N A8GJ12999 &
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
DASH COVER / STEERING COLUMN COVER (S/N A8HD13000 & ABOVE, S/N A8GW13000
& ABOVE, S/N A8GT13000 & ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141-1
INTERMEDIATE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-2

BOOM TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
STABILIZER FRAME (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-2

OPERATOR CAB (S/N A8HD12999 & BELOW, S/N Figure 50-10-3
A8GW12999 & BELOW, S/N A8GT12999 & BELOW, S/
N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW)
1
Figure 50-10-1
P-50821
1 Remove the three screws (Item 1) from the access cover

(Item 2) [Figure 50-10-3] located on the back of the
canopy.
P-29315B
Remove the access cover.

Raise the boom and install the boom stop (Item 1)

NOTE: Mark all hoses and electrical connectors for
[Figure 50-10-1].
Stop the engine.
Figure 50-10-4
Figure 50-10-2
P-44577
Disconnect the two electrical connectors (Item 1) [Figure

P-29253 50-10-4].

the battery.

(CONT’D)
Figure 50-10-5
P-44930
1
10-7].
P-44578
WARNING

50-10-5]. Hydraulic fluid escaping under pressure can have
Figure 50-10-6 penetrating the skin. This can cause serious injury
immediately.
W-2145-0290
2
1
IMPORTANT
P-44925 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Loosen the screw (Item 1) and disconnect the electrical

(CONT’D)
Removal And Installation (Cont’d) 1
Figure 50-10-8
1 1
P-44933
Remove the nut (Item 1) and ground wires (Item 2)

[Figure 50-10-10].
Figure 50-10-11
P-44931

Disconnect the five hydraulic hoses (Item 1) [Figure 50-
10-8].
Figure 50-10-9
1
1
2
P-44934
Remove the two wires (Item 1) [Figure 50-10-11] from

the fuel sending unit.
P-44932


(CONT’D)
1
Remove the travel / signal levers. (See Removal And

Remove the instrument panel. (See Removal And


Drain the radiator. (See Removing And Replacing The P-53570A

Figure 50-10-12
Figure 50-10-14

1
1
P-25592
P-53571
Remove the heater hoses (Item 1) [Figure 50-10-12]

from the heater assembly.
Remove the side cover (Item 1) [Figure 50-10-14].

(CONT’D)

2
Figure 50-10-15
1
P-53574
Remove the bolt (Item 1) and plate (Item 2) [Figure 50-

10-17]. Remove the A/C hoses.
NOTE: Plug the A/C hoses to prevent contamination.

P-53572
Figure 50-10-18

Remove the cover (Item 1) [Figure 50-10-15].
If machine is equipped with air conditioning, remove the

refrigerant from the A/C system. (See Reclamation
Procedure on Page 80-40-1.)
Figure 50-10-16
1 1
P-53575
Loosen the mounting bracket bolt (Item 1) [Figure 50-10-

18].
P-53573
Temporarily remove the protective covering (Item 1)

[Figure 50-10-16] from the A/C hoses and expansion
valve.

(CONT’D)
Figure 50-10-19
1 1
P-44924
Remove the three hoses (Item 1) [Figure 50-10-21].
Remove any necessary nylon ties.
P-53585
Figure 50-10-22

located under the fuse box.
Figure 50-10-20
1
P-44919
Remove the seven hoses on the right side of the cab

[Figure 50-10-22].
P-53576
Remove the two A/C hoses, heater hoses and harness

from the rear corner of the cab [Figure 50-10-20].

(CONT’D)
Figure 50-10-23 1
P-44936A
Remove the two screws (Item 1) from the access panel

(Item 2) [Figure 50-10-25]. Remove the access panel.
Figure 50-10-26
P-53603

Remove the engine speed control cable (Item 1) [Figure
50-10-23].
Figure 50-10-24
1 P-44935B
Install a hoist to lift and support the cab [Figure 50-10-

26].
P-53604

50-10-24] from the bracket.
Remove any necessary nylon ties, carefully remove the

speed control cable from the engine compartment and
into the cab.
NOTE: Adjust the engine speed control cable during

installation. (See Removal And Installation on
Page 70-20-1.)
Close the engine cover.

(CONT’D)
Figure 50-10-27
2 2
P-49050
Remove the two bolts (Item 1) and rubber cushions (Item

2) [Figure 50-10-29].
Figure 50-10-30
P-44937A

Remove the cab mount bolt (Item 1) [Figure 50-10-27]
from the front of the cab.
Figure 50-10-28
P-44938B
1
Lift and remove the cab [Figure 50-10-30].
P-44920
Remove the grounding strap (Item 1) and rear mounting

bolt (Item 2) [Figure 50-10-28].

OPERATOR CAB (S/N A8HD13000 & ABOVE, S/N Figure 50-11-3
A8GW13000 & ABOVE, S/N A8GT13000 & ABOVE, S/
N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE)
1
Figure 50-11-1
P-50821
1 Remove the three screws (Item 1) from the access cover

canopy.
P-29315B


NOTE: Mark all hoses and electrical connectors for
[Figure 50-11-1].
Stop the engine.
Figure 50-11-4
Figure 50-11-2
P-44577

P-29253 50-11-4].

the battery.

(CONT’D)
Figure 50-11-5
P-44930
1
11-7].
P-44578
WARNING

50-11-5]. Hydraulic fluid escaping under pressure can have
Figure 50-11-6 penetrating the skin. This can cause serious injury
immediately.
W-2145-0290
2
1
IMPORTANT
P-44925 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

(CONT’D)
Figure 50-11-8
1 1
P-44933

[Figure 50-11-10].
Figure 50-11-11
P-44931

Disconnect the five hydraulic hoses (Item 1) [Figure 50-
11-8].
Figure 50-11-9
1
1
2
P-44934

the fuel sending unit.
P-44932


OPERATOR CAB (S/N A8HD13000 & ABOVE, S/N If machine is equipped with air conditioning, remove the
A8GW13000 & ABOVE, S/N A8GT13000 & ABOVE, S/ refrigerant from the A/C system. (See Reclamation
N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE) Procedure on Page 80-40-1.)
(CONT’D)
Removal And Installation (Cont’d) Figure 50-11-14
Remove the travel / signal levers. (See Removal And

Installation on Page 60-61-1.) 2


Figure 50-11-12
S36333
1
Mark and remove both A/C hoses (Item 1) [Figure 50-11-
14].

NOTE: Plug the A/C hoses (Item 1) [Figure 50-11-14] to
prevent contamination.
Remove the heater hose (Item 2) [Figure 50-11-14] NOT

connected to the heater valve (Item 3) [Figure 50-11-15].
Figure 50-11-15
P-97028
Remove the fuse box cover (Item 1) [Figure 50-11-12]. 2

3
Remove the joystick panel. (See Removal And
Figure 50-11-13
S36334
Remove the heater hose (Item 1) [Figure 50-11-15].
Remove bolt, nut and clip (Item 2) [Figure 50-11-15].
S36381

(CONT’D)
Figure 50-11-16
P-53576
Remove the two A/C hoses, heater hoses and harness

from the rear corner of the cab [Figure 50-11-18].
Figure 50-11-19
S36344

Disconnect the connectors (Item 1) [Figure 50-11-16]
located under the dash cover. 1
Figure 50-11-17
P-44924
Remove the three hoses (Item 1) [Figure 50-11-19].

1
P-53575

17].

(CONT’D)
Figure 50-11-20
P-53604

Remove any necessary nylon ties, carefully remove the

P-44919
speed control cable from the engine compartment and
into the cab.

Remove the seven hoses on the right side of the cab
[Figure 50-11-20]. NOTE: Adjust the engine speed control cable during
installation. (See Removal And Installation on
Open the engine cover. Page 70-20-1.)
Figure 50-11-21 Close the engine cover.
P-53603

50-11-21].

(CONT’D)
Figure 50-11-23
2
P-44937A
1
Remove the cab mount bolt (Item 1) [Figure 50-11-25]
from the front of the cab.
Figure 50-11-26
P-44936A

Remove the two screws (Item 1) from the access panel
(Item 2) [Figure 50-11-23]. Remove the access panel.
2
Figure 50-11-24
P-44920
Remove the grounding strap (Item 1) and rear mounting

bolt (Item 2) [Figure 50-11-26].
P-44935B
Install a hoist to lift and support the cab [Figure 50-11-

24].

OPERATOR CAB (S/N A8HD13000 & ABOVE, S/N
(CONT’D)
Figure 50-11-27
2 2
P-49050

Remove the two bolts (Item 1) and rubber cushions (Item
2) [Figure 50-11-27].
Figure 50-11-28
P-44938B
Lift and remove the cab [Figure 50-11-28].

OPERATOR SEAT Figure 50-20-3
Figure 50-20-1
1
P-44527
1 Remove the two seat mount bolts (Item 1) [Figure 50-20-

P-44525 3] from both sides.
Remove the seat.

Figure 50-20-2

1
P-44526
Raise the seat mount cover (Item 1) [Figure 50-20-1] by

sliding the bottom edge of the seat mount cover to the
right to remove the cover retainers (Item 1) from the seat
frame (Item 2) [Figure 50-20-2].
NOTE: There are several retainers molded into the

bottom edge of the cover.


FIXED BOOM Figure 50-30-3
Removal
Remove the boom tray. (See Removal And Installation on

Page 50-160-1.)
Remove the extension cylinder. (See Cylinder Group 1

Remove the end boom. (See Removal on Page 50-40-1.)
Remove the intermediate boom. (See Removal on Page

50-150-1.)
S3622
Figure 50-30-1
NOTE: (See Removal And Installation on Page 20-20-

1.) for additional information.
Figure 50-30-4

S3212
1
Install a lifting chain on the front of the boom [Figure 50-

30-1]. Raise the boom to 45 degrees.
Figure 50-30-2
S3212
3 Using the lifting chain (Item 1) [Figure 50-30-4] on the

front of the boom, lower the boom onto 0 degrees. Lower
the lift cylinder onto a block and remove the cinch strap.
S3563
Support the lift cylinder using a cinch strap (Item 1).

Remove the upper pivot pin snap ring (Item 2) and the
sides of the pivot.

FIXED BOOM (CONT’D) Figure 50-30-7
Removal (Cont’d)
Figure 50-30-5 1
S6994
Remove the boom pin (Item 1) [Figure 50-30-7].

S3590
Figure 50-30-8
Install a lifting chain (Item 1) [Figure 50-30-5] on the rear

of the boom.
Raise the hoist until the weight of the boom is supported

by the hoist.
Figure 50-30-6
S3555
2 Lift and remove the boom assembly [Figure 50-30-8].
S3591
Remove the bolt (Item 1) and washer (Item 2) [Figure

50-30-6] at both sides of the boom pin.

Installation
Figure 50-30-9
S3620
Position the fixed boom (Item 1) [Figure 50-30-11] on the

frame of the machine.
S3212
Figure 50-30-12
Install a lifting chain (Item 1) [Figure 50-30-9] on the
front of the boom.
Figure 50-30-10 1

1
S6994
Install the boom pin (Item 1) [Figure 50-30-12].

S3590
Install a lifting chain (Item 1) [Figure 50-30-10] on the

rear of the boom.

Figure 50-30-13
1
1
S3622
Install the upper pivot pin (Item 1) [Figure 50-30-15].

S3591
Figure 50-30-16
Install the washer (Item 1) and the bolt (Item 2) [Figure

50-30-13] at both sides of the boom pin.
Figure 50-30-14

1
2
1
S3563
Install the upper pivot pin snap ring (Item 1) and the
sides of the pivot.
S3212
Connect the lift cylinder to the fixed boom, using a cinch

strap. Using the lifting chain (Item 1) [Figure 50-30-14]
on the front of the boom, raise the boom onto 45
degrees.

FIXED BOOM (CONT’D)
Figure 50-30-17
S3665
After installing the fixed boom, apply grease to the pivots,

using a grease pump (Item 1) [Figure 50-30-17].
Install the intermediate boom. (See Installation on Page

50-150-2.)
Install the end boom. (See Installation on Page 50-40-3.)
Install the extension cylinder. (See Cylinder Group

Install the boom tray. (See Removal And Installation on

Page 50-160-1.)
Adjust the extension and retraction chains. (See

Checking And Adjustment Procedure on Page 10-170-1.)


END BOOM Figure 50-40-3
Removal
3
Page 50-160-1.)
2
Remove the extension cylinder. (See Cylinder Group
Figure 50-40-1
1
S3611
1
Disconnect the grease nipple (Item 1), the spindle (Item
2), and the pulley (Item 3) [Figure 50-40-3] at the front of
the intermediate boom.
Figure 50-40-4

S3584
Disconnect the retraction chain (Item 1) [Figure 50-40-1]

at the rear of the end boom.
Figure 50-40-2
1
S3586
2
Disconnect the extension chain (Item 1) [Figure 50-40-4]

at the front of the fixed boom.
S3585
Disconnect the two bolts (Item 1) and the plate (Item 2)

[Figure 50-40-2] at the front of the intermediate boom.

END BOOM (CONT’D) Figure 50-40-7
Removal (Cont’d)
Figure 50-40-5
S3614
Disconnect the extension chain (Item 1) [Figure 50-40-7]

at the rear of the end boom.
S3612
Remove the rear wear pads of the end boom. (See

Begin sliding the inner boom from the main boom. Before Removal on Page 50-51-1.)
the inner boom is completely removed, position a hoist
and a lifting strap on the front of the boom (Item 1)
[Figure 50-40-5].

Remove the front wear pads of the intermediate boom.
(See Removal on Page 50-50-1.)
Figure 50-40-6
S3587
Carefully remove the inner boom completely [Figure 50-

40-6].

Installation
2 1
Figure 50-40-8
1
S3612
Install the end boom (Item 1) into the intermediate boom

(Item 2) [Figure 50-40-10] approximately 254 mm (10
S3613
in).
Apply grease to the inside top and bottom corners of the Install the front wear pads on the intermediate boom.
intermediate boom (Item 1) [Figure 50-40-8]. (See Installation on Page 50-50-2.) Remove the hoist and
lifting strap and slide the boom fully into the intermediate
Install the rear wear pads on the end boom. (See boom.

Figure 50-40-11
Figure 50-40-9
S3584
S3614
Connect the retraction chain at the rear of the inner boom

Connect the extension chain (Item 1) [Figure 50-40-9] at (Item 1) [Figure 50-40-11].
the rear of the end boom.

Figure 50-40-12
1 S3586
Connect the extension chain at the front of the fixed

boom (Item 1) [Figure 50-40-14].
S3611
Install the extension cylinder. (See Cylinder Group

Connect the grease nipple (Item 1), the spindle (Item 2) Removal And Installation on Page 20-40-1.)
and the pulley (Item 3) [Figure 50-40-12] at the front of
the intermediate boom. Install the boom tray. (See Removal And Installation on
Page 50-160-1.)

Figure 50-40-13
1
2
S3585
Connect the two screws (Item 1) and the plate (Item 2)

[Figure 50-40-13] at the front of the intermediate boom.

WEAR PADS (FRONT) Figure 50-50-3
Removal
Figure 50-50-1
1 1
S3595
Remove the upper and side wear pads (Item 1)

[Figure 50-50-3].
S3593
With both upper wear pads removed, use a hoist and

Extend the inner boom and mark the location of the inner lifting strap at the end of the boom, apply upwards
supports and wear pads (Item 1) [Figure 50-50-1]. pressure, lifting the inner boom off the bottom wear pads.
Remove the lower wear pads.
Figure 50-50-2

1
S3596
Remove the bolts of the upper, lower and side wear pads
(Item 1) [Figure 50-50-2].

WEAR PADS (FRONT) (CONT’D) Figure 50-50-6
Installation
1
Figure 50-50-4
S3596
Tighten the bolts (Item 1) [Figure 50-50-6] of the upper

wear pads to 58 N•m (43 ft-lb) .
S3594
Figure 50-50-7
Make sure that the surface of the boom is cleaned before
installing the pads.
Figure 50-50-5

1
S3597
1
Install the four wear pads at the left and right side of the
S3595
Install the two upper wear pads (Item 1) [Figure 50-50-

5].

WEAR PADS (FRONT) (CONT’D) Figure 50-50-10
Figure 50-50-8
S3600
Tighten the bolts (Item 1) [Figure 50-50-10] of the lower

wear pads to 43 N•m (58 ft-lb).
S3598
Figure 50-50-11
Tighten the bolts of the wear pads (Item 1) [Figure 50-
50-8] to 43 N•m (58 ft-lb).
With both upper wear pads installed, use a hoist and

lifting strap at the end of the boom, apply upwards
pressure, lifting the inner boom off the bottom wear pads.
Figure 50-50-9
S3601
Apply grease to the pads using a grease pump

[Figure 50-50-11].
S3599
Install the two lower wear pads (Item 1) [Figure 50-50-9].


WEAR PADS (REAR)
Removal
Figure 50-51-1
S3602
Remove the inner boom and mark the location of the

wear pads (Item 1) [Figure 50-51-1].
Figure 50-51-2

1
S3603
With the inner boom supported, remove the bolts and the
pads (Item 1) [Figure 50-51-2].

WEAR PADS (REAR) (CONT’D) Figure 50-51-5
Installation
Figure 50-51-3
S3606
Apply grease to the pads.

S3604
Figure 50-51-6
Make sure that the surface of the boom is cleaned before

installing the pads.
Figure 50-51-4

1
S3607
1
After installing the boom, apply grease to the pads using

a grease pump (Item 1) [Figure 50-51-6].
S3605
Install the six pads and tighten the bolts (Item 1) [Figure
50-51-4] to 39 N•m (29 ft-lb).

ENGINE COVER Removal And Installation
Gas Cylinder Removal And Installation Remove the gas cylinder.

1
S6854
Figure 50-60-3

1 1
S6852
Lift the engine cover [Figure 50-60-1]. Add a support to

prevent the cover from closing when the gas cylinder is
removed.
S6853
Remove the retainer clips (Item 1) [Figure 50-60-1] at
both of the ball joints ends. Remove the ball joints from
the ends. Remove the four hinge mounting bolts (Item 1) [Figure
50-60-2] and [Figure 50-60-3].
Remove the gas cylinder.
Remove the engine cover.
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288


AIR INTAKE COWLING Figure 50-71-2
Figure 50-70-1 1
S4596
While supporting the air intake cowling remove the two

S4594 bolts (Item 1) [Figure 50-71-2].
Remove the air intake cowling.

Remove the bolts (Items 1 and 2) [Figure 50-70-1].


FUEL TANK Figure 50-80-3
Figure 50-80-1
1
P-29256
Drain the fuel from the fuel tank by removing the plug
P-29315A (Item 1) [Figure 50-80-3].
Figure 50-80-4
[Figure 50-80-1].
1

Remove the battery. (See Cylinder Group Removal And
Figure 50-80-2
2
P-50821
Remove the three screws (Item 1) and remove the

access panel (Item 2) [Figure 50-80-4].
P-29280B
Install a hoist to lift and support the cab [Figure 50-80-2].

FUEL TANK (CONT’D) Figure 50-80-7
Figure 50-80-5
1
P-42457
1 1
P-29250 the fuel tank.

Remove the two bolts (Item 1) [Figure 50-80-5] from the
cab spring. Figure 50-80-8

Figure 50-80-6
P-29257
P-29251
Support the fuel tank using a forklift or jack [Figure 50-
80-8].
Remove the two wires (Item 1) [Figure 50-80-6] from the
fuel sending unit.
NOTE: Mark the wires for correct installation.

FUEL TANK (CONT'D) Figure 50-80-11
Figure 50-80-9
P-29253
1
Figure 50-80-12
P-29281
Remove the access panel (Item 1) [Figure 50-80-9].

Figure 50-80-10
P-29254
Remove the mounting bolts (Item 1) [Figure 50-80-11]

and [Figure 50-80-12] from the rear of the fuel tank.
P-29255

10] from the front of the fuel tank.

FUEL TANK (CONT'D)
Figure 50-80-13
P-29259
Carefully lower and remove the fuel tank [Figure 50-80-

13].

QUICK-TACH Figure 50-90-3
Figure 50-90-1
S3641

90-3].
S3623
Figure 50-90-4
Disconnect the hydraulic couplers (Item 1) [Figure 50-
90-1].
Figure 50-90-2

1
S3642

S3640
Remove the quick-tach.
Rotate the quick-tach forward fully, using a lifting hoist. Installation: Apply grease using a grease pump.
Support the quick-tach as shown [Figure 50-90-2].


REAR WEIGHTS Figure 50-100-3
Figure 50-100-1
P-32286
Position a hoist as shown to lift and support the rear

S7421 weight [Figure 50-100-3].
Figure 50-100-4
1

Figure 50-100-2
1
1
P-50986
3
P-50972 Remove the two weight mounting bolts (Item 1)
[Figure 50-100-4].
Disconnect the tail light connector (Item 1) [Figure 50- Remove the weight.
100-2] from the main harness.
Remove the cross bar mounting bolt (Item 2) (both sides)

and remove the cross bar (Item 3) [Figure 50-100-2].
Installation: Tighten the bolt to 255 - 285 N•m (188 - 210

ft-lb) torque.


FENDER Figure 50-110-6
Lift the front of the machine and place jack stands under
the frame. 1
Place a block in front and behind one of the rear wheels.
Figure 50-110-5
2
1
S1951
Remove the four nuts (Item 1) from the fender mount

brackets (Item 2) [Figure 50-110-6].
Remove the fender.
Installation: Tighten the nuts to 125 - 140 N•m (90 - 100

S1954 ft-lb) torque.
Remove the eight lug nuts and washers (Item 1)

[Figure 50-110-5] from the tire. Remove the tire.


PIVOT LINK Figure 50-120-3
Rotate the quick-tach back fully.
Figure 50-120-1
P-32150
Rotate the quick-tach forward until it is on the ground

[Figure 50-120-3].
P-32006 Figure 50-120-4

120-1] from the pivot.
1
Figure 50-120-2 1
P-29719
Remove the two mounting bolts (Item 1) and cover (Item

2) [Figure 50-120-4].
P-32007
Remove the pivot pin (Item 1) [Figure 50-120-2] and

lower the link.

PIVOT LINK (CONT'D) Figure 50-120-7
Figure 50-120-5
P-32008
Place a floor jack under the pivot link [Figure 50-120-7].

P-32001
Figure 50-120-8

120-5].

Figure 50-120-6
1
P-32004

120-8].
P-32002
Remove the pivot pin (Item 1) [Figure 50-120-6] from the

tilt cylinder.

PIVOT LINK (CONT'D) Figure 50-120-10
Figure 50-120-9
P-32009
Lower the floor jack and remove the pivot link [Figure 50-
P-32005 120-10].


JOYSTICK PANEL (S/N A8HD12999 & BELOW, S/N Figure 50-130-3

1
Remove the switch panel. (See Removal And Installation

on Page 60-80-1.)
Remove the dash cover / steering column cover. 1

(See Removal And Installation on Page 50-140-1.)
1
Figure 50-130-1
P-52338
Figure 50-130-4
1

P-52336
Remove the fuse box cover (Item 1) and side cover (Item 1
2) [Figure 50-130-1].
P-52339
Figure 50-130-2
Remove the joystick panel (Item 1) [Figure 50-130-4].
P-52337
Disconnect the frame leveling connector (Item 1)

[Figure 50-130-2].


JOYSTICK PANEL (S/N A8HD13000 & ABOVE, S/N Figure 50-131-3

Figure 50-131-1
1 S36359
Remove three screws (Item 1) [Figure 50-131-3].
Remove the joystick panel (Item 2) [Figure 50-131-3]

P-97028 and place on its side.
Figure 50-131-4

Figure 50-131-2
1 1
1 1 1
S36360
S36358 Remove the screw (Item 1) [Figure 50-131-4].
Remove the temperature control knob (Item 2)

[Figure 50-131-4].

JOYSTICK PANEL (S/N A8HD13000 & ABOVE, S/N
(CONT’D)
Figure 50-131-5
S36361

Remove the temperature control (Item 2) [Figure 50-

131-5] from the joystick panel.
Figure 50-131-6
1
S36362
Mark and remove the connectors from the joystick panel

(Item 1) [Figure 50-131-6].
Remove the joystick panel.

DASH COVER / STEERING COLUMN COVER (S/N Figure 50-140-3
A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/
N A8GT12999 & BELOW, S/NA8GV12999 & BELOW,
S/N A8GJ12999 & BELOW)

1
Remove the switch panel. (See Removal And Installation

on Page 60-80-1.)
Figure 50-140-1
P-52330
Remove the screw (Item 1) [Figure 50-140-3] from the

right side of the dash.
Figure 50-140-4
1 1

1
P-52328 1

the center of the dash cover.
Figure 50-140-2
1 1
P-52331
1 Remove the four screws (Item 1) [Figure 50-140-4] from

the right side of the dash cover.
1
P-42835
Remove the two dash cover mounting screws (Item 1)

[Figure 50-140-2].

N A8GT12999 & BELOW, S/N A8GV12999 & BELOW,
S/N A8GJ12999 & BELOW) (CONT'D)
Figure 50-140-5
P-42845
1
1 Remove the two screws (Item 1) [Figure 50-140-7] from
the right side of the column cover.
Figure 50-140-8
P-52332

Remove the five screws (Item 1) [Figure 50-140-5] from
the left side of the dash cover.
Figure 50-140-6
P-42846
Remove the screw (Item 1) [Figure 50-140-8] from the

left side of the column cover.
P-52335
Lift and remove the dash cover [Figure 50-140-6].

DASH COVER / STEERING COLUMN COVER (S/N
S/N A8GJ12999 & BELOW) (CONT'D)
Figure 50-140-9
P-42848

Remove the steering column cover [Figure 50-140-9].


DASH COVER / STEERING COLUMN COVER (S/N Remove the instrument panel. (See Removal And
A8HD13000 & ABOVE, S/N A8GW13000 & ABOVE, S/ Installation on Page 60-70-1.)
N A8GT13000 & ABOVE, S/N A8GV13000 & ABOVE,
S/N A8GJ13000 & ABOVE) Remove the switch panel.
Removal And Installation (See SWITCH PANEL (S/N A8HD13000 - 14999, S/N
A8GW13000 - 14999, S/N A8GT13000 - 14999, S/N
Figure 50-141-1 A8GV13000 - 14999, S/N A8GJ13000 - 14999) on Page
60-81-1.)
(See SWITCH PANEL (S/N A8HD15000 & ABOVE, S/N
A8GW15000 & ABOVE, S/N A8GT15000 & ABOVE, S/N
A8GV15000 & ABOVE, S/N A8GJ15000 & ABOVE) on
Page 60-82-1.)
Remove the signal / travel levers. (See Removal And

1
Figure 50-141-3
1
2
S36377

Figure 50-141-2
2
S36364
1
Remove the nut (Item 1) and knob (Item 2) [Figure 50-
141-3]
Figure 50-141-4
S36378
1
2
Remove the steering wheel (Item 2) [Figure 50-141-2].
Installation: Tighten the nut to 40 N•m (29.5 ft-lb) torque.
S36365
Remove the nut (Item 1) and washer (Item 2) [Figure 50-

141-4]

A8HD13000 & ABOVE, S/N A8GW13000 & ABOVE, S/
S/N A8GJ13000 & ABOVE) (CONT’D)

2
Figure 50-141-5
S36367
1
Pull out the blower hose [Figure 50-141-7].
Loosen the retainer screw (Item 1) [Figure 50-141-7]
S36366
Remove the cap (Item 2) [Figure 50-141-7].

Remove the louver cap (Item 1) [Figure 50-141-5]. Figure 50-141-8
Figure 50-141-6
1
S36371
S36372
Disconnect the connector (Item 1) [Figure 50-141-8].
Remove the two screws (Item 1) [Figure 50-141-6].

2
Figure 50-141-9
S36369
Pull out the blower hose [Figure 50-141-11].
Loosen the retainer screw (Item 1) [Figure 50-141-11]
S36368
Remove the cap (Item 2) [Figure 50-141-11].

Remove the louver cap (Item 1) [Figure 50-141-9]. Figure 50-141-12
Figure 50-141-10
1
S36370
S36373
Remove the two dash cover mounting plugs (Item 1)
[Figure 50-141-12].
Remove the two screws (Item 1) [Figure 50-141-10].

Figure 50-141-13
1
2
1
2
1 S36376
Remove the five screws (Item 1) [Figure 50-141-15] from

1 the column cover.
Remove the column cover (Item 2) [Figure 50-141-15].

S36375

Remove the seven screws (Item 1) from the dash cover
(Item 2) [Figure 50-141-13].
Lift up the dash cover (Item 2) [Figure 50-141-13].
Figure 50-141-14
S35374

from the dash cover.
Remove the dash cover.

INTERMEDIATE BOOM Figure 50-150-3
Removal

Page 50-160-1.)
Remove the extension cylinder. (See Cylinder Group

Remove the end boom. (See Removal on Page 50-40-1.)

1
Figure 50-150-1
2
S3618
Disconnect the two screws (Item 1) and the plate (Item 2)

[Figure 50-150-3] at the rear of the intermediate boom.
Figure 50-150-4

1
2
S3616
Disconnect the retraction chain at the front of the fixed

Figure 50-150-2
1 S3619
Disconnect the spindle (Item 1) and the pulley (Item 2)

Remove the rear wear pads of the intermediate boom.

(See Removal on Page 50-51-1.)
S3092
Begin sliding the intermediate boom from the fixed boom.

Before the intermediate boom is completely removed,
position a hoist and a lifting strap (Item 1) [Figure 50-
150-2] on the front of the boom.
Remove the front wear pads of the fixed boom. (See

Removal on Page 50-50-1.) Carefully remove the
intermediate boom completely.

INTERMEDIATE BOOM (CONT’D) Figure 50-150-7
Installation
Figure 50-150-5 1
S3619
Connect the spindle (Item 1) and the pulley (Item 2)

[Figure 50-150-7] at the rear of the intermediate boom
S3613
Figure 50-150-8
Apply grease to the inside top and bottom corners of the
fixed boom.
Install the rear wear pads on the intermediate boom.

(See Installation on Page 50-51-2.)
Figure 50-150-6
2
1
S3093
Install the intermediate boom (Item 1) into the fixed boom

1
(Item 2) [Figure 50-150-8] approximately 254 mm (10
in).
2 Install the front wear pads on the fixed boom. (See

S3618
Installation on Page 50-50-2.) Remove the hoist and
lifting strap and slide the boom fully into the end boom.
Connect the two screws (Item 1) and the plate (Item 2)

INTERMEDIATE BOOM (CONT’D)
Figure 50-150-9
S3584
Connect the retraction chain at the front of the fixed boom

(Item 1) [Figure 50-150-9].
Install the end boom. (See Installation on Page 50-40-3.)

Instal the extension cylinder. (See Cylinder Group
Instal the boom tray. (See Removal And Installation on

Page 50-160-1.)



BOOM TRAY Figure 50-160-3
Figure 50-160-1
S3578
Retract the boom gently and remove the remaining screw

(Item 1) [Figure 50-160-3].
S3211
Figure 50-160-4
Lower the boom onto adequate stands or blocks as
shown [Figure 50-160-1].
Figure 50-160-2

1
1
2
S3556

the machine.
S3575
Fully extend the boom and remove the two attachment

screws (Item 1) located on top of the last element, except
for the screw (Item 2) [Figure 50-160-2] located at the
head of the boom.

BOOM TRAY (CONT’D) Figure 50-160-7

1
Figure 50-160-5
2 S3592
Disconnect the four hydraulic hoses (Item 1) [Figure 50-

160-7] from the tubelines at the rear of the boom.
S3592
Figure 50-160-8
Disconnect the light harness connector (Item 1) (If
equipped) and the secondary auxiliary harness
connector (Item 2) [Figure 50-160-5] (If Equipped) at the
rear of the boom.

Figure 50-160-6
1 S3577
Disconnect the four hydraulic hoses (Item 1) [Figure 50-

160-8] at the front of the boom.
S3576
Disconnect the two connectors (Item 1) [Figure 50-160-

6] at the front of the boom (If Equipped).
IMPORTANT
damage the system.
I-2003-0888

BOOM TRAY (CONT’D) Figure 50-160-11
Figure 50-160-9
1
2
S3581
Remove the two attachment screws (Item 1) and skid

(Item 2) [Figure 50-160-11].
S3579
Figure 50-160-12
Remove the two attachment screws (Item 1) [Figure 50-
160-9] at the rear of the boom.
Figure 50-160-10

1
S3582
2
1
Extract the boom tray (Item 1) [Figure 50-160-12]
through the rear of the boom.
S3580
Remove the two attachment screws (Item 1) and the

plate (Item 2) [Figure 50-160-10].

BOOM TRAY (CONT’D)
Figure 50-160-13
S3609
Extend the boom tray by pulling at the end of the

tubelines (Item 1) [Figure 50-160-13].
Figure 50-160-14

1
S3610
Disconnect the tubelines (Item 1) [Figure 50-160-14].

STABILIZER FRAME (IF EQUIPPED) Figure 50-170-3
Removal
Figure 50-170-1
1
S2818

S3216 valve block. Put a blank plug on the hose and pull the
hose back into the machine frame.
Lift the stabilizers and extend and support the boom on Figure 50-170-4
adequate stands [Figure 50-170-1].

Figure 50-170-2
1
1
S7486
S3217 Support the stabilizer frame with a sling or chain (Item 1)

[Figure 50-170-4].
Remove the two hoses for oil flow from and to the NOTE: Position the sling / chain as close as possible
machine (Item 1) [Figure 50-170-2]. Put blank plugs on to the center of gravity of the stabilizer frame
the hoses and pull them back into the machine frame. (see [Figure 50-170-4]).
NOTE: Firmly tighten the blank plugs. When starting

the machine there will be permanent hydraulic
pressure on one of the hoses (port ‘P’ on
valve block).

STABILIZER FRAME (IF EQUIPPED) (CONT’D) Installation
Removal (Cont’d) Figure 50-170-7
Figure 50-170-5
S7486
S3214
Move the palet with the stabilizer frame under the boom.
Install a sling or chain on the stabilizer frame as shown
Place a hand pallet truck with empty pallet under the [Figure 50-170-7].
stabilizer frame and remove the two lower bolts (Item 1).
Then carefully remove the upper two bolts (Item 2) NOTE: Position the sling / chain as close as possible

[Figure 50-170-5]. to the center of gravity of the stabilizer frame
(see [Figure 50-170-7]).
Figure 50-170-6
Start the machine and slowly raise the boom until the
stabilizer frame is in the right position [Figure 50-170-7].
Slowly lower the boom on adequate stands [Figure 50-

170-7].
Figure 50-170-8
S7486
1
Start the machine and slowly lift the boom a bit [Figure
50-170-6].
Remove the stand which supports the boom.

S3214
Slowly lower the boom until the stabilizer frame rests
safely on the pallet [Figure 50-170-6].
Put the stabilizer frame in place and install the two upper
bolts (Item 2). The install the two lower bolts (Item 1)
[Figure 50-170-8].

STABILIZER FRAME (IF EQUIPPED) (CONT’D) Figure 50-170-11
1
Figure 50-170-9
S3217
Install the two hoses for oil flow from and to the machine
S7486 (Item 1) [Figure 50-170-11].
Figure 50-170-12
Remove the sling or chain (Item 1) [Figure 50-170-9]
from the stabilizer frame.

Figure 50-170-10
S3216
Raise the boom and remove the stands [Figure 50-170-

S2818 12].
Install the hose (Item 1) [Figure 50-170-10] to the valve

block.


ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION (S/N A8HD12999 & BELOW, S/N A8GW12999 &
BELOW, S/N A8GT12999 & BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW)
60-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
Fuses, Diode And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
ELECTRICAL SYSTEM INFORMATION (S/N A8HD13000 & ABOVE, S/N A8GW13000 &
ABOVE, S/N A8GT13000 & ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE) .
60-11-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-2
Fuses, Diode And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
TRAVEL / SIGNAL LEVER (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N
A8GT12999 & BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) . . . . 60-60-1
TRAVEL / SIGNAL LEVER (S/N A8HD13000 & ABOVE, S/N A8GW13000 & ABOVE, S/N
A8GT13000 & ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE) . . . . 60-61-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

SWITCH PANEL (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) . . . . . . . . . . . . . . . . 60-80-1
Parts Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2

SWITCH PANEL (S/N A8HD13000 - 14999, S/N A8GW13000 - 14999, S/N A8GT13000 -
14999, S/N A8GV13000 - 14999, S/N A8GJ13000 - 14999) . . . . . . . . . . . . . . . . . . . . . 60-81-1
SWITCH PANEL (S/N A8HD15000 & ABOVE, S/N A8GW15000 & ABOVE, S/N A8GT15000 &
ABOVE, S/N A8GV15000 & ABOVE, S/N A8GJ15000 & ABOVE) . . . . . . . . . . . . . . . . 60-82-1
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
WIPER MOTOR (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

WIPER MOTOR (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-101-1

WIPER MOTOR (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-102-1


PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
PEDAL ASSEMBLY (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
SERVICE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Connecting The Laptop Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Entering The Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3
Warnings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-5
Calibrate Inch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Calibrate Creep Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-7
Program / Update Susmic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
FRAME LEVEL SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8HD11001-14999, S/N

A8GW11001-14999, S/N A8GT11001-14999, S/N A8GV11001-14999, S/N A8GJ11001-
14999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Fitting The Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, S/N A8GW15000 & ABOVE, S/N
A8GT15000 & ABOVE, S/N A8GV15000 & ABOVE, S/N A8GJ15000 & ABOVE) . . . 60-160-1
System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-3
System Failure Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
System Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-8
LLMS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-10
LLMS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
LLMC Controller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-13
LLMC Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-16


621 of 1040
622 of 1040
623 of 1040
624 of 1040
625 of 1040
626 of 1040
627 of 1040
628 of 1040
629 of 1040
630 of 1040
631 of 1040
632 of 1040
633 of 1040
634 of 1040
635 of 1040
636 of 1040
637 of 1040
638 of 1040
639 of 1040
640 of 1040
641 of 1040
642 of 1040
643 of 1040
644 of 1040
645 of 1040
646 of 1040
647 of 1040
648 of 1040
649 of 1040
650 of 1040
651 of 1040
652 of 1040
653 of 1040
654 of 1040
655 of 1040
656 of 1040
657 of 1040
658 of 1040
659 of 1040
660 of 1040
661 of 1040
662 of 1040
663 of 1040
664 of 1040
665 of 1040
666 of 1040
667 of 1040
668 of 1040
669 of 1040
670 of 1040
671 of 1040
672 of 1040
673 of 1040
674 of 1040
675 of 1040
676 of 1040
677 of 1040
678 of 1040
679 of 1040
680 of 1040
681 of 1040
682 of 1040
683 of 1040
684 of 1040
685 of 1040
686 of 1040
687 of 1040
688 of 1040
689 of 1040
690 of 1040
691 of 1040
692 of 1040
693 of 1040
694 of 1040
695 of 1040
696 of 1040
697 of 1040
698 of 1040
699 of 1040
700 of 1040
701 of 1040
702 of 1040
703 of 1040
704 of 1040
705 of 1040
706 of 1040
707 of 1040
708 of 1040
709 of 1040
710 of 1040
711 of 1040
712 of 1040
713 of 1040
714 of 1040
715 of 1040
716 of 1040
ELECTRICAL SYSTEM INFORMATION (S/N
S/N A8GJ12999 & BELOW) WARNING
Troubleshooting Chart AVOID INJURY OR DEATH
The following troubleshooting chart is provided for servicing machine. Read and understand the
assistance in locating and correcting problems which are Operation & Maintenance Manual, Operator’s
most common. Many of the recommended procedures Handbook and signs (decals) on machine. Follow
must be done by authorized Bobcat Service Personnel warnings and instructions in the manuals when
only. making repairs, adjustments or servicing. Check for
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.


ELECTRICAL SYSTEM INFORMATION (S/N Fuses, Diode And Relay Location / Identification
N A8GT12999 & BELOW, S/N A8GV12999 & BELOW, The electrical system is protected by fuses, diodes and
S/N A8GJ12999 & BELOW) (CONT’D)
relays.
Description
Figure 60-10-1
The telescopic handler has a 12 volt, negative ground
alternator charging system. The electrical system is
protected by fuses located in the cab in the right console.
The fuses will protect the electrical system when there is
an electrical overload. The reason for the overload must 1
be found before starting the engine again.
S40025
Remove the console cover (Item 1) [Figure 60-10-1].

Figure 60-10-2
1 1
P-52172
Remove the cover(s) from the rows of fuses / relays /

diodes (Item 1) [Figure 60-10-2] to check or replace
fuses, diodes or relays.
Two relays and three fuses are located in the rear of the
engine compartment.

ELECTRICAL SYSTEM INFORMATION (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) (CONT’D)
Fuses, Diodes And Relay Location / Identification (Cont’d)
Figure 60-10-3
T35100(S)(L)

E18
F3
F2
F1
E2
E1
S6931

A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/ REF. GAUGE FUNCTION PROTECTED
N A8GT12999 & BELOW, S/N A8GV12999 & BELOW, 32 7.5 A Fan direction reversing (option)
correction
Fuses, Diode And Relay Location / Identification
(Cont’d) 01 20 A Air conditioning fan (option)
Fuses And Diodes For T35100(S)(L) model [Figure 02 7.5 A Air conditioning compressor
60-10-3] (option)
F1 50 A Switched power fuse (+)
REF. GAUGE FUNCTION PROTECTED F2 40 A Unswitched power fuse (+)
1 15 A Front work lights F3 50 A Preheat (glow plugs)
2 15 A Rear work lights Relays For T35100(S)(L) model [Figure 60-10-3]
3 10 A Lighting and full-beam control
4 15 A Headlamps REF. FUNCTION PERFORMED
5 7.5 A Road alarm and ceiling light 1 Front work lights
6 15 A Full-beam 2 Rear work lights
7 10 A Cigarette lighter 3 Road horn
8 7.5 A Left side-lights 4 Blue lights (option)
9 7.5 A Right side-lights 5 Hydraulic function on boom

10 7.5 A Hazard warning lights 6 Headlamps
11 DIODE 1 A Parking brake 7 Full-beam
12 DIODE 1 A Advance safety if parking brake 8 Advance safety if parking brake tight
tight 9 Starting safety if transmission is in gear
13 10 A Second hydraulic function on 10 Not used
boom (option)
11 Slow travel speed
14 15 A Joystick control box
12 Second hydraulic function on boom
15 7.5 A Stability indicator and fuel pump
13 Backup lights / backup alarm
16 3A Hydraulic function on boom
14 Not used
17 7.5 A Rotating beacon (option)
15 Prevent raising of the stabilizers
18 10 A Brake lights, rear hydraulic
options, stop lights 16 stabilizers
19 7.5 A Slow travel speed 17 Raise left stabilizer
20 15 A Front wiper 18 Raise right stabilizer
21 7.5 A Transmission control box supply 19 Radio control for acceleration of the engine
22 7.5 A Engine cutoff 20 Not used
23 7.5 A Joystick supply 21 Not used
24 7.5 A Direction indicators

25 10 A Steering mode control E01 Starting motor relay
26 20 A Heating fan E02 Preheat relay
27 7.5 A Direction of travel

28 7.5 A Instrument panel supply E15 12V power relay after contact
29 10 A Reversing light and roof E16 Air conditioning compressor (option)

windscreen wiper (option) E17 Air conditioning fan (option)
30 7.5 A Rear windscreen wiper: Rear E18 Center for the directional signals (located
windscreen and roof washer beneath the fuse box)
31 10 A Boom angle measurement

ELECTRICAL SYSTEM INFORMATION (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) (CONT’D)
Figure 60-10-4
T35120(S)L
E17 E16

E15
E18
F3
F2
F1
E2
E1 S6932

A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/ REF. GAUGE FUNCTION PROTECTED
N A8GT12999 & BELOW, S/N A8GV12999 & BELOW, 32 7.5 A Fan direction reversing (option)
correction
(Cont’d) 01 20 A Air conditioning fan (option)
Fuses And Diodes For T35120(S)L model [Figure 60- 02 7.5 A Air conditioning compressor
10-4] (option)
F1 50 A Switched power fuse (+)
REF. GAUGE FUNCTION PROTECTED F2 40 A Unswitched power fuse (+)
1 15 A Front work lights F3 50 A Preheat (glow plugs)
2 15 A Rear work lights Relays For T35120(S)L model [Figure 60-10-4]
3 10 A Lighting and full-beam control
4 15 A Headlamps REF. FUNCTION PERFORMED
5 7.5 A Road alarm and ceiling light 1 Front work lights
6 15 A Full-beam 2 Rear work lights
7 10 A Cigarette lighter 3 Road horn
8 7.5 A Left side-lights 4 Blue lights (option)
9 7.5 A Right side-lights 5 Hydraulic function on boom

10 7.5 A Hazard warning lights 6 Headlamps
11 DIODE 1 A Parking brake 7 Full-beam
12 DIODE 1 A Advance safety if parking brake 8 Advance safety if parking brake tight
tight 9 Starting safety if transmission is in gear
13 10 A Second hydraulic function on 10 Not used
boom (option)
11 Slow travel speed
14 15 A Joystick control box
12 Second hydraulic function on boom
15 7.5 A Stability indicator and fuel pump
13 Backup lights / backup alarm
16 3A Hydraulic function on boom
14 Not used
17 7.5 A Rotating beacon (option)
15 Prevent raising of the stabilizers
18 10 A Brake lights, rear hydraulic
options, stop lights 16 stabilizers
19 7.5 A Slow travel speed 17 Raise left stabilizer
20 15 A Front wiper 18 Raise right stabilizer
21 7.5 A Transmission control box supply 19 Radio control for acceleration of the engine
22 7.5 A Engine cutoff 20 Not used
23 7.5 A Joystick supply 21 Not used
24 7.5 A Direction indicators

25 10 A Steering mode control E01 Starting motor relay
26 20 A Heating fan E02 Preheat relay
27 7.5 A Direction of travel

28 7.5 A Instrument panel supply E15 12V power relay after contact
29 10 A Reversing light and roof E16 Air conditioning compressor (option)

windscreen wiper (option) E17 Air conditioning fan (option)
30 7.5 A Rear windscreen wiper: Rear E18 Center for the directional signals (located
windscreen and roof washer beneath the fuse box)
31 10 A Boom angle measurement


(Cont’d)
Figure 60-10-5
S3531

3 5
4
1
S3533

compartment. The relay / fuse receptacles are located
under the air conditioning compressor [Figure 60-10-5].
FUSES
Ref. Description Amp

1 Switched Power Fuse 50
2 Unswitched Power Fuse 40
3 Preheat Fuse 50
RELAYS
Ref. Description
4 Starting Motor Relay
5 Preheat Relay

S/N A8GJ13000 & ABOVE) WARNING
Troubleshooting Chart AVOID INJURY OR DEATH
The following troubleshooting chart is provided for servicing machine. Read and understand the
assistance in locating and correcting problems which are Operation & Maintenance Manual, Operator’s
most common. Many of the recommended procedures Handbook and signs (decals) on machine. Follow
must be done by authorized Bobcat Service Personnel warnings and instructions in the manuals when
only. making repairs, adjustments or servicing. Check for
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (S/N Fuses, Diode And Relay Location / Identification
N A8GT13000 & ABOVE, S/N A8GV13000 & ABOVE, The electrical system is protected by fuses, diodes and
relays.
Description
Figure 60-11-1
The telescopic handler has a 12 volt, negative ground 1
alternator charging system. The electrical system is 2
protected by fuses located in the cab in the right console.
The fuses will protect the electrical system when there is
an electrical overload. The reason for the overload must
be found before starting the engine again.
1
P-97028
Loosen the retainer screws (Item 1) and remove the

console cover (Item 2) [Figure 60-11-1].
Figure 60-11-2
1 1
P-97029
Remove the cover(s) from the rows of fuses / relays /

diodes (Item 1) [Figure 60-11-2] to check or replace
fuses, diodes or relays.
Two Relays and three Fuses are located in the rear of the
engine compartment.

ELECTRICAL SYSTEM INFORMATION (S/N A8HD13000 & ABOVE, S/N A8GW13000 & ABOVE, S/N A8GT13000 &
ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 & ABOVE) (CONT’D)
Figure 60-11-3
28
12 *
32 21 14 7
27
11
26 16
20 13 6 10
31 25
9
24 12 5 15
19 8
23
4 7
18 11
22 6
21 17 5
3
30 10 14
20 4
19 16 9 2 3
13
29 18 2
15

8 1
17 1
P-97030
The location and description are shown below and [Figure 60-11-3]
FUSES AND DIODES RELAYS

Ref Description. Amp Ref. Description Amp Ref Description
1 Rear Work Lights 15 21 Travel Controller 15 1 Rear Work Lights
2 Front Work Lights 15 22 Fuel Pump / Brake Fail Pressure 7.5 2 Front Work Lights
Switch (If Equipped)
3 Headlights 10 23 Joystick 10 3 Horn
4 Low Beam Headlights 15 24 Direction Signal 7.5 4 Blue Work Lights (If Equipped)
5 Horn, Cab Light 7.5 25 Steering Mode Valve 10 5 Front Auxiliary Hydraulic
6 High Beam Headlights 15 26 Heater and HVAC 30 6 Low Beam Headlights
7 12V Accessory Plug 10 27 Travel Direction 7.5 7 High Beam Headlights
8 Left Park Lights 7.5 28 Instrument Panel 7.5 8 Transmission / Parking Brake
9 Right Park Lights 7.5 29 Top Wiper, Rear Travel Light 10 9 Neutral Start
10 Hazard Lights 7.5 30 Rear Wiper, Rear and Top Washer 7.5 10 Not Used
11 Parking Brake D* 31 Boom Angle Sensor 10 11 Low Travel Speed
12 Transmission / Parking Brake D* 32 Reverse Cooling Fan / Frame Leveling 7.5 12 2nd Auxiliary Hyd
13 2nd Auxiliary Hyd 10 13 Back-up Lights / Back-up
Alarm
14 Fuel 7.5 14 Fuel Pump
15 Longitudinal Stability 7.5 15 Stabilizer Locking System
Indicator / AMA/LLMC (boom >25°) (Optional)
16 Front Auxiliary Hyd 3 16 Stabilizer Lockout
17 Rotating Beacon 7.5 17 Raise Left Stabilizer
18 Stop Lights / Rear Aux hyd 10 18 Raise Right Stabilizer
19 Low Travel Speed 7.5 19 Not Used
20 Front Wiper 15 20 Frame Leveling
21 Reverse Cooling Fan
*D - Diodes (Items 11 and 12) inserted with the tab toward the front of the machine [Figure 60-11-3].

Fuses, Diodes And Relay Location / Identification

(Cont’d)
Figure 60-11-4
S3531

3
1
5
4
2
S3533

compartment. The relay / fuse receptacles are located
next to the air conditioning compressor [Figure 60-11-4].
FUSES
REF. DESCRIPTION AMP

1 Switched Power Fuse 50
2 Unswitched Power Fuse 40
3 Preheat Fuse 50
RELAYS
REF. DESCRIPTION
4 Starting Motor Relay
5 Preheat Relay

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
P-42338
and wash eye with clean, cool water for at least 15
minutes.
Remove the battery hold down clamp (Item 1)
If electrolyte is taken internally drink large quantities [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Figure 60-20-3
W-2065-0807

Figure 60-20-1
2 1
P-42341
P-50821 Always disconnect the negative cable (Item 1)

[Figure 60-20-3] first to prevent sparks.
Remove the battery access door (Item 1) [Figure 60-20- Remove the positive battery cable (Item 2) [Figure 60-
1]. 20-3].
Remove the battery.

BATTERY (CONT'D)
Servicing
WARNING
Figure 60-20-4
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
P-29246
Figure 60-20-6
Figure 60-20-5

S4895
S4894
The battery cables must be clean and the connections
tight. Remove acid or corrosion from the battery and
Always clean the terminals and cable ends when cables with a sodium bicarbonate (baking soda) and
installing a new battery [Figure 60-20-4] and [Figure 60- water solution [Figure 60-20-6].
20-5].
Check the electrolyte level in the battery. Add distilled
When installing the battery in the machine, do not touch water as needed.
any metal parts with the battery terminal posts.
Put Battery Saver (P/N 6664458) or grease on the
Connect and tighten the battery cables. Connect the battery terminals and cable ends to prevent corrosion.
negative (-) cable last to prevent sparks.

BATTERY (CONT'D)
Using A Booster Battery (Jump Starting)
If it is necessary to use a booster battery to start the

IMPORTANT
engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and Damage to the alternator can occur if:
disconnect the battery cables. (Booster Cables) • Engine is operated with battery cables
disconnected.
The key switch must be OFF. The booster battery must • Battery cables are connected when using a fast
be 12 volt. charger or when welding on the Telescopic
Handler. (Remove both cables from the battery.)
Figure 60-20-7 • Extra battery cables (booster cables) are
connected wrong.
I-2345-0311
Figure 60-20-8
1
2
1

P-50821
Remove the battery access door (Item 1) [Figure 60-20-

7]. P-42339
NOTE: The battery compartment is located in front of

the left rear tire, on the back side of the cab. Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
the same cable to the positive terminal (Item 1)
[Figure 60-20-8] on the telescopic handler battery.
WARNING Connect the end of the second cable to the negative (-)
terminal of the booster battery. Connect the other end of
BATTERY GAS CAN EXPLODE AND CAUSE the same cable to the negative terminal (Item 2)
SERIOUS INJURY OR DEATH [Figure 60-20-8] on the telescopic handler battery.
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery Keep cables away from moving parts. Start the engine.
make final connection (negative) at machine frame.
After the engine has started, remove the ground (-) cable
Do not jump start or charge a frozen or damaged (Item 2) [Figure 60-20-8] first.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before Remove the cable from the positive terminal (Item 1)
connecting or disconnecting cables to battery. Never [Figure 60-20-8].
lean over battery while boosting, testing or charging.
W-2066-0910


ALTERNATOR Figure 60-30-3
Figure 60-30-1
1 S6841
Loosen and remove the alternator adjusting bolt (Item 1)

S6840 [Figure 60-30-3].
Figure 60-30-4
Page 10-160-1.)

Remove the four bolts (Item 1) and belt shield (Item 2)
1
[Figure 60-30-1].
Figure 60-30-2
S6842
Loosen and remove both mounting bolts (Item 1) [Figure

60-30-4].
1 Remove the alternator.

S6851
Remove the three connectors (Item 1) [Figure 60-30-2]

from the back of the alternator.

ALTERNATOR (CONT’D) Tighten the adjustment and mounting bolts.
Belt Adjustment Install the belt shield.
NOTE: Procedure is shown with air conditioning, the Close the engine cover. (See Opening And Closing on
procedure is the same with or without air Page 10-160-1.)
conditioning.
Belt Replacement
Stop the engine.
Loosen the alternator mounting bolt (Item 1) [Figure 60-
Open the engine cover. (See Opening And Closing on 30-6].
Page 10-160-1.)
Loosen the adjustment bolts (Item 2) [Figure 60-30-6].
Figure 60-30-5
Move the alternator until the belt can be removed.
2 Install the new belt and tighten.

S6810
Remove the four bolts (Item 1) and belt shield (Item 2)

[Figure 60-30-5].
Figure 60-30-6
2
2
P-97036
Loosen the alternator mounting bolt (Item 1) [Figure 60-

30-6].
Loosen the adjustment bolts (Item 2) [Figure 60-30-6].
Move the alternator until the belt has 8,0 mm (0.3125 in)
movement at the middle of the belt span (Item 3) [Figure
60-30-6] with 20 N•m (15 ft-lb) of force.

STARTER Removal And Installation
Testing Figure 60-40-3
Figure 60-40-1
Bat
S 1
M
Cranking
Motor
P18440
A-1992
The key switch must be in the OFF position. the battery.

The battery must be at full charge. Figure 60-40-4
The cable connections on the battery must be clean and
tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
2 1
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-2
Bat
S
M P-53364
Remove the access cover mounting bolt (Item 1) and

remove the access cover (Item 2) [Figure 60-40-4].
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

STARTER (CONT’D)
Figure 60-40-5
S6849
Remove the three wires (Item 1) [Figure 60-40-5] from

the starter.

Figure 60-40-6
1
S6850
Remove the three nuts and bolts (Item 1) [Figure 60-40-

6] and remove the starter.
Installation: Tighten to 54 - 61 N•m (40 - 45 ft-lb) torque.
NOTE: The starter is not serviceable. If starter is

damaged the entire assembly must be
replaced.

LIGHTS Figure 60-50-3
Rear Light Removal And Installation
Figure 60-50-1
1
1
P-29537
1
Remove the two lens retainer screws (Item 1)
1 [Figure 60-50-3].
S7421
Figure 60-50-4
Remove the two rear cover mounting bolts (Item 1)
[Figure 60-50-1]. Remove the cover.

Figure 60-50-2
1 1 1
P-27804
Remove the two light mounting bolts (Item 1) [Figure 60-

P-50973 50-4].
Remove the light assembly.

Disconnect the light harness connector (Item 1)
[Figure 60-50-2] from the main harness.

LIGHTS (CONT'D)
Front Light Removal And Installation

Figure 60-50-5
P-27805

Disconnect the harness (Item 1) [Figure 60-50-5] from
the light.
Figure 60-50-6
1
P-27806
Remove the two bolts (Item 1) [Figure 60-50-6] and

remove the light.

LIGHTS (CONT'D) Figure 60-50-9
Front Light Removal And Installation (Cont’d)

Figure 60-50-7
2
1
S36331
Disconnect the connectors (Item 1) and remove the light

(Item 2) [Figure 60-50-9].
Loosen the indicator light (Item 3) [Figure 60-50-9].

1 Figure 60-50-10
S36329

Remove six screws (Item 1) [Figure 60-50-7] from the
light.
2
1
Figure 60-50-8
S36332
Disconnect the connector (Item 1) and remove the

indicator light (Item 2) [Figure 60-50-10].
S36330
Loosen the front light (Item 1) [Figure 60-50-8].


TRAVEL / SIGNAL LEVER (S/N A8HD12999 & BELOW, Figure 60-60-3
S/N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 &
BELOW)
1

Figure 60-60-1
P-52344
1
Disconnect the two signal control wire connectors (Item
1) [Figure 60-60-3].
Figure 60-60-4

P-52340

the battery. 1
Figure 60-60-2
1
1 P-52345

the travel / signal levers.
P-52343
Disconnect the travel control wire harness connector

(Item 1) [Figure 60-60-2].

TRAVEL / SIGNAL LEVER (S/N A8HD12999 & BELOW, Figure 60-60-7
S/N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 &
BELOW) (CONT’D)
Figure 60-60-5
2
1
1
P-52349
Installation: Align the pin (Item 1) in the travel lever with

the top hole (Item 2) [Figure 60-60-7] in the steering
column.
P-52347

Remove the signal lever (Item 1) [Figure 60-60-5].
Figure 60-60-6
P-52348
Remove the travel lever (Item 1) [Figure 60-60-6].

TRAVEL / SIGNAL LEVER (S/N A8HD13000 & ABOVE, Figure 60-61-3
S/N A8GW13000 & ABOVE, S/N A8GT13000 &
ABOVE, S/N A8GV13000 & ABOVE, S/N A8GJ13000 &
ABOVE)
Figure 60-61-1
1
1
1
S36380

NOTE: Steering wheel is removed for photo clarity.

P-52340
Figure 60-61-4

the battery.

Figure 60-61-2
P-52347
Remove the signal lever (Item 1) [Figure 60-61-4].
S36379
Disconnect the signal and travel control wire harness

connectors (Item 1) [Figure 60-61-2].

TRAVEL / SIGNAL LEVER (S/N A8HD13000 & ABOVE,
ABOVE) (CONT’D)
Figure 60-61-5
P-52348

Remove the travel lever (Item 1) [Figure 60-61-5].
Figure 60-61-6
1
P-52349
Installation: Align the pin (Item 1) in the travel lever with

the top hole (Item 2) [Figure 60-61-6] in the steering
column.

INSTRUMENT PANEL Figure 60-70-3

1
Figure 60-70-1 1
1
1
P-52323
Remove the five instrument panel mounting bolts (Item 1)

[Figure 60-70-3].
Figure 60-70-4
P-25486

Remove the temperature control knob (Item 1)
[Figure 60-70-1] (If Equipped).
Figure 60-70-2
P-25580
1
Tilt the instrument panel forward and disconnect all

connectors [Figure 60-70-4]. Remove the instrument
panel.
NOTE: Mark the connectors for correct installation.

P-25487
Remove the nut (Item 1) [Figure 60-70-2] letting the

temperature controller fall inward.

INSTRUMENT PANEL (CONT’D)

Figure 60-70-5
1 1
S36324

Pry a sharp flat tool under the rim on both sides (Item 1)
of the instrument panel (Item 2) [Figure 60-70-5].
Push in on both sides (Item 1) and pull out the instrument

panel (Item 2) [Figure 60-70-5].
Figure 60-70-6
2
1
S36323
Disconnect the two connectors (Item 1) [Figure 60-70-6].
Remove the instrument panel (Item 2) [Figure 60-70-6].

SWITCH PANEL (S/N A8HD12999 & BELOW, S/N Figure 60-80-3
Figure 60-80-1
P-52326
1
Remove the switch panel [Figure 60-80-3].
1
P-52324
Remove the five screws (Item 1) [Figure 60-80-1].

Figure 60-80-2
P-52325
Disconnect the harness connectors from the back of the

switch panel [Figure 60-80-2].
NOTE: Mark all connectors for ease of installation.

SWITCH PANEL (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999 & BELOW,
S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) (CONT’D)
Parts Description
39
34 14
13
35 12
15
32 18
33
5
19
2 17 21
16 19
4
1
30 24
20
6
19
7
31
22

28 27
25 26
8
23
3
9
29
10
10
11
WITHOUT FRAME LEVELING
36 37 38 40 41 S3087

SWITCH PANEL (S/N A8HD12999 & BELOW, S/N 3. Knob
N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) 4. Set of keys
(CONT’D)
Parts Description (Cont’d) 5. Screw
1. L.H. control panel plate 6. Stability indicator and wire harness
2. R.H. control panel plate 7. Washer
3. Screw 8. Nut
4. Instrument panel 9. Support for frame leveling knob
5. Bezel 10. Screw
6. Switch, beacon light 11. Switch (proportional)
7. Warning Switch 12. Spacer
8. Heating Control Valve 13. Screw
9. Fan Speed Switch 14. Plate

10. Bezel for outer left and right positions
11. Bezel for middle positions
12. Trailer turn indicator
13. Steering mode indicator
14. Steering mode switch
15. Lever Switch
16. Switch, head lamp
17. Working light switch
18. Fog light switch
19. Blank Plug
20. Switch, rear wiper / washer
21. Switch, roof wiper (Option)
22. Switch, transmission mode
23. Locking switch
24. Switch, aux. hydr.
1. Start key Switch
2. Set of keys (Start)


SWITCH PANEL (S/N A8HD13000 - 14999, S/N Figure 60-81-3
A8GW13000 - 14999, S/N A8GT13000 - 14999, S/N
A8GV13000 - 14999, S/N A8GJ13000 - 14999)
Removal And Installation 2
Figure 60-81-1
S36354
1
1
Disconnect both LSI connectors from the back of the
switch panel [Figure 60-81-3].
2 Remove the switch panel (Item 2) [Figure 60-81-3].

S36355
Disconnect both LLMI connectors (Item 1) [Figure 60-

Remove the six screws (Item 1) [Figure 60-81-1]. 81-3].
Remove the Start key and nut cover (Item 2) [Figure 60- Remove the switch panel (Item 2) [Figure 60-81-3].
81-1] from the switch panel.
Figure 60-81-2
3
2
S39224
Take out the switch row (Item 1) from the switch panel in
order to have a grip on the Start key switch and remove
the nut from the Start key switch (Item 2) [Figure 60-81-
2].
Press the Start key switch (Item 2) [Figure 60-81-2] into

the switch panel.
Disconnect the connectors from the switch panel

switches.
NOTE: Mark all connectors for ease of installation.


SWITCH PANEL (S/N A8HD15000 & ABOVE, S/N Figure 60-82-2
Figure 60-82-1 1
1
3
2
1
S39224
1 Take out the switch row (Item 1) from the switch panel in
1 the nut from the Start key switch (Item 2) [Figure 60-82-
2].
Press the Start key switch (Item 2) [Figure 60-82-2] into

2

the switch panel.
S38712
Disconnect the connectors from the switch panel
switches.
Remove the six screws (Item 1) [Figure 60-82-1]. NOTE: Mark all connectors for ease of installation.
Remove the Start key and nut cover (Item 2) [Figure 60- Figure 60-82-3
82-1] from the switch panel.
S39443
Disconnect both LLMI connectors (Item 1) [Figure 60-82-

3].


BRAKE LIGHT SWITCH Adjustment
Removal And Installation Figure 60-90-3

2

For All Models:

P-27150
Figure 60-90-1

Removal And Installation on Page 50-140-1.).
Loosen the nut (Item 1) [Figure 60-90-3].

With the brake pedal at rest, turn the adjustment bolt
(Item 2) [Figure 60-90-3] until it touches the brake light
switch plug.
1 Tighten the nut (Item 1) [Figure 60-90-3].
P-52341
Disconnect the switch connector (Item 1) [Figure 60-90-

1] from the wiring harness.
Figure 60-90-2
P-27149
Loosen the nut (Item 1) [Figure 60-90-2]. Remove the

switch.


WIPER MOTOR (FRONT) Reposition the main wire harness to the right side of the
cab.
Figure 60-100-6
S/N A8GT12999 & Below, S/N A8GV12999 & Below, 1
1


Figure 60-100-4
P-25646
Remove the two mounting bracket bolts (Item 1)

1 1 [Figure 60-100-6].

Figure 60-100-7
P-25644
Remove the four lower mounting bracket bolts (Item 1)

[Figure 60-100-4].
Figure 60-100-5
P-25920
1 Reposition the steering column assembly (as shown)

[Figure 60-100-7].
P-25645
Disconnect the front wiper connector (Item 1) [Figure 60-

100-5] from the main harness.

WIPER MOTOR (FRONT) (CONT'D) Figure 60-100-10
Figure 60-100-8
P-25641
Remove the wiper arms from the wiper motor shafts

P-25639 [Figure 60-100-10].
Figure 60-100-11
Remove the spray tube (Item 1) [Figure 60-100-8].

Figure 60-100-9 1
1 1
P-25642
P-25640 Remove both outer nuts (Item 1) [Figure 60-100-11].
Flip the wiper covers and remove the two nuts (Item 1)
[Figure 60-100-9].

WIPER MOTOR (FRONT) (CONT'D)
Figure 60-100-12
P-25643
Remove both inner nuts and washers (Item 1)

[Figure 60-100-12].

Figure 60-100-13
P-25647
Remove the wiper motor from inside the cab [Figure 60-
100-13].


WIPER MOTOR (TOP) Figure 60-101-3
Figure 60-101-1
P-25655
1
Disconnect the wiper motor connector (Item 1)
P-52342 [Figure 60-101-3] from the harness.
Figure 60-101-4
Remove the three screws (Item 1) [Figure 60-101-1]
from the upper panel.

Figure 60-101-2
P-25649
Remove the squirter tube (Item 1) [Figure 60-101-4].

P-25654
Slide the upper panel forward on the support rails

[Figure 60-101-2].
Lower the panel.

WIPER MOTOR (TOP) (CONT'D) Figure 60-101-7

1
Figure 60-101-5
2 P-25651
Remove the plastic nut (Item 1) and extension post (Item

P-25648 2) [Figure 60-101-7].
Figure 60-101-8
Flip open the wiper covers and remove the nut (Item 1)
and clip (Item 2) [Figure 60-101-5].

1
Figure 60-101-6
P-25652
While supporting the wiper motor inside the cab, have an

P-25650 assistant remove the two nuts (Item 1) [Figure 60-101-
8].
Remove the wiper arms from the wiper shafts Remove the wiper motor.
[Figure 60-101-6].

WIPER MOTOR (REAR) Figure 60-102-3
Figure 60-102-1
P-25658
1
1 Flip open the wiper cover and remove the nut (Item 1)
P-52342 [Figure 60-102-3].
Figure 60-102-4
Remove the three screws (Item 1) [Figure 60-102-1]
from the upper panel and slide the upper panel forward.

Figure 60-102-2
P-25659
1 Remove the wiper arm [Figure 60-102-4].

P-25656
Disconnect the rear wiper motor connector (Item 1)

[Figure 60-102-2] from the harness.

WIPER MOTOR (REAR) (CONT'D)
Figure 60-102-5
P-25662
Have an assistant support the wiper motor [Figure 60-

102-5].

Figure 60-102-6
P-25660
Remove the plastic cover (Item 1) and two nuts (Item 2)

[Figure 60-102-6].
Remove the wiper motor.

PEDAL ASSEMBLY Figure 60-110-3

1


Removal And Installation on Page 50-141-1.) P-25249
Figure 60-110-1
Remove the accelerator cable (Item 1) from the pedal
and mounting bracket (Item 2) [Figure 60-110-3].
Figure 60-110-4

1
P-52341
1
from the brake light switch. P-25638
Figure 60-110-2
the brake valve.
1 NOTE: Mark hoses for correct installation.
IMPORTANT
damage the system.
P-42865 I-2003-0888

from the inching switch.

PEDAL ASSEMBLY (CONT’D)
Figure 60-110-5
1
P-25637
Remove the mounting bolts (Item 1) [Figure 60-110-5].

Remove the pedal assembly.

PEDAL ASSEMBLY (CONT’D) Figure 60-110-8
Figure 60-110-6
2
1 2
P-42871
Installation: Align the hole (Item 1) in the pedal with the

P-42869 hole (Item 2) [Figure 60-110-8] in the shaft.
Figure 60-110-9
Remove the bolt (Item 1) and spring (Item 2) [Figure 60-
110-6].

Figure 60-110-7 1
2
P-42872
Loosen the two set screws (Item 1) [Figure 60-110-9] on

P-42870 the two bearings.
Remove the roll pin (Item 1) and pedal (Item 2)

[Figure 60-110-7].

Disassembly And Assembly (Cont’d) 1
Figure 60-110-10
1 2
2
1 P-42876
1
Remove the flanges (Item 1) and bearings (Item 2)
P-42874 [Figure 60-110-12].
Figure 60-110-13
Remove the three bolts (Item 1) [Figure 60-110-10] from
both bearing flanges.

Figure 60-110-11
P-42878
Remove the three fittings (Item 1) [Figure 60-110-13]

P-42875 from the brake valve.
Remove the shaft and bearing assembly [Figure 60-110-

11].

Figure 60-110-14
1 2
1
P-42880
2 Remove the retainer pin (Item 1) and washer (Item 2)

P-42877 [Figure 60-110-16].
Figure 60-110-17
Remove the four bolts (Item 1), spacers (Item 2)
[Figure 60-110-14] and nuts from the brake valve.

Figure 60-110-15
1
P-42881
Remove the pedal (Item 1) [Figure 60-110-17].

P-42879
Remove the brake valve (Item 1) [Figure 60-110-15].


INCHING SWITCH Installation: Be sure the switch is on the front side of the
mounting bracket.
Remove the switch.
S/N A8GT12999 & Below, S/N A8GV12999 & Below, Adjustment
Figure 60-120-3


Figure 60-120-1

P-42865
Remove the tie-strap (Item 1) and disconnect the switch

connector (Item 2) [Figure 60-120-1] from the harness. S40034
Figure 60-120-2
With the brake pedal in the rest position, turn the

adjustment bolt (Item 1) so that it is 8 mm (0.31 in) away
from the switch body (Item 2) [Figure 60-120-3].
Check that the potentiometer rod (Item 3) [Figure 60-

120-3] is in contact with the center of the adjusting bolt.
When adjustment is complete, tighten the nut (Item 4)

1 [Figure 60-120-3] without turning the adjusting bolt.
1
P-27147
Remove the two mounting bolts and nuts (Item 1)

[Figure 60-120-2].


SERVICE SOFTWARE Figure 60-130-3
Connecting The Laptop Computer S/N A8GW12999 & BELOW
Figure 60-130-1 S/N A8GV12999 & BELOW
S/N A8GJ12999 & BELOW
1
1 S/N A8GV12999 & BELOW
P-47340
Figure 60-130-4
S40025
Figure 60-130-2 S/N A8GV13000 & ABOVE

1
1
S/N A8GW13000 & ABOVE S97029
S/N A8GJ13000 & ABOVE Locate the ACD connector (Item 1) [Figure 60-130-3]
P-97028 and [Figure 60-130-4].
Remove the fuse box cover (Item 1) [Figure 60-130-1]

and [Figure 60-130-2].

SERVICE SOFTWARE (CONT’D) Entering The Service Software
Connecting The Laptop Computer (Cont’d) Figure 60-130-7
Figure 60-130-5
2
1
P-45352
P-47342
Click the telescopic handler icon (Item 1) [Figure 60-130-
7] to enter the program.
Plug the connector (Item 1) from the laptop computer into
the ACD connector (Item 2) [Figure 60-130-5]. Figure 60-130-8

Figure 60-130-6
P-45350
S40027
The option screen will appear when entering the
telescopic handler service analyzer [Figure 60-130-8].
Open the laptop and begin [Figure 60-130-6]. The com port can be changed, if com port 1 is already
being used.

SERVICE SOFTWARE (CONT’D) Monitor Screen
Entering The Service Software (Cont’d) Figure 60-130-11
Figure 60-130-9
1
P-45348
P-45348
Select the Monitor icon (Item 1) [Figure 60-130-11].
This is the Main Screen of the telescopic handler Figure 60-130-12

analyzer program [Figure 60-130-9].

Figure 60-130-10
P-45329
P-45349 The Monitor screen displays the engine RPM, travel

control position, battery voltage, propel curve, sensor
voltage, brake release switch, inch / brake pedal, creep
The options icon will take you to the options screen potentiometer (is so equipped), transmission mode, drive
[Figure 60-130-10]. The com port can be changed, if switch and creep switch [Figure 60-130-12].
com port 1 is already being used.
If one of the icons does not change when the function is
operated, the circuit is not operating properly or the
susmic controller has a malfunction.

SERVICE SOFTWARE (CONT’D) Figure 60-130-15
Monitor Screen (Cont’d)
Figure 60-130-13
1
P-45332
1 The Work Switch is turned on, the icon (Item 1) will turn
P-45330 on and the Transmission mode will change to work (Item
2) [Figure 60-130-15].
The Inch / Brake pedal graph (Item 1) [Figure 60-130-13] Figure 60-130-16
should move as the pedal is pressed down.

Figure 60-130-14
1
P-45333
P-45331 With the Creep Switch turned on, the icon (Item 1)
[Figure 60-130-16] will turn on. The creep potentiometer
icon will change as the creep adjustment is turned.
The travel control position lever (Item 1) [Figure 60-130-
14] should move as the lever in the telescopic handler is
moved.

SERVICE SOFTWARE (CONT’D)
Warnings Screen Error # Description

Figure 60-130-17 01 Sensor supply voltage-sensor voltage out
of range
17 Software did not load properly-Restart
program and reload software
18 Inch pedal calibration failed-recalibrate
the inch pedal
1
19 Inch / brake potentiometer-no pedal
setup done, value too low, value too high
20 Engine speed pickup-engine speed
missed when starting engine
21 Propel current-short cut, open circuit
22 F-N-R switch-short cut between forward
and reverse
23 Engine speed pickup-engine speed inter-
P-45348 rupted
24 Hydro motor propel current-short cut,
open circuit
Select on the warning icon (Item 1) [Figure 60-130-17].
25 Creep drive calibration failed-recalibrate
the creep drive potentiometer

Figure 60-130-18
26 Creep drive potentiometer-value too low,
value too high
27 Motor speed pickup-motor speed inter-
rupted
P-45334
The warning screen will show codes and problem with

the controller [Figure 60-130-18].

Calibrate Inch Pedal
Figure 60-130-19
P-45345
Press the brake pedal down approximately half the stroke

P-45348 and click on the set max position icon (Item 1)
[Figure 60-130-21].
Select the calibrate inch pedal icon (Item 1) [Figure 60- Figure 60-130-22
130-19].

Figure 60-130-20
1 1
P-45351
P-45346 Release the brake pedal and click on the set min position
icon (Item 1) [Figure 60-130-22].
Click on the Start Calibration (Item 1) [Figure 60-130-

20].

Calibrate Inch Pedal (Cont’d)
Figure 60-130-23
1
2
P-45335
Select the creep box (Item 1) and then click the continue
P-45346 icon (Item 2) [Figure 60-130-25].
Click the exit (Item 1) [Figure 60-130-23] to get out of the

calibrate inch pedal.

Calibrate Creep Potentiometer
Figure 60-130-24
P-45348
Select the calibrate creep icon (Item 1) [Figure 60-130-

24].

Calibrate Creep Potentiometer (Cont’d)
Figure 60-130-26
1
1
P-45337
Turn the creep potentiometer counterclockwise and click

P-45341 on the set min position icon (Item 1) [Figure 60-130-28].
Figure 60-130-29
Click the start calibration icon (Item 1) [Figure 60-130-
26].

Figure 60-130-27
P-45339
1
Click the exit icon (Item 1) [Figure 60-130-29] to exit the
P-45338 creep calibration screen.
Turn the creep knob clockwise and click the set max
position icon (Item 1) [Figure 60-130-27].

Program / Update Susmic Controller
Figure 60-130-30
P-45347
Click the exit icon (Item 1) [Figure 60-130-32] after the

P-45348 controller has been programmed.
Select the Program / Update icon (Item 1) [Figure 60-

130-30].

Figure 60-130-31
P-45342
Click the program controller icon (Item 1) [Figure 60-

130-31].


FRAME LEVEL SPEED SWITCH Figure 60-140-3
Description
Figure 60-140-1
3
2
1
1
S3669
Disconnect the harness connector (Item 1), remove the

S3669 two bolts (Item 2) and the switch / bracket assembly (Item
3) [Figure 60-140-3].
The T35100(S)(L) and T35120(S)L telescopic handlers

are equipped with a frame level speed switch (Item 1)

[Figure 60-140-1] located on the left rear side of the
boom. This switch reduces the speed of the frame
leveling after the boom is raised over 25 degrees.
Removal
Lower the boom completely and turn off the engine.
Figure 60-140-2
1
1
S7421
Remove the two bolts (Item 1) and remove the rear cover
(Item 2) [Figure 60-140-2].

FRAME LEVEL SPEED SWITCH (CONT’D)
Installation
Figure 60-140-4
3
S3669
Install the switch / bracket assembly (Item 1) using the

two bolts (Item 2) [Figure 60-140-4].

Plug the connector (Item 3) [Figure 60-140-4] into the
harness.
Figure 60-140-5
P-50966A
Start the engine.
While holding the frame leveling switch (Item 1)

[Figure 60-140-5] raise the boom. When the boom
reaches 25 degrees the speed of the frame leveling
should decrease.

LONGITUDINAL STABILITY INDICATOR Calibration Procedure
CALIBRATION (S/N A8HD11001-14999, S/N
A8GW11001-14999, S/N A8GT11001-14999, S/N
A8GV11001-14999, S/N A8GJ11001-14999)
Fitting The Sensor

IMPORTANT
Figure 60-150-1
The following adjustments must be done on a flat
surface, without braking and must conform to the
telescopic handler safety prescriptions.
I-2346-EN-0511
Lower the boom completely and turn off the engine.

1
Figure 60-150-2
2
2
S3084

Remove the paint around the 2 M10-threaded holes on
the rear axle and verify flatness of the surface.
The surface must be perfectly flat.
22 1
1
Degrease the surface.
S3085
Apply Loctite® to the threads of both screws.
Install the sensor (P/N 6910655) (Item 1) [Figure 60- 1. Turn off the ignition. Push buzzer button (Item 1)
150-1] by alternately fastening both screws until a torque [Figure 60-150-2] and hold it.
value of 60 N•m is reached.
2. While holding the buzzer button (Item 1) [Figure 60-
150-2] pressed, start the machine. Hold the button for
another five seconds and release it when the green
LED’s light up.
3. With the machine unloaded and the boom retracted,

raise the boom until the maximum angle.
4. Wait until the machine stabilizes.
5. Push the buzzer button (Item 1) [Figure 60-150-2] for

five seconds and wait until the “ STOP” light turns red.
6. Lower the boom.
7. Take a load that can make the machine tip (do not
exceed the maximum authorized load) over and lift it
30 centimeters abover the ground.
8. Extend the boom till the rear wheels do no longer

touch the ground. Use, if needed, the shunt key
(located above te contact key).

LONGITUDINAL STABILITY INDICATOR
CALIBRATION (S/N A8HD11001-14999, S/N
A8GW11001-14999, S/N A8GT11001-14999, S/N
A8GV11001-14999, S/N A8GJ11001-14999) (CONT’D)
Calibration Procedure (Cont’d)
WARNING
The machine must be secured to the ground to
prevent tipping.
W-2920-0511
9. Push the buzzer button (Item 1) [Figure 60-150-2] for

five seconds and wait until all lights of the indicator
turn on.
10. If the shunt key has been activated, turn it off now.
11. Retract the boom and then extend again to check if

the LEDs (Item 2) [Figure 60-150-2] light up in the

right order and the buzzer works and if the system
works correctly.
The order is: green, orange, buzzer, red and “STOP”.
Aggravating movements (such as extending the
boom) will be stopped when the “STOP” light turns on.
12. Remove the load.

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, S/N Follow the procedure below to calibrate the LLMC
A8GW15000 & ABOVE, S/N A8GT15000 & ABOVE, S/ system:
NOTE: Calibration must be performed within a time
System Calibration span of 5 minutes. If longer, the LLMC will
return to its original settings.
Figure 60-160-1
NOTE: During the procedure below, the buzzer will
be activated whenever the TEST button is
pushed.
1
Figure 60-160-3
2
S39205
2
Before calibration, drive the machine for a while in order

to warm the axles, then check tightening torque of the
two bolts (Item 1) of the LLMS (Longitudinal Load
Moment Sensor) (Item 2) [Figure 60-160-1]. Torque S38711
value should be 65 N•m (48 ft-lb).

Figure 60-160-4
Park the machine on flat level ground and align the front
and rear wheels straight ahead.
NOTE: A load will be needed to topple the machine.
Figure 60-160-2
S0007
1. Push and hold the TEST button (Item 1) [Figure 60-

160-3] while starting the machine (START) [Figure
S39203 60-160-4] then quickly press the TEST button (Item 1)
[Figure 60-160-3] for 3 times within the first 4
seconds after power on.
Using the LLMC override switch, decrease the rear axle
load pressure by picking up a load and extending the
NOTE: To indicate that the system enters calibration
boom until the machine topples over (rear wheels off the
mode, the LED bar (Items 2 and 3) [Figure 60-
ground) [Figure 60-160-2].
160-3] will be blinking and the buzzer sounds
intermittent for 3 seconds.
NOTE: Do not move or reposition the machine after
decreasing the rear axle load pressure.
2. The green LED’s (Item 2) [Figure 60-160-3] light up
Retract the boom for 3 m (10 ft) and place the load on the to indicate the system is ready to record the first
ground. Then retract the boom and turn off the engine. calibration point.

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, S/N Figure 60-160-6
(CONT’D)
System Calibration (Cont’d)
Figure 60-160-5
S39203
6. Pick up the load and extend the boom until the

machine topples over (rear wheels off the ground)
[Figure 60-160-6].
S39202
7. Press and release the TEST button (Item 1)
[Figure 60-160-3] to record the second calibration

3. Without attachment and with the attachment carrier point.
fully tilted up, fully retract and raise the boom [Figure
60-160-5]. 8. To indicate the calibration has been validated, the
LED bar (Items 2 and 3) [Figure 60-160-3] lights up
4. Press and release the TEST button (Item 1) for 3 seconds and the buzzer sounds two times.
[Figure 60-160-3] to record the first calibration point.
NOTE: If the buzzer sounds and LED’s light up in a
5. The orange and red LED’s (Item 3) [Figure 60-160-3] particular configuration, a calibration failure
light up to indicate the system is ready to record the has occurred. (See System Failure Reports on
second calibration point. Page 60-160-4.)
Calibration is finished. The LLMC system automatically

returns to normal mode.
WARNING Always perform the LLMI / LLMC calibration test after

system calibration. (See Calibration Test on Page 60-
160-3.)
TIPPING CAN CAUSE SERIOUS INJURY OR DEATH
Keep the boom low, only raise the load 500 mm (20
in) when calibrating the LLMI / LLMC system.
W-2929-1111

(CONT’D)
Calibration Test 1
The Longitudinal Load Moment Control (LLMC) system

calibration can be tested by performing the following 3
procedure:
Park the machine on flat level ground and align the front 2
and rear wheels straight ahead.
NOTE: A load will be needed to topple the machine.
Figure 60-160-7 S38711
1. Raise the boom, fully retracted and without

attachment.
2. Tilt the attachment carrier fully up.
3. Push and hold the TEST button (Item 1) [Figure 60-

160-8].
4. After five seconds, all LED’s will shortly light up and

the buzzer sounds discontinuously.
5. The calibration test starts now. Two results are

possible:
S39203
- the four green LED’s (Item 2) [Figure 60-160-8] light

Using the LLMC override switch, decrease the rear axle up, calibration is OK.
load pressure by picking up a load and extending the - the orange and red LED’s (Item 3) [Figure 60-160-
boom until the machine topples over (rear wheels off the 8] light up, calibration is out of range. Please redo
ground) [Figure 60-160-7]. calibration of the LLMC system. (See System
Calibration on Page 60-160-1.)
NOTE: Do not move or reposition the machine after
decreasing the rear axle load pressure. 6. Release the TEST button (Item 1) [Figure 60-160-8].
Retract the boom for 3 m (10 ft) and place the load on the NOTE: After pressing the TEST button (Item 1)
ground. [Figure 60-160-8] longer than 60 seconds, the
procedure will automatically end and the
system will return to normal mode.
NOTE: The system always returns to normal mode

when the TEST button (Item 1) [Figure 60-160-
8] is released during the procedure.

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, S/N A8GW15000 & ABOVE, S/N A8GT15000 & ABOVE, S/N
A8GV15000 & ABOVE, S/N A8GJ15000 & ABOVE) (CONT’D)
System Failure Reports
During the occurrence of one or more of the failures below, the buzzer will sound discontinuous.
MACHINE
LOCATION FUNCTION DISPLAY CAUSE SOLUTION
BEHAVIOR
Power Supply LLMI Voltage Low Normal Battery voltage
low.
LLMI Voltage Out Normal

Of Range

LLMC Voltage Low No aggravating Battery voltage
movements low.
possible.
Shunt is allowed.
LLMC Voltage Out No aggravating

Of Range movements
possible.
Shunt is allowed.
Internal CRC Error - LLMI, LLMC or Identify the faulty

Program Flash BCC not controller and re-
programmed program.
correctly.
Test Button - The Test button is Release the Test

pressed for more button. After 10
than 10 seconds seconds, system
when the LLMI / startup can be
LLMC system is repeated.
started. If not successful,
- The Test button is replace the LLMI.
pressed for more
than 60 seconds in
the calibration test
procedure.

System Failure Reports (Cont’d)
MACHINE
BEHAVIOR
LLMS Sensor Scale Too No aggravating Calibration points Do system calibration
Tight movements too close. again within a time span
possible. of less than 5 minutes.
Shunt is allowed.
Calibration Values No aggravating Calibration not Do system calibration

Reversed movements successful. again within a time span
possible. (Recordings of first of less than 5 minutes.
Shunt is allowed. and second
calibration point
have been
swapped.)
Calibration Values No aggravating Do system calibration
Out of Range movements again within a time span

possible. of less than 5 minutes.
Shunt is allowed.
Calibration Time- No aggravating The calibration Do system calibration

out movements took more than 5 again within a time span
possible. minutes. of less than 5 minutes.
Shunt is allowed.
LLMI Linked The speed of the - The LLMI linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMI.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMI has the rear axle and do
stopped sending system calibration
CAN frame. again.
LLMC Linked The speed of the - The LLMC linked - Check the harness
Sensor (LLMS) aggravating sensor input is between the sensor and
movements is disconnected. the LLMC.
decreased (50%). - The sensor linked - Replace the sensor on
to the LLMC has the rear axle and do
stopped sending system calibration
CAN frame. again

MACHINE
BEHAVIOR
LLMS LLMI / LLMC No movement - The LLMS inputs - Check the harness
Sensor allowed. have been between the LLMS and
Signature swapped between the LLMI/LLMC.
the LLMI and the - Do system calibration
LLMC. again within a time span
- The LLMI and / or of less than 5 minutes.
the LLMC was
reprogrammed.
LLMS Value Shift After 30 seconds: No aggravating Do system calibration
(toward movements again within a time span
stability) possible. of less than 5 minutes.
Shunt is allowed.

LLMS Value Shift No aggravating Do system calibration
(toward movements again within a time span
instability) possible. of less than 5 minutes.
Shunt is allowed
Sensor Normal The difference - Do system calibration

Redundancy 1 between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
first level. needed.
Sensor No movement The difference - Do system calibration

Redundancy 2 allowed. between the dual again within a time span
LLMS values has of less than 5 minutes.
drifted over the - Replace the LLMS if
second level. needed.
Sensor Frame No aggravating Faulty LLMS. Replace the LLMS and

Default movements do system calibration
possible. again within a time span
Shunt is allowed of less than 5 minutes.

MACHINE
BEHAVIOR
Switches Retract Switch Boom considered - The retract switch - Check the harness
not retracted while is disconnected between the “boom
this failure is on. - There is a short- retracted” switch and
circuit in the switch the LLMC.
or in the harness. - Check the function of
the switch.
5° Switch Boom angle - The 5° switch is - Check the harness

considered over disconnected. between the 5° switch
5° while this - There is a short- and the LLMC.
failure is on. circuit in the 5° - Check the function of
switch or in the the switch.
harness.

(CONT’D)
System Components Identification 1
Figure 60-160-9
S39205
The LLMS (Longitudinal Load Moment Sensor) (Item 1)

[Figure 60-160-11] measures the actual load on the rear
axle.
S38711
The LLMS is equipped with dual electronics, which
independently measure the same load. The first

The LLMI (Longitudinal Load Moment Indicator) (Item 1) measurement is used by the LLMI, while the second
[Figure 60-160-9] which is located on the dashboard, measurement is used by the LLMC. The most critical
indicates the stability level of the machine, using a LED measurement of both will have priority.
bargraph and a buzzer.
Figure 60-160-12
Figure 60-160-10
EM7515
S39226
The proportional valve (Item 1) [Figure 60-160-12] is

The LLMC (Longitudinal Load Moment Controller) (Item used to reduce boom, auxiliary and tilt movement speed
1) [Figure 60-160-10] which is located under the as commanded by the LLMC.
dashboard, reduces and stops the boom movements in
relation to the machine stability. This controller combines
with other controllers in the machine.

(CONT’D) 1
System Components Identification (Cont’d)
Figure 60-160-13
S38712
The LLMC system override switch key (“shunt key”) (Item

1) [Figure 60-160-15] can be used to override the LLMC
system.
EM7515
Turned counterclockwise (unstable position), the switch
(Item 1) [Figure 60-160-15] overrides the LLMC system.

The safety valve (Item 1) [Figure 60-160-13] is used as a As soon as the key is released the LLMC system will be
safety back-up. If machine instability keeps increasing active again.
due to a certain failure, the safety valve will stop all boom
movements.
Figure 60-160-14
EM7519
The boom angle sensor (5°) (Item 1) [Figure 60-160-14]

measures the boom angle. If the boom angle is lower
than five degrees and the machine is in unstable
condition, boom movement speed is reduced.
The boom retracted sensor (Item 2) [Figure 60-160-14]

detects if the boom is fully retracted. When the boom is
retracted all boom movements will be fully operational at
any angle. The buzzer is deactivated with retracted
boom.

(CONT’D) 1
LLMS Removal
Figure 60-160-16
P-50821
Remove the three screws (Item 1) from the access cover

cab.
S39231
Remove the access cover (Item 2) [Figure 60-160-18].

For better access to the LLMS, turn the rear wheels fully Figure 60-160-19
to the left [Figure 60-160-20].
Figure 60-160-17
1
1
2
S39216

P-29253
160-19] (labeled as “XLLMS”).
Rotate the battery disconnect switch (Item 1) [Figure 60- Cut any tie-straps that hold the LLMS cable (Item 2)
160-17] to the right, to disconnect the power supply from [Figure 60-160-19] and fully extract the cable out of the
the battery. machine.

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, S/N LLMS Installation
N A8GV15000 & ABOVE, S/N A8GJ15000 & ABOVE) Raise the boom and install the approved boom stop. (See
(CONT’D)
the Operation & Maintenance Manual for more
LLMS Removal (Cont’d) information.)
Figure 60-160-20 Figure 60-160-21
1
2
1
S39217
S39215

Remove the two bolts (Item 1) and remove the LLMS Clean the axle sensor area (Item 1) [Figure 60-160-21]
(Item 2) [Figure 60-160-20]. to remove rust and/or dirt.
Figure 60-160-22
2
1
S39215
Position the LLMS (Item 1) and install the two bolts (Item
2) [Figure 60-160-22].
NOTE: Apply Loctite® #243 to the bolts.
Tighten the two bolts (Item 2) [Figure 60-160-22] in three

progressive steps:
- 25 N•m (18.4 ft-lb)
- 45 N•m (33.2 ft-lb)
- 65 N•m (47.9 ft-lb).

(CONT’D)
LLMS Installation (Cont’d) 3
Figure 60-160-23
2
2 4
3 1
S39220
1
Route further until the cable (Item 1) [Figure 60-160-25]
is fully extended.
The connector (Item 2) is now located next to the opening

S39218
(Item 3) [Figure 60-160-25] in the frame, which leads to
the back of the cab.

Route the LLMS cable (Item 1) [Figure 60-160-23]
through the opening inside the frame to the area under Install a tie-strap (Item 4) [Figure 60-160-25] to secure
the boom. the cable to the nearby hoses.
Install two tie-straps (Items 2 and 3) [Figure 60-160-23] Figure 60-160-26

to secure the cable to the nearby hose(s).
Figure 60-160-24
2
1
1
S39221
3
Plug the LLMS connector (Item 1) into the “XLLMS”

S39219
connector (Item 2) [Figure 60-160-26] at the back of the
cab.
Under the boom, route the LLMS cable (Item 1) further to
the cab side and then up through the opening (Item 2)
[Figure 60-160-24] in the frame.
Install a tie-strap (Item 3) [Figure 60-160-24] to secure

the cable to the nearby hoses.

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, LLMC Controller Removal
ABOVE, S/N A8GV15000 & ABOVE, S/N A8GJ15000 & Figure 60-160-29
ABOVE) (CONT’D)
LLMS Installation (Cont’d) 1
Figure 60-160-27
P-29253
2

P-50821
the battery.

Install the access cover (Item 1) [Figure 60-160-27]. Figure 60-160-30
3
Install the three screws (Item 2) of the access cover (Item
1) [Figure 60-160-27].
Figure 60-160-28
1
1 1
1
1 2
S39222
Remove the eleven screws (Item 1) [Figure 60-160-30]

from the column cover.
P-29253
Remove the column cover (Item 2) [Figure 60-160-30].
Rotate the battery disconnect switch (Item 1) [Figure 60- Remove the screw (Item 3) [Figure 60-160-30] from the
160-28] to the left, to connect the power supply from the dash cover.
battery.
Remove the approved boom stop and lower the boom.

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE, Figure 60-160-33
ABOVE) (CONT’D)
2
LLMC Controller Removal (Cont’d)
Figure 60-160-31
2
1 2
1
1
S38712
P-52345
Remove the Start key and nut cover (Item 1) [Figure 60-

Remove the two screws (Item 1) [Figure 60-160-31] from 160-33] from the switch panel.
Remove the screws (Item 2) [Figure 60-160-33] from the
Figure 60-160-32 switch panel.
Figure 60-160-34
3
2
S39223
S39224
Remove the travel / signal levers from the steering
column, such that the dash cover can be partly lifted
[Figure 60-160-32]. Take out the switch row (Item 1) from the switch panel in
the nut from the Start key switch (Item 2) [Figure 60-160-
34].
Press the Start key switch (Item 2) [Figure 60-160-34]

into the switch panel.
Partly remove the switch panel (Item 3) [Figure 60-160-

34], in order to access to the LLMC controller.

ABOVE) (CONT’D)
LLMC Controller Removal (Cont’d) 2

1
Figure 60-160-35
1
S39227
S39226
1 Remove the bolt (Item 1) and nut (Item 2) [Figure 60-

1 160-37] from the nearest left hand controller bracket.

S39225
the right hand side of the controller.

Remove and discard both plugs (Item 1) [Figure 60-160- NOTE: Only three brackets are used to mount the
35] from the dash cover. controller.
Lift the dash cover approximately 15 cm (6 in). Figure 60-160-38
Figure 60-160-36 1
2
S39228
S39230
Remove the controller (Item 1) from the dashboard and
disconnect both connectors (Item 2) [Figure 60-160-38]
Remove the tie-strap (Item 1) [Figure 60-160-36]. labeled as “XLLMC1” and “XLLMC2”.

ABOVE) (CONT’D)
LLMC Controller Installation 3

2
Figure 60-160-39
2
S39227
1 S39226
1 Install the two screws (Item 1) [Figure 60-160-41] at the

right hand side of the controller.
Install the bolt (Item 2) and nut (Item 3) [Figure 60-160-

S39229
41].

Remove the two right hand brackets (Item 1) [Figure 60- Figure 60-160-42
160-39] from the new LLMC controller. (The old controller
brackets, which are mounted on the machine, will be
used instead.)
Figure 60-160-40
1
2
S39230
Install a new tie-strap (Item 1) [Figure 60-160-42].
1 Lower the dash cover to its original position.

S39228
Plug both connectors (Item 1) labeled as “XLLMC1” and

“XLLMC2” onto the connectors of the new LLMC
controller (Item 2) [Figure 60-160-40].
NOTE: The connectors can not be erroneously

swapped.

ABOVE) (CONT’D)
1
LLMC Controller Installation (Cont’d)
Figure 60-160-43
1
1 2
1
S38712
S39225
Install the screws (Item 1) [Figure 60-160-45] of the

Install two new plugs (Item 1) [Figure 60-160-43]. switch panel.
Figure 60-160-44 Install the nut cover (Item 2) [Figure 60-160-45] of the
Start key switch.
Figure 60-160-46
1
1
2
S39224
1
Put the switch panel (Item 1) [Figure 60-160-44] back in P-52345

place.
Install the Start key switch (Item 2) into the switch panel Put the travel / signal levers back in place and install the
and install the nut that holds the Start key switch (Item two screws (Item 1) [Figure 60-160-46].
2) [Figure 60-160-44].
Install the switch row (Item 3) [Figure 60-160-44].

LLMI / LLMC SYSTEM (S/N A8HD15000 & ABOVE,
ABOVE) (CONT’D)
LLMC Controller Installation (Cont’d)
Figure 60-160-47
3
2
2
2
2 1
S39222

Put the column cover (Item 1) [Figure 60-160-47] back in
place.
Install the eleven screws (Item 2) [Figure 60-160-47] of

the column cover.
Install the screw (Item 3) [Figure 60-160-47] of the dash

cover.
Figure 60-160-48
P-29253

160-48] to the left, to connect the power supply from the
battery.

ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-12
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
OIL COOLER / RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
ENGINE AND ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1


ENGINE COMPONENTS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Injectors Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Checking The Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
Glow Plugs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-13
ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE / HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Turbocharger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Turbocharger Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Turbocharger Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Exhaust Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Fuel Injector Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-4
Rocker Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-5

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-6
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-8
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-9
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-12
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-12
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-13
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-14
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-15
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-16
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-17
Changing Valve Springs (With Cylinder Head Installed) . . . . . . . . . . . . . . . . . . . . 70-110-18
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-19
Timing Case And Drive Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Crankshaft Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Front Oil Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-20
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-21

Timing Case And Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-22
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-24
Camshaft And Tappets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-25
Pistons And Connecting Rods Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-26
Pistons And Connecting Rods Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-26
Pistons And Connecting Rods Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-28
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-29
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Connecting Rod Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-30
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Crankshaft And Bearings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-32
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-34
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-35
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-36
Rear Oil Seal Housing Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-36
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-37
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-37
Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-38
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-39
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Lubricating Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-40
Engine Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-41

Oil Filter Adapter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-42
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-42
Oil Screen And Pick-up Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-43
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-43
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-44
Oil Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-45
Oil Pressure Relief Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 70-110-45
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-46
Engine Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-46
Piston Cooling Jet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-47
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-48
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-49
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-50


ENGINE INFORMATION
Specifications
All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
General
Number Of Cylinders 4
Cylinder Arrangement In-line
Cycle 4 Stroke
Direction Of Rotation Clockwise From The Front
Intake System Turbocharged
Combustion System Direct Injection
Nominal Bore 100 (3.937)
Stroke 105 (4.134)
Compression Ratio 17.25:1
Displacement 4 L (243 in³)
Firing Order 1-3-4-2

Cylinder Head
Head Thickness 117,95 - 118,05 (4.643 - 4.647)

Head Thickness After Machining (Minimum) 117,20 (4.614)
Valve Seat Angle 30°
Leak Test Pressure 0,2 MPa (2 bar) (29 psi)
Valve Guides
Inside Diameter 8,250 - 8,350 (0.3248 - 0.3287)

Outside Diameter 13,034 - 13,047 (0.5131 - 0.5137)
Valve Guide Bore 13,000 - 13,027 (0.5118 - 0.5129)
Valve Guide Clearance In The Cylinder Head (Interference) 0,007 - 0,047 (0.0003 - 0.00019)
Overall Length:
Intake 128,92 - 129,37 (5.076 - 5.093)
Exhaust 128,92 - 129,37 (5.075 - 5.093)
Protrusion From Bottom 12,35 - 12,65 (0.486 - 0.498)

ENGINE INFORMATION (CONT'D)
Specifications (Cont’d)
parentheses.
Exhaust Valves
Valve Stem Diameter 8,93 - 8,96 (0.3515 - 0.3 528)

Valve Guide Clearance 0,040 - 0,84 (0.0016 - 0.0033)
Maximum 0,15 (0.006)
Valve Head Diameter 41,51 - 41,75 (1.634 - 1.644)
Valve Face Angle 30°
Overall Length 128,92 - 129,37 (5.075 - 5.093)
Seal Type Stem seal with integral seating washer
Valve Clearance 0,45 (0.018)
Exhaust Depth (Production) 1,53 - 1,81 (0.060 - 0.071)
Exhaust Depth (Service) 2,06 (0.081)

Intake Valves
Valve Stem Diameter 8,95 - 8,98 (0.3525 - 0.3535)

Valve Guide Clearance 0,025 - 0,069 (0.0010 - 0.0027)
Maximum 0,13 (0.005)
Valve Head Diameter 46,20 - 46,45 (1.819 - 1.829)
Valve Face Angle 30°
Overall Length 128,92 - 129,37 (5.076 - 5.093)
Seal Type Stem seal with integral seating washer
Valve Clearance 0,20 (0.008)
Intake Depth (Production) 1,58 - 1,84 (0.062 - 0.072)
Intake Depth (Service) 2,09 (0.082)
Valve Springs
Installed Height 34,5 (1.358)

Installed Height Pressure 229 N (51 lbf)
Number Of Active Coils 3.8

parentheses.
Rocker Shaft, Rockers And Bushings
Shaft Outside Diameter 24,962 - 24,987 (0.9828 - 0.9837)

Clearance Between Rocker Arm Bushing and Shaft 0,26 - 0,89 (0.0010 - 0.0035)
Maximum 0,17 (0.007)
Pistons And Piston Rings
Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 39,703 - 39,709 (1.5631 - 1.5633)
Piston Projection Above the Block Deck 0,21 - 0,35 (0.008 - 0.0137)
Top Ring Groove Width Tapered
Second Ring Groove Width 2,54 - 2,56 (0.0999 - 0.1007)

Third Ring Groove Width 3,52 - 3,54 (0.1385 - 0.1393 )
Top Ring Barrel Face, Molybdenum insert, Keystone
Second Ring Taper Face, Cast Iron, Internal Bottom Step
Oil Control Ring Two Piece Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 2,48 - 2,49 (0.097 - 0.098)
Third Ring Width 3,47 - 3,49 (0.1366 - 0.1374)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0,05 - 0,09 (0.002 - 0.003)
Third Ring Side Clearance 0,03 - 0,07 (0.0011 - 0.0027)
Top Ring End Gap 0,30 - 0,55 (0.011 - 0.021)
Second Ring End Gap 0,70 - 0,95 (0.027 - 0.037)
Third Ring End Gap 0,30 - 0,55 (0.0118 - 0.0216)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 39,694 - 39,700 (1.5628 - 1.5630)
Piston Boss Clearance 0,003 - 0,015 (0.0001 - 0.0006)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 43,66 - 43,84 (1.7190 - 1.7259)
Bushing Inside Diameter (Reamed) 39,723 - 39,738 (1.5638 - 1.5645)
Piston Pin Bushing Clearance 0,023 - 0,044 (0.0009 - 0.0017)

parentheses.
Connecting Rods And Bearings
Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 67,21 - 67,22 (2.6460 - 2.6465)
Piston Pin End 43,01 - 43,03 (1.693 - 1.694)
Length Between Centers 219,05 - 219,10 (8.624 - 8.626)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 31,55 - 31,88 (1.240 - 1.255)
Bearing Thickness At The Center 1,835 - 1,842 (0.0723 - 0.0725)
Bearing Clearance 0,03 - 0,081 (0.0012 - 0.0032)
Bearing Undersize Available -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)
Crankshaft

Main Journals 76,16 - 76,18 (2.998 - 2.999)
Maximum Wear And Out Of Round Of The Journals And 0,04 (0.0016)
Crank Pins
Width Of Center Journal 44,15 - 44,22 (1.738 - 1.741)
Width Of Other Journals 39,24 - 39,34 (1.545 - 1.549)
Crank Pin Diameters 63,47 - 63,49 (2.499 - 2.500)
Width Of Crank Pins 40,35 - 40,42 (1.589 - 1.591)
Crankshaft End Play 0,05 - 0,38 (0.0002 - 0.015)
Thrust Washer Thickness: Std. 2,26 - 2,31 (0.089 - 0.091)
Oversize 2,45 - 2,50 (0.096 - 0.098)
Main Bearing Oil Clearance 0,057 - 0,117 (0.0022 - 0.0046)
Undersize Journals And Crank Pins -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)

parentheses.
Crankshaft (Cont'd)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0,10 (0.004)
Journal #1 Mounting
Journal #2 0,08 (0.003)
Journal #3 0,15 (0.006)
Journal #4 0,08 (0.003)
Journal #5 Mounting
Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
ITEM 0,25 (0.010) 0,51 (0.020) 0,76 (0.030)

1 75,909 - 75,930 75,649 - 75,670 75,399 - 75,420
(2.9884 - 2.9892) (2.9784 - 2.96792) (2.9684 - 2.9692)
2 63,220 - 63,240 62,962 - 62,982 62,708 - 62,728
(2.488 - 2.4896) (2.4788 - 2.4796) (2.4688 - 2.4696)
3 39,47 (1.554) maximum - -
4 37,44 (1.474) maximum - -
5 44,68 (1.759) maximum - -
6 40,55 (1.596) maximum - -
7 Do not machine this diameter - -
8 Do not machine this diameter - -
9 3,68 - 3,69 (0.1448 - 0.1452) - -
Crankshaft Heat Treatment: 60 Hour Nitride
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0,25 (0.010) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.

parentheses.
Main Bearings
Type Steel Back, 20% Tin Aluminium

All Others 31,62 - 31,88 (1.244 - 1.255)
Bearing Thickness (center) 2,083 - 2,089 (0.0820 - 0.0823)
Bearing Clearance 0,057 - 0,117 (0.0022 - 0.0046)
Bearing Undersize Available -0,25 (-0.010), -0,50 (-0.020), -0,75 (-0.030)
Thrust Washers
Type Steel back, bearing material

Position Each Side Of Center Main Bearing
Standard 2,26 - 2,31 (0.089 - 0.091)
Oversize 2,45 - 2,50 (0.096 - 0.098)

Camshaft And Thrust Washer
Journal #1 Diameter 50,71 - 50,74 (1.997 - 1.998)

Cam Lift (Intake) 7,03 - 7,13 (0.2768 - 0.2807)
Cam Lift (Exhaust) 7,963 - 8,063 (0.3135 - 0.3174)
Maximum Wear And Out Of Round 0,05 (0.021)
Camshaft End Play (Production) 0,10 - 0,55 (0.004 - 0.022)
Service Limits 0,60 (0.023)
Thrust Washer Type 360°
Thrust Washer Thickness 5,49 - 5,54 (0.216 - 0.218)
Thrust Washer Recess Depth 5,54 - 5,64 (0.218 - 0.222)
Cylinder Block
Cylinder Bore Diameter 105,000 - 105,025 (4.1338 - 4.1348)

Main Bearing Bore Diameter 80,416 - 80,442 (3.166 - 3.167)

parentheses.
Cylinder Liners
Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 104,25 - 104,28 (4.105 - 4.106)
Production Liner Clearance 0,03 - 0,08 (0.001 - 0.003)
Production Liner Inside Diameter 100,00 - 100,03 (3.937 - 3.938)
Service Liner Clearance ±0,03 (±0.001)
Inside Diameter Of Service Liner With Flame Ring 100,0 - 100,63 (3.937 - 3.961)
(Installed)
Maximum 0,25 (0.010)
Flange Thickness 3,81 - 3,86 (0.150 - 0.152)
Liner Projection From Deck Surface 0,10 (0.004) Above or 0,10 (0.004) Below
Hose Angle 30 / 35°

Piston Cooling Jets 9 N•m (79.7 in-lb)
Fuel Injection Pump
Type DELPHI DP 210 with locking screw

Rotation From Drive End Clockwise
Fuel System Self Vent
Fuel Injectors
Working Pressure 29,4 MPa (294 bar) (4263 psi)
Fuel Lift Pump
Type Electrically operated

Method of Drive Electric Motor 12V / 24V
Standard Pressure 41- 69 kPa (0,41 - 0,69 bar) (6-10 psi)
Minimum Pressure 26 kPa (0,26 bar) (3.75 psi)

parentheses.
Timing Case And Timing Gears
Camshaft Gear Number Of Teeth 68

Camshaft Gear Bore Diameter 34,93 - 34,95 (1.375 - 1.376)
Camshaft Hub Outside Diameter 34,90 - 34,92 (1.374 - 1.375)
Fuel Pump Gear Number Of Teeth (Electronic) 68
Fuel Pump Gear Bore (Electronic) 29,99 - 30,02 (1.417 - 1.419)
Crankshaft Gear Number Of Teeth 34
Crankshaft Gear Bore Diameter 47,625 - 47,650 (1.875 - 1.8760)
Crankshaft Gear Hub Diameter 47,625 - 47,645 (1.875 - 1.8758)
Crankshaft Gear Clearance -0,020 - +0,020 (-0.0008 - +0.0008)
Idler Gear Number Of Teeth 73
Idler Gear Bore Diameter 57,14 - 57,18 (2.250 - 2.251)

(With Needle Bearings) 72,35 - 72,36 (2.848 - 2.849)
Width Of Idler Gear And Bushing Assembly (Installed) 30,14 - 30,16 (1.186 - 1.187)
Flanged Bushing Inside Assembly (Installed) 50,78 - 50,80 (1.999 - 2.000)
Idler Gear Hub Outside Diameter 50,70 - 50,74 (1.9990 - 1.9999)
Idler Gear Hub Bushing Clearance 0,04 - 0,10 (0.0016 - 0.0039)
Gear End Play (Production Limits) 0,10 - 0,20 (0.004 - 0.008)
Service Limit 0,38 (0.015)
Backlash For All Gears 0,08 (0.003) Minimum

parentheses.
Oil Pump, Gear And Relief Valve
Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 5, Outer 6
Clearance Of Outer Rotor To Body 0,15 - 0,34 (0.006 - 0.013)
End Play
Inner Rotor 0,04 - 0,09 (0.001 - 0.004)
Outer Rotor 0,025 - 0,076 (0.0010 - 0.0029)
Oil Pump Idler Gear Bushing I.D. 16,012 - 16,038 (0.6303 - 0.6314)
Idler Shaft O.D. 15,966 - 15,984 (0.6285 - 0.5292)
Idler Gear Shaft Bushing Clearance 0,028 - 0,072 (0.0011 - 0.0028)
Oil Pump Idler Gear End Play 0,050 - 0,275 (0.0019 - 0.0108)
Relief Valve Plunger Bore Diameter 19,250 - 19,300 (0.7578 - 0.7598)

Relief Valve Plunger Outside Diameter 19,186 - 19,211 (0.7553 - 0.7563)
Clearance 0,039 - 0,114 (0.0015 - 0.0044)
Length Of The Spring (Installed) 59,8 (2.35)
Load On The Spring (Installed) 25 - 65 kPa (0,25 - 0,36 bar) (3.6 - 5.2 psi)
Pressure To Open Pressure Relief Valve 414 - 469 kPa (4,14 - 4,69 bar) (60 - 68 psi)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open Bypass Valve In Oil Filter 55 - 83 kPa (0,55 - 0,83 bar) (8 - 12 psi)
Turbocharger
Type Garrett GT25
Flywheel
Run-Out Less than 0,30 (0.012)

Misalignment 0,03 (0.001)@ 25 (1.0)

parentheses.
Water Pump And Thermostat
Type Centrifugal, Gear Drive

Shaft Outside Diameter 21,425 - 21,438 (0.8435 - 0.8440)
Drive Gear Bore Diameter 21,375 - 21,400 (0.8415 - 0.8425)
Drive Gear Shaft Clearance 0,025 - 0,063 (0.0009 - 0.0024)
Impeller Bore Diameter 11,943 - 11,971 (0.4701 - 0.4712)
Impeller Shaft Outside Diameter 11,997 - 12,008 (0.4723 - 0.4727)
Impeller Clearance On Shaft 0,026 - 0,065 (0.0010 - 0.0025)
Bearing Bore Diameter 39,989 - 40,014 (1.5743 - 1.5753)
Bearing Diameter 39,989 - 40,000 (1.5743 - 1.5747)
Bearing Clearance In Pump Body +0,025 / -0,011 (+0.0009 / -0.0005)
Thermostat Type Wax Pellet, Bypass Blanking

NOMINAL TEMPERATURE
STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BYPASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
82°C (180°F) 77° / 85°C (170° / 185°F) 92° / 98°C (198° / 208°F) 9,0 (0.35)

Engine Torque Component
COMPONENT NM FT-LBS
Bridge Piece To Block 16 12
Camshaft Gear Bolt 95 70
Connecting Rod Nuts
Step 1 18 13
Final 70 52
Crank Pulley Bolts 115 85
Cylinder Head Bolt
Step One 50 37
Step Two 100 74
Step Three 225°
Step Three - Long Bolts 270°
Engine Mounting Bridge To Frame 271 200
Exhaust Manifold Bolts 33 24
Flywheel Cover To Housing 61 45
Flywheel Housing To Cylinder Block 70 52
Flywheel To Crankshaft Bolts 105 77

Fuel Injector Nut 30 22
Fuel Injection Pump Gear Nut 24 18
Fuel Injection Pump Flange Nuts 24 18
Fuel Lift Pump Bolts 22 16
High Pressure Fuel Lines Fittings 30 22
Idler Gear Hub Bolts 44 33
Main Bearing Bolts
Step 1 88 65
Step 2 170 125
Step 3 250 185
Oil Pan Bolts 22 16
Oil Pan Plug 34 25
Oil Pump Cover 22 16
Oil Pump To Front Main Cap 22 16
Oil Transfer Plate Bolts 30 22
Piston Cooling Jets 9 7
Rear Oil Seal Housing Bolts 22 16
Rocker Cover Nuts (With Shim Washer) 9 7
Rocker Shaft Bracket Nuts 27 20
Timing Case To Block 22 16
Timing Case Cover To Timing Case Bolts 22 16
Turbocharger To Manifold Nuts 44 33
Water Pump To Timing Case Bolts & Nuts 22 16

Troubleshooting
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue / white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52

Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45

TROUBLESHOOTING (CONT'D)
Troubleshooting (Cont'd)

1. Battery capacity low. 27. Poor boost pressure.
2. Bad electrical connections 28. Fuel leak.
3. Faulty starter motor. 29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil. 30. Sticking valves.
5. Incorrect grade of fuel. 31. Leaking head gasket.
6. Incorrect use of cold starting equipment. 32. Worn valve guides / stems.
7. Faulty cold starting equipment. 33. Faulty thermostat.
8. Insufficient fuel in tank. 34. Incorrect piston height.
9. Faulty stop control. 35. Broken / worn piston rings.
10. Broken fuel injection pump drive. 36. Worn cylinder liners.
11. Air in the fuel system 37. Worn wrist pins.
12. Restricted fuel feed. 38. Excessive camshaft end play.
13. Fuel tank vent blocked. 39. Excessive timing gear backlash.
14. Plugged fuel filters. 40. Oil leaks.

15. Faulty fuel pump. 41. New or rebuilt engine not broken in.
16. Low compression. 42. Plugged breather pipe.
17. Incorrect valve clearance. 43. Glazed cylinder liners.
18. Incorrect valve timing. 44. Worn pistons.
19. Incorrect fuel pump timing. 45. Worn valve stem seals.
20. Faulty injectors. 46. Coolant level low.
21. Faulty fuel injection pump. 47. Faulty water pump.
22. Plugged air filter. 48. Loose or broken blower fan belt.
23. Broken or weak valve springs. 49. Radiator cooling fins plugged.
24. Overheating. 50. Damaged blower fan.
25. Restricted exhaust system. 51. Loose flywheel.
26. Water in fuel. 52. Broken engine mounts.


ENGINE SPEED CONTROL Figure 70-20-3
Figure 70-20-1
2 P-53128

P-25249 Page 10-160-1.)

Remove the floor mat and insulation from the cab floor. 70-20-3] from the linkage.

Remove the speed control cable (Item 1) from the pedal Figure 70-20-4
and mounting bracket (Item 2) [Figure 70-20-1].
Remove the battery box cover.
Figure 70-20-2
P-53127
1
Remove the engine speed control cable from the

mounting bracket (Item 1) [Figure 70-20-4].
P-25250
Remove any necessary cable ties, carefully remove the
speed control cable.
Carefully pull the speed control cable (Item 1) [Figure
70-20-2] through the cab and into the battery box.


MUFFLER Figure 70-30-2
Figure 70-30-1
S40029
1
Remove the clamp (Item 1) [Figure 70-30-2].

P-53129
Remove the muffler.

Page 10-160-1.)

Remove the exhaust mounting bolts (Item 1) [Figure 70-
30-1].


AIR CLEANER
Housing Removal And Installation
Figure 70-40-1
P-53131

Page 10-160-1.)

Loosen the clamps (Item 1) [Figure 70-40-1] and remove
the hoses from the air cleaner.
Figure 70-40-2
P-53132
Remove both mounting bolts (Item 1) [Figure 70-40-2].
Remove the air cleaner housing assembly.


OIL COOLER / RADIATOR S/N A8HD12999 & Below, S/N A8GW12999 & Below,
Removal And Installation S/N A8GJ12999 & Below:
Remove the engine cover. (See Removal And Installation Figure 70-50-3
on Page 50-60-1.)
Drain the hydraulic reservoir. (See Removing And 1


Coolant on Page 10-70-1.) 1
Remove the fan motor. (See Removal And Installation on

Page 20-140-1.)
Figure 70-50-1
2
S6891
Remove the two nuts (Item 1) [Figure 70-50-3] from the

condenser.

1
Figure 70-50-4
S6859
1
Remove the two lower radiator hoses (Item 1) [Figure
70-50-1].
Remove the lower hydraulic hose (Item 2) [Figure 70-50-

1].
Figure 70-50-2
S6860
Position the condenser (Item 1) [Figure 70-50-4] (as

shown).
S6890
Remove the upper hydraulic hose (Item 1) [Figure 70-50-

2].

OIL COOLER / RADIATOR (CONT’D)

Figure 70-50-5
S36349

Loosen the nut (Item 2) [Figure 70-50-5].
Figure 70-50-6
S36350
Position the condenser (Item 1) [Figure 70-50-6] (as

shown).

OIL COOLER / RADIATOR (CONT’D) Figure 70-50-9
For All Models:
Figure 70-50-7
S7438

Install a hoist and chain to the oil cooler / radiator [Figure
70-50-7].
Figure 70-50-8
S7437
Lift and remove the oil cooler / radiator assembly [Figure

70-50-9].
P-22025
Remove both oil cooler / radiator mounting bolts (Item 1)

[Figure 70-50-8] from the bottom of the engine pan.

Figure 70-50-10
1
1
S6865
Remove the wear pads (Item 1) [Figure 70-50-12].

S6863
Figure 70-50-13
Remove both rubber mounts (Item 1) [Figure 70-50-10]

by turning counterclockwise.

Figure 70-50-11
1 1
2 1
2
1 S6866
Remove the bolts (Item 1) and remove the upper bracket

1
(Item 2) [Figure 70-50-13].
S6864
Remove the seven bolts (Item 1) and remove the bracket

(Item 2) [Figure 70-50-11].

Figure 70-50-14
2
2
S6869
Remove the plate (Item 1) by removing the four screws

S6867 (Item 2) [Figure 70-50-16].
Separate the oil cooler from the intercooler.

Support the oil cooler / radiator assembly as shown
[Figure 70-50-14].

Figure 70-50-15
2 1 1
1
S6868
Remove the three bracket mounting bolts (Item 1) (both

sides) and remove the condenser mounting bracket (Item
2) and shroud (Item 3) [Figure 70-50-15].


ENGINE AND ENGINE MOUNTS Figure 70-60-3

NOTE: Put the engine / hydrostat assembly on blocks,

to allow access to remove the motor mount
bolts. 1
Remove the hydrostatic pump. (See Removal And
Remove the flywheel and housing. (See Removal And

If equipped with air conditioning, remove the hoses from S6872

the compressor. (See Removal And Installation on Page
70-90-1.) Remove the lower radiator hose (Item 1) [Figure 70-60-
3] from the water pump.
Figure 70-60-1
Figure 70-60-4

1
1
S6870
P-53808
thermostat housing.
Remove the intake hose (Item 1) [Figure 70-60-4] from
Figure 70-60-2 the turbo.
S6871
Remove the hose (Item 1) [Figure 70-60-2] and

reposition.

ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-60-7
Figure 70-60-5
S6909
1 Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-60-7].
S6916
Figure 70-60-8
Loosen the hose clamp (Item 1) [Figure 70-60-5] and
remove the hose from the engine.
2

Figure 70-60-6
1 P-53809
Remove the three bolts (Item 1) and exhaust tube (Item

2) [Figure 70-60-8].
P-55515
Remove the intake tube from the turbo by loosening the

clamp (Item 1) [Figure 70-60-6].

Figure 70-60-9
1
2
P-53812
Reposition the electrical harness [Figure 70-60-11] (as

shown).
P-53810
Figure 70-60-12
Remove the bolt and nut (Item 1) at the rear of the engine
compartment and remove the access panel (Item 2)
[Figure 70-60-9].

Figure 70-60-10 1
2 S6919
Install a lifting bracket (Item 1) [Figure 70-60-12] in the

position shown.
P-53811
Remove the two bolts (Item 1) and remove the two fuse
assemblies (Item 2) [Figure 70-60-10].

Figure 70-60-13
S6918
Lift and remove the engine [Figure 70-60-15].

S6917
Install a hoist and chain to the lifting brackets [Figure 70-

60-13] (as shown).

Figure 70-60-14
S6873
Remove both front engine mount bolts (Item 1) [Figure

70-60-14].
Installation: Tighten the engine mount bolts to 250 - 271


ENGINE COMPONENTS AND TESTING Figure 70-70-2
Fuel Injection Pump Removal
NOTE: Read and fully understand the following

procedure before removing the fuel injection
pump. Failure to remove the pump correctly
will result in incorrect pump timing and the 2
pump will have to be sent to an authorized
Delpi dealer to be retimed. The internal
adjustment for pump timing is tamper proof.
High and low idle adjustments of the fuel
injection pump are factory set and
adjustments cannot be made to the fuel 1
pump.
P-55774
Set the engine to TDC number one cylinder compression
stroke. (See ENGINE TIMING on Page 70-80-1.)
Loosen the lock bolt (Item 1) and move the washer (Item
Figure 70-70-1 2) [Figure 70-70-2] (to the position shown). Retighten
the locking screw to 17 N•m (12 ft-lb) torque.
Remove the nut and washer (Item 1) [Figure 70-70-1].

Figure 70-70-3
1
P-55531
NOTE: If the fuel pump nut (Item 1) [Figure 70-70-1] is

loosened before the fuel pump timing is set
and the pump locked, the fuel pump timing P-55529
will be lost and the fuel pump will have to be
sent into the dealer to be reset.
Using a gear puller, remove the fuel pump gear [Figure
Apply pressure counterclockwise by hand to the fuel 70-70-3].
pump gear to remove backlash from the gears.

ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-6
Fuel Injection Pump Removal (Cont'd)
Figure 70-70-4
P-55524
Remove the fuel line (Item 1) [Figure 70-70-6] from the

P-55522 front of the pump.
Figure 70-70-7
Remove the harness (Item 1) [Figure 70-70-4].

NOTE: Mark the connectors for correct installation.
Figure 70-70-5
1
P-55525
Remove the fuel line (Item 1) [Figure 70-70-7] from the

rear of the pump.
P-55523
Remove the connector (Item 1) [Figure 70-70-5] from the

top of the pump.

Fuel Injection Pump Removal (Cont'd)
Figure 70-70-8
1
1
P-55533
Disconnect the return spring (Item 1) [Figure 70-70-10]

P-55526 from the pump linkage.
Figure 70-70-11
Remove the four fuel tubelines (Item 1) [Figure 70-70-8].

IMPORTANT
Do not bend the high pressure fuel injection tubes 1
when removing or installing them.
I-2029-0289
Figure 70-70-9
P-55528
Remove the mount bolt (Item 1) [Figure 70-70-11] from

the bracket.
P-55527
Remove the tubeline (Item 1) [Figure 70-70-9] from the

top of the pump.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Installation
Fuel Injection Pump Removal (Cont'd) NOTE: The new fuel pump will be supplied with the
pump shaft in the locked position. Do not
Figure 70-70-12 unlock the shaft of the fuel pump until the fuel
pump gear is installed.
1 The engine must be set to TDC number one cylinder,

1 compression stroke before the pump is installed. (See
ENGINE TIMING on Page 70-80-1.)
Install a new O-ring onto the pump flange.
Figure 70-70-13
1
1
1
P-55532
Remove the three mount bolts (Item 1) [Figure 70-70-12]

and remove the pump.

1
P-55532
Install the fuel pump and tighten the three bolts (Item 1)
Figure 70-70-14
P-55528
Install the mount bolt (Item 1) [Figure 70-70-14]. Do not

tighten at this time.

Fuel Injection Pump Installation (Cont'd)
Figure 70-70-15
2
1
2
P-55775
Loosen the locking bolt (Item 1) and move the washer

P-55531 (Item 2) [Figure 70-70-17] to the position shown and
tighten the bolt to 12 N•m (9 ft-lb) torque.
Install the gear (Item 1) onto the tapered shaft. Make Retighten the nut (Item 1) [Figure 70-70-16] to 88 N•m
sure the fuel pump gear is correctly in mesh with the idler (65 ft-lb) torque.

gear and install the washer and nut (Item 2) [Figure 70-
70-15]. Do not tighten at this time. Figure 70-70-18
NOTE: The backlash must be removed before the fuel

injection pump is released. Failure to do so
will make the fuel pump timing incorrect.
1
Figure 70-70-16
P-55776
Remove the two timing pins (Item 1) [Figure 70-70-18].
Lightly lubricate each gear with clean engine oil.

P-55530
Install the timing case cover. (See Timing Cover
Apply pressure counterclockwise by hand to the fuel
pump gear to remove the backlash from all the gears. Install the glow plugs. (See Glow Plugs Removal And
Tighten the nut (Item 1) [Figure 70-70-16] to 24 N•m (18 Installation on Page 70-70-13.)
ft-lb) torque.
Install the rocker cover. (See Rocker Cover Removal And

Figure 70-70-19
1
1 1
P-55525
Install the tubelines (Item 1) [Figure 70-70-21] to the

P-55528 pump and tighten to 30 N•m (22 ft-lb) torque.
Do not overtighten.
Tighten the mount bolt (Item 1) [Figure 70-70-19] to 44
N•m (32 ft-lb) torque. Figure 70-70-22

Figure 70-70-20
1
1
P-55524
P-55533
Connect the return spring (Item 1) [Figure 70-70-20] to

the pump linkage.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injectors Removal And Installation
Figure 70-70-23
WARNING
1 death. Fluid leaks under pressure may not be visible.
2 Use a piece of cardboard or wood to find leaks. Do
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
Figure 70-70-25
P-55523
1
Install the two fuel lines (Item 1) [Figure 70-70-22] and
[Figure 70-70-23].

Install the electrical connector (Item 2) [Figure 70-70-
1 2
23].
Figure 70-70-24
1
S6894
Remove the three bolts (Item 1) and remove the fuel

injector cover (Item 2) [Figure 70-70-25].
1
Installation: Tighten the bolts to 9 N•m (79.7 in-lb)
torque.
P-55522
Install the harness (Item 1) [Figure 70-70-24].
Remove air from the system.

Fuel Injector Removal And Installation (Cont'd)

1
Figure 70-70-26
1
P-55777
Disconnect the four injector tubelines (Item 1) [Figure

S6895 70-70-28] from the injector pump.
Installation: Tighten the tubelines to 27 N•m (20 ft-lb)

Remove the breather hose (Item 1) [Figure 70-70-26].
torque.
Figure 70-70-27

3
4
IMPORTANT
3
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
1 Figure 70-70-29
S6896
1
Remove the bolt (Item 1) and remove the breather fitting 1
(Item 2) [Figure 70-70-27]. 1
Remove the three bolts (Item 3) and remove the fuel filter
assembly (Item 4) [Figure 70-70-27].
S6897
Disconnect the injector tubelines (Item 1) [Figure 70-70-

29] from the injectors.
Installation: Tighten the tubelines to 30 N•m (22 ft-lb)

torque.
Remove the tubelines.

Fuel Injectors Removal And Installation (Cont'd)
Figure 70-70-30
1
1
2 1
P-55617
3
Installation: The roll pin must be in the position shown
P-55614 [Figure 70-70-32].
Figure 70-70-33
Remove the fuel return hoses (Item 1) and remove the
bolt (Item 2) and clamp (Item 3) [Figure 70-70-30].

Installation: Tighten bolt to 35 N•m (26 ft-lb) torque.
Figure 70-70-31
P-55616
Installation: Always replace the copper washer (Item 1)

[Figure 70-70-33] at the nozzle. If the washer remains in
the cylinder head, it must be removed.
P-55615
Remove the injector from the cylinder head [Figure 70-

70-31].

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Lift Pump Removal And Installation
Checking The Fuel Lift Pump Figure 70-70-35
Figure 70-70-34
S6898
P-55525
Remove the two fuel lines (Item 1) and electrical harness
(Item 2) [Figure 70-70-35] from the fuel lift pump / filter
Remove the fuel lift pipe (Item 1) [Figure 70-70-34] from assembly.
the injector pump, install a suitable pipe with a pressure

test point and connect a pressure gauge. Figure 70-70-36
Operate the engine at idle for 2 minutes to allow any

trapped air to be removed.
Standard pressure should be 41 - 69 kPa (0,41 - 0,69

bar) (6 - 10 psi). 1
S6899
Remove the two fuel lines (Item 1) and three bolts (Item
2) [Figure 70-70-36] and remove the fuel lift pump / filter
assembly.

Compression Checking
The tools listed will be needed to do the following

procedure:
MEL10630 - Engine Compression Kit

MEL1352 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Glow Plugs Removal And

P-55632
Figure 70-70-37
Connect the compression gauge to the adapter [Figure

70-70-38].
Make sure the engine speed control is fully backward

(engine idle).
Disconnect the fuel stop solenoid.

Crank the engine with the starter at 200 - 300 RPM.
P-55631
Install the correct compression adapter (Item 1) [Figure

70-70-37] into the cylinder head.

ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Checking
Compression Checking (Cont’d) Disconnect the glow plug cables and leads.
If the measurement is below the allowable limit, check the Figure 70-70-40
cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 0,2 - 0,3 MPa (2 - 3

bar) (43.5 - 72.5 psi).
Compression tests should only be used to compare

between the cylinders of an engine. (If one or more
cylinders vary by more than 0,35 MPa (3,5 bar) (51 psi)
then those cylinders can be faulty.
Figure 70-70-39
P-55629
Use an ohmmeter to check the glow plugs [Figure 70-70-

40].

Figure 70-70-41
P-55633
Push the button on the compression gauge to release

pressure [Figure 70-70-39].
Connect the fuel stop solenoid.
P-55630
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-70-41].
The reading must be between 1 and 2 ohm [Figure 70-

70-41]. If the resistance is infinite, the coil of the glow
plug is broken.
Repeat the procedure for each glow plug.

Glow Plugs Removal And Installation
Disconnect the negative (-) cable from the battery. 1

2 1
1
Figure 70-70-42
3
1 2
S6900
Remove the nut (Item 1) [Figure 70-70-44] from the top

of each glow plug.
1
S6894 Installation: Tighten to 2 N•m (17.7 in-lb) torque.
Disconnect the engine harness wire (Item 2) [Figure 70-

Remove the three bolts (Item 1) and remove the fuel 70-44] from the glow plug.
injector cover (Item 2) [Figure 70-70-42].
Remove the glow plug connecting strap (Item 3) [Figure
Installation: Tighten the bolts to 9 N•m (79.7 in-lb) 70-70-44].
torque.
Figure 70-70-45
Figure 70-70-43
3
1
1
2
S6901
S6895
Loosen and remove the glow plugs (Item 1) [Figure 70-

Remove the hose clamp (Item 1), the bolt (Item 2) and 70-45].
remove the breather (Item 3) [Figure 70-70-43].
Installation: Tighten the glow plug to 15 N•m (13 ft-lb)
torque.


ENGINE TIMING Figure 70-80-2
Procedure
The tool listed will be needed to do the following

procedure:
MEL-1638 Camshaft Timing Pin 1

MEL-1639 Crankshaft Timing Pin
Remove the rocker cover. (See Rocker Cover Removal

Remove the glow plugs. (See Glow Plugs Removal And

P-55601
Remove the timing case cover. (See Timing Cover
Removal on Page 70-110-20.) Carefully rotate the crankshaft in the normal direction of
rotation. Align the hole in the crankshaft with the hole in
NOTE: The marks on the timing gears are not to be the cylinder block and timing case and install the
used as timing marks. The marks indicate the crankshaft timing pin (MEL-1639) (Item 1) [Figure 70-80-
front of the gear only. 2]. Push the pin fully into the hole.
Figure 70-80-3
Figure 70-80-1

1
1 2
P-55602
P-55600
Insert the camshaft timing pin (MEL-1638) (Item 1)

[Figure 70-80-3] through the hole in the camshaft gear
To set the number one piston to TDC on the correct
and into the body of the timing case. With the two pins
stroke, rotate the crankshaft in the normal direction of
installed the engine is set at TDC number one on the
rotation until the intake valve (Item 1) of the number four
compression stroke.
cylinder has just opened and the exhaust valve (Item 2)
[Figure 70-80-1] of the same cylinder has not closed NOTE: The camshaft timing pin is a push fit into the
completely. timing case. The camshaft gear can rotate a
small amount when the pin is installed. This
allows the assembly of the gears and removal
of the backlash from the gears, with the timing
pins installed.
Install the timing case cover. (See Timing Cover
Install the glow plugs. (See Glow Plugs Removal And


ENGINE / HYDROSTAT ASSEMBLY Figure 70-90-2
Remove the engine cover. (See Removal And Installation

on Page 50-60-1.)
Remove the air intake cowling. (See Removal And

1
Drain the hydraulic reservoir. (See Removing And
P-44577
Remove the battery. (See Removal And Installation on 70-90-2].
Page 60-20-1.)
Figure 70-90-3
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)

Remove the drive shaft. (See Removal And Installation
on Page 40-70-1.)
If equipped with air conditioning, remove the refrigerant

from the A/C system. (See Reclamation Procedure on
Page 80-40-1.)
1
Figure 70-90-1
P-44578

70-90-3].
2
S4592
Remove the three screws (Item 1) from the access cover

canopy.
NOTE: Mark all hoses and electrical connectors, for


ENGINE / HYDROSTAT ASSEMBLY (CONT'D) Figure 70-90-6
Figure 70-90-4
2
2
1
P-44932

P-44925 connector (Item 2) [Figure 70-90-6].
Figure 70-90-7

Figure 70-90-5
1
1 P-44933

P-44930 [Figure 70-90-7].

90-5].


1
Figure 70-90-8
P-53572
Figure 70-90-11
P-53570A

Remove the fuse box cover (Item 1) [Figure 70-90-8]. 1
Figure 70-90-9
P-53573
1
Temporarily remove the protective covering (Item 1)

[Figure 70-90-11] from the A/C hoses and expansion
valve.
P-53571

ENGINE / HYDROSTAT ASSEMBLY (CONT'D) S/N A8HD13000 & Above, S/N A8GW13000 & Above,
Removal And Installation (Cont'd) S/N A8GJ13000 & Above:
Figure 70-90-12 Figure 70-90-14
P-53574 P-97028
Remove the bolt (Item 1) and plate (Item 2) [Figure 70- Remove the fuse box cover (Item 1) [Figure 70-90-14].
90-12]. Remove the A/C hoses.

Remove the dash cover / steering column cover.
NOTE: Plug the A/C hoses to prevent contamination. (See Removal And Installation on Page 50-141-1.)
Figure 70-90-13 Remove the joystick panel. (See Removal And

Figure 70-90-15
P-53585

S36381
located under the fuse box.

Figure 70-90-16
1
S36344

S36333 located under the fuse box.

16].

NOTE: Plug the A/C hoses (Item 1) [Figure 70-90-16]
to prevent contamination.
Remove the heater hose (Item 2) [Figure 70-90-16] NOT

connected to the heater valve (Item 3) [Figure 70-90-17].
Figure 70-90-17
2
3
S36334
Remove the heater hose (Item 1) [Figure 70-90-17].
Remove bolt, nut and clip (Item 2) [Figure 70-90-17].


1
For All Models:
Figure 70-90-19
1 1
P-56463

1 the backside of the pump.
P-53575 Figure 70-90-22

19].
Figure 70-90-20
2
1
P-56477
2
Remove the four bolts (Item 1) and remove the hose
(Item 2) [Figure 70-90-22] from the hydrostatic pump.
1
P-53576
Remove the two A/C hoses (Item 1) and harness (Item 2)

[Figure 70-90-20] completely from the rear corner of the
WARNING
cab.
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

Figure 70-90-23
P-56468
Loosen the hose clamp (Item 1) [Figure 70-90-25] and

P-56478 remove the hose.
Figure 70-90-26
backside of the pump.

Figure 70-90-24
1
P-56470
Loosen the hose clamp (Item 1) and remove the hose

P-56464 (Item 2) [Figure 70-90-26].
IMPORTANT
IMPORTANT When repairing hydrostatic and hydraulic systems,
When repairing hydrostatic and hydraulic systems, tubelines and ports to keep dirt out. Dirt can quickly
clean the work area before disassembly and keep all damage the system.
parts clean. Always use caps and plugs on hoses, I-2003-0888
damage the system.
I-2003-0888

Figure 70-90-27
1 P-56486
Remove the tubeline (Item 1) [Figure 70-90-29].

P-58089
Figure 70-90-30

hydrostatic pump.

Figure 70-90-28 1
1
P-56488

the solenoids.
P-56485

Figure 70-90-31
P-56491

P-58092
Figure 70-90-34

tubeline.

Figure 70-90-32
P-56493
1
P-56490
Remove the four bolt flange hose (Item 1) [Figure 70-90-

32] from the front of the pump.

Figure 70-90-35
1 1
S6839
1

P-58088 the tow valve.
Figure 70-90-38
the hydraulic reservoir.

Figure 70-90-36
1
P-53603

S6902 70-90-38].
Remove the two heater hoses (Item 1) [Figure 70-90-36]

from the engine.

Figure 70-90-39
P-29534
Remove the heater hoses, fuel lines and speed control

P-53604 cable from the engine compartment and route through
the access hole [Figure 70-90-41].
Remove the engine speed control cable (Item 1) [Figure Figure 70-90-42

Figure 70-90-40
1
1
2
2 1
P-44924
S6903 Remove the three hoses (Item 1) [Figure 70-90-42].

Cut the tie-strap (Item 1) and remove the two fuel lines
(Item 2) [Figure 70-90-40].

Figure 70-90-43
S7483
Install a chain hoist to lift and secure the engine

S6904 assembly [Figure 70-90-45].
Figure 70-90-46
Remove nut (Item 1) [Figure 70-90-43] from the starter.

Figure 70-90-44
P-53619
P-53624 Remove the engine assembly mounting bolt (Item 1)

[Figure 70-90-46] from the lower front.
Remove the ground strap mounting bolt (Item 1) [Figure

70-90-44].

Figure 70-90-47
S6907
Remove the three engine assembly mounting bolts (Item

S6906 1) [Figure 70-90-47], [Figure 70-90-48], and [Figure 70-
90-49].
Figure 70-90-48 Figure 70-90-50

1
S6908 P-53629
Lift the engine assembly up approximately 25 mm (1 in)

and remove the engine assembly from the machine
[Figure 70-90-50].


FLYWHEEL AND HOUSING Figure 70-100-3

1
NOTE: Set the engine / hydrostat assembly on
blocks, to allow access to remove the motor
mount bolts.
Remove the hydrostatic pump. (See Removal And

Remove the starter. (See Removal And Installation on

Page 60-40-1.) P-53796
Figure 70-100-1
Remove both rear engine mounting bolts (Item 1) [Figure
70-100-2] and [Figure 70-100-3].
Installation: Tighten engine mounting bolts to 250 - 271


Figure 70-100-4
P-53793
Install lifting brackets and hoist on the housing to lift and

support [Figure 70-100-1].
Figure 70-100-2
P-53797
Lifting from the housing assembly, raise the engine

slightly and place support blocks under the oil pan
1 [Figure 70-100-4].
Lower the engine assembly on the support blocks.
P-53794

FLYWHEEL AND HOUSING (CONT'D) Figure 70-100-7
Figure 70-100-5 1
1
1
P-53800
Remove the six coupler mounting bolts (Item 1) [Figure

P-53798 70-100-7]. Remove the coupler.
Installation: Tighten the bolts to 54 - 61 N•m (40 - 45 ft-

Loosen and remove the ten flywheel housing mount bolts lb) torque.
(Item 1) [Figure 70-100-5].

Figure 70-100-8
Installation: Tighten the bolts to 54 - 61 N•m (40 - 45 ft-
lb) torque.
Figure 70-100-6
P-53801
Remove two of the flywheel mount bolts and install two

P-53799 guide studs (Item 1) [Figure 70-100-8] in the flywheel to
prevent the fly wheel from falling.
Remove the flywheel housing from the engine [Figure

70-100-6].

FLYWHEEL AND HOUSING (CONT'D) Figure 70-100-11
Figure 70-100-9
B-05559
2 Install a dial indicator to check the flywheel run out

P-53803 [Figure 70-100-11].
Flywheel run out must be less than 0,30 mm (0.012 in).

Install a chain hoist (Item 1) [Figure 70-100-9].
Figure 70-100-12

Remove the remainder of the bolts (Item 2) [Figure 70-
100-9]. Remove the flywheel by sliding outward over the
guide studs.
203 mm (8”)
Installation: Tighten the flywheel bolts to 115 N•m (85 ft-
lb) torque.
Figure 70-100-10
3 3
2 2
1
B-05560
2 Check the alignment of the flywheel face [Figure 70-100-

2 12].
The misalignment must not be more than 0,03 mm (0.001

in) total indicator reading for every 25 mm (1.0 inch) of
P-53804 the flywheel radius from the crankshaft axis to the dial
gauge plunger.
If removing the backing plate (Item 1) is required, loosen Example: The misalignment must not be greater than
and remove the eight mounting bolts (Item 2 and 3) 0,203 mm (0.008 in) at 203 mm (8 in) from the centerline
[Figure 70-100-10]. of the crankshaft towards the outside of the flywheel.
Installation: Tighten the bolts (Item 2) to 63 N•m (46 ft- During this check keep the crankshaft pressed toward the
lb) and the bolts (Item 3) to 75 N•m (55 ft-lb) torque. front so crankshaft end play will not affect the reading.
Check the flywheel and ring gear for wear or damage.

Replace as needed.

FLYWHEEL AND HOUSING (CONT'D) Ring Gear Installation
Removal And Installation (Cont'd) The ring gear is a heat expansion fit on the flywheel.
Ring Gear Removal Do not heat the ring gear to a temperature greater than
250°C (480°F) make sure the ring gear chamfer is in the
Before the ring gear is removed note the position of the correct position.
chamfer on the teeth.
Heat the ring gear enough to expand it and hit it with a

hammer evenly to remove it.
Be careful not to damage the flywheel during this

operation.

RECONDITIONING THE ENGINE
Turbocharger Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Two Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Two Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35

Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35

1. Air filter element dirty. 17. Restricted lubricating oil drain pipe.
2. Restricted crankcase breather. 18. Turbine housing damage or restricted.
3. Air filter element missing, leaking or not sealing 19. Leakage from turbocharger seals.
correctly. Loose connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 20. Worn turbocharger bearings.
turbocharger.
5. Damaged / restricted crossover pipe, turbocharger to 21. Excessive dirt in turbocharger housing.
induction manifold.
6. Restriction between air filter and turbocharger. 22. Excessive carbon behind turbine rotor.
7. Restriction in exhaust system. 23. Engine speed raised too rapidly at initial start.
8. Turbocharger loose or clamps / setscrews loose. 24. Insufficient engine idle period.
9. Induction manifold cracked or loose, flanges distorted. 25. Faulty fuel injection pump.
10. Exhaust manifold cracked or loose. 26. Worn or damaged fuel injectors.
11. Restricted exhaust system. 27. Valves burned.
12. Delay of lubricating oil to turbocharger at engine start. 28. Worn piston rings. flanges distorted.
13. Insufficient lubrication. 29. Lubricating oil leakage from supply pipe.
14. Dirty lubricating oil. 30. Excessive starting fluid (on initial engine start).
15. Incorrect lubricating oil. 31. Excessive engine idle period.
16. Restricted lubricating oil supply pipe. 32. Restriction in turbocharger bearing housing.
33. Restriction in lubricating oil filter.
34. Engine stopped too soon from high load.
35. Insufficient lubricating oil.
36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.

RECONDITIONING THE ENGINE (CONT'D) Turbocharger Removal And Installation
Turbocharger Description Figure 70-110-2
WARNING
1
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
2
Figure 70-110-1
P-55619
Remove the two bolts (Item 1) and remove the exhaust

elbow (Item 2) [Figure 70-110-2].
Figure 70-110-3

1
P-55618
The turbocharger (Item 1) [Figure 70-110-1] is located

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than 1
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
P-55515
The oil flows from the filter adapter through the bearing
housing and returns to the engine block. Loosen the intake tube clamp (Item 1) [Figure 70-110-3].
The turbocharger should only be serviced by an
authorized dealer or repair shop.

RECONDITIONING THE ENGINE (CONT'D) Figure 70-110-6
Turbocharger Removal And Installation (Cont'd)
Figure 70-110-4
2
1
P-55621
Remove the oil return line (Item 1) [Figure 70-110-6].

S6909
Figure 70-110-7
Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-110-4].

Figure 70-110-5
1 1
1 P-55624
Remove the four nuts (Item 1) [Figure 70-110-7] for the

turbocharger to exhaust manifold flange.
P-55623
Installation: Apply anti-seize compound to the mounting
studs. Tighten the nuts to 44 N•m (33 ft-lb) torque.
Disconnect the oil supply tubeline (Item 1) [Figure 70-
110-5]. Remove the turbocharger and gasket from the exhaust
manifold.
Installation: Fill the bearing housing with clean oil
through the oil supply port. Tighten banjo fitting to 22 The turbocharger must only be serviced by an authorized
N•m (16 ft-lb) torque. repair shop.
Before starting the engine, disconnect the electrical stop

control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.

RECONDITIONING THE ENGINE (CONT'D) Fuel Injector Cover Removal And Installation
Exhaust Manifold Removal And Installation Figure 70-110-10
Remove the turbocharger. (See Turbocharger Removal

And Installation on Page 70-110-2.) 1
Figure 70-110-8
1
1 1
1
S6894
Remove the three bolts (Item 1) [Figure 70-110-10] and

remove the cover.
P-55625
Installation: Tighten the bolts to 9 N•m (79.7 in-lb)

torque.
Remove the eight mount bolts (Item 1) [Figure 70-110-
8].
Remove the exhaust manifold and gasket.
Figure 70-110-9
5 2 8
1
4 3 7
6
P-55625
Installation: Tighten the bolts in the sequence shown


Rocker Cover Removal And Installation
Remove the fuel injector cover. (See Fuel Injector Cover

Figure 70-110-11 1
S6895
Remove the breather hose (Item 1) [Figure 70-110-13].

1
Figure 70-110-14
P-55515

Loosen the intake tube clamp (Item 1) [Figure 70-110-
11].
Figure 70-110-12
1
2
2
1
S6896
Remove the bolt (Item 1) and remove the breather fitting

(Item 2) [Figure 70-110-14].
S6909
Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-110-12].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Removal
Rocker Cover Removal And Installation (Cont'd) Remove the turbo charger. (See Turbocharger Removal
Figure 70-110-15
Remove the exhaust manifold. (See Exhaust Manifold
1 1
Remove the alternator. (See Removal And Installation on
Page 60-30-1.)
Remove the fuel lift pump. (See Fuel Lift Pump Removal
Remove the fuel injectors. (See Fuel Injectors Removal

1
1 Remove the glow plugs. (See Glow Plugs Removal And

1 Installation on Page 70-70-13.)
P-55519
Figure 70-110-17
Remove the ten mount bolts (Item 1) [Figure 70-110-15].

Figure 70-110-16
1 10 3 5
8
P-55681
7
6 4 9 2 Disconnect the engine cooling temperature sensor (Item
P-55519 1) [Figure 70-110-17].
NOTE: Mark wires for correct installation.

Installation: Tighten the bolts in the sequence shown
[Figure 70-110-16] to 9 N•m (79.7 in-lb) torque.

Cylinder Head Removal (Cont'd)

2
Figure 70-110-18 1
1
P-55684
1
Remove the two bolts (Item 1) and remove the coolant
P-55682 bypass tube (Item 2) [Figure 70-110-20].
Remove the rocker cover. (See Rocker Cover Removal

Disconnect the intake manifold pressure sensor (Item 1) And Installation on Page 70-110-5.)
[Figure 70-110-18].

Remove the rocker shaft assembly. (See Rocker Shaft
Reposition the harness. Disassembly And Assembly on Page 70-110-12.)
Figure 70-110-19 Figure 70-110-21
P-55683 P-8718A
Remove the tubeline (Item 1) [Figure 70-110-19]. Remove the push rods [Figure 70-110-21].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Inspection
Cylinder Head Removal (Cont'd) Figure 70-110-23
Figure 70-110-22
1 1 1 1 1 3
8
9 5 1 4
2
3
10 7
6 2 3
B-5564
B-23183
Put a straight edge on the cylinder head as shown in
[Figure 70-110-23].
Release the cylinder head bolts evenly and gradually in
the sequence shown [Figure 70-110-22]. Using a feeler gauge between the straight edge and

head, check for warping.
Check the head bolts for distortion and damage. Replace
as needed. Maximum allowed (Item 1) is 0,03 mm (0.0012 in), (Item
2) is 0,05 mm (0.0019 in) and (Item 3) [Figure 70-110-
Lift off the cylinder head and clean the bottom face. 23] is 0,05 mm (0.0019 in).
The head can be machined removing only a minimum

amount. Head thickness must not be less than 117,20
mm (4.614 in).
Completely clean the rest of the head.
Check for cracks or other damage.

Cylinder Head Installation

3
2 6 10 7
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
Clean any debris out of the cylinder bores.
Figure 70-110-24 1
5 9 8 4
B-23183
2
1
Tighten the head bolts to 50 N•m (37 ft-lb) in the
FRONT TOP
sequence shown [Figure 70-110-25].
Tighten the head bolts to 100 N•m (74 ft-lb) in the

sequence shown [Figure 70-110-25].

Figure 70-110-26
B-5562
1
NOTE: The locating pins (Item 1) are pressed in the
engine block so the head gasket (Item 2)
[Figure 70-110-24] can be positioned
correctly.
The head gasket is installed with no sealer.
Place the head gasket in position with the Front Top (Item
2) [Figure 70-110-24] marks in the correct position.
P-8839
Lower the cylinder head in position.
Additional tightening of the head bolts requires the use of

a torque angle gauge (Item 1) [Figure 70-110-26].
Tighten the short bolts to 225° and long bolts to 270° in
the same sequence as shown in [Figure 70-110-26].

Cylinder Head Installation (Cont'd)
Figure 70-110-27 2
225° 270°
2
P-55684
Install the coolant bypass pipe (Item 1) and two screws

B-5563A (Item 2) [Figure 70-110-29].
Tighten the screws to 22 N•m (16 ft-lb) torque.

If no angle gauge is available make a suitable mark on
the head bolt corner. Make another mark on the cylinder Figure 70-110-30

head the correct number of flats away [Figure 70-110-
27]. Turn the head bolt until the lines match.
Figure 70-110-28
1
P-55683
Install the tubeline (Item 1) [Figure 70-110-30].

P-8718A
Install the push rods [Figure 70-110-28].
Make sure the push rods seat in the tappet sockets.
Install the rocker shaft assembly. (See Rocker Shaft

Disassembly And Assembly on Page 70-110-12.)


Cylinder Head Installation (Cont'd)
Figure 70-110-31
P-55681
1
Connect the engine cooling temperature sensor (Item 1)

P-55682 [Figure 70-110-32].
Install the glow plugs. (See Glow Plugs Removal And

Connect the intake manifold pressure sensor (Item 1) Installation on Page 70-70-13.)
[Figure 70-110-31].

Install the fuel injectors. (See Fuel Injectors Removal And
Install the fuel lift pump. (See Fuel Lift Pump Removal
Install the alternator. (See Removal And Installation on

Page 60-30-1.)
Install the exhaust manifold. (See Exhaust Manifold

Install the turbo charger. (See Turbocharger Removal


RECONDITIONING THE ENGINE (CONT'D) Valve Removal
Rocker Shaft Disassembly And Assembly NOTE: Mark all components so they can be returned
to the same position.
NOTE: Make an identification mark on each rocker
arm assembly in order to show the location. Figure 70-110-34
Figure 70-110-33
4 5
2 3
3
2 P-8720A
P-8719A
Using a valve spring compressor compress the springs

and remove the retainers (Item 1) [Figure 70-110-34].
Remove the clips (Item 1) [Figure 70-110-33] from both
ends of the shaft. Release the compressor and remove the valve spring
cap (Item 2), spring (Item 3), valve seal / spring seat
Remove the rocker arm (Item 2) and spring (Item 3) washer (Item 4) and valve (Item 5) [Figure 70-110-34].
[Figure 70-110-33].
Clean and inspect all components.
Continue to disassemble the rocker shaft.
Clean and inspect all components for damage and wear.
Check the clearance between the rocker arms and shaft.
Using a press and adapter, remove the old bushing and

press in the new one making sure the oil holes line up.
Shaft O.D. 24,962 - 24,987 mm

(0.9828 - 0.9837 in)
Rocker Arm Bore Dia. 25,013 - 25,051 mm
(0.9848 - 09.863 in)
Clearance Between Rocker Arm 0,026 - 0,089 mm
and Shaft (0.0010 - 0.0035)
If the clearance is more than 0,13 mm (0.005 in) replace

the bushing(s).

RECONDITIONING THE ENGINE (CONT'D) Valve Depth Checking
Valve Springs Checking Figure 70-110-36
Figure 70-110-35
35,17 mm
(1.3846 in)
N-00533
B-5552
Check the valve depth as shown in [Figure 70-110-36].
Use the following chart [Figure 70-110-35]. The maximum depth is 2,06 mm (0.0811 in) for both
intake and exhaust valves.

Valve Springs
If the valve is below the limits, install a new valve and
Compressed Height 35,17 mm (1.3846 in)
recheck the valve depth. If it is still below limits a new
Installed Pressure 335 N (75 lb) valve seat insert must be installed.
When the depth is less than 1,53 - 1,81 mm (0.060 -

0.071 in) the seat can be ground to lower the valve depth.

RECONDITIONING THE ENGINE (CONT'D) Use the following chart to check valve guides.
Valve Guides Checking

Inside Diameter
Figure 70-110-37 (Item 1) [Figure 70-110-37] 9,00 - 9,022 mm
(0.3543 - 0.3552 in)
1
4
Outside Diameter (Item 2) [Figure 70-110-37]
Intake and Exhaust 13,034 - 13,047 mm
(0.5131 - 0.5137 in)
3
Interference fit of valve guide to cylinder head: 0,007 -
0,047 mm (0.0003 - 0.0019 in).
2
Overall Diameter (Item 3) [Figure 70-110-37]
Intake and Exhaust 51,00 - 51,50 mm
B-5551
(2.018 - 2.027 in)
Figure 70-110-38

Protrusion from bottom recess for valve spring;
(Item 4) [Figure 70-110-37] 12,35 - 12,65 mm
(0.486 - 0.498 in)
1 3
To check the valve guides for wear using a valve.
Set up dial indicator gauge (Item 1) [Figure 70-110-37]

as shown.
Lift the valve (Item 2) 15,0 mm (0.60 in) and move the
2 valve in and away from the gauge (Item 1) [Figure 70-
110-37]. Record this reading.
B-5566A
If the clearance exceeds 0,13 mm (0.005 in) for intake or
0,15 mm (0.006 in) for exhaust (Item 3) [Figure 70-110-
The valve guides can be checked for wear with either of 38] the valve guide needs to be replaced.
the operations listed in [Figure 70-110-37] or [Figure 70-
110-38].

RECONDITIONING THE ENGINE (CONT'D) Valve Guide Installation
Valve Guide Removal Figure 70-110-40
Clean the guide bore in the head.
Figure 70-110-39

B-5548
Clean the guide bore in the head.
Lubricate the outer surface of the new guide (Item 1)

B-5549 [Figure 70-110-40] with the engine oil.
Put the guide in position on the valve guide removal /

Install a valve guide removal / installation tool (Item 1) on installation tool (Item 2) [Figure 70-110-40].
the valve guide (Item 2) [Figure 70-110-39].
Pull the guide into the cylinder head.
Pull the guide (Item 2) [Figure 70-110-39] out of the
cylinder head. When correctly positioned the top of the guide should
extend 12,35 - 12,65 mm (0.486 - 0.498 in) above the
valve spring seat [Figure 70-110-37].

RECONDITIONING THE ENGINE (CONT'D) Cutting A Valve Seat
Valves Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
Figure 70-110-41 Select the correct size cutter.
Valve Seat Angle Inlet / Exhaust 45° / 30°
Figure 70-110-42
4
1
B-5567

Use the following chart [Figure 70-110-41] to check the
valve dimensions.
N-00532
Ref. Valve Specifications

1. Intake 128,838 - 129,288 mm Carefully turn the cutter in a clockwise direction using
(5.0724 - 5.0901 in) even downward pressure. Keep the valve seat as narrow
Exhaust 128,184 - 128,634 mm as possible [Figure 70-110-42].
(5.0466 - 5.0643 in)
2. Intake 8,953 - 8,975 mm Remove any cutting debris.
(0.3525 - 0.3533 in)
Exhaust 8,938 - 8,960 mm Install the valve and lightly tap.
(0.3519 - 0.3528 in)
Check the valve depth to make sure that it is within limits.
3. Intake 46,28 - 46,53 mm
(See Valve Guides Checking on Page 70-110-14.)
(1.8220 - 1.8319 in)
Exhaust 41,51 - 41,75 mm NOTE: If the valve seat is worn or damaged, a new
(1.634 - 1.644 in) valve seat insert can be installed.
4. Intake (Pro- 1,60 - 1,85 mm
duction) (0.0630 - 0.0728 in)
Intake (Service 2,09 mm
Max.) (0.0823 in)
Exhaust (Pro- 1,55 - 1,81 mm
duction) (0.0610 - 0.0713 in)
Exhaust (Ser- 2,06 mm
vice Max.) (0.0811 in)
Intake / Exhaust 45° / 30°
Valve Face
Angle

RECONDITIONING THE ENGINE (CONT'D)
Valve Seat Assembly
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
W-2019-0907
Figure 70-110-43
4 5

1
2 3
P-8720A
Lubricate the valve stems (Item 1) [Figure 70-110-43]

with clean engine oil and install them in the respective
guides.
Install new valve seals / spring seat washer (Item 2)

[Figure 70-110-43].
Install the spring (Item 3) [Figure 70-110-43] on the

washer (make sure the larger diameter is against the
cylinder head).
Place the valve cap (Item 4) [Figure 70-110-43] on the

spring.
Using a valve spring compressor compress the springs

and install the retainers (Item 5) [Figure 70-110-43].

Changing Valve Springs (With Cylinder Head

Installed)
Remove the rocker cover.
Figure 70-110-44
N-00531
Install the valve spring compressor and adapter [Figure

70-110-45].
Compress the valve springs squarely and remove the

B-5565 retainers.

NOTE: Do not rotate the crankshaft while the valve
Rotate the crankshaft clockwise until the intake valve has springs are removed.
opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [Figure 70-110-44] will be at Release the compressor and remove the valve spring(s).
approximately T.D.C.
Place the new valve springs in position.
Remove the rocker shaft assembly.
Compress the valve springs and install the retainers.

Valve Clearance Adjustment
Adjust the valve clearance as follows:
Figure 70-110-46
1 2 3 4 5 6 7 8
2 1
B-5569
Figure 70-110-48
3 Cylinder 1 2 3 4
B-5568 No.
Valve No. 1 2 3 4 5 6 7 8
Valve I E I E I E I E

Loosen the lock nut (Item 1) [Figure 70-110-46]. 1=Intake
E=Exhaust
Turn the adjustment screw (Item 2) [Figure 70-110-46]
until the correct clearance is obtained. Use the following sequence to set the valves [Figure 70-
110-47] and [Figure 70-110-48].
NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [Figure
70-110-46]. a. With the rocker arm rocking (valves 7 and 8) on No.
4 cylinder set clearance at No. 1 cylinder (valves 1
and 2).
Adjust the valve clearance as follows:
b. With the rocker arm rocking (valves 3 and 4) on No.
0,20 mm (0.008 in) Intake 2 cylinder set clearance at No. 3 cylinder (valves 5
and 6).
0,45 mm (0.018 in) Exhaust
c. With the rocker arm rocking (valves 1 and 2) on No.
and 8).
d. With the rocker arm rocking (valves 5 and 6) on No.
and 4).

RECONDITIONING THE ENGINE (CONT'D) Crankshaft Pulley Removal And Installation
Timing Case And Drive Assembly Description Figure 70-110-50
The timing case is made of aluminum and the cover is

made of tin and in most applications, the timing gears are
made of steel. The drive from the crankshaft passes to
the idler gear, to the camshaft gear, to the gear on the 1
fuel injection pump and to the water pump.
The camshaft and fuel injection pump run at half the

speed of the crankshaft. 1
Timing Cover Removal 2
Remove the water pump. (See Water Pump Removal on

Page 70-110-40.)
S6912
Figure 70-110-49
Remove the three bolts (Item 1) and thrust block (Item 2)

[Figure 70-110-50].
Installation: Tighten the bolts to 115 N•m (85 ft-lb)

1 torque.
2
1
Remove the pulley.
Front Oil Seal Removal And Installation

1
Remove the crankshaft pulley. (See Crankshaft Pulley
1 Removal And Installation on Page 70-110-20.)
1 Remove the oil seal using a seal removal tool.

S6911
Do not damage the edge of the seal housing.

Remove the timing cover bolts (Item 1) and remove the Figure 70-110-51
timing cover (Item 2) [Figure 70-110-49].
Timing Cover Installation
Clean the gasket mating surfaces.
Place the gasket and timing cover on the engine.
Remove the timing pins if installed.
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.
1
Install the water pump. (See Water Pump Installation on
P-55686
Page 70-110-40.)
Do not tighten bolts at this time. Install the oil seal (Item 1) [Figure 70-110-51] into the
housing using the special tool.
Tighten the cover bolts and water pump bolts to 22 N•m
(16 ft - lb) torque. Install crankshaft pulley. (See Crankshaft Pulley Removal

Timing Case And Gear Removal
Remove the timing cover. (See Timing Cover Removal on 1

Page 70-110-20.)
Remove the crankshaft pulley. (See Crankshaft Pulley

Remove the fuel injection pump. (See Fuel Injection

Pump Removal on Page 70-70-1.)
Figure 70-110-52
P-55689
1
Remove the idler gear (Item 1) [Figure 70-110-54] by
moving the gear assembly forward and lifted over the
front oil seal housing.
NOTE: Do not turn the crankshaft with the idler gear

2
removed.

Figure 70-110-55
1
P-55684
2 1
Remove the two bolts (Item 1) and remove the coolant
bypass tube (Item 2) [Figure 70-110-52].
Figure 70-110-53
3 1
P-55690
Remove the bolt (Item 1) and washer (Item 2) [Figure

70-110-55].
2
1
P-55688
Remove the three bolts (Item 1) and plate (Item 2) from

the idler gear (Item 3) [Figure 70-110-53].

RECONDITIONING THE ENGINE (CONT'D) Timing Case And Gear Installation
Timing Case And Gear Removal (Cont'd) Clean the mating surfaces, if the oil pan was not removed
trim the oil gasket flush with the block.
Figure 70-110-56
Figure 70-110-58
1
1 2
2
2
2
2
P-55691
2 P-55692
Remove the camshaft gear (Item 1) [Figure 70-110-56].

Install the timing case (Item 1) onto the cylinder block and

NOTE: Use care not to lose the key from the key way. hand tighten the bolts (Item 2) [Figure 70-110-58].
Figure 70-110-57 After the cover is correctly aligned, tighten the mount
bolts (Item 2) [Figure 70-110-58] to 22 N•m (16 ft-lb)
torque.
1
1
Figure 70-110-59
1
1
1
2
2
2 P-55692
Remove all the timing case mount bolts (Item 1) and the
four bolts (Item 2) [Figure 70-110-57] from the front of
P-55691
the oil pan.
Remove the timing case from the engine. Install the camshaft gear (Item 1) onto the shaft using
alignment pin (Item 2) [Figure 70-110-59] for correct
alignment.

Timing Case And Gear Installation (Cont'd)
Figure 70-110-60
2
1 P-55688
Install the plate (Item 1) and three bolts (Item 2) [Figure

P-55690 70-110-62].
Tighten the bolts to 44 N•m (33 ft- lb) torque.

Install the washer (Item 1) and bolt (Item 2) [Figure 70-
110-60] and tighten to 95 N•m (70 ft-lb) torque. Figure 70-110-63

Figure 70-110-61
1
2
2
P-55684
P-55689
Install the coolant bypass tube (Item 1) using the two
bolts (Item 2) [Figure 70-110-63].
Install the idler gear (Item 1) make sure the hole (Item 2)
[Figure 70-110-61] is towards the cylinder head. Install the fuel injection pump. (See Fuel Injection Pump
Install the crankshaft pulley. (See Crankshaft Pulley

Install the timing cover. (See Timing Cover Installation on

Page 70-110-20.)

Camshaft And Tappets Removal
Remove the timing case cover. (See Timing Cover

Removal on Page 70-110-20.)
1
Remove the timing case. (See Timing Case And Gear

Removal on Page 70-110-21.)
Remove the rocker cover, rocker assembly and push

rods. (See Rocker Cover Removal And Installation on
Page 70-110-5.) P-8741
Remove the fuel pump and gasket.

Remove the camshaft thrust washer (Item 1) [Figure 70-
Figure 70-110-64 110-65].
2 Figure 70-110-66

1
1
P-8740
P-8742
Turn the engine over and remove the oil pan mounting
bolts (Item 1) [Figure 70-110-64].
Carefully remove the camshaft (Item 1) [Figure 70-110-
Remove the oil pan (Item 2) [Figure 70-110-64] and 66].
gasket.
Installation: Tighten the oil pan mounting bolts to 22

N•m (16 ft-lb) torque.

Camshaft And Tappets Removal (Cont’d)
Figure 70-110-67
1
1
1
1
P-08743
Install the tappets (Item 1) [Figure 70-110-68].

P-8743
Figure 70-110-69
Remove the tappets (Item 1) [Figure 70-110-67] from the

block.

Camshaft And Tappets Installation
Clean and inspect the camshaft and tappets for 1

excessive wear and damage.
Inspect the camshaft bushing for excessive wear and

damage.
NOTE: Only the front camshaft journal bore has a

bushing.
P-8742
Clearance between the camshaft journals, the bushing
and camshaft bore is 0,06 - 0,14 mm (0.0025 - 0.0055
in). Carefully install the camshaft (Item 1) [Figure 70-110-
69].
Make sure all components are clean and lubricated with
clean engine oil.

RECONDITIONING THE ENGINE (CONT'D) Pistons And Connecting Rods Description
Camshaft And Tappets Installation (Cont’d) The pistons have a Quadram combustion chamber. They
have two compression rings and one oil control ring. The
Figure 70-110-70 top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by
snap rings.
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
1 steel. The connecting rods on the turbocharged engines
2 have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by
serrations and the cap is retained by two bolts.
The pistons used in the 1000 series engines have two

compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine
P-8741 identification number to order new parts.
Pistons And Connecting Rods Removal

Install the camshaft thrust washer (Item 1). Make sure
that the dowel pin (Item 2) [Figure 70-110-70] lines up Figure 70-110-71

with the hole in the thrust washer.
Install the timing case. (See Timing Case And Gear

Check camshaft end play. The end play for a new engine
is 0,10 - 0,55 mm (0.004 - 0.022 in), service limits 0,60
mm (0.023 in).
Install the timing gears. (See Timing Case And Gear

Install the injection pump. (See Fuel Injection Pump 1

P-08744
Install the push rods and rocker assembly. (See Rocker
Shaft Disassembly And Assembly on Page 70-110-12.)
Remove the cylinder head. (See Cylinder Head Removal
Install the timing cover. (See Timing Cover Installation on on Page 70-110-6.)
Page 70-110-20.)
Remove all the carbon from the top of the cylinder liners.
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.) Remove the oil pan. (See Oil Pan Removal And
Remove the oil pick up screen and tube (Item 1) [Figure

70-110-71].

Pistons And Connecting Rods Removal (Cont’d)
Figure 70-110-72
1 1
1 1 1 1
1
1
P-08746
Inspect the crankshaft journals (Item 1) [Figure 70-110-

P-08743 74] for wear or damage.
NOTE: Keep all parts together so they can be

Mark and remove the connecting rod caps (Item 1) replaced in their original position.
[Figure 70-110-72].

NOTE: Before installing the pistons check cylinder
NOTE: Do not allow the connecting rods to hit the bore for wear or damage. (See Cylinder Liner
cooling jets. Inspection on Page 70-110-48.)
Figure 70-110-73
P-08745
Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [Figure 70-110-73]. Push the
piston and rod assemblies out the top of the cylinder.

RECONDITIONING THE ENGINE (CONT'D) Piston Ring End Gap
Pistons And Connecting Rods Disassembly Figure 70-110-77
Figure 70-110-75
1 1
4
4
B-05571
B-05570
Place the piston rings in the upper part of the cylinder to
check the end gap [Figure 70-110-77].
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-110-75] as shown on the connecting rod. Top Ring End Gap 0,30 - 0,45 mm

(0.0118 - 0.0117 in)
Figure 70-110-76
Second Ring End Gap 0,65 - 0,85 mm
(0.0256 - 0.0335 in)
1 Third Ring End Gap 0,30 - 0,55 mm
4 (0.0118 - 0.0216 in)
Piston Ring Installation
Figure 70-110-78
P-13999
Remove the piston rings (Item 1) [Figure 70-110-76] with

a ring expander.
Remove the snap rings (Item 2) [Figure 70-110-76]

which retain the piston pin.
B-05572
Push the piston pin (Item 3) [Figure 70-110-76] out by
hand. If the pin doesn't push out easily, heat the piston to
40°-50°C (100°-120°F) for easier removal. Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring
Remove the connecting rod (Item 4) [Figure 70-110-76]. [Figure 70-110-78].

RECONDITIONING THE ENGINE (CONT'D) Piston Ring Groove Clearance
Piston Ring Installation (Cont'd) Figure 70-110-80
Use a ring expander to install the piston rings.
Install the oil spring on the bottom groove of the piston

with the latch pin inside both ends of the spring.
Figure 70-110-79
2
B-05576
With the piston rings installed, check the groove

1 clearance [Figure 70-110-80].
Top Ring Wedge

B-05575
Second Ring Side 0,065 - 0,110 mm
Clearance (0.0026 - 0.0043 in)
Install the oil control ring over the spring (Item 1) [Figure Third Ring Side Clearance 0,03 - 0,07 mm
70-110-79]. (0.0011 - 0.0027 in)
Make sure the ring gap is 180° from the latch pin.
Install the cast iron ring with the tapered face (Item 2)
[Figure 70-110-79] in the second groove with the word
TOP or symbol facing the top of the piston.
New second rings have a green identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is upright.
The second ring has an external step at the bottom of the

tapered face.
Place the chromium ring (Item 3) [Figure 70-110-79] with

the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-110-79] has an internal

step.
New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is uptight.
Make sure the ring gaps are 120° apart.

RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Assembly
Connecting Rod Inspection Figure 70-110-82
Figure 70-110-81
127 mm 127 mm
(5”) (5”)
± 0,25 mm ± 0,25 mm 2
(0.010”) (0.010”)
P-13999
B-05577
Install the connecting rod (Item 1), piston pin (Item 2) and
two snap rings (Item 3) [Figure 70-110-82] in the piston.
Checking the connecting rod for distortion [Figure 70-
110-81]. Piston And Connecting Rod Installation

NOTE: The large and small end bores must be square Apply a light coat of oil to the piston and piston rings.
and parallel within the limits of ± 0,25 mm
(0.010 in). NOTE: Make sure the piston ring end gaps are 120°
apart.
Measure this 127 mm (5.0 in) on each side of the
connecting rod axis on a test fixture. Figure 70-110-83
With the piston pin bushing installed the limit is reduced

to ± 0,06 mm (0.0025 in).
Check the pin bushing for wear or damage. Replace as

needed.
Connecting Rod Bushing Replacement
Press out the old bushing. Clean the bore and remove
any burrs.
Press in the new bushing making sure the oil feed holes
line up.
B-05578
Ream the bushing to get the proper clearance of 0,023 -
0,044 mm (0.0009 - 0.0017 in) between the small end
bushing and piston pin. Install the ring compressor over the piston rings [Figure
70-110-83].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.

Piston And Connecting Rod Installation (Cont'd)
Figure 70-110-84 1
FRONT B-05580
Install the upper and lower bearing shells in position

B-05579 making sure the locating tang (Item 1) [Figure 70-110-
86] is in the correct position.
When the piston has cleared the cooling jet, rotate the NOTE: New connecting rod nuts must be installed
piston assembly so that the arrow or FRONT mark is each time the rod caps are removed.

toward the front of the engine [Figure 70-110-84].
Figure 70-110-87
Figure 70-110-85
1 1
1
1
1 1
P-08743
P-08745
Install the caps (Item 1) [Figure 70-110-87] and nuts.

Clean the bearing surfaces and crank pin. Lubricate the Gradually tighten the nuts to 18 N•m (13 ft-lb) torque.
crank pin (Item 1) [Figure 70-110-85] with clean engine Tighten to a final torque of 70 N•m (52 ft-lb). The
oil. fasteners must be tightened a further 120°.
Rotate the crankshaft. The crankshaft must rotate

smoothly.

RECONDITIONING THE ENGINE (CONT'D) Crankshaft And Bearings Description
Piston And Connecting Rod Installation (Cont'd) The crankshaft is a chrome-moly forging which has five
main journals. End play is controlled by two half thrust
Figure 70-110-88 washers on both sides of the center main bearing.
The main bearings have steel backs with an aluminium /

tin bearing material. The main bearing caps are made of
cast iron.
The front and rear oil seals are viton lip seals with a dust
lip to the outside of the main lip.
Crankshaft And Bearings Removal
Figure 70-110-89
1
1
P-08744
Install the oil pick up tube and screen (Item 1) [Figure

70-110-88].

Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.)
Checking Piston Height
Rotate the crankshaft until the piston is approximately at

P-08748
top dead center (T.D.C.).
Using a dial indication gauge, pre-load the plunger on the Remove the water pump. (See Water Pump Removal on
top surface of the block and zero the gauge. Page 70-110-40.)
Carefully move the dial gauge so that the plunger is on Remove timing case cover. (See Timing Cover Removal
top of the piston above the axis of the piston pin. on Page 70-110-20.)
Rotate the crankshaft to bring the piston to it's highest Remove the fuel injection pump. (See Fuel Injection
point. Record this gauge reading. Pump Removal on Page 70-70-1.)
When installed, the top surface of the piston is slightly Remove the timing gears and timing case. (See Timing
above the surface of the cylinder block. Case And Gear Removal on Page 70-110-21.)
The height above the surface of the block should be 0,21 Remove the flywheel. (See Removal And Installation on
to 0,35 mm (0.008 to 0.014 in). Page 70-100-1.)
Install the cylinder head. (See Cylinder Head Installation Remove the pistons and connecting rods, keeping them
on Page 70-110-9.) in order. (See Pistons And Connecting Rods Removal on
Page 70-110-26.)
Remove the rear oil seal housing (Item 1) [Figure 70-

110-89].

Crankshaft And Bearings Removal (Cont’d)
Figure 70-110-90
1 1
1 1 1 1
1
P-08750
Remove the main bearing caps (Item 1) [Figure 70-110-

P-08749 92].
Figure 70-110-93
Remove the two bolts (Item 1) [Figure 70-110-90]
retaining the bridge piece.

Remove the bridge piece.
Figure 70-110-91
1 1 1 1 1
P-08753
Remove the thrust washers from the sides of the center

main bearing bore [Figure 70-110-93].
P-08746
Mark the main bearing caps (Item 1) [Figure 70-110-91]

for correct installation.
Remove the main bearing cap bolts.

RECONDITIONING THE ENGINE (CONT'D) Inspection Of Crankshaft And Bearings
Crankshaft And Bearings Removal (Cont'd) Figure 70-110-96
Figure 70-110-94
A-02763
P-08751
Check the crankshaft for wear [Figure 70-110-96]. The
maximum wear and out of round of the crank journals is
Remove the crankshaft [Figure 70-110-94]. 0,04 mm (0.0016 in).

Figure 70-110-95 The main journals and the crank pins of standard size
can be machined 0,25 mm (0.010 in) 0,50 mm (0.020 in)
or 0,75 mm (0.030 in).
NOTE: (See Specifications on Page 70-10-1.) for more

crankshaft specifications.
Check the oil clearance of the bearings.
All Main Bearings 0,057 - 0,117 mm

(0.0022 - 0.0046 in)
Thrust Washer Thickness

Standard 2,26 - 2,31 mm
P-08752
(0.089 - 0.091 in)
Oversize 2,45 - 2,50 mm
(0.096 - 0.098 in)
Remove the crankshaft bearings from the engine block
[Figure 70-110-95].
Keep the bearings with their respective caps for

installation.

Crankshaft And Bearings Installation
Figure 70-110-97
P-08753
Clean and install the upper and lower thrust bearings on

P-08754 each side of the center main bearing [Figure 70-110-99].
Clean the main caps and install the bearings.

Clean the main bearing bores and install the upper
bearing shells in position. Lubricate the bearings with Lubricate the bearings with clean engine oil.

clean engine oil [Figure 70-110-97].
Install the main cap bolts and torque in steps working
NOTE: Only the upper half of the bearings has oil from the center outward.
lubrication holes and must be installed in the
cylinder block. Step 1 88 N•m (65 ft-lb)
Figure 70-110-98 Step 2 170 N•m (125 ft-lb)

Step 3 245 N•m (180 ft-lb)
Clean the bridge piece and apply a bead of Loctite®

#518 in the corners and around the thread holes on the
block.
P-08751
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-110-98].
Make sure the locating pins for the main caps are in
position.

RECONDITIONING THE ENGINE (CONT'D) Rear Oil Seal Removal
Crankshaft And Bearings Installation (Cont'd) Remove the bolts that retain the seal housing. Remove
the housing.
Figure 70-110-100
Inspect the seal for wear or damage. Replace even if
there is only a small nick or scratch.
Inspect the crankshaft flange for damage.
Clean the block, seal housing, and crankshaft.
Rear Oil Seal Housing Positioning
The tool listed will be needed to do the following

procedure;
MEL1532 - Rear Crankshaft Seal Installation Tool
P-08755 Figure 70-110-102
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-110-100].

Tighten the bridge retaining bolts to 16 N•m (12 ft-lb)
torque.
Figure 70-110-101
1
2
B-05581
The seal can be installed from flush with the housing face
2 (Item 1) to 6,86 mm (0.27 in) (Item 2) [Figure 70-110-
102] back from the housing face. Install seal so that the
seal lip does not line up with any worn areas on the
crankshaft.
P-08756
Inject Loctite® #518 into the groove (Item 1) at each end

of the bridge piece. Continue to inject sealant until it
oozes out of the lower groove (Item 2) [Figure 70-110-
101] at the front and rear of the piece.

Rear Oil Seal Housing Positioning (Cont’d)

1
Figure 70-110-103
P-08748
Tighten the bolts (Item 1) [Figure 70-110-105] to 22 N•m

N-00550 (16 ft-lb) torque.
Install the seal in the seal housing using the seal Checking Crankshaft End Play
installation tool. Seat the seal to the correct depth
[Figure 70-110-103]. The axial movement of the crankshaft is controlled by two

half thrust washers placed on both sides of the center
Rear Oil Seal Installation main bearing.
Install the new seal in the housing. Figure 70-110-106

Figure 70-110-104
1
P-08840
B-05581
Install a dial indicator on the end of the crankshaft

Make sure the dowels (Item 1) [Figure 70-110-104] are [Figure 70-110-106].
in the block correctly.
Pry the crankshaft to the rear of the cylinder block and
Install the new gasket (Item 2) on the housing (Item 3)
set the dial indicator to zero.
[Figure 70-110-104].
Install the seal replacer tool (PD145-3) (Item 4) [Figure
70-110-104] on the crankshaft.
Lubricate the seal, tool, and crankshaft with clean engine
oil.
Carefully push the seal and housing (Item 3) [Figure 70-
110-104] over the tool and crankshaft and into position
on the dowels. Remove the tool.

RECONDITIONING THE ENGINE (CONT'D) Cooling System Description
Checking Crankshaft End Play (Cont'd) Figure 70-110-109
Figure 70-110-107
1
S6913
P-08841
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-110-109], to assist the
Remove the pry bar and record the dial indicator reading flow of the coolant through the system.
[Figure 70-110-107].

The water pump is gear driven from the gear off the fuel
The end play specification is 0,05-0,38 mm (0.002-0.015 injection pump.
in) maximum.
From the water pump, the coolant passes through a
If end play is excessive there is over size thrust washers passage in the timing case.
available to reduce movement.
The coolant passes through a passage in the left side of
Figure 70-110-108 the cylinder block to the rear of the cylinder block.
Figure 70-110-110
B-05583
S6914
The end play can also be checked using a feeler gauge
[Figure 70-110-108].
The oil cooler (Item 1) [Figure 70-110-110] is installed on
Pry the crankshaft to the rear of the cylinder block and the left side of the engine. Coolant from the bypass
measure the distance between the thrust washer and connection at the rear of the coolant pump passes
crankshaft. through a pipe to the oil cooler.

RECONDITIONING THE ENGINE (CONT'D) Thermostat Removal and Installation
Cooling System Description (Cont'd) Drain the engine coolant until it is below the thermostat
level.
Figure 70-110-111
Figure 70-110-112
1 1
P-55778
P-55778
The coolant then passes around the cylinders and in the

cylinder head. The coolant exits the cylinder head at the Remove the bolts (Item 1) [Figure 70-110-112] and

front and passes into the thermostat housing (Item 1) thermostat housing.
[Figure 70-110-111].
Installation: Make sure all gasket surfaces are clean.
If the thermostat is closed, the coolant goes directly Replace the gasket before installing the thermostat
through a bypass to the inlet side of the water pump. If housing.
the thermostat is open, the thermostat closes the bypass
and the coolant passes to the radiator. Figure 70-110-113
P-55780
Remove the housing and thermostat [Figure 70-110-

113].

RECONDITIONING THE ENGINE (CONT'D) Water Pump Removal
Thermostat Testing Remove the coolant from the cooling system.
Hang the thermostats in a suitable container filled with Figure 70-110-115

coolant.
1
Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
open.
1
If the thermostats do not operate correctly they must be 1
replaced.
NOTE: Identify thermostat temperature by the

stamping on the bypass valve.
1
Lubricating Oil Cooler Removal And Installation
Figure 70-110-114 S6913
1 1
from the water pump.

Remove the water pump.
2 Water Pump Installation
Clean the gasket surfaces and replace the gasket.
Install the water pump in the timing cover. The pump is a

tighten fit in the cover and is pulled into position by
tightening the bolts evenly.
1 1
P-55782
Install the water pump bolts (Item 1) [Figure 70-110-115]
and tighten to 22 N•m (16 ft-lb) torque.
Remove the eight mounting bolts (Item 1) and remove
the cooler (Item 2) [Figure 70-110-114].
Installation: Check oil level using the dipstick add oil as

needed.

Engine Lubrication System Description
Figure 70-110-116
1 3
S6915
The engine oil passes from the filter (Item 1) [Figure 70-
P-08834 110-118] to the cylinder block.
The oil passes to the main bearings of the crankshaft and

Pressure lubrication is supplied by a rotor type pump through passages in the crankshaft to the big end
(Item 1) [Figure 70-110-116] which is driven through an bearings. The pistons and the cylinder bores are

idler gear from the crankshaft gear. lubricated by splash and oil mist.
Engine oil from the oil pan sump passes through a Engine oil passes from the main bearings through
strainer (Item 2) [Figure 70-110-116] and pipe to the passages in the cylinder block to the journals of the
suction side of the pump. camshaft. Engine oil passes from the center journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-110- shaft, at a reduced pressure, to feed the rocker bushing.
116], which is installed in the bottom left side of the The oil passes through a passage in the rocker shaft to
cylinder block. The relief valves opens if the oil pressure the bearings of the rocker levers. The valve stems, valve
is too high; this allows some of the engine oil to return to springs and the tappets are lubricated by splash and oil
the sump. mist.
Figure 70-110-117 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
1 The turbocharger is lubricated by oil after the filter. Oil is

supplied from a connection on the right side of the
cylinder block through an external pipe to the
turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.
S6449
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-110-117].

RECONDITIONING THE ENGINE (CONT'D) Oil Pan Removal And Installation
Engine Lubrication System Description (Cont'd) Figure 70-110-121
Figure 70-110-119 2
P-8740
P-08745
Remove the oil pan retaining bolts (Item 1) [Figure 70-
110-21].
Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-110-119]. These jets are connected to the oil Remove the pan (Item 2) and gasket [Figure 70-110-21].

pressure rail and spray lubricating oil inside the pistons to
keep them cool. Clean the pan in solvent and dry with compressed air.
Oil Filter Adapter Removal And Installation Clean the block surface.
Figure 70-110-120 Installation: Place a new gasket on the oil pan. Place
two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts to 22 N•m
2 (16 ft-lb) torque [Figure 70-110-21].
1
1
S6915
Remove the oil filter.
Remove the four bolts (Item 1) and the filter adapter (Item
2) [Figure 70-110-120].
Clean the filter adapter and the block mounting surfaces.
Using a new gasket, install the adapter (Item 2) [Figure

70-110-120] on the block.
Install the oil filter.

Oil Screen And Pick-up Tube

1
Figure 70-110-122
2
4
1
3
P-08744
Remove the oil pressure relief valve (Item 1) [Figure 70-

P-08834
110-123].
Remove the bolt (Item 1) that holds the bracket (Item 2) Remove the oil screen and pick-up tube.
[Figure 70-110-122] to the main bearing cap.
The oil pump is installed on the number 1 main bearing

Remove the bolts (Item 3) [Figure 70-110-122] from the cap.
pick-up tube flange.
NOTE: The pump can be removed with the main
Remove the pick-up tube (Item 4) [Figure 70-110-122] bearing cap if a spanner wrench is available
and gasket. that will allow the torque to be applied directly
to the main cap bolts.
Wash the assembly in solvent and dry with compressed
air. If there is no spanner wrench, the front timing case cover
must be removed. (See Timing Cover Removal on Page
Check the tube and strainer for cracks or other damage. 70-110-20.)
Replace as necessary.
Figure 70-110-124
Loosely assemble the bracket (Item 2) [Figure 70-110-
122] with the pick-up tube to the main bearing cap.
Install the pick up tube gasket and mounting bolts (Item

3) [Figure 70-110-122].
Tighten the mounting bolts to 22 N•m (16 ft-lb) torque.
Tighten the bolt (Item 1) [Figure 70-110-122] for the pick-

up tube bracket. 2
Tighten the bolt to 22 N•m (16 ft-lb)) torque.

1
Oil Pump Removal
P-08835
NOTE: The oil pump has a channel in the body of the
pump. Oil from the front main bearing passes
down the channel of the pump to an oil hole in Remove the snap ring (Item 1), idler gear (Item 2)
the idler shaft for lubrication of the idler shaft [Figure 70-110-124], and washer.
bushing.
Remove the bolts and oil pump.
Remove the oil pan. (See Oil Pan Removal And

Oil Pump Installation
Figure 70-110-125
B-05588
1
Check that there is a minimum of 0,076 mm (0.003 in)
P-08835 backlash between the idler gear and oil pump gear
[Figure 70-110-126].
Fill the pump with engine oil. End play for the idler gear should be 0,050 - 0,275 mm
(0.0019 - 0.0108 in).

If the number one main cap was removed, reinstall and
tighten to 250 N•m (185 ft-lb) torque. Install the oil screen and pick-up tube. (See Oil Screen
And Pick-up Tube on Page 70-110-43.)
Install the pump on the main cap and tighten to 122 N•m
(16 ft-lb) torque. Install the pressure relief valve.
Check the idler gear and bushing for wear. Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.)
Lubricate with clean engine oil and install the washer,
idler gear (Item 1) and snap ring (Item 2) [Figure 70-110-
125].
Check the backlash between oil pump and idler gears.
There must be a minimum of 0,076 mm (0.003 in).

Oil Pump Disassembly And Assembly
Figure 70-110-127
B-05593
Check the rotor end play [Figure 70-110-129].
Rotor end play must be 0,038 - 0,089 mm (0.0014 -

B-05591
0.0035 in) for the inner rotor.
NOTE: If any part is worn enough to effect Rotor end play must be 0,025 - 0,076 mm (0.0010 -
performance replace the complete oil pump. 0.0029 in) for the outer rotor.

Remove the cover of the oil pump. Install the cover and tighten the bolts to 22 N•m (16 ft-lb)
torque.
Remove the outer rotor and thoroughly clean. Check for
cracks or other damage. Oil Pressure Relief Valve Disassembly And Assembly
Install the outer rotor and check the outer rotor to body Figure 70-110-130
clearance [Figure 70-110-127].
Clearance between the outer rotor and body must be

0,152 - 0,330 mm (0.0059 - 0.0129 in). 2
Figure 70-110-128
5
4
1
3
B-05606
Press the end plate (Item 1) in the valve body (Item 2)

and remove the snap ring (Item 3) [Figure 70-110-130].
Remove the end plate (Item 1), spring (Item 4), and
B-05592 plunger (Item 5) from the body (Item 2) [Figure 70-110-
130].
Check the inner rotor to outer rotor clearance [Figure 70- Clean the parts in solvent and dry with compressed air.
110-128].
Lubricate the bore of the valve body (Item 2), plunger
Clearance between the inner rotor and outer rotor must (Item 5) and the end plate (Item 1) [Figure 70-110-130]
be 0,040 - 0,127 mm (0.0015 - 0.005 in). with clean engine oil before assembly.

RECONDITIONING THE ENGINE (CONT'D) Engine Block Disassembly And Assembly
Engine Block Description Remove the water pump. (See Water Pump Removal on
Page 70-110-40.)
Figure 70-110-131
Remove the oil cooler. (See Removal And Installation on

Page 70-50-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
1
Remove the turbocharger. (See Turbocharger Removal
Remove the lift fuel pump. (See Fuel Lift Pump Removal
P-08837
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
The cylinder block is made of cast iron and provides full
length support for the dry liners. Remove the cylinder head. (See Cylinder Head Removal

on Page 70-110-6.)
The liners (Item 1) [Figure 70-110-131] are made of cast
iron. Production liners are a press fit and service liners Remove the timing case and gears. (See Timing Case
are a transion fit. Both types of liners are honed with And Gear Removal on Page 70-110-21.)
silicon carbide tools to a specially controlled finish to
ensure long engine life and low oil consumption. Remove the piston and connecting rod assemblies. (See
Pistons And Connecting Rods Removal on Page 70-110-
Figure 70-110-132 26.)
Remove the camshaft and tappets. (See Camshaft And

Tappets Removal on Page 70-110-24.)
Remove the engine mounting bracket and flywheel. (See

1 Removal And Installation on Page 70-100-1.)
Remove the rear oil seal and the crankshaft. (See Rear
Oil Seal Removal on Page 70-110-36.)
P-08842
A bushing (Item 1) [Figure 70-110-132] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.

RECONDITIONING THE ENGINE (CONT'D) Piston Cooling Jet Alignment
Piston Cooling Jet Removal Figure 70-110-135
Figure 70-110-133
1 1
55,25 mm
(2.2”)
14 mm
(0.55”)
N-00535
P-08754
Insert a 1,70 mm (0.067 in) diameter rod of suitable
length, in the jet.
Remove the piston cooling jet assembly (Item 1) [Figure
70-110-133] from the engine block. The tip of the rod must extend out the top of the cylinder

in an area 55,25 mm (2.2 in) in height and 14 mm (0.55
Figure 70-110-134 in) of width to provide proper cooling jet alignment to cool
the pistons [Figure 70-110-135].
Inspection
Clean all passages of coolant and oil.

2
Check the block for cracks or other damage.
NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
3 cylinder block.
1
Check the camshaft bushing for wear. If the bushing
P-08836 needs to be replaced, press out old one. Press a new
one in, insuring that the oil holes line up.
Inspect the jet tube (Item 1), mount bolt (Item 2) and
alignment pin (Item 3) [Figure 70-110-134] for damage.
Replace as needed.
Piston Cooling Jet Installation
Clean all parts in solvent and dry with compressed air.
Install the cooling jet (Item 1) being sure it is seated

correctly on the dowel (Item 3) [Figure 70-110-134] in
the block.
Install the mounting bolt (Item 2) [Figure 70-110-134]

and tighten to 9 N•m (79.7 in-lb) torque.

Cylinder Liner Inspection
Figure 70-110-136
B-04066
Check the cylinder liner bore for out of round or wear

P-08837 beyond service limits [Figure 70-110-137]. The inside
diameter of the service liner should be 105,000 - 105,025
mm (4.1338 - 4.1348 in).
The condition of a cylinder liner is decided by:
A flex type hone can be used to clean up small scoring or

• The amount and location of polished areas. pitting.
• Wear. Damaged or worn liners must be replaced.
• Damage to the liner wall.
NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.
Examine the liner surface (Item 1) [Figure 70-110-136]

for cracks, deep scratches and polished areas where the
honed finish is worn away.

RECONDITIONING THE ENGINE (CONT'D)
Cylinder Liner Removal
Figure 70-110-138

6
B-05556
NOTE: Where several liners are to be removed or a

very tight production liner is found, a press
should be used.
When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.
Rotate the crankshaft (if installed) to provide access to

the liner and protect the crank pin from damage.
Place the tool (Item 1) over the center of the liner (Item
2). Make sure the flat bearing race (Item 3) [Figure 70-
110-138] is against the bottom of the recess.
Install the rod (Item 4) through the handle (Item 5)

[Figure 70-110-138].
Place the adapter (Item 6) [Figure 70-110-138] under

the cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.

RECONDITIONING THE ENGINE (CONT'D) Place the threaded rod (Item 4) through the handle (Item
5) and liner (Item 1) [Figure 70-110-139].
Cylinder Liner Installation
Adjust the rod until it is below the bottom of the block
surface.
Install the adapter (Item 6) [Figure 70-110-139] on the

IMPORTANT rod. Center the adapter against the bottom of the block.
For the first five hours after the new liners have been Tighten the nut and washer.
installed:
• Do not operate at full load. Turn the handle and press the liner in the bore, stopping
• Do not operate at high speed. when approximately 50 mm (2 in) remain. Apply Loctite®
• Do not allow engine to idle for extended periods. #603 to the outer surface below the flange and to the
I-2117-1196 flange recess.
Continue to press the liner into position. Remove the tool.

Figure 70-110-139
NOTE: Do Not hit the cylinder liners with a hammer.
4 They will be damaged.
5 Figure 70-110-140
3 2

1 1
2
B-0507
Check liner protrusion with a dial gauge [Figure 70-110-

140].
The liner can have 0,10 mm (0.004 in) protrusion or

recession from the block face.
6 Allow 15 minutes before measuring the bore. The liner

B-05555 will take six hours to reach full strength.
The inside diameter of the service liner should be

Clean the cylinder bore and the outside of the liner. 105,000 - 105,025 mm (4.1338 - 4.1348 in).
Lubricate the cylinder bore with engine oil. New piston rings must be used when the cylinder liners
have been replaced.
Start the liner (Item 1) [Figure 70-110-139] in the bore.
Make sure it is started straight. The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2)
With the adapter (Item 2) on the top of the liner, place the [Figure 70-110-140].
bearing (Item 3) [Figure 70-110-139] in the recess at the
top.

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor And Alternator Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-2
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-3

Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-5
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
HVAC Repairs And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-12
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Charging Procedure With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-4
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-5
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4
CONDENSER (S/N A8HD12999 & BELOW, A8GW12999 & BELOW, A8GT12999 & BELOW,
A8GV12999 & BELOW, A8GJ12999 & BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
CONDENSER (S/N A8HD13000 & ABOVE, A8GW13000 & ABOVE, A8GT13000 & ABOVE,
A8GV13000 & ABOVE, A8GJ13000 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-61-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

EVAPORATOR / BLOWER UNIT (S/N A8HD12999 & BELOW, S/N A8GW12999 & BELOW, S/
N A8GT12999 & BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999 & BELOW) . . 80-90-1
EVAPORATOR / BLOWER UNIT (S/N A8HD13000 & ABOVE, A8GW13000 & ABOVE,
A8GT13000 & ABOVE, A8GV13000 & ABOVE, A8GJ13000 & ABOVE) . . . . . . . . . . . 80-91-1
EXPANSION VALVE (S/N A8HD12999 & BELOW, A8GW12999 & BELOW, A8GT12999 &
BELOW, A8GV12999 & BELOW, A8GJ12999 & BELOW) . . . . . . . . . . . . . . . . . . . . . . 80-100-1
EXPANSION VALVE (S/N A8HD13000 & ABOVE, A8GW13000 & ABOVE, A8GT13000 &
ABOVE, A8GV13000 & ABOVE, A8GJ13000 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . 80-101-1
HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-2

Core Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-3

AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2.).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the blower fan (Item
6) (See Chart on Page 80-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and produces
cooled air, which is pushed into the cab by the blower fan. The moisture in the air condenses on the evaporator coil and

drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1 1
S6876
1
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

S6874 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5 1
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2
P-27595
1
Pressure Switch: The pressure switch (Item 1)

[Figure 80-10-4] is located on the receiver / drier
assembly (Item 2) [Figure 80-10-3]. It will disengage the
compressor clutch if the pressure readings are too low or
too high, which indicates loss of refrigerant.
S6875
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)

Figure 80-10-5 1
S6924
1
Blower Fan Switch: This is a three position switch (Item

1) [Figure 80-10-7]. When the blower fan switch is in the
OFF position the A/C will not engage.
P-27489

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
10-5] is located behind the operator seat inside the cab.
The unit delivers the cold air for the A/C into the cab. The
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable.
Figure 80-10-6
P-27596
Expansion Valve: The expansion valve (Item 1)

[Figure 80-10-6] controls the amount of refrigerant
entering the evaporator coil.

Components (Cont'd)

Figure 80-10-8
1
2 3 1
P-97010
1. Blower Fan Switch - This is a three position switch

(Item 1) [Figure 80-10-10]. When the blower fan
switch is in the OFF position the A/C will not engage.
2. Temperature Control - Turn clockwise to increase cab

S36335 temperature; counterclockwise to decrease.

3. Air Conditioning Switch (If Equipped) - Press the top
Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
of the switch (Item 3) [Figure 80-10-10] to turn the Air
10-8] is located under the dashboard inside the cab. The
Conditioning ON - Press the bottom of the switch to
unit delivers the cold air for the A/C into the cab. The unit
turn the Air Conditioning OFF.
also contains the blower fan, evaporator coil and
thermostat which are not serviceable.
Figure 80-10-9
S36333
Expansion Valve: The expansion valve (Item 1)

[Figure 80-10-9] controls the amount of refrigerant
entering the evaporator coil.

Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-10-11
P-16398
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 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

P-16398 gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-10-
11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
WARNING
connectors. Safety glasses or a transparent face shield
are practical safety Items and one or the other is HFC R-134a refrigerant can be dangerous if not
absolutely required. properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
WARNING when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
In the event of a leak, wear safety goggles. Escaping even small amounts of R-134a in the air.
refrigerant can cause severe injuries to eyes. In Any servicing work that involves release or addition
contact with a flame, R-134a refrigerant gives a toxic of R-134a to the system must be done by a
gas. competent refrigeration dealer who has the proper
W-2371-0611 equipment, knowledge, and experience to service
refrigeration equipment.
W-2373-0611

REGULAR MAINTENANCE Compressor And Alternator Drive Belt Inspection
Filters Inspect the compressor drive belt for wear regularly.

(See SERVICE SCHEDULE on Page 10-50-1.)
Fresh Air Filters
Figure 80-20-1 Page 10-160-1.)
1 Remove the belt cover.

1
Figure 80-20-3
2
1
P-97023A

The fresh air filter is located on the front of the operator
cab. Remove the two nuts (Item 1) and filter cover
S6874
(Item 2) [Figure 80-20-1].
Figure 80-20-2 Check the tension on the compressor belt (Item 1)

[Figure 80-20-3].
1 1
2
P-97025
Remove the two bolts and nuts (Item 1), the filter cover
(Item 2) and filter (Item 3) [Figure 80-20-2] (both sides).
Clean or replace the filter as necessary.

REGULAR MAINTENANCE (CONT'D) S/N A8HD13000 & Above, S/N A8GW13000 & Above,
Cleaning The Condenser S/N A8GJ13000 & Above:
Open the engine cover. (See Opening And Closing on Figure 80-20-5
Page 10-160-1.)
2
Figure 80-20-4 1
S36349
Clean the condenser (Item 1) [Figure 80-20-5] using

1 water or air pressure.

Loosen the nut (Item 2) [Figure 80-20-5] and tilt the
P-52613 condenser forward.
Figure 80-20-6
Clean the condenser (Item 1) [Figure 80-20-4] using
water or air pressure.
NOTE: Clean between the oil cooler and condenser. 1

2
S36350
Clean between the oil cooler (Item 1) and the condenser

(Item 2) [Figure 80-20-6].
Air Conditioning Lubrication
Run the air conditioning for about 5 minutes every week

to lubricate the internal components.

REGULAR MAINTENANCE (CONT'D)
Air Conditioning Service Chart
Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:


TROUBLESHOOTING
Blower Motor Does Not Operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse / wiring. Replace fuse / repair
wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Evaporator /
Blower Unit.
4. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction clean evaporator fins with
air or water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator /

switch (frozen Blower unit.
evaporator).
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on The high side pressure will be low and bubbles can be present Repair any leaks and
refrigerant. in sight glass on receive drier. recharge the refrigerant to
the correct level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture
excess refrigerant. Charge
to the correct refrigerant
level.

Chart (Cont’d)
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic
clutch.
5. Oil on the clutch Clutch slips. Replace or clean the
surface. clutch surface.
6. Open coil. Clutch does not engage and there is not reading when a Replace clutch.
circuit tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and connections. Repair.
ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.

Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 2000 rpm are:
High pressure side pressure: 1,44 - 1,82 MPa (14,4 - 18,2 bar) (210 - 265 psi)
Low pressure side pressure: 0,1 - 0,22 MPa (1,0 - 2,2 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve opens Frost is present on the suction hose. Replace expansion valve
too far.
2.Defective compressor The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is disengaged.
Low pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge

present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed ex- The expansion valve's inlet side is frosted. Moisture or Clean or replace the expansion
pansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading can be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Replace Evaporator / Blower unit.
tion.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the fan.
formance. Operating.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil charge The high pressure side will be high. Evacuate system. Remove oil
from condenser and compressor.
Measure oil from compressor
and add correct oil charge back
into compressor. Flush system
with nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.

Gauge Pressure Related Troubleshooting (Cont’d)

High pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles can be Repair any leaks and recharge
present in sight glass on receiver drier. the refrigerant to the correct
level.
System pressures Equal
1. Clutch not operating See magnetic clutch related topics above.
2.Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
P-90410

Troubleshooting Tree (Cont’d)
P-90411

P-90412

P-90413

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP °C (°F) BAR (PSI) TEMP °C (°F) BAR (PSI)
-8,9 (16) 1,08 (15.69) 33,9 (93) 7,60 (110.20)
-7,8 (18) 1,17 (17.04) 34,4 (94) 7,73 (112.10)
-6,7 (20) 1,27 (18.43) 35 (95) 7,87 (114.10)
-5,6 (22) 1,30 (19.87) 37,8 (100) 8,57 (124.30)
-4,4 (24) 1,47 (21.35) 38,9 (102) 8,56 (128.50)
-3,3 (26) 1,58 (22.88) 40 (104) 9,16 (132.90)
-2,2 (28) 1,69 (24.47) 41,1 (106) 9,47 (137.30)
-1,1 (30) 1,80 (26.10) 42,2 (108) 9,78 (141.90)
0 (32) 1,92 (27.79) 43,3 (110) 10,10 (146.50)
1,1 (34) 2,04 (29.52) 44,4 (112) 10,43 (151.30)
2,2 (36) 2,16 (31.32) 45,6 (114) 10,76 (156.10)
3,3 (38) 2,29 (33.17) 46,7 (116) 11,11 (161.10)
4,4 (40) 2,42 (35.07) 47,8 (118) 11,45 (166.10)
5,6 (42) 2,55 (37.03) 48,9 (120) 11,81 (171.30)
6,7 (44) 2,70 (39.05) 50 (122) 12,18 (176.60)

7,2 (45) 2,76 (40.09) 51,1 (124) 12,55 (182.00)
10 (50) 3,14 (45.48) 52,2 (126) 12,93 (187.50)
12,8 (55) 3,53 (51.27) 53,3 (128) 13.31 (193.10)
15,6 (60) 3,96 (57.47) 54,4 (130) 13,71 (198.90)
18,3 (65) 4,42 (64.10) 57,2 (135) 14,73 (213.70)
21,1 (70) 4,91 (71.19) 60 (140) 15,82 (229.40)
23,9 (75) 5,43 (78.75) 62,8 (145) 16.95 (245.80)
26,7 (80) 5,98 (86.80) 65,6 (150) 18,13 (263.00)
29,4 (85) 6,58 (95.40) 68,3 (155) 19,38 (281.10)
32,2 (90) 7,20 (104.40) 71,1 (160) 20,69 (300.10)
32,8 (91) 7,33 (106.30) 73,9 (165) 22,07 (320.10)
33,3 (92) 7,46 (108.20) 76,7 (170) 23,50 (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 12,2 - 13,3°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4,4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature = 32,2°C (90°F)

32,2°C (90°F)
+ 4,4°C (40°F)
54,4°C (130°F) condenser temperature = 1.38 MPa (13,8 bar), (200 psi)
Conditions and pressures will vary from system to system.

TROUBLESHOOTING (CONT’D) Figure 80-50-3
Poor A/C Performance
Start the telescopic handler, engage the parking brake.

Engage the A/C system with the blower fan on high. Run
the telescopic handler at full RPM for approximately 15
minutes, with the cab door closed.
Figure 80-50-1
1 S/N A8GT12999 & BELOW
P-27746
Check the temperature at the louvers (Item 1) [Figure

80-50-1] and [Figure 80-50-2] with a thermometer
[Figure 80-50-3].
The louver temperature should be between 2,2 - 11,6°C

P-27747 (36 - 53°F) depending on the amount of humidity in the

air.
Figure 80-50-2 If the louver temperature is too high. (See

S/N A8HD13000 & ABOVE TROUBLESHOOTING on Page 80-30-1.)
S/N A8GT13000 & ABOVE Check the blower fan for proper operation or noise, and
S/N A8GV13000 & ABOVE replace if necessary. (See EVAPORATOR / BLOWER
1 UNIT (S/N A8HD12999 & BELOW, S/N A8GW12999 &
BELOW, S/N A8GT12999 & BELOW, S/N A8GV12999 &
BELOW, S/N A8GJ12999 & BELOW) on Page 80-90-1.)
Check the belt tension on the A/C compressor. (See

Compressor And Alternator Drive Belt Inspection on
Page 80-20-1.)
Check the A/C condenser for dirt or mud, and clean if

necessary. (See Cleaning The Condenser on Page 80-
S36340 20-2.)
Inspect the sight glass located on the receiver / drier for

air bubbles. (See REGULAR MAINTENANCE on Page
80-20-1.)

HVAC Repairs And Leaks
Figure 80-50-4
S6876
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 80-50-4] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT'D) Figure 80-50-7
Electrical System S/N A8HD13000 & ABOVE

Figure 80-50-5 S/N A8GV13000 & ABOVE
S36336
1
Turn the blower fan switch (Item 1) [Figure 80-50-6] and
S6874 [Figure 80-50-7] to the first on position. The compressor
clutch should make a click sound, which indicates the
clutch is engaging.
Check to see if the compressor clutch (Item 1) [Figure
80-50-5] is engaging. Figure 80-50-8

Turn the Start key switch to the RUN position without
starting the machine.
Figure 80-50-6
S/N A8GT12999 & BELOW 1
P-52598
If the compressor clutch does not engage, check the fuse

S6924 (Item 1) [Figure 80-50-8]. Replace the fuse if needed.

Electrical System (Cont'd)
Figure 80-50-9
1
1
P-27738
With a multimeter, check the voltage to the compressor

P-52593 clutch at the main harness (Item 1) [Figure 80-50-11].
If there is no power at the clutch, check the wiring

Disconnect the connector (Item 1) [Figure 80-50-9] from harness for broken wires.
the compressor.

If there is still no voltage at the clutch, reconnect the
Figure 80-50-10 wiring harness to the compressor clutch.
Figure 80-50-12
P-52597
S6876
With a multimeter check the resistance to the compressor
clutch connector (Item 1) [Figure 80-50-10].
Disconnect the machine harness (Item 1) [Figure 80-50-
If there is no resistance value replace the compressor 12] from the pressure switch.
clutch. (See COMPRESSOR on Page 80-50-1.)

Electrical System (Cont'd) S/N A8GW12999 & BELOW
1 1
P-27597
Figure 80-50-16
S6877 S/N A8HD13000 & ABOVE
With the key switch to the run position (engine off) and S/N A8GV13000 & ABOVE
the blower fan switch on the first position. Use a S/N A8GJ13000 & ABOVE

multimeter to check the main harness (Item 1) [Figure
80-50-13] for voltage.
There should be 12 volt. If there is no voltage, check the

harness for broken wires.
1
Figure 80-50-14
S36344
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-50-15] and [Figure 80-50-16] from the main
harness.
1
S6878
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 a low refrigerant

level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-40-1.)
If good resistance value is observed, the pressure switch

is good.
Reconnect the main harness to the pressure switch.

TROUBLESHOOTING (CONT'D) S/N A8HD12999 & Below, S/N A8GW12999 & Below,
Electrical System (Cont'd) S/N A8GJ12999 & Below:
Figure 80-50-17 Figure 80-50-19
1
1
P-27742 S4598
Check the main harness (Item 1) [Figure 80-50-17] for Remove the fuse box cover (Item 1) [Figure 80-50-19].
voltage. The voltage should be 12 volt. If there is no

voltage, check the harness for broken wires. Figure 80-50-20
Figure 80-50-18
P-27744
P-27743
Disconnect the main wire harness connectors (Item 1)
[Figure 80-50-20] from the switch.
If there is voltage at the wiring harness, check the
thermostat wire (green) for resistance. The resistance NOTE: Mark the wires for correct assembly.
value should be 10 ohm at 20°C (68°F) [Figure 80-50-
18].
If there is no resistance, replace the entire blower fan

unit.


1
Figure 80-50-21
S36341
P-27745
Disconnect the main wire harness connector (Item 1)
[Figure 80-50-23] from the switch.
Check the main harness (Item 1) [Figure 80-50-21] for
voltage. The voltage should be 12 volt. If there is no Figure 80-50-24
voltage check the harness for broken wires.

S/N A8HD13000 & Above, S/N A8GW13000 & Above, 1
Figure 80-50-22
1 S36342
Check the main harness (Item 1) [Figure 80-50-24] for

voltage. The voltage should be 12 volt. If there is no
1 voltage check the harness for broken wires.
S36336
Remove the four screws (Item 1) [Figure 80-50-22].
Remove the panel (Item 2) [Figure 80-50-22].

For All Models:
Figure 80-50-25
H C
M B
N-22288
If there is voltage at the main harness check the blower

fan switch [Figure 80-50-25] for resistance.

With the switch in the OFF position, there should be zero
resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-25].

also between the C terminal and the M terminal frame
[Figure 80-50-25].

also between the C terminal and the H terminal frame
[Figure 80-50-25].
If any of the above resistance tests fail, replace the

blower fan switch.


SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
WARNING
Figure 80-40-1
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611
1
NOTE: This test is run with the engine OFF, and the A/
C switch in the OFF position.
2
Figure 80-40-3
1
P-52599

Remove the access cover mounting bolt (Item 1) [Figure
80-40-1].
Remove the access cover (Item 2) [Figure 80-40-1].
Figure 80-40-2 N-23024
NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of
1 refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-3]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
2 that can be present in the system. Thus
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
P-27478 MEL 1581 Recovery / Recycling / Recharging
Machine.
Locate the low pressure port (Item 1) and high pressure Remove the protective cap and connect the refrigerant
port (Item 2) [Figure 80-40-2] on the back side of the identifier to the low pressure hose (Item 1) [Figure 80-
compressor. 40-2].
Connect the refrigerant identifier to its power source.

SYSTEM CHARGING AND RECLAMATION (CONT'D)
Reclamation Procedure (Cont'd)
Figure 80-40-4
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper
equipment, knowledge, and experience to service
refrigeration equipment.
S6879 W-2373-0611
Follow the steps displayed on the refrigerant identifier Figure 80-40-5

screen [Figure 80-40-4].

Allow 2 minutes for the refrigerant identifier to display the
type of refrigerant and air content. An alarm will sound if
potentially flammable hydrocarbons are present and will
also indicate on the visual display.
Disconnect the refrigerant identifier from the A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.
If R134a is found, evacuate the system.

N-22291
Use an approved recovery / charging unit [Figure 80-40-

WARNING 5] to evacuate the system.
Connect the reclaimer to the A/C charge ports.

gas.
W-2371-0611

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-8
Reclamation Procedure (Cont'd)
Figure 80-40-6
2
N-22381
NOTE: The reclaimer unit, has a complete step by

P-25225 step set of instructions [Figure 80-40-8] to
follow for reclamation and recharging of the
A/C system. A trained technician should
Connect the Red hose (Item 1) [Figure 80-40-6] to the follow these instructions as they can vary
high pressure port and open the valve. slightly depending on the model and brand of

reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-40-6] to the
low pressure port and open the valve.
Figure 80-40-7
N-22292
Turn the reclaimer unit [Figure 80-40-7] to the ON

position and follow the on screen instructions.

Charging Procedure With A Manifold Gauge Set
Open the hood.
WARNING
2
contact with a flame, R-134a refrigerant gives a toxic 1
gas.
W-2371-0611
S6880
Figure 80-40-9
Connect the Red hose (Item 1) [Figure 80-40-10] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-40-10] to the

low pressure port and open the valve.
1

1 Figure 80-40-11
P-52622 1
Check to see that the hand valves (Item 1) [Figure 80-

40-9] 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 80-40-1.) S6882
Connect the gauges to the A/C charge ports.

Connect the Yellow hose (Item 1) [Figure 80-40-11] to
the vacuum pump.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Determine the problem with the A/C system and repair it.
Charging Procedure With A Manifold Gauge Set Figure 80-40-14

(Cont’d)
Figure 80-40-12
1 1
P-27485
P-52626 A thermistor vacuum gauge (Item 1) [Figure 80-40-14]

can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
Start the vacuum pump and open ISO-valve (Item 1) monitors and visually indicates the vacuum level.

[Figure 80-40-12] on the vacuum pump.
The thermistor vacuum gauge is used with the vacuum
Run the vacuum pump for at least 5-10 minutes to insure pump [Figure 80-40-14].
that a vacuum has been pulled on the system.
Start the vacuum pump and open ISO-valve on the
Close the ISO-valve (Item 1) [Figure 80-40-12] (which vacuum pump.
isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump. Be sure that both hand valves, and both charge port
valves are open.
Charging Procedure
Run the vacuum pump for at least 45 minutes to insure
Figure 80-40-13 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

1
remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermistor vacuum

gauge.
S6880
Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-40-13]. Let stand for 5-
10 minutes and recheck the pressure for changes.
If the pressure drops, this can be an indication of a leak

in the A/C system.

Charging Procedure (Cont’d) S/N A8GW12999 & BELOW
S6924
1 Figure 80-40-18
2
S6883 S/N A8GW13000 & ABOVE
Place a refrigerant container with R134a (Item 1) on a S/N A8GJ13000 & ABOVE
charging scale (Item 2) [Figure 80-40-15] and zero out

the scale. 1
Connect the yellow hose (Item 3) [Figure 80-40-15] from

the manifold gauge set to the valve on the refrigerant
tank.
Figure 80-40-16
S36336
2
Turn the A/C fan switch (Item 1) [Figure 80-40-17] and

[Figure 80-40-18] to HIGH position.
Start the machine, and run at medium speed.
Watch the scale and run system until the predetermined

1 amount of refrigerant is added to the A/C system.
The A/C system holds 0,800 kg (1.76 lb) of refrigerant.
S6884 Turn off the valve on the refrigerant container, and hand
valves on the manifold gauge set.
Open the valve on the refrigerant container (Item 1) and Turn off the engine and remove the A/C charging
open the low pressure hand valve (Blue) (Item 2) [Figure equipment from the machine.
80-40-16] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes. Install access cover.
Close the engine cover.

COMPRESSOR

WARNING
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-40-1.) In the event of a leak, wear safety goggles. Escaping
Remove the alternator. (See Removal And Installation on contact with a flame, R-134a refrigerant gives a toxic
Page 60-30-1.) gas.
W-2371-0611
Remove the compressor belt.
Figure 80-50-3
Figure 80-50-1
1
1

P-52609
S6885
Remove the compressor hoses (Item 1) [Figure 80-50-

Remove the two tensioner pulley mount belts (Item 1) 3].
[Figure 80-50-1]. Remove the pulley assembly.
Installation: Tighten the hoses to 29,8 N•m (22 ft-lb)
Figure 80-50-2 torque.
Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
1
Figure 80-50-4
1
P-52608
Disconnect the connector (Item 1) [Figure 80-50-2] from

the compressor.
S6886
Mark the compressor hoses for correct installation.
Remove the mount bolts (Item 1) [Figure 80-50-4].
Remove the compressor.

COMPRESSOR (CONT'D) Oil Check
Oil The compressor oil should be checked as follows when

oil is being added to an in service machine.
Figure 80-50-5
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-40-1.)
1
Open the cab door and windows.
Run the blower fan at maximum speed.

P-27538
Run the compressor for at least 20 minutes at 800 - 1200
RPM.
The compressor (Item 1) [Figure 80-50-5] is factory filled
with 150 - 170 cc's of PAG oil (Poly Alkelene Glycol). Remove the compressor from the machine. (See

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver-drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any related problems occur in the cooling cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, 30 cc (1 U.S. fl oz) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check (Cont'd)
Figure 80-50-6
1
P-27542
NOTE: After draining the oil through the drain hole

P-27539 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-7 8] several times by hand.

Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-50-9
1
2
P-27545 1
Remove the oil drain plug (Item 1) [Figure 80-50-6] and

drain the oil through the connectors and the oil drain hole
(Item 2) [Figure 80-50-7].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.
P-27543
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 large port on the
compressor.

Clutch Disassembly And Assembly

1
Figure 80-50-10
32 MM 32 MM
(1.25”) (1.25”)
32 MM
(1.25”)
P-27524
1
The armature plate puller (Item 1) [Figure 80-50-12] can
P-27519 be constructed by drilling three 8 mm (0.315 in) holes in a
flat circular plate, located 31,75 mm (1.25 in) apart.
Remove the center armature nut (Item 1) [Figure 80-50- Figure 80-50-13
10].

Assembly: Tighten the armature nut to 12 N•m (8 ft-lb).
Figure 80-50-11
1
P-27522
Attach the armature puller plate (Item 1) to the armature

plate using the three bolts (Item 2) [Figure 80-50-13].
P-27520
To remove the armature plate (Item 1) [Figure 80-50-11]

from the clutch face you must make an armature plate
puller.

COMPRESSOR (CONT'D) The specified clearance for the clutch is 0,3 - 0,6 mm
(0.01 - 0.02 in) adjusting shims are available in the
Clutch Disassembly And Assembly (Cont'd) following thicknesses.
Figure 80-50-14 0,1 mm (0.0039 in)

0,3 mm (0.0118 in)
0,5 mm (0.0197 in)
Figure 80-50-16
P-27521
Attach a slide hammer puller to the armature puller tool

[Figure 80-50-14].
P-27525

Figure 80-50-15
Remove the snap ring (Item 1) [Figure 80-50-16] from
the pulley assembly.
Figure 80-50-17
2 1
P-27523
Remove the armature plate (Item 1) [Figure 80-50-15]

from the compressor clutch.
P-27526
Remove the shims (Item 2) [Figure 80-50-15] from the

armature shaft or armature plate. Remove the pulley from the compressor [Figure 80-50-
17].
Assembly: Insure that the clutch has the correct
clearance by adding the shims (Item 2) [Figure 80-50-
15].

Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-18
P-27529
Remove the harness retainer screw assembly (Item 1)

P-27527 [Figure 80-50-20].
Figure 80-50-21
The pulley assembly and bearing [Figure 80-50-18] must
be replaced as a complete unit.

Figure 80-50-19
1
2
1
P-27530
Remove the snap ring (Item 1) [Figure 80-50-21] from

P-27528 the coil.
Remove the lock (Item 1) and connector (Item 2) [Figure

80-50-19] from the compressor harness.

COMPRESSOR (CONT'D)
Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-22
P-27531
Remove the coil from the compressor [Figure 80-50-22].

Figure 80-50-23
P-27527
The compressor [Figure 80-50-23] must be replaced as

a complete unit.


CONDENSER (S/N A8HD12999 & BELOW, Figure 80-60-1
A8GW12999 & BELOW, A8GT12999 & BELOW,
A8GV12999 & BELOW, A8GJ12999 & BELOW)
Remove the refrigerant from the A/C system. 1

(See Reclamation Procedure on Page 80-40-1.)
WARNING
contact with a flame, R-134a refrigerant gives a toxic P-52611
gas.
W-2371-0611
Remove the A/C hose (Item 1) [Figure 80-60-1] from the
condenser.
Figure 80-120-1
Figure 80-60-2

1
P-52612
P-52614

condenser. Remove the two nuts (Item 1) [Figure 80-60-2] from
each side of the condenser.
NOTE: Install caps and plugs on all fittings.
Tilt the condenser forward and remove.


CONDENSER (S/N A8HD13000 & ABOVE, Figure 80-61-2
A8GW13000 & ABOVE, A8GT13000 & ABOVE,
A8GV13000 & ABOVE, A8GJ13000 & ABOVE)
Remove the refrigerant from the A/C system. (See 2

SYSTEM CHARGING AND RECLAMATION on Page 80-
40-1.)
1
WARNING
refrigerant can cause severe injuries to eyes. In S36353
gas.
W-2371-0611 Remove two nuts (Item 1) from the condenser mount
(Item 2) [Figure 80-61-2].
Figure 80-61-1 NOTE: One nut is hidden on [Figure 80-61-2].
3 Figure 80-61-3

1
1
2
S36351
S36352
Remove the tie-straps (Item 1) [Figure 80-61-1] from the
condenser.
Remove the nut (Item 1) [Figure 80-61-3] from the
Remove the hose (Item 2) [Figure 80-61-1] from the condenser.
condenser.
Tilt the condenser forward and remove.
Remove the A/C hose (Item 3) [Figure 80-61-1] from the
condenser.


RECEIVER / DRIER Figure 80-70-1
Remove the refrigerant from the A/C system. (See

40-1.)

Reclamation Procedure on Page 80-40-1.)
WARNING P-52616
In the event of a leak, wear safety goggles. Escaping Remove the two hoses (Item 1) [Figure 80-70-1] from
refrigerant can cause severe injuries to eyes. In the Receiver / Drier.
gas. NOTE: Mark the hoses for correct installation.
W-2371-0611

Figure 80-130-1
Loosen the bolt (Item 2) [Figure 80-70-1] on the
mounting bracket.
S6876

from the pressure switch.


PRESSURE SWITCH Figure 80-80-1

Page 10-160-1.)
Remove the refrigerant from the A/C system. (See 1

40-1.)
WARNING
P-52616
contact with a flame, R-134a refrigerant gives a toxic Remove the pressure switch (Item 1) [Figure 80-80-1]
gas. from the Receiver / Drier assembly.
W-2371-0611
Figure 80-140-1

2
S6876
Disconnect the connector (Item 1) from the pressure

switch (Item 2) [Figure 80-140-1].


EVAPORATOR / BLOWER UNIT (S/N A8HD12999 & Figure 80-90-3
BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999
& BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999
& BELOW)

1
40-1.)
WARNING
refrigerant can cause severe injuries to eyes. In P-25243
gas.
W-2371-0611 Temporarily remove the covering (Item 1) [Figure 80-90-
3] from the A/C hoses and expansion valve.

1 2
P-25221
P-25244

Figure 80-90-2 90-4]. Remove both A/C hoses.
NOTE: Plug the A/C hoses to avoid contamination.
P-25242
Remove the rear panel (Item 1) [Figure 80-90-2].

BELOW, S/N A8GW12999 & BELOW, S/N A8GT12999
& BELOW, S/N A8GV12999 & BELOW, S/N A8GJ12999
& BELOW) (CONT'D)
Figure 80-90-5
P-27599
Remove the front mounting bolt (Item 1) [Figure 80-90-

7].
1
Place the evaporator / blower unit on the seat.
P-27597
Figure 80-90-8

Disconnect the thermostat wiring connector (Item 1)
[Figure 80-90-5].
Figure 80-90-6
1
2
1 1
P-27600
Remove the drain hose (Item 1) [Figure 80-90-7].
P-27598
Remove the evaporator / blower unit from the machine.
Remove the three mount bolts (Item 1) and ground wire

(Item 2) [Figure 80-90-6] from the back of the evaporator
unit.

ABOVE, A8GW13000 & ABOVE, A8GT13000 &
ABOVE, A8GV13000 & ABOVE, A8GJ13000 &
ABOVE) 2
Remove the refrigerant from the A/C system.

(See SYSTEM CHARGING AND RECLAMATION on
Page 80-40-1.)
1
WARNING
In the event of a leak, wear safety goggles. Escaping S36343
gas. Remove the two screws (Item 1) [Figure 80-91-2].
W-2371-0611
Remove the vent (Item 2) [Figure 80-91-2].
Remove the dash cover / steering column cover.
Figure 80-91-3
(See Removal And Installation on Page 50-141-1.)

Figure 80-91-1
S36344
S36333 Disconnect the connectors (Item 1) [Figure 80-91-3]

located under the dashboard.
1].
NOTE: Plug the A/C hoses (Item 1) [Figure 80-91-1] to

avoid contamination.
Remove the two heater hoses (Item 2) [Figure 80-91-1].

ABOVE, A8GW13000 & ABOVE, A8GT13000 &
ABOVE, A8GV13000 & ABOVE, A8GJ13000 &
ABOVE) (CONT’D)
1
Figure 80-91-4
S36347
1
Remove the evaporator / blower unit (Item 1) [Figure 80-

91-6].
S36345

Remove the two bolts (Item 1) [Figure 80-91-4] on the
right side of the evaporator / blower unit.
Figure 80-91-5
S36346
Remove the two bolts (Item 1) [Figure 80-91-5] on the

left side of the evaporator / blower unit outside the cab.

EXPANSION VALVE (S/N A8HD12999 & BELOW, Figure 80-100-3

1
Remove the refrigerant from the A/C system.
(See Reclamation Procedure on Page 80-40-1.)
WARNING
P-25243
gas.
W-2371-0611 Temporarily remove the covering (Item 1) [Figure 80-
100-3] from the A/C hoses and expansion valve.
Figure 80-100-1
Figure 80-100-4

2
P-25221
P-25244

100-4]. Remove both A/C hoses.
Figure 80-100-2
NOTE: Plug the A/C hoses to avoid contamination.
P-25242
Remove the rear panel (Item 1) [Figure 80-100-2].

EXPANSION VALVE (S/N A8HD12999 & BELOW,
(CONT'D)
Figure 80-100-5
P-27667
Remove the two mount bolts (Item 1) [Figure 80-100-5].

Remove the expansion valve.
Figure 80-100-6
P-27666
The expansion valve (Item 1) [Figure 80-100-6] is

replaced as a complete unit.

EXPANSION VALVE (S/N A8HD13000 & ABOVE, Figure 80-101-2
A8GW13000 & ABOVE, A8GT13000 & ABOVE,
A8GV13000 & ABOVE, A8GJ13000 & ABOVE)

40-1.)
WARNING
refrigerant can cause severe injuries to eyes. In S36363
gas.
W-2371-0611 Remove the two evaporator fittings (Item 1) [Figure 80-
101-2] from the expansion valve.
Remove the dash cover / steering column cover. (See Installation: Tighten the two evaporator fittings to 29,8
Removal And Installation on Page 50-141-1.) N•m (22 ft-lb) torque.
Figure 80-101-1

NOTE: Plug the evaporator tubelines to prevent
contamination.
Figure 80-101-3
1 2
1
S36333
Mark and remove both A/C hoses (Item 1) [Figure 80-

S36348
101-1].
NOTE: Plug the A/C hoses (Item 1) [Figure 80-101-1] Remove the two mount bolts (Item 1) [Figure 80-101-3].
to prevent contamination.
Remove the expansion valve (Item 2) [Figure 80-101-3].
NOTE: The expansion valve (Item 2) [Figure 80-101-3]

is replaced as a complete unit.


HEATER ASSEMBLY Figure 80-110-2
S/N A8HD13000 & Above, S/N A8GW13000 & Above, S/

N A8GT13000 & Above, S/N A8GV13000 & Above, S/N
A8GJ13000 & Above:
Remove the evaporator / blower unit. (See Removal And

S/N A8HD13000 & Above, S/N A8GW13000 & Above, S/

N A8GT13000 & Above, S/N A8GV13000 & Above, S/N 1
A8GJ12999 & Below:
1
Remove the travel / signal levers. (See Removal And P-25590

Remove the instrument panel. (See Removal And Remove the vent hoses (Item 1) [Figure 80-110-2] from
Installation on Page 60-70-1.) the top of the assembly.
Remove the switch panel. (See Removal And Installation Figure 80-110-3
on Page 60-80-1.)

Figure 80-110-1
P-25591
1
Clamp the heater hoses [Figure 80-110-3].
P-25589
Disconnect the connector (Item 1) [Figure 80-110-1].

HEATER ASSEMBLY (CONT'D) Fan Removal And Installation
Removal And Installation (Cont'd) Figure 80-110-6
Figure 80-110-4
P-25594
P-25592
Carefully remove the clip (Item 1) and cable (Item 2)
[Figure 80-110-6].
Remove the heater hoses (Item 1) [Figure 80-110-4]
from the heater assembly. Figure 80-110-7

Figure 80-110-5
1
1
1
P-25595
1
Remove the fan mounting bolts (Item 1) [Figure 80-110-
P-25593 7] and remove the fan.

and remove the heater assembly.

HEATER ASSEMBLY (CONT'D) Figure 80-110-10
Core Removal And Installation
Figure 80-110-8
1
P-25604
1
Remove the two bolts (Item 1) [Figure 80-110-10] and

P-25602 save for later use.
Figure 80-110-11
Remove the two flange mounting nuts (Item 1)
[Figure 80-110-8]. 1

1
Figure 80-110-9
1
1
P-25601
Remove the four screws (Item 1) [Figure 80-110-11]

P-25603 from the vent bracket.
Remove the flange / linkage assembly (Item 1)

[Figure 80-110-9] from assembly.

HEATER ASSEMBLY (CONT'D) Figure 80-110-14
Core Removal And Installation (Cont'd)
Figure 80-110-12
P-25607
2
Slide the core from the housing [Figure 80-110-14].

P-25605
Remove the end bracket (Item 1) and spacer (Item 2)

[Figure 80-110-12] from the assembly.

Figure 80-110-13
P-25606
Be sure to separate the bracket (Item 1) and tab (Item 2)

[Figure 80-110-13].

SPECIFICATIONS
(T35100) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
(T35100L) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-10-7

Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7

Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-8
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-9
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-10
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-11
(T35100SL) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . .SPEC-10-13

Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-13
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-14
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-15
987 of 1040 SPEC-01 T35100(S)(L), T35120(S)L Service Manual

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-16
(T35120L) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .SPEC-10-19

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-20
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-20
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-21
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-21
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-21
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-21
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-22

(T35120SL) TELESCOPIC HANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . .SPEC-10-25
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-26
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-26
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-27
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-27
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-27
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-27
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-28
MACHINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1


(T35100) TELESCOPIC HANDLER SPECIFICATIONS
Each attachment and each Telescopic Handler have different Load

Capacity Charts. For example: An 84 inch bucket used on a T2250 will
WARNING have its own chart; that same 84 inch bucket when used on a T3571 will
have a different chart. Be sure you use the correct chart for your
attachment and Telescopic Handler combination.
Dimensions are given for machine equipped with standard tires and can vary with other tire types.
Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Dimensional Specifications

(A) Overall length (with forks) 6486 mm (255.3 in)
(B) Overall length (with carriage) 5285 mm (208.0 in)
(C) Overall length (without attachment) 5070 mm (199.6 in)
(D) Overall length (to front tires) 4406 mm (173.5 in)
(E) Overall height (with rotating beacon) 2610 mm (102.8 in)
(F) Overall height 2295 mm (90.4 in)
(G) Carriage rotation angle 145°
(I) Height to back of the machine 2079 mm (81.9 in)
(J) Ground clearance 419 mm (16.5 in)
(M) Wheelbase 2850 mm (112.2 in)
(N) Rear axle to back of machine 800 mm (31.5 in)
(O) Operator cab outside width 930 mm (36.6 in)
(P) Track width (front and rear) 1812 mm (71.3 in)
(Q) Width over standard tires 2216 mm (87.2 in)
(R) External turning radius (with forks spaced 1200 mm [47.24 in] ext.) 5400 mm (212.6 in)
(R) External turning radius (with forks spaced 1040 mm [41 in] ext.) 5350 mm (210.6 in)
(S) External turning radius (at tires) 3900 mm (153.5 in)
(T) External turning radius (at counterweight) 4000 mm (157.5 in)
(U) Internal turning radius 1370 mm (53.9 in)
Height to steering wheel 1600 mm (63 in)
Operator cab inside width 920 mm (36.6 in)
991 of 1040 SPEC-10-1 T35100(S)(L), T35120(S)L Service Manual

(T35100) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)
Performance Specifications
Crowding force 4600 daN (10341 lbf)

Drawbar pull 4700 daN (10566 lbf)
Ground pressure on tires 600 kPa (6 bar) (87 psi)
Rated operation capacity* 3500 kg (7716 lb)
Capacity at max. height 750 kg (1653.5 lb)
Capacity at max. reach 600 kg (1322.8 lb)
Push force (20” standard tires) 5700 daN (12814 lbf)
Push force (20” option tires) 4700 daN (10566 lbf)
Tipping load 750 kg (1653.5 lb)
Lifting height 10200 mm (401.6 in)
Max. reach 6910 mm (272.0 in)
Banking corrector -
* Static and dynamic tests have been carried out and passed according to EN1459.
Weights
Weight (unladen) 7200 kg (15873.3 lb)

Front axle weight unladen 2790 kg (6150.9 lb)
Rear axle weight unladen 4275 kg (9424.8 lb)
Weight with pallet frame and forks 7375 kg (16259.0 lb)
Front axle weight with pallet frame and forks 3260 kg (7187.0 lb)
Rear axle weight with pallet frame and forks 4145 kg (9138.2 lb)
Weight with pallet frame, forks and 3500 kg (7716 lb) load 10875 kg (23975.2 lb)
Front axle weight with pallet frame, forks and 3500 kg 9295 kg (20491.9 lb)
(7716 lb) load
Rear axle weight with pallet frame, forks and 3500 kg 1580 kg (3483.3 lb)
(7716 lb) load
Engine
Make / Model PERKINS / 1104D-44TA Turbo

Fuel Diesel
Cooling Liquid
Rated power (DIN 6271) at 2200 rpm 74,5 kW (100 hp)
Rated speed 2200 rpm
Maximum torque at 1400 rpm 410 N•m (302.4 ft-lbf)
Number of cylinders 4
Displacement 4,4 L (1.16 U.S. gal)
Bore 105 mm (4.1 in)
Stroke 127 mm (5 in)
Ignition Diesel-compression

Controls
Engine Foot accelerator pedal

Starting Key-type starter switch and shutdown. Key activated air intake
heater
Front auxiliary Variable thumbwheel on joystick
Hydraulics lift and tilt Electro-hydraulic joystick
Hydraulics telescope in and telescope out Variable thumbwheel on joystick
Service brake Pedal-activated wet multi-disc on front axle
Secondary brake Hydrostatic transmission
Parking brake Hand lever activates spring-applied pressure release multi-disc
brake
Steering Proportional hydraulic steering via a conventional steering wheel
Speed range and reverse selection Left-hand multi-function lever on the central console
4WD / 2WD / parallel drive selection Three-position switch on the right-hand console
Auxiliary pressure release Button activated in cab
Drive System

Transmission Hydrostatic with electronic regulation
Main drive 2-speed hydrostatic motor
Traction
Standard tires TITAN 400/70x20 150B 166A2 LIFT RIGGER II

(400 kPa [4 bar] [58 psi] front / rear)
Optional tires DUNLOP 400/70x20 150B T37
(550 kPa [5,5 bar] [80 psi] front / rear)
(425 kPa [4,25 bar] [61,6 psi] front / rear)
Optional tires DUNLOP 405/70x20 SPT9
Low speed (forward / reverse) 7 km/h (4.35 mph)
High speed (forward / reverse) 30 km/h (18.6 mph)
Driving modes Direct drive / soft drive
Steering
Steering pump Casappa gear pump mounted on equipment pump

Steering modes 2WS / 4WS / CRAB
(R) External turning radius (with forks) 5400 mm (212.5 in)
Brakes
Engine braking Hydrostatic

Parking and emergency brake Negative brake with hydraulic command
Service brake Oil-immersed disc

Fluid Capacities
Axle and reduction gears front / rear 9 / 8,1 L (2.4 / 2.1 U.S. gal)
Cooling system 17 L (4.5 U.S. gal)
Engine oil 8,5 L (2.25 U.S. gal)
Engine lubrication plus oil filter 8,5 L (2.25 U.S. gal)
Fuel tank 140 L (37 U.S. gal)
Hydraulic reservoir 77 L (20.3 U.S. gal)
Hydraulic system plus reservoir 125 L (33 U.S. gal)
Hydraulic System
Pump type Gear pump with LS valve

Pump capacity 105 L/min (27.7 U.S. gpm)
Relief valve pressure setting 26,5 MPa (265 bar) (3843.5 psi)
Auxiliary flow 80 L/min (21.1 U.S. gpm)
Electrical

Alternator 90 A - open
Battery 12 V - 105 Ah - 720 A cold cranking A at -18°C (0°F) - 180 min
reserve capacity
Starter 12 V - gear reduction type

Instruments
The following functions are monitored by a combination of gauges and warning lights in the operator's line of sight.
The system alerts the operator of monitored malfunctions by way of audible and visual indicators.
Gauges
Rev counter
Total operating hours
Fuel gauge
Hydraulic fluid temperature gauge
Engine coolant temperature gauge
Sight level gauge
Indicators
Front and rear wheel alignment status
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Trailer turn indicators operational
Parking brake
Longitudinal Stability Indicator alarm active
Longitudinal Stability Indicator alarm neutralised
Windscreen wipers

Work lights
Flashing warning lights
Hazard warning lights
Transmission mode
Hydraulic function lock
Rear fog lights
Heater fan
End of high stroke for the winch
Boom-head hydraulic function locked
Boom-head hydraulic function in continuous mode
Warning lights
Hydraulic fluid temperature over 95°C (203°F)
Engine coolant over 103°C (217.4°F)
Low oil pressure
Battery not charging
Longitudinal stability alarm
Green - less than 61% of load
Amber - 63 to 68% of load`
Red - over 71% of load
Environmental
Noise level LpA (EU Directive 2000/14/EC) 82 dB(A) Noise level LWA (EU Directive 2000/14/EC) 106 dB(A)
Operator position noise level (EU Directive 104 dB(A) Uncertainties YY dB(A)
2006/42/EC)
Whole body vibration (ISO 2631-1) 0,7 m/s² Uncertainties 0,2 m/s²
(limit 0,5 m/s²)
Hand-arm vibration (ISO 5349-1) N/A Uncertainties N/A
(limit 2,5 m/s²)
Temperature Range
Operation and storage - 20°C / + 40°C (-4 /104°F)


(T35100L) TELESCOPIC HANDLER SPECIFICATIONS



(T35100L) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)

Capacity at max. height 3000 kg (6613.9 lb)
Capacity at max. reach 600 kg (1322.8 lb)
Push force (20” standard tires) 5700 daN (12814 lbf)
Push force (20” option tires) 4700 daN (10566 lbf)
Tipping load 750 kg (1653.5 lb)
Lifting height 10090 mm (397.2 in)
Max. reach 6910 mm (272.0 in)
Banking corrector 6° / 2°
Weights


Weight with pallet frame, forks and 3500 kg (7716 lb) load 10910 kg (24052.4 lb)
Front axle weight with pallet frame, forks and 3500 kg 9330 kg (20569.1 lb)
(7716 lb) load
Rear axle weight with pallet frame, forks and 3500 kg 1580 kg (3483.3 lb)
(7716 lb) load
Engine

Fuel Diesel
Cooling Liquid

Controls

heater
brake
Drive System

Traction

Steering

Brakes


Fluid Capacities
Hydraulic System

Electrical

reserve capacity

Instruments
Gauges
Rev counter
Fuel gauge
Sight level gauge
Indicators
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Parking brake
Windscreen wipers

Work lights
Transmission mode
Rear fog lights
Heater fan
Warning lights
Low oil pressure
Environmental
2006/42/EC)
(limit 0,5 m/s²)
(limit 2,5 m/s²)
Temperature Range


(T35100SL) TELESCOPIC HANDLER SPECIFICATIONS

External turning radius (at lifted stabilizers with blocks flipped over) 4340 mm (170.9 in)
Height to steering wheel 1600 mm (63.0 in)
Width with stabilizers down 2475 mm (97.4 in)
Height of lifted stabilizers 1165 mm (45.9 in)
Front wheel lifting when on stabilizers 120 mm (4.7 in)

(T35100SL) TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)

Ground pressure on stabilizers 1700 kPa (246.6 PSI)
Rated capacity 3500 kg (7716.2 lb)
Capacity (at max. height on stabilizers) 3200 kg (7054.8 lb)
Capacity (at max. height on tires) 2500 kg (5511.6 lb)
Capacity (at max. reach on stabilizers) 1200 kg (2645.5 lb)
Capacity (at max. reach on tires) 500 kg (1102.3 lb)
Push force 5700 daN (12814 lbf)
Tipping load 630 kg (1388.9 lb) on tires / 1500 kg (3306.9 lb) on
stabilizers
Lifting height - on stabilizers 11080 mm (436.2 in)
Lifting height - on tires 10770 mm (424.0 in)
Max. reach on tires 7450 mm (293.3 in)
Max. reach on stabilizers 7360 mm (289.8 in)

Weights

Weight with pallet frame, forks and 3500 kg load 11860 kg (26146.8 lb)
Front axle weight with pallet frame, forks and 10605 kg (23380 lb)
3500 kg load
Rear axle weight with pallet frame, forks and 1250 kg (2755.8 lb)
3500 kg load
Engine

Fuel Diesel
Cooling Liquid

Controls

heater
brake
Drive System

Traction

Steering

Brakes


Fluid Capacities
Hydraulic System

Electrical

reserve capacity

Instruments
Gauges
Rev counter
Fuel gauge
Sight level gauge
Indicators
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Parking brake
Windscreen wipers

Work lights
Transmission mode
Rear fog lights
Heater fan
Warning lights
Low oil pressure
Environmental
2006/42/EC)
(limit 0,5 m/s²)
(limit 2,5 m/s²)
Temperature Range


(T35120L) TELESCOPIC HANDLER SPECIFICATIONS

(C) Overall length (without attachment) 5461 mm (215 in)


Ground pressure on tires -
Capacity (at max. height) 2300 kg (5070 lb)
Capacity (at max. reach) 350 kg (771 lb)
Tipping load 500 kg (1102 lb)
Lifting height 11530 mm (454 in)
Max. reach 8190 mm (322 in)
Weights
Weight (unladen) 7770 kg (17130 lb)

Front axle weight unladen 3160 kg (6967 lb)

Rear axle weight unladen 4610 kg (10163 lb)
Weight with pallet frame and forks 8080 kg (17813 lb)
Front axle weight with pallet frame and forks 3660 kg (8069 lb)
Rear axle weight with pallet frame and forks 4420 kg (9744 lb)
Weight with pallet frame, forks and 3500 kg 11580 kg (25530 lb)
(7716 lb) load
3500 kg (7716 lb) load
Rear axle weight with pallet frame, forks and 1270 kg (2800 lb)
3500 kg (7716 lb) load
Engine

Fuel Diesel
Cooling Liquid

Controls

heater
brake
Drive System

Traction
Standard tires TITAN 400/70x20 150B 166A2 LIFT RIGGER II (400 kPa [4 bar] [58 psi]
front / rear)
Optional tires DUNLOP 400/80x24 150B T37 (425 kPa [4,25 bar] [61.6 psi] front / rear)
Optional tires DUNLOP 405/70x20 156B T37 (400 kPa [4 bar] [58 psi] front / rear)
Optional tires DUNLOP 405/70x20 SPT9 (550 kPa [5,5 bar] [80 psi] front / rear)
Optional tires BF GOODRICH 400/70x20
Steering

Brakes


Fluid Capacities
Hydraulic System

Electrical

reserve capacity

Instruments
Gauges
Rev counter
Fuel gauge
Sight level gauge
Indicators
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Parking brake
Windscreen wipers

Work lights
Transmission mode
Rear fog lights
Heater fan
Warning lights
Low oil pressure
Environmental
2006/42/EC)
(limit 0,5 m/s²)
(limit 2,5 m/s²)
Temperature Range


(T35120SL) TELESCOPIC HANDLER SPECIFICATIONS

(C) Overall length (without attachment) 5461 mm (215 in)
Width with stabilizers down 2475 mm (97.4 in)
Height of lifted stabilizers 1165 mm (45.9 in)
Front wheel lifting when on stabilizers 120 mm (4.7 in)
External turning radius (at lifted stabilizers with blocks flipped over) 4360 mm (171.6 in)


Ground pressure on stabilizers 1700 kPa (17 bar) (246.5 psi)
Capacity (at max. height on stabilizers) 3200 kg (7055 lb)
Capacity (at max. height on tires) 2300 kg (5070 lb)
Capacity (at max. reach on stabilizers) 1200 kg (2646 lb)
Capacity (at max. reach on tires) 350 kg (771 lb)
Tipping load 437 kg (963.4 lb) on tires / 1500 kg (3306.9 lb) on
stabilizers
Lifting height - on stabilizers 11850 mm (466.5 in)
Lifting height - on tires 11530 mm (454 in)
Max. reach on tires 8190 mm (322 in)
Max. reach on stabilizers 8120 mm (320 in)

Weights
Weight (unladen) 8240 kg (18166 lb)

Front axle weight unladen 3740 kg (8245 lb)
Rear axle weight unladen 4500 kg (9921 lb)
Weight with pallet frame and forks 8550 kg (18850 lb)
Front axle weight with pallet frame and forks 4240 kg (9348 lb)
Rear axle weight with pallet frame and forks 4310 kg (9502 lb)
Weight with pallet frame, forks and 3500 kg (7716 12050 kg (26566 lb)
lb) load
3500 kg (7716 lb) load
Rear axle weight with pallet frame, forks and 1160 kg (2557 lb)
3500 kg (7716 lb) load
Engine

Fuel Diesel
Cooling Liquid

Controls

heater
brake
Drive System

Traction
Standard tires TITAN 400/70x20 150B 166A2 LIFT RIGGER II (400 kPa [4 bar] [58 psi]
front / rear)
Optional tires DUNLOP 400/80x24 156B T37 (425 kPa [4.25 bar] [61.6 psi] front / rear)
Optional tires DUNLOP 405/70x20 SPT9 (550 kPa [5,5 bar] [80 psi] front / rear)
Steering

Brakes


Fluid Capacities
Hydraulic System

Electrical

reserve capacity

Instruments
Gauges
Rev counter
Fuel gauge
Sight level gauge
Indicators
Headlight full beam
Headlight low beam
Sidelights
Left and right turn
Parking brake
Windscreen wipers

Work lights
Transmission mode
Rear fog lights
Heater fan
Warning lights
Low oil pressure
Environmental
Operator position noise level 104 dB(A) Uncertainties YY dB(A)
(EU Directive 2006/42/EC)
(limit 0,5 m/s²)
(limit 2,5 m/s²)
Temperature Range
Operation and storage - 20°C / + 40°C (-4 / 104°F)


MACHINE TORQUE SPECIFICATIONS
Axle
N•M FT-LB
Axle To Frame Mounting Bolts 370-410 275-300
Brake Housing Hex Bolt 80 59
Brake Housing Spring Bolts 10 7
Brake Housing Stud 120 88
Differential Lock Retainer Bolt 13 10
Fender Mount Bolt 125-140 90-100
Housing Bolt 320 236
Housing Nut 190 140
King Pin Mount Bolts 190 140
Pinion Ring Gear Bolts 13 10
Planetary Cover Bolts 25 18
Planetary Gear Mount Bolts 120 88
Steering Cylinder Bolts 120 88
Tie Rod Jam Nut 250 185
Tie Rod Nut 220 160
Tie Rod Swivel End 406 300

Turn Stop Adjust Jam Nut 150 110
Wheel Nuts 300 221
Boom
N•M ft-lb
Extension Cylinder Base End 180 133
Extension Cylinder Rod End 255-285 188-210
Wear Pads Front 58 43
Wear Pads Rear 39 29
Drive Box
N•M ft-lb
Cover Bolts 60 44
Inner Housing Bolts 120 88
Mounting Flange Bolts 60 44
Drive Motor
N•M ft-lb
End Cap Bolts 115 85
Mounting Bolts 210 155
Mounting Plate Bolts 63 46

MACHINE TORQUE SPECIFICATIONS (CONT’D)
Engine
N•M ft-lb
A/C Compressor Mount Bolts 120 88
Alternator Mount Bolts 54 45
Starter Mount Bolts 54 45
Hydraulic Pump
N•M FT-LB
Filter Head 122 90
Flange Adapter 122 90
Guide Post Bolts 23 17
Mounting Bolts 106 78
Retaining Plate 13 10
Servo End Cap 13 10
Side Cover Bolts 32 24

TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9 - 10 13 - 14
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
0.375 34 - 38 48 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 82 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 125 - 135
(65 - 70) (90 - 100)
0.5625 125 - 135 170 - 190
(90-100) (125 - 140)
0.625 170 - 190 240 - 190

(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
N•m 0.875 450 - 490 645 - 710
(ft-lb) (330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size (Dia. x Material

Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 -12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11-16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 8 - 14 N•m 30 - 41 N•m 49 - 68 N•m
(13 -18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M 14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-40-2
IMPORTANT Nut Nut
When repairing hydrostatic and hydraulic systems, Washer

clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, O-ring
O-ring
damage the system.
I-2003-0888
Figure SPEC-40-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
2].

Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-07575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
40-1].

HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it just makes metal to metal contact,
(CONT'D) you can feel the resistance.
Port Seal Fitting Tighten the nut with a wrench no more than one hex flat
maximum.
Figure SPEC-40-3
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE N•M

Nut Seals THREAD SIZE
WRENCH SIZE (FT-LB)
to Fitting
11/16" 9/16" - 18 30 (22)
15/16" 3/4" - 16 54 (40)

1-1/8" 7/8" - 14 81 (60)
Nut Seals
to Port 1-1/4" 1-1/16" - 12 114 (84)
1-1/2" 1-5/16" - 12 160 (118)
Figure SPEC-40-4
Secondary O-ring Seal
P-13008
2
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-3].
1
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Use the following procedure to tighten the port seal P-13571

fitting:
Port seal and nut, washer and O-ring (O-ring Boss) Do not use port seal fittings when a thread in orifice (Item
fittings use the same tightening torque valve chart. 1) [Figure SPEC-40-4] is used in the port. The orifice
can interfere with the fitting and prevent it from sealing.
If a torque wrench cannot be used, use the following
method. Use an O-ring boss fitting (Item 2) [Figure SPEC-40-4]
as shown.

HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications WARNING
Use Bobcat Axle / Transmission Oil LS (P/N 6987724), During cold weather (0°C [32°F] and below), do not
for the transfer case, planetaries and axle housings. operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
Use Bobcat Superior SH Hydraulic / Hydrostatic Oil (P/N period is necessary for foot pedal operation and safe
6987721). stopping. Do not operate controls during warm-up
period.
DO NOT use automatic transmission fluids in the
machine or permanent damage to the hydraulic/ When temperatures are below -30°C (-20°F), the
hydrostatic system will result. hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
WARNING W-2027-0311

death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do

enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
When temperatures below -18°C (0°F) are common, the

machine must be kept in a warm building. Extra warm-up
time must be used each time the machine is started
during cold temperature conditions. Cold fluid will not flow
easily and it makes action on the hydraulic function
slower. Loss of fluid flow to the hydrostatic pump can
cause damage in less than 60 seconds.


CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion


ALPHABETICAL INDEX
(T35100) TELESCOPIC HANDLER DASH COVER / STEERING COLUMN COVER

SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-1 (S/N A8HD13000 & ABOVE, S/N A8GW13000 &
(T35100L) TELESCOPIC HANDLER ABOVE, S/N A8GT13000 & ABOVE, S/N
SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-10-7 A8GV13000 & ABOVE, S/N A8GJ13000 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . 50-141-1
(T35100SL) TELESCOPIC HANDLER
SPECIFICATIONS . . . . . . . . . . . . . . SPEC-10-13 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 1-13
(T35120L) TELESCOPIC HANDLER DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
SPECIFICATIONS . . . . . . . . . . . . . . SPEC-10-19 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . 40-70-1
(T35120SL) TELESCOPIC HANDLER ELECTRICAL SYSTEM INFORMATION (S/N
SPECIFICATIONS . . . . . . . . . . . . . . SPEC-10-25 A8HD12999 & BELOW, S/N A8GW12999 &
ACCUMULATOR . . . . . . . . . . . . . . . . . . 20-230-1 BELOW, S/N A8GT12999 & BELOW, S/N
A8GV12999 & BELOW, S/N A8GJ12999 &
AIR CLEANER SERVICE . . . . . . . . . . . . 10-60-1 BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . 70-40-1 ELECTRICAL SYSTEM INFORMATION (S/N
AIR CONDITIONING SYSTEM FLOW . . 80-10-1 A8HD13000 & ABOVE, S/N A8GW13000 &
AIR INTAKE COWLING . . . . . . . . . . . . . . 50-70-1 ABOVE, S/N A8GT13000 & ABOVE, S/N
A8GV13000 & ABOVE, S/N A8GJ13000 &
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . 60-30-1 ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11-1
APPROVED BOOM STOP . . . . . . . . . . 10-150-1 EMERGENCY EXIT . . . . . . . . . . . . . . . 10-200-1
ATTACHMENT CARRIER . . . . . . . . . . . 10-130-1

END BOOM . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
AXLE AND DIFFERENTIAL (FRONT) . . 40-20-1 ENGINE AND ENGINE MOUNTS . . . . . . 70-60-1
AXLE AND DIFFERENTIAL (REAR) . . . . 40-21-1 ENGINE COMPONENTS AND TESTING 70-70-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . 40-40-1 ENGINE COOLING SYSTEM . . . . . . . . . 10-70-1
AXLES (FRONT AND REAR) . . . . . . . . 10-110-1 ENGINE COVER . . . . . . . . . . . . . . . . . . 10-160-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 ENGINE COVER . . . . . . . . . . . . . . . . . . . 50-60-1
BOBCAT TELESCOPIC HANDLER ENGINE INFORMATION . . . . . . . . . . . . . 70-10-1
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 1-14
ENGINE LUBRICATION SYSTEM . . . . . 10-90-1
BOOM TRAY . . . . . . . . . . . . . . . . . . . . . 50-160-1
ENGINE SPEED CONTROL . . . . . . . . . . 70-20-1
BRAKE LIGHT SWITCH . . . . . . . . . . . . . 60-90-1
ENGINE TIMING . . . . . . . . . . . . . . . . . . . 70-80-1
BRAKE VALVE . . . . . . . . . . . . . . . . . . . 20-120-1
ENGINE / HYDROSTAT ASSEMBLY . . . 70-90-1
BUCKET POSITIONING CYLINDER . . . 20-30-1
EVAPORATOR / BLOWER UNIT (S/N
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1 A8HD12999 & BELOW, S/N A8GW12999 &
COMPRESSOR . . . . . . . . . . . . . . . . . . . 80-50-1 BELOW, S/N A8GT12999 & BELOW, S/N
CONDENSER (S/N A8HD12999 & BELOW, A8GV12999 & BELOW, S/N A8GJ12999 &
A8GW12999 & BELOW, A8GT12999 & BELOW, BELOW) . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
A8GV12999 & BELOW, A8GJ12999 & BELOW) EVAPORATOR / BLOWER UNIT (S/N
80-60-1 A8HD13000 & ABOVE, A8GW13000 & ABOVE,
CONDENSER (S/N A8HD13000 & ABOVE, A8GT13000 & ABOVE, A8GV13000 & ABOVE,
A8GW13000 & ABOVE, A8GT13000 & ABOVE, A8GJ13000 & ABOVE) . . . . . . . . . . . . . . 80-91-1
A8GV13000 & ABOVE, A8GJ13000 & ABOVE) . EXPANSION VALVE (S/N A8HD12999 & BELOW,
80-61-1 A8GW12999 & BELOW, A8GT12999 & BELOW,
CONVERSIONS . . . . . . . . . . . . . . . . SPEC-60-1 A8GV12999 & BELOW, A8GJ12999 & BELOW)
80-100-1
DASH COVER / STEERING COLUMN COVER
(S/N A8HD12999 & BELOW, S/N A8GW12999 & EXPANSION VALVE (S/N A8HD13000 & ABOVE,
BELOW, S/N A8GT12999 & BELOW, S/ A8GW13000 & ABOVE, A8GT13000 & ABOVE,
NA8GV12999 & BELOW, S/N A8GJ12999 & A8GV13000 & ABOVE, A8GJ13000 & ABOVE) .
BELOW) . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1 80-101-1
EXTENSION CYLINDER . . . . . . . . . . . . 20-40-1
1031 of 1040 INDEX-01 T35100(S)(L), T35120(S)L Service Manual

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . 20-140-1 LONGITUDINAL STABILITY INDICATOR
FENDER . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 CALIBRATION (S/N A8HD11001-14999, S/N
A8GW11001-14999, S/N A8GT11001-14999, S/N
FIRE PREVENTION . . . . . . . . . . . . . . . . . . 1-10 A8GV11001-14999, S/N A8GJ11001-14999) .60-
FIXED BOOM . . . . . . . . . . . . . . . . . . . . . 50-30-1 150-1
FLOW CONTROL VALVE . . . . . . . . . . . 20-190-1 LUBRICATING THE TELESCOPIC HANDLER . .
FLYWHEEL AND HOUSING . . . . . . . . . 70-100-1 10-120-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 MACHINE TORQUE SPECIFICATIONS . .SPEC-
20-1
FRAME LEVEL SPEED SWITCH . . . . . 60-140-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . 20-80-1
FRAME LEVELING CYLINDER . . . . . . . 20-100-1
MAINTENANCE SAFETY . . . . . . . . . . . . . . . .1-1
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . 40-30-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10-80-1
OIL COOLER / RADIATOR . . . . . . . . . . . 70-50-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . 30-20-1
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . 20-130-1
OPERATOR CAB (ROPS / FOPS) . . . . . 10-20-1
HEATER ASSEMBLY . . . . . . . . . . . . . . . 80-110-1
OPERATOR CAB (S/N A8HD12999 & BELOW, S/
HYDRAULIC / HYDROSTATIC FLUID N A8GW12999 & BELOW, S/N A8GT12999 &
SPECIFICATIONS . . . . . . . . . . . . . . . SPEC-50-1 BELOW, S/N A8GV12999 & BELOW, S/N
HYDRAULIC / HYDROSTATIC SYSTEM . 10-100- A8GJ12999 & BELOW) . . . . . . . . . . . . . . 50-10-1
1 OPERATOR CAB (S/N A8HD13000 & ABOVE, S/
HYDRAULIC CONNECTION SPECIFICATIONS . N A8GW13000 & ABOVE, S/N A8GT13000 &

SPEC-40-1 ABOVE, S/N A8GV13000 & ABOVE, S/N
HYDRAULIC CONTROL VALVE . . . . . . 20-170-1 A8GJ13000 & ABOVE) . . . . . . . . . . . . . . 50-11-1
HYDRAULIC FLUID RESERVOIR . . . . . 20-150-1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . 50-20-1
HYDRAULIC SYSTEM INFORMATION . . 20-10-1 PARKING BRAKE . . . . . . . . . . . . . . . . . 20-210-1
HYDROSTATIC DRIVE MOTOR . . . . . . . 30-30-1 PARKING BRAKE . . . . . . . . . . . . . . . . . . 40-50-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . 30-40-1 PEDAL ASSEMBLY . . . . . . . . . . . . . . . . 60-110-1
HYDROSTATIC SYSTEM INFORMATION . 30-10- PIVOT LINK . . . . . . . . . . . . . . . . . . . . . . 50-120-1
1 PORT RELIEF VALVES . . . . . . . . . . . . . 20-180-1
INCHING SWITCH . . . . . . . . . . . . . . . . . 60-120-1 PRESSURE REDUCING VALVE . . . . . . 20-220-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . 60-70-1 PRESSURE SWITCH . . . . . . . . . . . . . . . 80-80-1
INTERMEDIATE BOOM . . . . . . . . . . . . . 50-150-1 QUICK-TACH CYLINDER . . . . . . . . . . . . 20-90-1
JOYSTICK PANEL (S/N A8HD12999 & BELOW, QUICK-TACH . . . . . . . . . . . . . . . . . . . . . . 50-90-1
S/N A8GW12999 & BELOW, S/N A8GT12999 & REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
BELOW, S/N A8GV12999 & BELOW, S/N
A8GJ12999 & BELOW) . . . . . . . . . . . . . 50-130-1 REAR WEIGHTS . . . . . . . . . . . . . . . . . . 50-100-1
JOYSTICK PANEL (S/N A8HD13000 & ABOVE, RECEIVER / DRIER . . . . . . . . . . . . . . . . 80-70-1
S/N A8GW13000 & ABOVE, S/N A8GT13000 & RECONDITIONING THE ENGINE . . . . 70-110-1
ABOVE, S/N A8GV13000 & ABOVE, S/N REGULAR MAINTENANCE . . . . . . . . . . 80-20-1
A8GJ13000 & ABOVE) . . . . . . . . . . . . . 50-131-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . .1-9
JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
SERIAL NUMBER LOCATION . . . . . . . . . . .1-12
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . 20-20-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . 40-80-1
LIFTING AND BLOCKING THE TELESCOPIC
HANDLER . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 SERVICE MANUAL REVISION . . . . . . . . .SMR-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 SERVICE MANUAL REVISION . . . . . . . . .SMR-1
LLMI / LLMC SYSTEM (S/N A8HD15000 & SERVICE SCHEDULE . . . . . . . . . . . . . . . 10-50-1
ABOVE, S/N A8GW15000 & ABOVE, S/N SERVICE SOFTWARE . . . . . . . . . . . . . 60-130-1
A8GT15000 & ABOVE, S/N A8GV15000 & STABILIZER CONTROL VALVE (IF EQUIPPED)
ABOVE, S/N A8GJ15000 & ABOVE) . . . 60-160-1 20-260-1
1032 of 1040 INDEX-02

STABILIZER CYLINDER (IF EQUIPPED) 20-250- WIPER MOTOR (TOP) . . . . . . . . . . . . . 60-101-1
1
STABILIZER FRAME (IF EQUIPPED) . . 50-170-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STEERING ANGLE ADJUSTMENT . . . . 40-60-1
STEERING CYLINDER (FRONT) . . . . . . 20-60-1
STEERING CYLINDER (REAR) . . . . . . . 20-61-1
STEERING MODE VALVE BLOCK . . . . 20-110-1
STEERING VALVE . . . . . . . . . . . . . . . . 20-160-1
STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER . . . . . . . . . . . 10-190-1
SWITCH PANEL (S/N A8HD12999 & BELOW, S/
N A8GW12999 & BELOW, S/N A8GT12999 &
BELOW, S/N A8GV12999 & BELOW, S/N
A8GJ12999 & BELOW) . . . . . . . . . . . . . . 60-80-1
SWITCH PANEL (S/N A8HD13000 - 14999, S/N
A8GW13000 - 14999, S/N A8GT13000 - 14999,
S/N A8GV13000 - 14999, S/N A8GJ13000 -
14999) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1
SWITCH PANEL (S/N A8HD15000 & ABOVE, S/N

A8GW15000 & ABOVE, S/N A8GT15000 &
ABOVE, S/N A8GV15000 & ABOVE, S/N
A8GJ15000 & ABOVE) . . . . . . . . . . . . . . 60-82-1
SYSTEM CHARGING AND RECLAMATION . 80-
40-1
TELESCOPIC HANDLER STORAGE AND
RETURN TO SERVICE . . . . . . . . . . . . . 10-180-1
TILT CYLINDER . . . . . . . . . . . . . . . . . . . 20-50-1
TIRE MAINTENANCE . . . . . . . . . . . . . . 10-140-1
TORQUE SPECIFICATIONS FOR BOLTS SPEC-
30-1
TOW VALVE . . . . . . . . . . . . . . . . . . . . . 20-240-1
TOWING THE TELESCOPIC HANDLER 10-40-1
TRANSPORTING THE TELESCOPIC HANDLER
ON A TRAILER . . . . . . . . . . . . . . . . . . . . 10-30-1
TRAVEL / SIGNAL LEVER (S/N A8HD12999 &
BELOW, S/N A8GW12999 & BELOW, S/N
A8GT12999 & BELOW, S/N A8GV12999 &
BELOW, S/N A8GJ12999 & BELOW) . . . 60-60-1
TRAVEL / SIGNAL LEVER (S/N A8HD13000 &
ABOVE, S/N A8GW13000 & ABOVE, S/N
A8GT13000 & ABOVE, S/N A8GV13000 &
ABOVE, S/N A8GJ13000 & ABOVE) . . . 60-61-1
TROUBLESHOOTING . . . . . . . . . . . . . . 40-10-1
TROUBLESHOOTING . . . . . . . . . . . . . . 80-30-1
WEAR PADS (FRONT) . . . . . . . . . . . . . . 50-50-1
WEAR PADS (REAR) . . . . . . . . . . . . . . . 50-51-1
WIPER MOTOR (FRONT) . . . . . . . . . . . 60-100-1
WIPER MOTOR (REAR) . . . . . . . . . . . . 60-102-1
1033 of 1040 INDEX-03 T35100(S)(L), T35120(S)L Service Manual

1034 of 1040
INDEX-04
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: T35100(S)(L), T35120(S)L - 2

Date: 01 March 2011
Product: Telescopic Handler
Model: T35100(S)(L), T35120(S)L
Manual No: 6986766 (03-11)

The following Sections are a revision to the above Service Manual.
60-81
60-82
60-170
60-180
1035 of 1040 SMR-1

1036 of 1040
SMR-2
ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 27 May 2011
Model: T35100(S)(L), T35120(S)L
Manual No: 6986766 (06-11)

completely revised
1037 of 1040 SMR-1

1038 of 1040
SMR-2
ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 26 July 2012
Model: T35100(S)(L), T35120(S)L
Manual No: 6986766 (07-12)

10-60
60-160
hydraulic schematic
electrical schematic
1039 of 1040 SMR-1

1040 of 1040
SMR-2

T35100 - T35120 6986766 enUS SM 08-12

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T35100 - T35120 6986766 enUS SM 08-12

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Service Manual

T35100, T35100S, T35100L,

Dealer Copy -- Not for Resale

6986766-EN (11-07) Revised (08-12) Printed in Belgium © Bobcat Company 2012

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-16081 B-16078 B-6589

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 1040 1-3 T35100(S)(L), T35120(S)L Service Manual

6 of 1040 1-4 T35100(S)(L), T35120(S)L Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Dealer Copy -- Not for Resale

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

7 of 1040 1-5 T35100(S)(L), T35120(S)L Service Manual

8 of 1040 1-6 T35100(S)(L), T35120(S)L Service Manual

2. Check that ROPS mounting 10. Attachment locking pins must

3. The seat belt must be 11. Safety treads must be in good

Dealer Copy -- Not for Resale

5. Machine signs must be 13. Check hydraulic fluid level,

7. Check for correct function of 15. Lubricate the Telescopic SPECIFICATIONS

8. The parking brake must 16. Check the condition of the

9 of 1040 1-7 T35100(S)(L), T35120(S)L Service Manual

19. Inspect for loose or broken 22. Recommend to the owner

Dealer Copy -- Not for Resale

10 of 1040 1-8 T35100(S)(L), T35120(S)L Service Manual

Dealer Copy -- Not for Resale

• The Telescopic Handler Operator Training Course is

DANGER available through your local dealer or at

The dealer and owner / operator review the

WARNING recommended uses of the product when delivered. If the

11 of 1040 1-9 T35100(S)(L), T35120(S)L Service Manual

The machine and some attachments have components

Flammable debris (leaves, straw, etc.) must be removed

The operator’s area, engine compartment and engine

Dealer Copy -- Not for Resale

All fuels, most lubricants and some coolants mixtures are

Do not use the machine where exhaust, arcs, sparks or

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

12 of 1040 1-10 T35100(S)(L), T35120(S)L Service Manual

Hydraulic System Always clean the machine and attachment, disconnect

Stop the engine and let it cool before adding fuel. No

Dealer Copy -- Not for Resale

Do not use ether or starting fluids on any engine that has

Spark Arrestor Exhaust System

The spark arrestor exhaust system is designed to control

Check the spark arrestor exhaust system regularly to

13 of 1040 1-11 T35100(S)(L), T35120(S)L Service Manual

Always use the serial number of the telescopic handler Figure 2

Telescopic Handler Serial Number

Dealer Copy -- Not for Resale