Service Manual S100 Skid-Steer Loader: S/N A8ET20001 & Above

Service Manual
S100 Skid-Steer Loader
S/N A8ET20001 & Above
Dealer Copy -- Not for Resale
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6987403-EN (10-12) Printed in U.S.A. © Bobcat Company 2012
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-15590 B-15591

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

B-15592 B-15593 B-15599
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0409
3 of 692 1-1 S100 Service Manual


CONTENTS
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

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

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16


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

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

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

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

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

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

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

the work lights.
FW SSL-1008 SM
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17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire

approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
FW SSL-1008 SM
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1-9
FW SSL-1008 SM
SAFETY INSTRUCTIONS The dealer and owner / operator review the
recommended uses of the product when delivered. If the
Before Operation owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
Carefully follow the operating and maintenance recommendations on the new use.
instructions in this manual.
The Bobcat loader is highly maneuverable and compact.

It is rugged and useful under a wide variety of conditions.
This presents an operator with hazards associated with
off motorway, rough terrain applications, common with
Bobcat loader usage.
The Bobcat loader has an internal combustion engine

with resultant heat and exhaust. All exhaust gases can
kill or cause illness so use the Loader with adequate
ventilation.
The dealer explains the capabilities and restrictions of

the Bobcat loader and attachment for each application.
The dealer demonstrates the safe operation according to
Bobcat instructional materials, which are also available to
operators. The dealer can also identify unsafe
modifications or use of unapproved attachments. The

attachments and buckets are designed for a Rated
Operating Capacity (some have restricted lift heights).
They are designed for secure fastening to the Bobcat
loader. The user must check with the dealer, or Bobcat
literature, to determine safe loads of materials of
specified densities for the machine - attachment
combination.
The following publications and training materials provide

information on the safe use and maintenance of the
Bobcat machine and attachments:
• The Delivery Report is used to assure that complete

instructions have been given to the new owner and
that the machine and attachment is in safe operating
condition.
• The Operation & Maintenance Manual delivered with

the machine or attachment gives operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation

and care of your Bobcat machine or attachment. The
signs and their locations are shown in the Operation
& Maintenance Manual. Replacement signs are
available from your Bobcat dealer.
• An Operator’s Handbook is fastened to the operator

cab of the loader. Its brief instructions are convenient
to the operator. See your Bobcat dealer for more
information on translated versions. SI SSL EMEA-0213
12 of 692 1-10
SAFETY INSTRUCTIONS (CONT’D) Safe Operation Needs A Qualified Operator
For an operator to be qualified, he or she must not use
Safe Operation Is The Operator’s Responsibility
drugs or alcoholic drinks which impair alertness or co-
ordination while working. An operator who is taking
Safety Alert Symbol prescription drugs must get medical advice to determine
if he or she can safely operate a machine.
This symbol with a warning statement means: A Qualified Operator Must Do The Following:
“Warning, be alert! Your safety is involved!”
Carefully read the message that follows. Understand the Written Instructions, Rules and
Regulations
• The written instructions from Bobcat Company
include the Delivery Report, Operation &
Maintenance Manual, Operator’s Handbook, Safety
WARNING Manual and machine signs (decals).
• Check the rules and regulations at your location. The
rules may include an employer’s work safety
Operator must have instructions before operating the
requirements. For driving on public roads, the
machine. Untrained operators can cause injury or machine must be equipped as stipulated by the local
death. regulations authorising operation on public roads in
W-2001-0502 your specific country. Regulations may identify a
hazard such as a utility line.
Have Training with Actual Operation
• Operator training must consist of a demonstration and
IMPORTANT

verbal instruction. This training is given by your
Bobcat dealer before the product is delivered.
This notice identifies procedures which must be • The new operator must start in an area without
followed to avoid damage to the machine. bystanders and use all the controls until he or she can
I-2019-0284 operate the machine and attachment safely under all
conditions of the work area. Always fasten seat belt
before operating.
Know the Work Conditions
• Know the weight of the materials being handled.
DANGER Avoid exceeding the Rated Operating Capacity
(ROC) of the machine. Material which is very dense
will be heavier than the same volume of less dense
The signal word DANGER on the machine and in the material. Reduce the size of the load if handling
manuals indicates a hazardous situation which, if not dense material.
avoided, will result in death or serious injury. • The operator must know any prohibited uses or work
D-1002-1107 areas, for example, he or she needs to know about
excessive slopes.
• Know the location of any underground lines.
• Wear tight fitting clothing. Always wear safety glasses
WARNING when doing maintenance or service. Safety glasses,
respiratory equipment, hearing protection or Special
Applications Kits are required for some work. See
The signal word WARNING on the machine and in the
your Bobcat dealer about Bobcat Safety Equipment
manuals indicates a potentially hazardous situation
for your model.
which, if not avoided, could result in death or serious
injury.
W-2044-1107
The Bobcat loader and attachment must be in good

operating condition before use.
Check all of the items on the Bobcat Service Schedule
Decal under the 8-10 hour column or as shown in the
Operation & Maintenance Manual. SI SSL EMEA-0213
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SAFETY INSTRUCTIONS (CONT’D) FIRE PREVENTION
Avoid Silica Dust
Maintenance
The machine and some attachments have components

that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Cutting or drilling concrete containing sand or rock the engine and exhaust system. The electrical system, if
containing quartz may result in exposure to silica dust. damaged or incorrectly maintained, can be a source of
Use a respirator, water spray or other means to control arcs or sparks.
dust.
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 SSL EMEA-0213
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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 petrol or diesel fuel Toxic dust or gas can be produced.
for cleaning parts. Use commercial non-flammable
solvents. Dust generated from repairing non-metallic 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 or air intake heater. These starting aids can Know where fire extinguishers and first aid kits are
cause explosion and 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 Arrester Exhaust System
The spark arrester 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 arrester exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrester muffler (if equipped).
Sl SSL EMEA-0213
15 of 692 1-13
SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) can use different parts, or it can be necessary to
use a different procedure in doing a specific service
operation.
Figure 1
EM1492
1
The engine serial number is located on top of the engine

(Item 1) [Figure 2].
S4464

Loader Serial Number
The loader serial number plate (Item 1) [Figure 1] is

located inside the cab on the right-hand side.
Explanation of loader Serial Number:

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

Combination
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.
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DELIVERY REPORT
Figure 3
B-16315
The delivery report [Figure 3] must be completed by the

dealer and signed by the owner or operator when the
Bobcat Loader is delivered. An explanation of the form
must be given to the owner.
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LOADER IDENTIFICATION
FRONT LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
FRONT AUXILIARY
TILT QUICK COUPLERS
CYLINDER
STEPS

[3] BUCKET S0183
BUCKET STEP
[2] OPERATOR CAB
(ROPS / FOPS) LIFT ARM
SUPPORT
DEVICE
LIFT ARM
REAR
GRILLE
LIFT
BACK-UP CYLINDER
ALARM
(OPTION)
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
S0184
[1] TIRES
[1] TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
[2] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.
Level II is available.
[3] BUCKET - Several different Buckets and other Attachments are available.
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SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

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

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

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

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

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

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
REMOTE START TOOL (SERVICE TOOL) KIT -7217666 . . . . . . . . . . . . . . . . . . . . . . . 10-61-1

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

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

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

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

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

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-3
Removing And Replacing Case Drain Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

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

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

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

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1



LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
S6030
Put the floor jack under the rear of the loader.

B-7023A
Lift the rear of the loader and install jack stands [Figure
10-10-2].
Figure 10-10-3

WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
S6031
Always park the loader on a level surface.

Put the floor jack under the front of the loader [Figure 10-
10-3].
WARNING Lift the front of the loader and put jack stands under the
axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners NOTE: Make sure the jack stands do not touch the
of the frame before running the engine for service. tires. Make sure tires clear floor or any
Failure to use jackstands can allow the machine to obstacles.
fall or move and cause injury or death.
W-2017-0286
23 of 692 10-10-1
24 of 692
10-10-2
LIFT ARM SUPPORT DEVICE
Installing
WARNING
Maintenance and service work can be done with the lift
arms lowered. If the lift arms are raised, use the following
Before the cab or the lift arms are raised for service,
procedures to engage and disengage an approved lift
jackstands must be put under the rear corners of the
arm support device.
frame. Failure to use jackstands can allow the
machine to tip backward causing injury or death.
W-2014-0895
WARNING Figure 10-20-1
Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.

W-2572-0407 1
1
P43747
DANGER Install jackstands (Item 1) [Figure 10-20-1] under the

rear corners of the loader frame.
Figure 10-20-2
P-90328
3
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure 2
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm 1
support. Replace if damaged.
D-1009-0409
P-54468A
Remove attachment from the loader.

Disconnect the spring (Item 1) from the lift arm support
device retaining pin Support the lift arm support device
(Item 2) with your hand and remove the retaining pin
(Item 3) [Figure 10-20-2].
25 of 692 10-20-1 S100 Service Manual

LIFT ARM SUPPORT DEVICE (CONT’D) Removing
Installing (Cont’d) Remove the retaining pin (Item 1) [Figure 10-20-4] from
the lift arm support device.
Figure 10-20-3
Figure 10-20-5
P54469
P54472
Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure Connect the spring (Item 1) [Figure 10-20-5] from the lift
10-20-3] to the lift arm support device so the spring does arm support device to the bracket below the lift arms.
not interfere with the support device engagement.

Sit in the operator’s seat, fasten the seat belt and lower
Sit in the operator seat, fasten the seat belt and lower the the seat bar. Start the engine.
seat bar. Start the engine.
Figure 10-20-6
Figure 10-20-4
1 2
P-54468A
P-54470A N-20524B
Raise the lift arms a small amount. The spring will lift the
Raise the lift arms until the lift arm support device drops support device off the lift cylinder rod. Lower the lift arms.
onto the lift cylinder rod (Item 1) [Figure 10-20-4]. Stop the engine.
Lower the lift arms slowly until the support device is held Raise the seat bar, unbuckle the seat belt, move the
between the lift arm and the lift cylinder. Stop the engine. pedals until both lock and exit the cab.
Raise the seat bar, disconnect the seat belt and move the Disconnect the spring from the bracket.
pedals until both lock.
Raise the support device into storage position and insert
Install the retaining pin (Item 2) [Figure 10-20-4] into the the retaining pin (Item 1) [Figure 10-20-6] through the lift
rear of the lift arm support device below the cylinder rod. arm support device and through the bracket. Connect the
spring to the retaining pin.
Remove the jackstands.

OPERATOR CAB Raising
Description Always stop the engine before raising or lowering the

The Bobcat loader has an operator cab (ROPS and cab.
FOPS) as standard equipment to protect the operator
from rollover and falling objects. The seat belt must be Stop the loader on a level surface and lower the lift arms.
worn for rollover protection. If the lift arms must be up while raising the operator cab,
install the lift arm support device. (See LIFT ARM
Check the cab, mounting, and hardware for damage. SUPPORT DEVICE on Page 10-20-1.)
Never modify the cab. Replace the cab and hardware if
damaged. See your Bobcat dealer for parts.
ROPS - Roll-Over Protective Structure per ISO 3471 and

FOPS - Falling-Object Protective Structure per ISO 3449, WARNING
Level I. Level II is available.
Before the cab or the lift arms are raised for service,
Level I - Protection from falling bricks, small concrete
jackstands must be put under the rear corners of the
blocks, and hand tools encountered in operations such
frame. Failure to use jackstands can allow the
as motorway maintenance, landscaping, and other
machine to tip backward causing injury or death.
construction sites.
W-2014-0895
Level II - Protection from falling trees, rocks: for machines

involved in site clearing, overhead demolition or forestry. Figure 10-30-1

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
1
1
P43747
DANGER
Install jackstands (Item 1) [Figure 10-30-1] under the
rear corners of the loader frame.
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure
unless supported by an approved lift arm
D-1009-0409
27 of 692 10-30-1
OPERATOR CAB (CONT’D) Lowering
Raising (Cont’d) Always stop the engine before raising or lowering the
cab.
Figure 10-30-2
NOTE: Always use the grab handles to lower the cab.
NOTE: Move the engine speed control lever forward

before lowering the operator cab to prevent
2 damage to lever or cab.
1
Figure 10-30-4
1
S4011 S4012
Remove the nut and plate (Items 1 and 2) [Figure 10-30-

2] on the inside front corner of the cab (Both sides).
NOTE: Move the engine speed control lever forward

before raising the operator cab to prevent

damage to lever or cab.
Figure 10-30-3 N20120 S4013
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
NOTE: The weight of the cab increases when

equipped with options and accessories such
as cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised
slightly from the latch to be able to release the
latch.
WARNING
S4078
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
Lift on the grab handle and bottom of the operator cab when the cab is past the latch stop.
slowly until the cab is all the way up and the latching W-2469-0803
mechanism engages [Figure 10-30-3].
Support the cab and release the latching mechanism
(Inset) [Figure 10-30-4]. Remove your hand from the
latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way.
28 of 692 10-30-2
OPERATOR CAB (CONT’D) Figure 10-30-7
Lowering (Cont’d)
Figure 10-30-5
1
2
1
P-76459B
2
1 The LIFT & TILT VALVE light (Item 1) [Figure 10-30-7]

will be OFF when the door is closed, the key switch is
S4012 S4011
turned to RUN or the RUN / ENTER button is pressed,
SXXXX SXXXX
the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.
Install the plates and nuts (Items 1 and 2) [Figure 10-30-
5] (both sides). Figure 10-30-8
Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.

Cab Door Sensor
This machine can be equipped with a Cab Door Sensor.
Figure 10-30-6
P-76461Q
The LIFT & TILT VALVE light (Item 1) [Figure 10-30-7]

will be ON when the door is open, the key switch is
turned to RUN or the RUN / ENTER button is pressed,
the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.
1 [DOOR] will appear in the data display [Figure 10-30-8].
P-68116B
The cab door (option) has a sensor (Item 1) [Figure 10-

30-6] installed which deactivates the lift and tilt valves
when the door is open.
29 of 692 10-30-3
OPERATOR CAB (CONT’D)
Special Applications Kit
WARNING
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508
Figure 10-30-9

B-25286A
Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.5 in) poly
carbonate front door, top and rear windows.
See your Bobcat dealer for availability.
Special Applications Kit Inspection And Maintenance
• Inspect for cracks or damage. Replace if required.
• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm

water.
• Use a sponge or soft cloth. Rinse well with water and

dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.
30 of 692 10-30-4
TRANSPORTING THE LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2

Rear Tie-Down Front Tie-Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can S4759 S4758
break and cause personal injury.

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

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

S2865
Alternate Front Tie-Down Alternate Front Tie-Down

(Earlier Models) (Later Models)
S1077
A loader with an empty bucket or no attachment must be S1848 S36104

loaded backward onto the transport vehicle [Figure 10-
40-1].
Use the following procedure to fasten the Bobcat loader
The rear of the trailer must be blocked or supported to the transport vehicle to prevent the loader from moving
[Figure 10-40-1] when loading or unloading the loader to during sudden stops or when going up or down slopes
prevent the front end of the trailer from raising up. [Figure 10-40-2].
1. Lower the bucket or attachment to the floor.
2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie down

positions.
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.
31 of 692 10-40-1
32 of 692
10-40-2
TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

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

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The wheels will not turn.) There might be slight wear
to the wheels when the loader is skidded.
The towing chain (or cable) must be rated at 1.5 times

the weight of the loader. (See Performance on Page
SPEC-10-2.)
33 of 692 10-50-1
34 of 692
10-50-2
REMOTE START TOOL KIT-MEL1563 Figure 10-60-2
Tools that will be needed to complete the following steps

are:
MEL1563 - Remote Start Tool

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

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

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

the Pressure Release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.
35 of 692 10-60-1
REMOTE START TOOL KIT-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565
Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5
Figure 10-60-3
2
1 1
P16114
P16116
The service tool harness control (Item 1) is used to
connect the remote start tool (Item 2) [Figure 10-60-5] to
Figure 10-60-4 the electrical system on the loader.

1 Figure 10-60-6
P16120
EM1477
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the cap (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
The panel must be removed from inside the operator cab

and plugged into this connector [Figure 10-60-4].
36 of 692 10-60-2
REMOTE START TOOL KIT-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566
Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-60-8
Figure 10-60-7 2
1
1
P16119
EM1478
The service tool harness communicator (Item 1) is
required to connect remote start tool to the Service PC
Loaders equipped with an attachment harness (Item 1) (Item 2) [Figure 10-60-8].
must disconnect the attachment harness from the loader

harness (Item 2) [Figure 10-60-7].
Connect the service tool harness to the ACD connector

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

the Service PC must be connected to the
Remote Start Tool switch.
37 of 692 10-60-3
REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-10
Remote Start Procedure
The tool listed will be needed to do the following 1

procedure:
MEL1563: Remote Start Tool Kit
Figure 10-60-9
1
EM1477
Figure 10-60-11

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

required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader. EM1478
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. Remove the cap (Item 1) [Figure 10-60-10] or
disconnect the attachment control harness (Item 1)
Raise the operator cab (if required by the procedure). [Figure 10-60-11] if connected.
Open the rear door of the loader.
38 of 692 10-60-4
REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-13
Remote Start Procedure (Cont'd)
Figure 10-60-12
P16116
The remote start tool (Item 1) [Figure 10-60-13] has

EM1479 three rocker switches.
Figure 10-60-14
Connect the remote start tool to the loader harness
connector [Figure 10-60-12].

NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.
2
1
WARNING 3
UNAUTHORIZED AND UNEXPECTED ENGINE

START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF P16118
position, the engine can be started from the operator
panel inside the cab.
• Place the key switch of the Remote Start Tool in The Traction Lock switch (Item 1) [Figure 10-60-14] is
the RUN position to disconnect the operator used to turn traction lock on or off. Push the switch to the
panel from the start circuit. override position. The switch will illuminate to indicate
• Remove the operator panel key (key switch), lock traction lock OVERRIDE, in this position the wheels are
the keypad with a unique password (keyless) or able to turn.
otherwise disable the starter before working in
the engine area. The Maximum Flow / Variable Flow switch (Item 2)
W-2457-1110 [Figure 10-60-14] is used to activate the auxiliary
hydraulics. Pressing the switch once will activate variable
flow. Pressing the switch again will activate maximum
flow. The switch will illuminate to indicate which flow rate
is active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-

14] is used to release hydraulic pressure to the front and/
or rear auxiliary couplers. To release pressure; push and
hold the switch for 3 seconds.
39 of 692 10-60-5
REMOTE START TOOL KIT-MEL1563 (CONT'D)

engine to stop in 3 seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
WARNING
• Use traction lock override switch for service work
with seat bar raised.
• Traction lock is engaged when light is OFF.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

engine to stop in 3 seconds. To relieve the
pressure at the rear or right hand auxiliary (if
equipped), continue to hold the switch for 3
seconds after the engine has stopped.
Figure 10-60-15
P-34661
Push the couplers on the front auxiliary block toward the

block and hold for 5 seconds to release the front auxiliary
pressure [Figure 10-60-15].
40 of 692 10-60-6
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL 1563 Remote Start Tool and
MEL 1400B - BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7217666,

can be used to service older loaders with the BOSS®
system using the supplied BOSS® Service Tool Harness
P/N 6689745.
The Remote Start Tool (Service Tool) Kit, P/N 7217666,

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

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.
41 of 692 10-61-1
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7217666 (CONT'D)
2
Remote Start Tool (Service Tool) - 7022042
Tools that will be needed to complete the following steps

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

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

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

The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader ignition power. The button will illuminate to
indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.
P-76678 The Traction Lock button (Item 5) [Figure 10-61-2] is

used to turn traction lock ON or OFF. Push the button and
the button will illuminate indicating the traction lock is
The remote start tool (Item 1) [Figure 10-61-1] is disabled in which the wheels or tracks are able to turn.
required when the service technician is inspecting the
hydraulic / hydrostatic system or adjusting the steering The Auxiliary button (Item 6) [Figure 10-61-2] is used to
linkage. activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.
42 of 692 10-61-2
7217666 (CONT'D)
Loader Service Tool Harness - 6689747
Figure 10-61-3
1
1 2
EM1478
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].
The loader service tool harness (Item 1) is used to When the remote start procedure is completed, replace

connect the remote start tool (service tool) (Item 2) the loader connector cap (Item 1) [Figure 10-61-4] or
[Figure 10-61-3] to the electrical system on the loader. connect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4
EM1477
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-4] and
connect the Loader Service Tool Harness, from the
Remote Start Tool (Service Tool), to the loader harness
connector.
43 of 692 10-61-3
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666(CONT'D)
Loader Service Tool Harness - 6689747 (Cont’d) WARNING

Figure 10-61-6
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
2
3 start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409
Computer Service Tool Harness - 6689746

1
Figure 10-61-7
EM1479
NOTE: The Remote Start Tool (Service Tool) 1

connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent 2
damage or corrosion when not in use. This P-76450
connector is not used on the S100 model.
Connect the Remote Start Tool (Service Tool) connector The computer service tool harness (Item 1) is required to
(Item 1) to the loader harness connector (Item 2) and the connect remote start tool (service tool) to the Service PC
other Remote Start Tool (Service Tool) connector to the (Item 2) [Figure 10-61-7].
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The right instrument panel (Standard Key

Panel or Deluxe Instrumentation Panel) must
be in the off position or the Remote Start Tool
(Service Tool) will not operate.
44 of 692 10-61-4
REMOTE START TOOL (SERVICE TOOL) KIT - Raise the operator cab (if required by the procedure).
7217666 (CONT'D)
Remote Start Procedure
Figure 10-61-9
WARNING 1
UNAUTHORIZED AND UNEXPECTED ENGINE

START-UP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool RUN button not illuminated,
the engine can be started from the operator panel
inside the cab.
• Press the RUN button of the Remote Start Tool to
disconnect the operator panel from the start
circuit.
• Remove the operator panel key (key switch), lock EM1477
the keypad with a unique password (keyless) or
otherwise disable the starter before working in
the engine area. Loaders without an attachment control harness, remove
W-2661-1110 the loader harness cap (Item 1) [Figure 10-61-9] and

connect the Loader Service Tool Harness, from the
Remote Start Tool (Service Tool), to the loader harness
The tool listed will be needed to do the following
connector.
procedure:
Figure 10-61-10
7217666: Remote Start Tool (Service Tool) Kit
Figure 10-61-8
EM1478
P-76450 Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
The Remote Start Tool (Service Tool) (Item 1) [Figure disconnected from the loader harness (Item 2) [Figure
10-61-8] is required when the operator cab is in the 10-61-10].
raised position for service and the service technician
needs to turn on the loader or start the engine. Example: When the remote start procedure is completed, replace
adjusting the steering linkage. the loader connector cap (Item 1) [Figure 10-61-10] or
the attachment control harness to the loader harness
Lift and block the loader. [Figure 10-61-10].
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
45 of 692 10-61-5
7217666 (CONT'D)
Remote Start Procedure (Cont'd) 2
Figure 10-61-11
5 3
6 4
1
3
1 P-76439
The Remote Start Tool (Service Tool) (Item 1) [Figure

10-61-12] has five buttons.
EM1479
The STOP button (Item 2) [Figure 10-61-12] is used to

NOTE: The Remote Start Tool (Service Tool) stop the Remote Start Tool (Service Tool) from
connection harness has two connectors (Item communicating and stop the loader engine.

1) and (Item 3). The main connector (Item 1)
[Figure 10-61-11] is always used for The RUN button (Item 3) [Figure 10-61-12] is used to
connection to the loader harness. turn the Remote Start Tool (Service Tool) on and
activates the loader ignition power. The button will
The second connector (Item 3) [Figure 10-61- illuminate to indicate the service tool is active.
11] is used for attachment ACD upgrades or
attachment operational diagnostics only. This The START button (Item 4) [Figure 10-61-12] is used to
connector has a cap attached to it to prevent start the loader engine.
damage or corrosion when not in use.
The Traction Lock button (Item 5) [Figure 10-61-12] is
Connect the Remote Start Tool (Service Tool) connector used to turn traction lock ON or OFF. Push the button and
(Item 1) to the loader harness connector (Item 2) and the the button will illuminate indicating the traction lock is
other Remote Start Tool (Service Tool) connector to the disabled in which the wheels or tracks are able to turn.
ACD harness connector (Item 3) [Figure 10-61-11].
The Auxiliary button (Item 6) [Figure 10-61-12] is used to
NOTE: The right instrument panel (Standard Key activate the auxiliary hydraulics. The button will illuminate
Panel or Deluxe Instrumentation Panel) must to indicate the auxiliary hydraulics are active. Pressing
be in the off position or the Remote Start Tool the button a second time will turn the flow OFF. The
(Service Tool) will not operate. button is used when checking pressures and flow rate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409
46 of 692 10-61-6
7217666 (CONT'D)
Figure 10-61-13
1 2
P-34661
Push the couplers on the front auxiliary block toward the

block and hold for 5 seconds to release the front auxiliary
P-76441 pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure

10-61-13] will illuminate and blink when the RUN button
is pressed and the loader is communicating with the
service tool.
The computer icon with the right facing arrows (Item 2)

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

secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the Auxiliary (AUX) Hydraulics button
on the remote start tool and move the
AUXILIARY Hydraulic switch to the right and
left several times.
47 of 692 10-61-7
48 of 692
10-61-8
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
SERVICE SCHEDULE HOURS

[1] [1] [1]
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check indicator. Service only when required. Check for leaks and damaged
components.
Engine Cooling System Clean debris from oil cooler, radiator and grille. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multipurpose lithium based grease.
Pivot Pins and Wedges
Tyres Check for damaged tyres and correct air pressure. Inflate to MAXIMUM
pressure shown on the sidewall of the tyre.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.

Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS™) bar raised. See details in this Manual.
Front Horn Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TYRE [3]
MAINTENANCE in this manual.)
Spark Arrester Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. [2]
Drive Belts (Alternator, water Check condition and tension. Adjust or replace as needed.
pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS™)
Engine Oil and Filter Replace oil and filter. [2] [5]
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir [4]
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. [2]
Engine Valves Adjust the engine valves. [6]
Coolant Replace the coolant Every 2 years
[1] Or every 12 months.
[2] Perform at first 50 hours, then as scheduled.
[3] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[4] Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when service code [M0217] is displayed or as
scheduled.
[5] Change oil and filter every 100 hours when operating under severe conditions.
[6] Perform at first 500 hours, then as scheduled.
NOTE: The Inspection Checkbook can be ordered for you by your local dealer. Part number 4420300.
49 of 692 10-70-1
50 of 692
10-70-2
AIR CLEANER SERVICE Figure 10-80-3
Replacing Filter Elements
Figure 10-80-1
2 1
1
P-90147
Pull the outer element (Item 1) [Figure 10-80-3] straight

P-90146
out.
Install a new outer element.

Replace the large (outer) filter element only when the red
ring shows in the window of the condition indicator (Item Install the dust cover.

1) [Figure 10-80-1].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
NOTE: Before replacing the filter element, push the
button on the condition indicator (Item 2) Inner Filter
[Figure 10-80-1]. Start the engine. If the red
ring does not show, do not replace the filter Replace the inner filter every third time the outer filter is
element. replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.
Outer Filter
Figure 10-80-4
Figure 10-80-2
2
1
P-90148
P-90149
Remove the inner filter (Item 1) [Figure 10-80-4].

Open the evacuator valve (Item 1) [Figure 10-80-2] to
get rid of large particles of dust and dirt. NOTE: Make sure all sealing surfaces are free of dirt
and debris. DO NOT use compressed air.
Remove the dust cover by lifting the lever (Item 2)
[Figure 10-80-2] and rotating the dust cover. Install a new inner element.
Install the outer element and the dust cover.
51 of 692 10-80-1
52 of 692
10-80-2
ENGINE COOLING SYSTEM Checking Level
Inspect the cooling system every day to prevent over- Open the rear door and remove the rear grille.
heating, loss of performance or engine damage. (See Removal And Installation on Page 50-60-1.)
Cleaning Figure 10-90-2
Open the rear door and raise the rear grille.
NOTE: Be careful when raising and lowering the rear

grille so that it does not fall on the radiator
and damage the fins.
1
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist: S4757
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running. Check coolant level using the level markers (Item 1)

• Tools are being used. [Figure 10-90-3] on the tank. Coolant must be at the
W-2019-0907 bottom marker when the engine is cold; top marker when
hot.
Figure 10-90-1
Close the rear door before operating the loader.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
1 Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
S4082
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Use low air pressure or water pressure to clean the top of boiling point and freeze protection of the system.
the radiator (Item 1) [Figure 10-90-1].
Always add a premixed solution. Adding full strength
Inspect the cooling system for leaks. concentrated coolant can cause serious premature
engine damage.
Lower the rear grille and close the rear door. I-2124-0497
53 of 692 10-90-1
ENGINE COOLING SYSTEM (CONT’D) Use a refractometer to check the condition of propylene
glycol in your cooling system and reinstall the coolant fill
Removing And Replacing Coolant cap.
Open the rear door and remove the rear grille. NOTE: When installing the coolant fill cap, the cap
(See Removal And Installation on Page 50-60-1.) must be tightened until it clicks.
Figure 10-90-3 Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level when cool. Add
coolant as needed.
Reinstall the rear grille and close the rear door.
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
S4757
damage.

Remove the coolant fill cap (Item 1) [Figure 10-90-3]. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Connect a hose to the engine block drain valve. Open the boiling point and freeze protection of the system.
drain valve and drain the coolant into a container.
Always add a premixed solution. Adding full strength
After all the coolant is removed, close the drain valve and concentrated coolant can cause serious premature
remove the hose. engine damage.
I-2124-0497
NOTE: Fluids such as engine oil, hydraulic fluid,
coolant, etc. must be disposed of in an
environmentally safe manner. Some
regulations require that certain spills and
leaks on the ground must be cleaned in a
specific manner. See local, state and federal
regulations for correct disposal.
Mix the coolant in a separate container. (See

Specifications on Page SPEC-40-1.)
NOTE: The loader is factory filled with propylene

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

glycol to the recovery tank. (See Checking Level on Page
10-90-1.)
The correct mixture of coolant to provide a -37°C (34°F)

freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Fill the tank until it is at the lower marker on the tank.
54 of 692 10-90-2
FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE °C (°F) NO. 2 NO. 1 corrosion and plugging of fuel system components.
-9° (+15°) 100% 0% • Use of biodiesel blend fuel can result in premature
Down to -29° (-20°) 50% 50% failure of fuel system components, such as plugged
Below -29° (-20°) 0% 100% fuel filters and deteriorated fuel lines.
• Shorter maintenance intervals can be required, such

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

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

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

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

oil change intervals can cause engine damage.
• Before 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 three months.
55 of 692 10-100-1
FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Figure 10-100-1 B15650
Use a clean, approved safety container to add fuel of the

correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-

100-1].
1
WARNING
P-90150A
Always clean up spilled fuel or oil. Keep heat, flames,
Open the rear door. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Remove the fuel fill cap (Item 1) [Figure 10-100-1]. explosion or fire.
W-2103-0508
56 of 692 10-100-2
FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter. (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water
WARNING
Figure 10-100-3
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909
2
Figure 10-100-4
1

1
P107109
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter.
Replacing Element
2
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on P107109
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See Removing Air housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until air bubbles do not come up any more.
Close the vent (Item 1) [Figure 10-100-4] on the fuel filter

WARNING housing.
AVOID INJURY OR DEATH Close the rear door before starting the engine.
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
57 of 692 10-100-3
58 of 692
10-100-4
ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2

ENGINE OIL
Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
engine for the work shift. (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Figure 10-110-1
P-90145A
1
2
P107110

Park the machine on level ground. Open the rear door TEMPERATURE RANGE ANTICIPATED BEFORE
and remove the dipstick (Item 1) [Figure 10-110-1]. Keep NEXT OIL CHANGE (DIESEL ENGINES MUST USE
the oil level between the marks on the dipstick. Do not API CLASSIFICATION CI-4 OR BETTER)
overfill.
[1] Synthetic Oil - Use recommendation from Synthetic
Oil Manufacturer.
Use good quality engine oil that meets API Service

Classification of CI-4 or better [Figure 10-110-2].
59 of 692 10-110-1
ENGINE LUBRICATION SYSTEM (CONT’D)
Removing And Replacing Oil And Filter

WARNING
For the service interval for replacing the engine oil and
filter. (See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
Run the engine until it is at operating temperature. Stop sparks or lighted tobacco away from fuel and oil.
the engine. Failure to use care around combustibles can cause
explosion or fire.
Open the rear door and remove the drain hose (Item 2) W-2103-0508
[Figure 10-110-1] from its storage position.
Figure 10-110-3

P-90153A
Remove the oil drain cap (Item 1) [Figure 10-110-3] and

drain the oil into a container. Recycle or dispose of used
oil in an environmentally safe manner.
Install and tighten the oil drain cap and return the drain
hose to the stored position.
Remove the oil filter (Item 2) [Figure 10-110-3] and clean

the filter housing surface. Use genuine Bobcat filter only.
Put clean oil on the new oil filter gasket, install the filter
and hand tighten.
Remove the fill cap (Inset) [Figure 10-110-1]. Put oil in

the engine. For the correct quantity (See Capacities on
Page SPEC-10-4.) Do not overfill.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 1) [Figure 10-110-1] and

check the oil level. Add oil as needed if it is not at the top
mark on the dipstick. Install the dipstick and close the
rear door.
60 of 692 10-110-2
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-2

HYDRAULIC / HYDROSTATIC FLUID
Stop the loader on a level surface. RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI)
Lower the lift arms and tilt the Bob-Tach™ fully back.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

1 DURING MACHINE USE
S4028
[1] VG 100; Minimum VI 130
[2] VG 46; Minimum VI 150
[3] BOBAT All-Season Fluid
[4] BOBCAT Synthetic Fluid

P100361
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
Use only recommended fluid in the hydraulic system

2 [Figure 10-120-2]. (See Specifications on Page SPEC-
3 40-1.)
P100360 S4030
Remove the fill cap (Item 1) [Figure 10-120-1].
Add oil until it is at the center of the sight gauge (Item 2)

[Figure 10-120-1]. Do not overfill.
Remove the screen (Item 3) [Figure 10-120-1] and clean

with solvent as needed.
Reinstall the fill cap (Item 1) [Figure 10-120-1].
61 of 692 10-120-1
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) NOTE: Fluids such as engine oil, hydraulic fluid,
coolant, etc. must be disposed of in an
Removing And Replacing Hydraulic Fluid environmentally safe manner. Some
regulations require that certain spills and
For the correct service interval. (See Chart on Page 10- leaks on the ground must be cleaned in a
70-1.) specific manner. See local, state and federal
regulations for correct disposal.
Replace the fluid if it becomes contaminated or after
major repair.
Always replace the hydraulic / hydrostatic filter, the case

drain filters and the hydraulic charge filter whenever the
WARNING
hydraulic fluid is replaced. (See Removing And Replacing
Hydraulic / Hydrostatic Filter on Page 10-120-3.) AVOID INJURY OR DEATH
Figure 10-120-3 sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
Recycle or dispose of used fluid in an environmentally

safe manner.
Add the correct fluid to the reservoir until the fluid level is
1

at the center of the sight gauge. (See Checking And
S4028
Adding Fluid on Page 10-120-1.)
Install the fill cap.

P100361
Lower the operator cab. (See Lowering on Page 10-30-
2.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the fill cap (Item 1) [Figure 10-120-3].
Figure 10-120-4
S4033 S4032
Disconnect the hose (Item 1) [Figure 10-120-4] from the

hydraulic reservoir and drain the fluid into a container.
Connect the hose when the reservoir is empty.
62 of 692 10-120-2
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic / Hydrostatic

Filter WARNING
For the correct service interval (See Chart on Page 10-
70-1.)
Stop the engine and open the rear door.
Figure 10-120-5
W-2072-EN-0909
Stop the engine and check for leaks at the filter.
Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)
1
Close the rear door.

P-90158A
Remove the filter (Item 1) [Figure 10-120-5].
Clean the surface of the filter housing where the filter seal
contacts the housing.
Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.
WARNING
explosion or fire.
W-2103-0508
Start the engine and operate the loader hydraulic

controls.
63 of 692 10-120-3
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Disassemble the case drain filters and discard the filter
elements. Thoroughly clean the filter housings with
Removing And Replacing Case Drain Filters solvent. Install new filter elements and reassemble.
Install the filters into the loader and connect the fittings.
For the correct service interval. (See SERVICE
SCHEDULE on Page 10-70-1.) Lower the operator cab. (See Lowering on Page 10-30-
2.)
Figure 10-120-6 controls. Stop the engine and check for leaks.
1
WARNING
S4034 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
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

S4032 Check the fluid level in the reservoir and add as needed.
The case drain filters are located under the cab, next to
the transmission, one on each side (Item 1) [Figure 10-
120-6].
Disconnect the fittings at the end of the case drain filters

and remove both filters.
WARNING
explosion or fire.
W-2103-0508
64 of 692 10-120-4
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic Charge Filter

WARNING
For the correct service interval. (See Chart on Page 10-
70-1.)
NOTE: SJC equipped machines do not have a
Hydraulic Charge Filter.
Figure 10-120-7
W-2072-EN-0909
Stop the engine and check for leaks.
1 Check the fluid level in the reservoir and add as needed.

2 Breather Cap
For the correct service interval (See Chart on Page 10-

1

70-1.)
S4254 Figure 10-120-8
Disconnect the hydraulic connections (Item 1) and

remove the charge filter (Item 2) [Figure 10-120-7].
Install new filter.

1
Connect and tighten hydraulic connections.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames, P100362

Failure to use care around combustibles can cause Remove the hydraulic fill / breather cap (Item 1) [Figure
explosion or fire. 10-120-8] and discard.
W-2103-0508
Install a new cap.

2.)

controls.
65 of 692 10-120-5
66 of 692
10-120-6
FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil
Checking And Adding Oil Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
The chaincase contains the final drive sprockets and
chains. Use the same type of oil as the hydraulic / Figure 10-130-2
hydrostatic system. (See Specifications on Page SPEC-
40-1.)
Stop the loader on a level surface.
Stop the engine.
Figure 10-130-1
P31287A
Use a pump to suction the oil from the chaincase [Figure

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

safe manner.
P31287
Add new oil until you can reach the oil with the tip of your
finger through the hole.
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing. Reinstall and tighten the plug.
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add lubricant through the check plug

hole until it reaches the desired level.
WARNING
Install and tighten the plug.
explosion or fire.
W-2103-0508
67 of 692 10-130-1
68 of 692
10-130-2
BOB-TACH (HAND LEVER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
Inspection And Maintenance 140-2].
Figure 10-140-1 If the wedge does not contact the lower edge of the hole
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
N17027
Move the Bob-Tach™ levers down to engage the wedges

[Figure 10-140-1].

The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-140-2
B-17460
2
Inspect the mounting frame on the attachment and Bob-
Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
Wedge must contact damaged, bent or missing. Keep all fasteners tight.
lower edge of hole in the
attachment. Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
P-31233 B-15177
Lubricate the wedges. (See Chart on Page 10-70-1.)
(See LUBRICATING THE LOADER on Page 10-150-1.)
The wedges (Item 1) [Figure 10-140-2] must extend
through the holes in the attachment mounting frame.
69 of 692 10-140-1
70 of 692
10-140-2
BOB-TACH (POWER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
This machine may be equipped with a Power Bob-TachTM. 141-2].
Inspection And Maintenance If the wedge does not contact the lower edge of the hole
[Figure 10-141-2], the attachment will be loose and can
Figure 10-141-1 come off the Bob-Tach.
Figure 10-141-3
1
B-15993R
Push and hold the BOB-TACH “WEDGES UP” switch

(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down.
The levers and wedges must move freely.

WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-141-2
B-17460
Wedge must contact Inspect the mounting frame on the attachment and the
lower edge of hole in Bob-Tach, linkages and wedges for excessive wear or
the attachment. damage [Figure 10-141-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
P-31233 B-15177
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
The wedges (Item 1) [Figure 10-141-3] must extend
through the holes in the attachment mounting frame. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
71 of 692 10-141-1
72 of 692
10-141-2
LUBRICATING THE LOADER Figure 10-150-3
Lubrication Locations
Lubricate the loader as specified for the best

performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.) 2
Record the operating hours each time you lubricate the

Bobcat Loader.
Always use a good quality lithium based multipurpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
S4085
Lubricate the following locations on the loader:
Figure 10-150-1 2. Base End Lift Cylinder (Both Sides) (Item 2) [Figure
10-150-2] and [Figure 10-150-3].
Figure 10-150-4
3
2
4

1
3
S4137
S4086
Figure 10-150-2
3. Lift Arm Pivot Pin (Both Sides) (Item 3) [Figure 10-
150-1] and [Figure 10-150-4].
S1080
1. Rod End Lift Cylinder (Both Sides) (Item 1) [Figure

10-150-1] and [Figure 10-150-2].
73 of 692 10-150-1
LUBRICATING THE LOADER (CONT’D) Figure 10-150-7
Lubrication Locations (Cont’d)
Figure 10-150-5
P100410
8. 250 Hours: Steering Lever Shaft (2) under the

S4037
operator cab [Figure 10-150-7].
4. Base End Tilt Cylinder (Both Sides) (Item 4) [Figure

10-150-1] and [Figure 10-150-5].

Figure 10-150-6
6 7
S4139
5. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

150-6].
6. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-

6].
7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-6].
74 of 692 10-150-2
TIRE MAINTENANCE It is important to keep all tires the same size. If different
sizes are used, each tire will be turning at a different rate
Wheel Nuts and cause excessive wear. The tread bars of all the tires
must face the same direction.
Figure 10-160-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Mounting
Tires are to be repaired only by an authorized person

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

before mounting. Check rim and tire bead for damage.
S4503 The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a

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

cause serious injury or death.
When installing wheel nuts, tighten to 217 N•m (160 ft-lb)
torque.
During inflation of the tire, check the tire pressure
frequently to avoid over inflation.
When checking wheel nut torque, set the torque wrench
to 190 N•m (140 ft-lb) torque to prevent over-tightening.
Rotating
WARNING
Check the tires regularly for wear, damage and pressure.
Inflate tires to the maximum pressure shown on the AVOID INJURY OR DEATH
sidewall of the tire. Do not inflate tyres above specified pressure. Failure
to use correct tyre mounting procedure can cause an
Figure 10-160-2 explosion which can result in injury or death.
W-2078-EN-0909
IMPORTANT
Inflate tyres to the MAXIMUM pressure shown on the
sidewall of the tyre. DO NOT mix brands of tyres
used on the same machine.
I-2057-EN-1010
B9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].
75 of 692 10-160-1
76 of 692
10-160-2
SPARK ARRESTER MUFFLER
Cleaning Procedure
WARNING
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrester muffler. (See Chart on Page When the engine is running during service, the
10-70-1.) driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
Do not operate the loader with a defective exhaust
cause injury or death.
system. W-2006-1209
Start the engine and run for about 10 seconds while a

IMPORTANT second person, wearing safety goggles, holds a piece of
wood over the outlet of the muffler.
This machine is factory equipped with a spark This will force contaminants out through the cleanout
arrester exhaust system. hole.
The spark arrester muffler, if equipped, must be Stop the engine.

cleaned to keep it in working condition. The spark
arrester muffler must be serviced by dumping the Reinstall and tighten the plug.
spark chamber every 100 hours of operation.
On some models, the turbocharger functions as the

spark arrester and must operate correctly for proper
spark arrester function.
WARNING
If this machine is operated on flammable forest,
brush, or grass covered land, a spark arrester AVOID INJURY OR DEATH
attached to the exhaust system may be required and When an engine is running in an enclosed area, fresh
must be maintained in working order. Refer to local air must be added to avoid concentration of exhaust
laws and regulations for spark arrester requirements. fumes. If the engine is stationary, vent the exhaust
I-2284-EN-0909 outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Figure 10-170-1
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
1
WARNING
P-90158A
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-170-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285
77 of 692 10-170-1
78 of 692
10-170-2
PIVOT PINS Figure 10-180-2
Inspection And Maintenance
Figure 10-180-1
3
1 4
1 2
5
S4137
Figure 10-180-3
N20575A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure 6

10-180-1].
S4139
Check that the lock nuts are tightened to 48 - 54 N•m (35

- 40 ft-lb) torque (Both Sides) (Items 1 - 6) [Figure 10-
180-2] and [Figure 10-180-3].
79 of 692 10-180-1
80 of 692
10-180-2
LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat Loader has been in storage, it is

necessary to follow a list of items to return the loader to
Sometimes it can be necessary to store your Bobcat service.
Loader for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
compartment. • Install a fully charged battery.
• Lubricate the loader.
• Remove grease from exposed cylinder rods.
• Replace worn or damaged parts.
• Check all belt tensions.
• Park the loader in a dry protected shelter.
• Be sure all shields and guards are in place.
• Lower the lift arms all the way and put the bucket flat
on the ground.
• Lubricate the loader.
• Put blocks under the frame to remove weight from the
tires. • Check tire inflation and remove blocks from under
frame.
• Put grease on any exposed cylinder rods.
• Remove cover from exhaust pipe opening.
• Put fuel stabilizer in the fuel tank and run the engine

a few minutes to circulate the stabilizer to the pump
• Start the engine and let run for a few minutes while
and fuel injectors.
observing the instrument panels and systems for
If biodiesel blend fuel has been used, perform the correct operation.
following:
• Operate machine, check for correct function.
Drain the fuel tank, refill with 100% petroleum diesel
fuel, add fuel stabilizer and run the engine for at least • Stop the engine and check for leaks. Repair as
30 minutes. 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.
81 of 692 10-190-1
82 of 692
10-190-2
STOPPING THE ENGINE AND LEAVING THE LOADER NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Procedure Deluxe Instrumentation Panel allows
operation of the loader without using a
Stop the loader on level ground. password.
Lower the lift arms fully and put the attachment flat on the Figure 10-200-3
ground.
Figure 10-200-1
S4006
Pull the engine speed control lever (Item 1) [Figure 10-

200-1] fully backward to decrease the engine speed.
Engage the parking brake.

P66668A
S0597
Figure 10-200-2
1 2 Exit the loader using grab handles, safety tread and steps
(maintaining a 3-point contact) [Figure 10-200-3].
2
P-76603 P-90809A B-15553L WARNING
Turn the key switch to the STOP position (Item 1) or
press the STOP button (Item 2) [Figure 10-200-2]. Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
NOTE: If the loader lights are ON, they will remain ON the ground.
for approximately 90 seconds after turning • Stop the engine.
the loader OFF. • Engage the parking brake.
• Raise the seat bar.
Move auxiliary control out of detent position. • Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
Raise the seat bar and make sure the lift and tilt functions drive functions are deactivated.
are deactivated.
The seat bar system must deactivate these functions
Unbuckle the seat belt. when the seat bar is up. See your Bobcat dealer for
service if controls do not deactivate.
Remove the key from the switch (Standard Key Panel) to W-2463-1110
prevent operation of the loader by unauthorized
personnel.
83 of 692 10-200-1
84 of 692
10-200-2
EMERGENCY EXIT Front Door
The front opening on the operator cab and rear window The Bobcat loader can be equipped with a front door.
provide exits.
NOTE: When an Operator Cab Enclosure Kit is
Rear Window installed, the window of the front door can be
used as an emergency exit [Figure 10-210-3].
Figure 10-210-1
NOTE: If the loader has a Special Application Door
Kit installed, the window of the front door is
NOT an emergency exit.
Figure 10-210-3
S4046 S4045
Pull the tag on the top of the rear window to remove the

rubber cord [Figure 10-210-1].
Push the rear window out of the rear of the operator cab.
P-85439
Figure 10-210-2
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-210-3].
Figure 10-210-4
X X
P-45260B
X X
Exit through the rear of the operator cab [Figure 10-210-
2].
S0363
Push the window out with your foot at any corner of the
window [Figure 10-210-4].
Exit through the front door.
85 of 692 10-210-1
86 of 692
10-210-2
SEAT BELT Figure 10-220-1
Inspection And Maintenance 1
WARNING 3
Failure to properly inspect and maintain the seat belt

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

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

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,

retractor (if equipped), hardware or any other obvious
problem should be replaced immediately.
B-22283
The items below are referenced in [Figure 10-220-1].
1. Check the webbing. If the system is equipped with a

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

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

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

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength can have deteriorated.
See your Bobcat dealer for seat belt system replacement

parts for your machine.


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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Rod End Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . 20-21-3
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
MAIN RELIEF VALVE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-2

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
BICS™ Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-40-5
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-40-6
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-7
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-7
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . . 20-40-8
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-22
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33

HYDRAULIC CONTROL VALVE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-4
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
BICS™ Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-41-9
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-12
Port Relief / Anti-Cavitation Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-41-12
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2

Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Charge Filter Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-3
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC) . . . . . . . . . . . . . . . . . . . 20-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
AUXILIARY HYDRAULIC INTERLOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

HYDRAULIC/HYDROSTATIC SCHEMATIC
S100 (S/N A8ET20001 AND ABOVE)
(PRINTED MARCH 2013)

V-1321 legend
LEGEND
1 VARIABLE DISPLACEMENT BIDIRECTIONAL 17 RELIEF VALVE – MAIN: 34 INLET SCREEN / FILTER: Inside of Inlet
HYDROSTATIC PUMP 20700 kPa (207 bar) (3000 psi) Fitting
2 HYDRAULIC PUMP.............Gear Type: 18 RELIEF / ANTICAVITATION VALVE – 35 PULL BUTTON ACTIVATED
49,6 L/min (13.1 U.S. gpm) at High Engine Idle PORT: 27600 kPa (276 bar) (4000 psi) DIRECTIONAL CONTROL VALVE:
3 CHARGE PUMP: Lift Arm Bypass Valve
19 ANTICAVITATION VALVE
24,2 L/min (6.4U.S. gpm) at High Engine Idle
36 SOLENOID AVTIVATED DIRECTIONAL
4 RELIEF / REPLENISHING VALVE – HIGH 20 LOAD CHECK VALVE CONTROL VALVE – Auxiliary Hydraulic Lock
PRESSURE: 29300 kPa (293 bar) (4000 psi) 37 RESTRICTION
21 QUICKCOUPLER MALE
5 RELIEF VALVE – CHARGE INLET:
38 FILTER - Bob-Tach Valve
2400 kPa (24 bar) (348 psi) 22 QUICKCOUPLER FEMALE
6 39 PILOT ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC DRIVE
MOTOR 23 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC
CONTROL VALVE: Bucket Positioning POWERED BOB-TACH
7 DRIVE MOTOR SHUTTLE VALVE On / Off 40 RESTRICTION - 2,26 mm (0.089 in)
24 FLOW DIVIDER ADJUSTMENT VALVE 41 RESTRICTION - 0,6 mm (0.025 in)

8 SHUTTLE RELIEF VALVE:
1520 kPa (15,2 bar) (220 psi) 25 42
PILOT ACTIVATED DIRECTIONAL CONTROL RELIEF VALVE: 13700 kPa (137 bar) (2000 psi)
VALVE: FLOW CONTROL SPOOL
9 FILTER - CASE DRAIN 43 RELIEF VALVE: 8300 kPa (83 bar) (1200 psi)
26 CHECK VALVE – BUCKET POSITION VALVE
10 FILTER – CHARGE 44 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
27 PILOT ACTIVATED DIRECTIONAL 45 CHECK VALVE - With 550 kPa (5,5 bar) (80 psi) Spring
11 FILTER BYPASS VALVE: CONTROL VALVE: UNLOADING SPOOL
276 kPa (2,76 bar) (40 psi)
28 TILT CYLINDER 46 CHECK VALVE - With 20700 kPa (21 bar) (300 psi)
12 ATMOSPHERIC RESERVOIR Spring with 0,40 mm (0.016 in) orifice
29 LIFT CYLINDER
13 FILTER – HYDRAULIC 30 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE: BICS Cartridge
14 FILTER BYPASS VALVE:
31 SOLENOID AVTIVATED DIRECTIONAL
345 kPa (3,45 bar) (50 psi)
CONTROL VALVE – BICS Control
15 DIFFERENTIAL PRESSURE SWITCH:
276 kPa (2,76 bar) (40 psi) 32 INLET SCREEN / FILTER
16 OIL COOLER 33 CHECK VALVE: Inside of Inlet Fitting

NOTE: Unless otherwise specified, springs have
NO significant pressure value.
V-1321 legend (3-4-13)

Printed in Europe.
93 of 692

(V-1321)
QUICK COUPLERS
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE
HYDRAULIC FILTER
16
13
21
36
OIL
DRIVE MOTOR 12 14 COOLER
FEMALE
22
7 8 15
BUCKET POSITION VALVE (OPTIONAL)
D
26
6
B A
24
HYDRAULIC AND
HYDROSTATIC PUMPS
A
1 HYDRAULIC CONTROL VALVE
4 4 23 C
25

5
27
AUXILIARY
SPOOL B
B A
HYDRAULIC
POWERED
CHARGE
BOB-TACH
INLET
(OPTIONAL)
45 42
1 DR
TILT CYLINDERS
19 20 BICS CONTROL VALVE
46
43
4 4 41
28
D C 44 40
PP
2 38 TILT CYLINDER
B A SPOOL 30
P1 P2
3 OUTLET
INLET 39
19 20 28
18
LIFT CYLINDERS
6 18
30
LIFT CYLINDER
B A SPOOL
37
29
9
20
7 8 IN-LINE FILTER
10 34 33
17 32 31
DRIVE MOTOR LIFT ARM BY PASS VALVE
11 35
Printed in Europe.
94 of 692
V-1321 (3-4-13)
With SJC

V-1370 legend
LEGEND
1 VARIABLE DISPLACEMENT BIDIRECTIONAL 15 RELIEF / ANTICAVITATION VALVE – 30 INLET SCREEN / FILTER: Inside of Inlet Fitting
HYDROSTATIC PUMP PORT: 27600 kPa (276 bar) (4000 psi)
2 HYDRAULIC PUMP.............Gear Type: 16 RELIEF / ANTICAVITATION VALVE – 31 PULL BUTTON ACTIVATED DIRECTIONAL
49,6 L/min (13.1 U.S. gpm) at High Engine Idle PORT (OPTIONAL): 27600 kPa (276 bar) CONTROL VALVE: Lift Arm Bypass Valve
(4000 psi) 32 PILOT ACTIVATED DIRECTIONAL
3 RELIEF / REPLENISHING VALVE – HIGH
PRESSURE: 27600 kPa (276 bar) (4000 psi) 17 ANTICAVITATION VALVE CONTROL VALVE: Hyd. Powered Bob-Tach
4 RELIEF VALVE – CHARGE INLET: 33 FILTER – Bob-Tach Valve

18 LOAD CHECK VALVE
2406 kPa (24 bar) (350 psi)
19 SOLENOID AVTIVATED DIRECTIONAL 34 RESTRICTION: 2,26 mm (0.089 in)
5 BIDIRECTIONAL HYDROSTATIC
DRIVE MOTOR CONTROL VALVE – Auxiliary
35 RESTRICTION: 0,6 mm (0.025 in)
6 20 FRONT AUXILIARY MANUAL PRESSURE
DRIVE MOTOR SHUTTLE VALVE
BLEED OFF VALVE 36 SOLENOID AVTIVATED DIRECTIONAL
7 SHUTTLE RELIEF VALVE: CONTROL VALVE – (Two Coil)
21 SOLENOID ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
1520 kPa (15,2 bar) (220 psi) CONTROL VALVE: Bucket Positioning 37 RELIEF VALVE: 8300 kPa (83 bar) (1200 psi)
8 FILTER - CASE DRAIN On / Off
38 RELIEF VALVE: 13700 kPa (137 bar) (2000 psi)
22 FLOW DIVIDER ADJUSTMENT VALVE
9 HYDRAULIC RESERVOIR:
(To Center of Site Gauge) 39 CHECK VALVE: With 550 kPa (5,5 bar) (80 psi) Spring
23 PILOT ACTIVATED DIRECTIONAL CONTROL
Reservoir Capacity . . 13.0 L (13.7 qt)
VALVE: FLOW CONTROL SPOOL 40 CHECK VALVE: With 2070 kPa (20,7 bar) (300 psi)
System Capacity . . . . 22.0 L (23.2 qt)
Spring And With 0,4 mm (0.016 in) Orifice
24 CHECK VALVE – BUCKET POSITION VALVE
10 FILTER – HYDRAULIC
25 41 SOLENOID AVTIVATED CONTROL VALVE –
PILOT ACTIVATED DIRECTIONAL
11 FILTER BYPASS VALVE: 345 kPa FORWARD / REVERSE
CONTROL VALVE: UNLOADING SPOOL
(3,45 bar) (50 psi)
42 SERVO PISTION – Swash Plate
26 PILOT ACTIVATED DIRECTIONAL
12 DIFFERENTIAL PRESSURE SWITCH:
CONTROL VALVE: BICS Cartridge
276 kPa (2,76 bar) (40 psi)
13 OIL COOLER 27 SOLENOID AVTIVATED DIRECTIONAL
CONTROL VALVE – BICS Control
14 RELIEF VALVE – MAIN: 28 INLET SCREEN / FILTER
20684 kPa (207 bar) (3000 psi)
29 CHECK VALVE: Inside of Inlet Fitting
NOTE: Unless otherwise specified, springs have

NO significant pressure value.
V-1370 legend (3-4-13)

Printed in Europe.
95 of 692
HYDRAULIC SCHEMATIC
With SJC
Quick coupler block
(PRINTED MARCH 2013) Hydraulic filter 10 13
7180085 20
Male
Bucket position valve

6 7 Male (optional)
Drive motor
Female
24
11
Main control valve
8 25
12
5 22
16
Hydrostatic pumps
19
19a
23
41
19
42
1
21
Auxiliary spool
15
15b
4 18
18b
3
Power bobtach valve
Dealer Copy -- Not for Resale BICS Control valve
Tilt cylinders
3
3a (Optional)
15
15a
39
Charge inlet
38
Tilt cylinder spool
37 BALL SCREW ACTUATOR WITH
PROPORTIONAL FEEDBACK 26
1
1a
36
17 18
18a
26
26a
? ? 15
3
3b 42
42a
34
3c
3
35 40 Lift cylinders
BALL SCREW ACTUATOR WITH
PROPORTIONAL FEEDBACK Lift cylinder spool
41
41a
33
18
28
Hydraulic gear pump 14

32
27
2
5
5a
LIFT ARM BYPASS VALVE
(TWIST & PULL)
30 29
8
8a
31
6
6a
9
Drive motor
Hydraulic reservoir
7
7a
96 of 692 7180085 (3-4-13)

Printed in Europe.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

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

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

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.

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

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

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

noise.
97 of 692 20-10-1
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic

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

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

BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).
98 of 692 20-10-2

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

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

RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRONT
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.
99 of 692 20-10-3

PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

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

RELIEF / ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

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

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

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).
100 of 692 20-10-4

Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If the service code appears in the left instrument panel.
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
Lift arm bypass control valve stuck. 12
Lift arm bypass control valve stem bent or broke. 13

KEY TO CORRECT THE CAUSE
1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid.
8. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Lift arm bypass control valve assembly.
101 of 692 20-10-5

102 of 692
20-10-6
CYLINDER (LIFT) Figure 20-20-2
Testing
2
WARNING
1
enters skin or eyes, get immediate medical attention P-45266
W-2072-EN-0909
Install a plug (Item 1) [Figure 20-20-2] in the hose and
tighten.
Figure 20-20-1
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the

engine. Press the PRESS TO OPERATE button. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
Repeat the procedure to check the other lift cylinder.
P-45265
WARNING
Lower the lift arms. Stop the engine. Pull up the lift arm
bypass control to release the hydraulic pressure. AVOID INJURY OR DEATH
Check only one cylinder at a time. Open the rear door. sparks or lighted tobacco away from fuel and oil.
Disconnect the negative ground cable from the battery. explosion or fire.
W-2103-0508

lift cylinder base end port.
103 of 692 20-20-1

CYLINDER (LIFT) (CONT’D) NOTE: Remove the air cleaner (See Removal And
Installation on Page 20-20-2.) to remove the
Removal And Installation left base end pivot pin. The pin must be driven
out from the engine compartment.
The removal procedure will be explained for the right lift
cylinder. The removal of the other cylinder is similar. Figure 20-20-5
Figure 20-20-3
S4324
S4344
To remove the lift cylinder rod end pivot pin use a pin

puller (Item 1) [Figure 20-20-5].
Stop the engine. Pull up the lift arm bypass control to
release the hydraulic pressure.
Open the rear door and disconnect the negative ground

cable from the battery.
Disconnect and plug the hoses (Item 1) [Figure 20-20-3]

from the lift cylinder.
Figure 20-20-4
S3467
Remove the retainer bolt (Item 1) and nut (Item 2)

[Figure 20-20-4] from the lift arm pins (both rod and base
end).
Installation: Tighten the bolt and nut to 35 - 38 N•m (25 -

28 ft-lb) torque.
104 of 692 20-20-2

CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Rod 9. Tube Line Assy * 6 and 7 were replaced by a one-piece seal.

2. Wiper Seal 10. Plug See parts manual for replacement parts.
3. Rod Seal 11. O-ring
4. Head 12. Nut
5. O-ring 13. O-ring
6. Back-up Ring* 14. Spacer
7. O-ring*
8. Cylinder
S4379
105 of 692 20-20-3

CYLINDER (LIFT) (CONT’D) Figure 20-20-7
Disassembly And Assembly

4
Use the following tools to service the cylinder:
3
2
• MEL1074 - O-ring Seal Hook.
1
• Spanner Wrench.
• MEL1033 - Rod Seal Installation Tool.
• MEL1396 - Seal Installation Tool.
• Piston Ring Compressor.

P-48036
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
damage. Replace any damaged parts. and head (Item 4) [Figure 20-20-7].
Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-20-7] to
814 N•m (600 ft-lb) torque.
Lubricate all O-rings and seals with hydraulic oil during

installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit. Use
Hold the hydraulic cylinder over a drain pan and move the Loctite® while tightening the nut.
rod in and out slowly to remove the fluid from the cylinder.
Figure 20-20-8
Put the base end of the cylinder in a vise.
Figure 20-20-6 2
1 1
P-48038
P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
20-8] from the piston.
Use a spanner wrench to loosen the head (Item 1) NOTE: If the fiber surface (Item 3) [Figure 20-20-8] on
[Figure 20-20-6] from the cylinder case. the piston head becomes damaged, the
complete piston head must be replaced.
Assembly: Tighten the head with a spanner wrench to
106 of 692 20-20-4

Disassembly And Assembly (Cont’d)
Figure 20-20-9
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-11] from

P7424 the cylinder head.
Figure 20-20-12
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-9]. Allow the

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

compressor on the piston for 3 minutes to compress the
seal into place.
1
Figure 20-20-10
1
3
P-48041A P-48042
Assembly: Install the wiper seal, with the wiper side of

the seal (Item 1), toward the outside of the head (Item 2)
2 [Figure 20-20-12].
P-48039
Remove the O-ring (Item 1), back-up ring (Item 2) and O-

ring (Item 3) [Figure 20-20-10] from the cylinder head.
NOTE: O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-20-10] were replaced by a one-
piece seal. Use the version currently supplied
through parts.
107 of 692 20-20-5

Figure 20-20-13
P7425
Assembly: Install the rod seal in the head. Rotate the

P-48042 handles to collapse the rod seal [Figure 20-20-15].
Remove the rod seal (Item 1) [Figure 20-20-13] from the

cylinder head.

Figure 20-20-14
P-48043A P7427
Assembly: Install the rod seal on the rod seal tool

[Figure 20-20-14].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-14] must be installed
toward the inside of the cylinder.
108 of 692 20-20-6

CYLINDER (TILT) Removal And Installation
Testing
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar.
WARNING
WARNING sparks or lighted tobacco away from fuel and oil.
explosion or fire.
Hydraulic fluid escaping under pressure can have W-2103-0508
Removal procedure will be explained for the right tilt
cylinder. Removal procedure for the left cylinder is
similar.
immediately.
W-2145-EN-0210
Figure 20-21-2
Figure 20-21-1

1
EM1475
S4137
Remove the attachment. Roll the Bob-Tach forward and
lower the lift arms.
Disconnect the hose which goes to the base end of the
tilt cylinder (Item 1) [Figure 20-21-1].
Place the Bob-Tach flat on a pallet to allow the tilt cylinder
base end pin enough clearance to be removed [Figure
Install a cap on the hose fitting and tighten.
20-21-2].
Engage the parking brake. Lower the seat bar.
Stop the engine. Move the tilt pedal to release the
hydraulic pressure. Raise the seat bar.
Start the engine and push the Press to Operate button.
Push the bottom (heel) of the tilt pedal.
If there is leakage from the open port, remove the tilt

cylinder for repair.
109 of 692 20-21-1

CYLINDER (TILT) (CONT’D) Figure 20-21-5
Removal And Installation (Cont’d)

1
Figure 20-21-3
1
2 3
2
S4321
Remove the retainer bolt (Item 1) and nut (Item 2)

S4220 [Figure 20-21-5] from the base end pivot pin.
Remove the base end pivot pin (Item 3) [Figure 20-21-5].

Disconnect both hydraulic hoses (Items 1 and 2) [Figure
20-21-3]. Remove the cylinder.

Figure 20-21-4
WARNING
1 AVOID INJURY OR DEATH
2 explosion or fire.
W-2103-0508
S4309
Remove the retainer nut (Item 1) and bolt (Item 2)

[Figure 20-21-4] from the cylinder rod end pivot pin.
Drive the pin through with a punch.
Installation: Tighten the retainer nut to 34 - 38 N•m (25 -

28 ft-lb) torque.
110 of 692 20-21-2

CYLINDER (TILT) (CONT’D) Base End Pivot Pin Removal And Installation
Rod End Pivot Pin Bushing And Seal Removal And Figure 20-21-7
Installation
2
Figure 20-21-6
3
1
1
1
S4321
N-18556 Remove the retainer nut (Item 1) and bolt (Item 2)

[Figure 20-21-7] from the base end pivot pin.
Remove the old seal (both sides) from the end of the tilt Installation: Tighten the retainer nut and bolt to 34 - 38

cylinder [Figure 20-21-6]. N•m (25 - 28 ft-lb) torque.
Apply a light coat of grease on the new seals (Item 1) Remove the base end pivot pin (Item 3) [Figure 20-21-7].
[Figure 20-21-6].
Remove the tilt cylinder from the loader.
Install the new seals with the lip facing in [Figure 20-21-
6].
Install the rod end of the tilt cylinder into the Bob-Tach.
Be careful not to damage the new seals during

installation.
Reverse the removal procedure to install the pivot pin

bushing and seal.
111 of 692 20-21-3

CYLINDER (TILT) (CONT’D)
1. Piston 9. Back-up Ring* .

2. O-ring 10 O-ring
3. Seal 11. Head * 8 and 9 were replaced by a one-piece seal.
4. Nut 12. Wiper Seal See parts manual for replacement parts.
5. Plug 13. Rod Seal
6. O-ring 14. Rod
7. Cylinder
8. O-ring*
S4378
112 of 692 20-21-4


3
Use the following tools to service the cylinder: 2
• MEL1074 - O-ring Seal Hook.

1
• Spanner Wrench.
• MEL1033 - Rod Seal Installation Tool.
• MEL1396 - Seal Installation Tool.
• Piston Ring Compressor.

P-48071
Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2) and head (Item
damage. Replace any damaged parts. 3) [Figure 20-21-9].
Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-21-9] to
Lubricate all O-rings and seals with hydraulic oil during

installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. Figure 20-21-10
Put the base end of the cylinder in a vise.
Figure 20-21-8
P-48088 P-48089
Assembly: Mark the end of the shaft and nut. Tighten

P-48034
the nut an additional 135 degrees or 2-1/4 flats [Figure
20-21-10]. Use Loctite® while tightening the nut.
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-8] from the cylinder case.

113 of 692 20-21-5

Disassembly And Assembly (Cont’d) 1

3
Figure 20-21-11
2
2
P-48039

P-48073 ring (Item 3) [Figure 20-21-13] from the cylinder head.

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- [Figure 20-21-13] were replaced by a one-
21-11] from the piston. piece seal. Use the version currently supplied

through parts.
Figure 20-21-12
Figure 20-21-14
P7424
P-48040

stretch it until it fits the piston [Figure 20-21-12]. Allow Remove the wiper seal (Item 1) [Figure 20-21-14] from
the seal to stretch for 30 seconds before installing it on the cylinder head.
the piston.

seal into place.
114 of 692 20-21-6

Figure 20-21-15
1
P-48043 P7427

P-48041 P-48042 [Figure 20-21-17].

Assembly: Install the wiper seal, with the wiper side of (Item 1) [Figure 20-21-17] must be installed
the seal (Item 1) toward the outside of the head (Item 2) toward the inside of the cylinder.

[Figure 20-21-15].
Figure 20-21-18
Figure 20-21-16
P7425
P-48042

Remove the rod seal (Item 1) [Figure 20-21-16] from the handles to collapse the rod seal [Figure 20-21-18].
cylinder head.
115 of 692 20-21-7

116 of 692
20-21-8
CYLINDER (BOB-TACH) Figure 20-22-1
Testing
WARNING
explosion or fire.
W-2103-0508 1
S5919
Tilt the Bob-Tach forward, so it is parallel to the floor

WARNING [Figure 20-22-1].
AVOID INJURY OR DEATH Disconnect the hose (Item 1) [Figure 20-22-1] from the
Diesel fuel or hydraulic fluid under pressure can power Bob-Tach cylinder base end port.

death. Fluid leaks under pressure may not be visible. Install a plug in the hose (Item 1) [Figure 20-22-1] and
Use a piece of cardboard or wood to find leaks. Do tighten.
enters skin or eyes, get immediate medical attention Engage the parking brake. Lower the seat bar. Start the
from a doctor familiar with this injury. engine.
W-2072-EN-0909
Push and hold the BOB-TACH “WEDGES UP” switch
(Front Accessory Panel).
If there is any leakage from the base end cylinder port

(Item 2) [Figure 20-22-1], remove the Bob-Tach cylinder
for repair.
The verification of the rod end side of the cylinder is

similar.
117 of 692 20-22-1

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-3
Removal And Installation
Figure 20-22-2
1 1
S5918
2
1 Remove the bolts (Item 1) [Figure 20-22-3].
S5919
Installation: Tighten the bolts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Disconnect and cap the hoses (Items 1 and 2) [Figure
20-22-2] from the cylinder fittings. Remove the washers and cylinder from the lever pivots.

Cap the fittings. Remove the cylinder.
118 of 692 20-22-2

CYLINDER (BOB-TACH) (CONT’D)
1. Cylinder
2. Plug
3. O-ring
4. Nut
5. Piston
6. O-ring
7. Ring
8. Spacer
9. O-ring*
10. Back-up Ring*
11. O-ring
12. Head
13. Seal
14. Seal
15. Rod
* 9 and 10 were replaced
by a one-piece seal.
See parts manual for
1
replacement parts.

3
2
14
13 12
11
10
9
8 7 6
5
4
15
PE1064
119 of 692 20-22-3


4 3 2
Use the following tools to service the cylinder:
1
MEL1074 - O-ring Seal Hook
Spanner Wrench
MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts. P16294
Always install new O-rings and seals during assembly.

Remove the head and rod assembly from the cylinder
Lubricate all O-rings and seals with hydraulic oil during [Figure 20-22-5]. Put the rod end in a vise.
installation.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Hold the hydraulic cylinder over a drain pan and move the and head (Item 4) [Figure 20-22-5] from the rod.
rod in and out slowly to remove the fluid from the cylinder.

Assembly: Grease the piston where the nut contacts the
Put the base end of the cylinder in a vise. piston. Do not get grease on the threads. Install the new
nut (Item 1) [Figure 20-22-5]. Use Loctite® while
Figure 20-22-4 tightening the nut.
Assembly: Tighten the nut to 190 N•m (140 ft-lb) torque.
Figure 20-22-6
3
2
1
1
4
P-43212
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-22-4]. P16295

183 N•m (135 ft-lb) torque. Remove the O-ring (Item 1), and seal (Item 2) from the
piston (Item 3) [Figure 20-22-6].
NOTE: The piston center hole (Item 4) [Figure 20-22-

6] has a bevel on one end. The bevel goes
toward the rod when assembling.
120 of 692 20-22-4

Figure 20-22-7
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-22-9] from

P7424 the cylinder head.
Figure 20-22-10
stretch it until it fits the piston [Figure 20-22-7]. Allow the

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

seal into place.
1
Figure 20-22-8
3 1
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal
(Item 1), toward the outside of the head (Item 2) [Figure
2 20-22-10].
P-48039

ring (Item 3) [Figure 20-22-8] from the cylinder head.

[Figure 20-22-8] were replaced by a one-piece
seal. Use the version currently supplied
through parts.
121 of 692 20-22-5

Figure 20-22-11
P7425

P-48042 handles to collapse the rod seal [Figure 20-22-13].
Reverse the disassembly procedure to assemble the

Remove the rod seal (Item 1) [Figure 20-22-11] from the Bob-Tach cylinder.
cylinder head.

Figure 20-22-12
P-48043A P7427

[Figure 20-22-12].

(Item 1) [Figure 20-22-12] must be installed
toward the inside of the cylinder.
122 of 692 20-22-6

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

hydraulic control valve near the bottom, facing the front of
2 1
the loader.
Testing
IMPORTANT S2851
The hydraulic tester must be in the fully open

position before you start the engine. Connect the IN port (Item 1) [Figure 20-30-1] of the
I-2024-0284 hydraulic tester to the bottom (female) quick coupler on
the loader.

Connect the OUT port (Item 2) [Figure 20-30-1] of the
WARNING hydraulic tester to the top (male) quick coupler on the
loader.
When the engine is running during service, the Engage the parking brake. Lower the seat bar. Start the
driving and steering controls must be in neutral and engine. Press the PRESS TO OPERATE button.
cause injury or death. Figure 20-30-2
W-2006-1209
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
W-2017-0286
The tools listed will be needed to do the following

S0186
procedure:
MEL10003 - Hydraulic Tester Move the handle all the way to the right, to put the control
MEL10006 - Hydraulic Test Kit valve in the locked position for a constant flow of
hydraulic fluid under pressure to the quick couplers
Turn the key switch to the OFF position. To release the [Figure 20-30-2].
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for Move the handle out of the locked position before leaving
three seconds. the operator cab.
123 of 692 20-30-1

MAIN RELIEF VALVE (CONT’D) Removal And Installation
Testing (Cont’d) Raise the operator cab. (See Raising on Page 10-30-1.)
Watch the flow meter on the hydraulic tester to make sure Figure 20-30-4
the flow is correct. Increase the engine speed to full rpm.
See Specifications, for both flow and pressure

specifications of the hydraulic system. (See Hydraulic
System on Page SPEC-10-3.)
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

relief valve opens. Check the relief pressure.
If the relief pressure is not correct, stop the engine and 1

adjust the main relief valve.
Adjusting S35965
Figure 20-30-3
Clean the area around the control valve. Loosen and
remove the main relief valve (Item 1) [Figure 20-30-4].

Remove the O-rings and back-up washers [Figure 20-
O-ring 30-3].
Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.
1 Install new O-rings and back-up washers. Install the main

relief valve (Item 1) [Figure 20-30-4] and tighten. Check
Back-up the pressure again.
Installation: Tighten the main relief valve to 47 - 54 N•m

B-6764 (35 - 40 ft-lb) torque.
If the pressure is not correct, adjust the main relief valve.

Remove the end cap (Item 1) [Figure 20-30-3].
WARNING
Turn the adjusting screw in or out until the pressure is
correct. AVOID INJURY OR DEATH
NOTE: If the correct pressure cannot be reached, servicing machine. Read and understand the
replace the main relief valve. Check the Operation & Maintenance Manual, Operator’s
pressure setting of the new relief valve. Handbook and signs (decals) on machine. Follow
W-2003-0807
124 of 692 20-30-2

MAIN RELIEF VALVE (SJC) Lift and block the loader. (See LIFTING AND BLOCKING
Description
Figure 20-31-1
The main relief valve limits the hydraulic system pressure
by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
2 1
the loader.
Testing
IMPORTANT S2851

position before you start the engine. Connect the IN port (Item 1) [Figure 20-31-1] of the
I-2024-0284 hydraulic tester to the bottom (female) quick coupler on
the loader.

Connect the OUT port (Item 2) [Figure 20-31-1] of the
WARNING hydraulic tester to the top (male) quick coupler on the
loader.
When the engine is running during service, the Engage the parking brake. Lower the seat bar. Start the
driving and steering controls must be in neutral and engine. Press the PRESS TO OPERATE button.
cause injury or death. Figure 20-31-2
W-2006-1209
(SJC) Right Steering Control Lever
WARNING
W-2017-0286
1
procedure: P-73289
MEL10003 - Hydraulic Tester

MEL10006 - Hydraulic Test Kit Push the switch (Item 1) [Figure 20-31-2] to give the
front quick couplers a constant flow of fluid.
Turn the key switch to the OFF position. To release the
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds.
125 of 692 20-31-1

MAIN RELIEF VALVE (SJC) (CONT’D) Figure 20-31-4
Testing (Cont’d)
Watch the flow meter on the hydraulic tester to make sure

the flow is correct. Increase the engine speed to full rpm.
2
2
See the Specifications, for both flow and pressure
specifications of the hydraulic system. (See Hydraulic
System on Page SPEC-10-3.)
1
Check the free flow specification.
3
Turn the restrictor control, on the tester, until the main 3
relief valve opens. Check the relief pressure.
EM1016
If the relief pressure is not correct, stop the engine and
adjust the main relief valve.
Adjusting
Turn the adjusting screw in or out until the pressure is
If the pressure is not correct, adjust the main relief valve. correct.
Figure 20-31-3 NOTE: If the correct pressure cannot be reached,

replace the main relief valve. Check the
pressure setting of the new relief valve.
S35974
Loosen the screw (Item 1) [Figure 20-31-3] and push the

lift actuator down for easier access to the main relief
valve.
126 of 692 20-31-2

MAIN RELIEF VALVE (SJC) (CONT’D) Figure 20-31-7
Figure 20-31-5
S9970
Clean the area around the control valve. Loosen and

remove the main relief valve (Item 1) [Figure 20-31-7].
S35975 Remove the O-rings (Item 2) and back-up washers (Item

3) [Figure 20-31-4].

Disconnect the hose (Item 1) [Figure 20-31-5] from the Clean the main relief valve in clean solvent. Use air
bottom of the bob-tach (power) block to provide extra pressure to dry the valve.
space.
Install new O-rings and back-up washers. Install the main
Figure 20-31-6 relief valve (Item 1) [Figure 20-31-7] and tighten. Check
the pressure again.
Installation: Tighten the main relief valve to 47 - 54 N•m

(35 - 40 ft-lb) torque.
1 WARNING
servicing machine. Read and understand the
S35974
Remove the two screws (Item 1) [Figure 20-31-6] and correct function after adjustments, repairs or
pull the lift actuator out for easier access to the main service. Untrained operators and failure to follow
relief valve. instructions can cause injury or death.
W-2003-0807
127 of 692 20-31-3

128 of 692
20-31-4
HYDRAULIC CONTROL VALVE
Description
The hydraulic control valve is located inside the

IMPORTANT
mainframe, below the operator cab.
When repairing hydrostatic and hydraulic systems,
The hydraulic control valve is the hydraulic component clean the work area before disassembly and keep all
that uses spools to direct the flow of hydraulic fluid to the parts clean. Always use caps and plugs on hoses,
lift, tilt and auxiliary functions. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The lift and tilt functions are operated using mechanical I-2003-0888
linkages to connect the foot pedals to the lift and tilt
spools.
Lift and block the loader. (See LIFTING AND BLOCKING
The auxiliary functions are operated using mechanical THE LOADER on Page 10-10-1.)
linkages to connect the right steering lever to the auxiliary
spool. Move the lever to the right or left to activate the Raise the lift arms and install an approved lift arm
auxiliary hydraulics. support device. (See Installing on Page 10-20-1.)
The hydraulic control valve contains a main relief valve Raise the operator cab. (See Raising on Page 10-30-1.)
which is adjustable.
Removal And Installation Clean the area around the control valve.
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)

DANGER Open the rear door of the loader.
NOTE: Before disconnecting the tubelines, first mark

the tubelines and the fittings to make sure the
tubelines are on the right fitting when
connecting.
Remove the right and left steering linkage (See Linkage

Removal And Installation on Page 50-100-6.).
P-90328
Figure 20-40-1
AVOID DEATH
• Disconnecting or loosening any hydraulic 1
D-1009-0409 1
1
WARNING
Never work on a machine with the lift arms up unless S3773
support device can allow the lift arms or attachment Disconnect the three plugs (Item 1) [Figure 20-40-1]
to fall and cause injury or death. from the hydraulic control valve.
W-2059-0598
129 of 692 20-40-1

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-4
Figure 20-40-2
5 6 12
1 1
11
13
10 4
3 9
1 S3788
2
7 8
14 Remove the two screws (Item 1) [Figure 20-40-4].
S6676

lb) torque.
Disconnect the 14 hydraulic tubelines (Items 1 to 14)
[Figure 20-40-2] from the hydraulic control valve.
Figure 20-40-5

Upon disconnection, cap the tubelines and the fittings on
the hydraulic control valve.
Remove the bucket position valve (See Removal And

Installation on Page 20-100-2.).
Figure 20-40-3
2 2
S4184
Remove the hydraulic control valve from the loader by

1 means of a hoist [Figure 20-40-5].
NOTE: Make sure the hydraulic control valve is well

supported when putting it down.
EM1474
Remove the bar (Item 1) that connects the control valve

with the lever. Also remove the two chain links (Item 2)
[Figure 20-40-3].
130 of 692 20-40-2

HYDRAULIC CONTROL VALVE (CONT’D)
Identification Chart
Figure 20-40-6
G1 E2 C1
J1 F4
F5
J3 B1 MR
E3 F3
A1
H1
H2
E1
B2
A2
A3
B3 D1 F1
E1 D5
C3 C2
D3 F2 D4
D2 J4 J6

J2 J5
S9796
ITEM S100 LOADER ITEM S100 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Lift Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function F5 Auxiliary Spool
C3 Load Check Valve Auxiliary Function G1 BICS™ Valve Solenoid
D1 Anti-Cavitation Valve H1 BICS™ Lock Valve (Tilt)
Lift (Rod End) H2 BICS™ Lock Valve (Lift)
D2 Port Relief / Anti-Cavitation Valve – 27,6 MPa J1 Inlet Fluid Flow (From Pump)
(276 bar) (4000 psi) J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End)
J3 Lift Arm bypass Orifice
D3 Port Relief / Anti-Cavitation Valve – 27,6 MPa
J4 Hydraulic Reservoir
(276 bar) (4000 psi)
Tilt (Base End) J5 Lift Arm bypass Valve (Drain)
D4 Port Relief / Anti-Cavitation Valve – 27,6 MPa J6 Brake Valve
(276 bar) (4000 psi) MR Main Relief Valve – 20,7 MPa (207 bar) (3000
Tilt (Rod End) psi)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27,6 MPa (276 bar) (4000 psi) (Optional)
131 of 692 20-40-3

BICS™ Load Check Valve Removal And Installation 1
Figure 20-40-7
2
S10588
Check for free movement of the BICS™ load check valve

S10586 (Item 1) [Figure 20-40-9].
Figure 20-40-10
Remove the fitting (Item 1) [Figure 20-40-7] from the
check valve.

Remove the BICS™ load check valve (Item 2) [Figure
20-40-7].
Installation: Lubricate and tighten the valve to 74 - 88 1

N•m (55 - 65 ft-lb) torque.
Figure 20-40-8
S10590
1
Remove the snap ring (Item 1) [Figure 20-40-10] from

the fitting.
S10587
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-8].
132 of 692 20-40-4

HYDRAULIC CONTROL VALVE (CONT’D) Load Check Valve Removal And Installation (Tilt And
Auxiliary)
BICS™ Load Check Valve Removal And Installation
(Cont’d) Figure 20-40-12
Figure 20-40-11
1
2
3 2 1
S3787
S10591
Locate the tilt section load check valve (Item 1) [Figure
20-40-12] on the hydraulic control valve.
Remove the spring base (Item 1), spring (Item 2) and

spring seat (Item 3) [Figure 20-40-11] from the fitting. Locate the auxiliary section load check valve (Item 2)
[Figure 20-40-12] on the hydraulic control valve.
NOTE: The tilt and auxiliary load check valves are

interchangeable.
Figure 20-40-13
2 1 3
2
1
S4188
Pull the springs (Item 1) and poppets (Item 2) [Figure 20-

40-13] out of the hydraulic control valve.
Check the orifice in the poppet to be sure it is not

plugged.
Remove the O-ring (Item 3) [Figure 20-40-13] from the

plug.
Installation: Lightly lubricate with oil before installing and

tighten the plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
133 of 692 20-40-5

Anti-Cavitation Valve Removal And Installation (Lift,

Rod End)
3
Figure 20-40-14
2
1
S4203
1
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-15].
S4201
Check the orifice in the poppet to be sure it is not

plugged.
Remove the lift section anti-cavitation valve (Item 1)

[Figure 20-40-14] from the control valve.
plug.
Installation: Lightly lubricate with oil before installing.

IMPORTANT Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.

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
134 of 692 20-40-6

HYDRAULIC CONTROL VALVE (CONT’D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End) Figure 20-40-18
Figure 20-40-16
1
S5922
S5922
Loosen the tilt circuit port relief / anti-cavitation valve
(Item 1) [Figure 20-40-18] from the control valve.
Loosen the lift circuit port relief / anti-cavitation valve

(Item 1) [Figure 20-40-16] from the control valve. Figure 20-40-19
Figure 20-40-17
1
S4202
1
S4202
port relief / anti-cavitation valve.
port relief / anti-cavitation valve. Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
135 of 692 20-40-7

HYDRAULIC CONTROL VALVE (CONT’D) Port Relief Valve Removal And Installation
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-22

Installation (Tilt, Rod End)
Figure 20-40-20
1
S4201
S4201 Remove the port relief plug (Item 1) [Figure 20-40-22]

from the control valve.
Remove the tilt port relief / anti-cavitation valve (Item 1) Figure 20-40-23

Figure 20-40-21
S4204
1
S4202 Remove the O-rings (Item 1) [Figure 20-40-23] from the

port relief valve.
Remove the O-ring (Item 1) [Figure 20-40-21] from the Installation: Tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
136 of 692 20-40-8

HYDRAULIC CONTROL VALVE (CONT’D) Rubber Boot Removal And Installation
Plug Removal And Installation Figure 20-40-26
Figure 20-40-24
2
1
2
1
1 2
S3785
S5922
Remove the four screws (Item 1) [Figure 20-40-26] on
the rubber boot retainer plate.
At the left side of the control valve, remove the plug (Item
1) [Figure 20-40-24]. Installation: Tighten the screws to 10,5 - 11,5 N•m (95 -

105 in-lb) torque.
Installation: Always use new O-rings. Tighten to 51 - 61
N•m (38 - 45 ft-lb) torque. Remove the rubber boots (Item 2) [Figure 20-40-26]
from the retainer plate.
Figure 20-40-25
S3784
At the right side of the control valve, remove the plug

(Item 1) [Figure 20-40-25].
Installation: Always use new O-rings. Tighten to 153 -

167 N•m (113 - 123 ft-lb) torque.
137 of 692 20-40-9

HYDRAULIC CONTROL VALVE (CONT’D) Lift Spool And Detent Removal And Installation
End Cap / Spool Lock Block Removal And The tool listed will be needed to do the following
Installation procedure:
Figure 20-40-27 MEL 1278 - Detent Tool
1 MEL 1285 - Detent Spring Tool

2
3 Remove the end cap / spool lock block from the control
valve. (See End Cap / Spool Lock Block Removal And
Installation on Page 20-40-10.)
Figure 20-40-29
S4189 2
1
Remove the lift spool lock solenoid (Item 1) and the tilt

spool lock solenoid (Item 2) [Figure 20-40-27] from the
end cap / spool lock block.
Remove the four end cap / spool lock block mount screws 3
(Item 3) [Figure 20-40-27]. S5923A
Installation: Tighten the screws to 10,5 - 11,5 N•m (95 -

105 in-lb) torque. Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-29] from the lift spool.
Remove the rubber boots and retainer plate from the lift
and tilt spools. Remove the O-ring (Item 3) from the spacer (Item 1)
[Figure 20-40-29].
Figure 20-40-28
Figure 20-40-30
1
1
S3784
S5924
Remove the end cap / spool lock block (Item 1) [Figure

20-40-28] from the control valve. Remove the end cap (Item 1) [Figure 20-40-30].
138 of 692 20-40-10

Lift Spool And Detent Removal And Installation

(Cont'd) IMPORTANT
Figure 20-40-31 The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-33
1
2
S5925
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-31].
S5927
Remove the washer (Item 2) [Figure 20-40-31].
Figure 20-40-32
Put a rag around the detent assembly [Figure 20-40-33].
This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
Figure 20-40-34
2
1
1
1 2
S5926
3
Remove the screws (Item 1) [Figure 20-40-32] from the

detent bonnet. 2
S5928
Remove the detent bonnet (Item 2) [Figure 20-40-32].
Installation: Lubricate the screws and tighten to 10,5 - Remove the detent sleeve (Item 1), detent balls (Item 2)
11,5 N•m (95 - 105 in-lb) torque. and spring (Item 3) [Figure 20-40-34].
139 of 692 20-40-11


(Cont'd)
Figure 20-40-35
P-8988
1
Clamp the linkage end of the spool in a vise [Figure 20-
40-37].
S5929
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-40-38

20-40-35] from the control valve.
2
Figure 20-40-36
1
3
N-18915
S5930 Install the spring tool (Item 1) [Figure 20-40-38] over the
centering spring.
Remove the lift spool seal (Item 1) [Figure 20-40-36] NOTE: Be careful when removing the detent adapter
from the linkage end of the valve. (Item 2) [Figure 20-40-38] from the centering
spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-38]

is white on all 700 series loaders.
140 of 692 20-40-12


1
(Cont'd)
Figure 20-40-39
N-19009
1 Remove spring tool (Item 1) [Figure 20-40-41] from the

2 spring assembly.
N-18916
Figure 20-40-42

1

This will prevent the detent balls and spring from being 2
lost when the detent adapter is removed.
3
Remove the detent adapter with an Allen wrench.
Remove the back-up washer (Item 1) and spool seal 4

(Item 2) [Figure 20-40-39].
Figure 20-40-40
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-42].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-40]

from the spring assembly.
141 of 692 20-40-13

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: DO NOT USE LOCTITE® ON THE STUD
THREADS.
(Cont'd) Figure 20-40-45
Figure 20-40-43
2
1
N-18961
N-18918
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-45].
Remove the stud from the end of the spool [Figure 20-

40-43]. NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
Figure 20-40-44 this O-ring. Always replace the O-ring and
recheck the lift spool before the control valve
is replaced.
Figure 20-40-46
N-18920
Removal of the plastic plug:

N-18963
Make a center point in the plug using a 1,6 mm (1/16 in)
drill.
Install the plastic plug and O-ring in the spool [Figure 20-
Drill a hole all the way through the plug using a 2,8 mm 40-46].
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-44] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
142 of 692 20-40-14


(Cont'd)
Figure 20-40-47 2
O-ring
1 3
2
Plastic N-18958
Plug
15,2 mm
(0.60 inch) Apply grease on all the detent component surfaces
before assembly [Figure 20-40-49].
B-14712
Install the spring (Item 1) and detent balls (Item 2) into
the adapter (Item 3) [Figure 20-40-49] and compress
Install the stud and tighten until the other end of the stud with the detent pliers (Item 1) [Figure 20-40-50].

is out about 15,2 mm (0.600 inch) from the spool [Figure
20-40-47]. Figure 20-40-50
Figure 20-40-48
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-50].
Clamp the collar (Item 1) [Figure 20-40-48] in a vise. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
143 of 692 20-40-15


(Cont'd)
Figure 20-40-51
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-53].
N-19004
Remove the spring tool.
Install the spring tool (Item 1) [Figure 20-40-51] over the Check the alignment of the detent adapter and the

washer, spring, collar and detent adapter. washer.
Figure 20-40-52 Tighten the adapter to 10,5 - 11,5 N•m (95 - 105 in-lb)
torque.
NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-40-53].
2
Figure 20-40-54
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-52].
CD-15051
Install the detent balls and spring [Figure 20-40-54].
144 of 692 20-40-16


(Cont'd)
Figure 20-40-55
1 2
S5926
Install the lift spool assembly in the spool bore [Figure

20-40-57].
N-19007
Install the detent bonnet (Item 1) [Figure 20-40-57].
Hold the detent balls in place with the detent pliers Install the mounting screws (Item 2) [Figure 20-40-57].

[Figure 20-40-55].
Installation: Lubricate the screws and tighten to 10,5 -
Figure 20-40-56 11,5 N•m (95 - 105 in-lb) torque.
Figure 20-40-58
1
2
N-19008
S5925
Install the detent sleeve (Item 1) [Figure 20-40-56] to the
detent adapter.
Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-58].
145 of 692 20-40-17


(Cont'd)
Figure 20-40-59
3
1 2
1
S5923A
Install the O-ring (Item 1) on the spacer (Item 2) [Figure

20-40-61].
S5924
Install the O-ring (Item 3) and spacer (Item 2) [Figure 20-
40-61] on the lift spool.
Install the end cap (Item 1) [Figure 20-40-59].

Figure 20-40-62
Figure 20-40-60
S3794
S5930
Install the O-ring (Item 1) [Figure 20-40-62] on the

Install the spool seal (Item 1) [Figure 20-40-60] on the control valve.
linkage end of the valve.
146 of 692 20-40-18

HYDRAULIC CONTROL VALVE (CONT’D) Tilt Spool Removal And Installation
Lift Spool And Detent Removal And Installation Remove the lift and tilt end cap / spool lock block. (See
(Cont'd) End Cap / Spool Lock Block Removal And Installation on
Page 20-40-10.)
Figure 20-40-63
Figure 20-40-65
1 2
2
3
S5932
3 S5934A
Install the end cap / spool lock block (Item 1) [Figure 20-
40-63].

Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-65] from the tilt spool.
Install the lift and tilt spool rubber boots and mount plate
(Item 2) and install the four mounting screws (Item 3)
Remove the O-ring (Item 3) from the spacer (Item 1)
[Figure 20-40-63].
[Figure 20-40-65].
Installation: Tighten the screws to 10,5 - 11,5 N•m (95 -
Figure 20-40-66
105 in-lb) torque.
Figure 20-40-64
S5935
S5933 Remove the end cap (Item 1) [Figure 20-40-66].
Use an Ohm meter to measure the lock solenoid coils

resistance.
The correct resistance for the coil is 5.5 ± 0.28 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

(Item 2) [Figure 20-40-64] lock solenoids and tighten to
51 - 61 N•m (38 - 45 ft-lb) torque.
147 of 692 20-40-19

Tilt Spool Removal And Installation (Cont'd)
Figure 20-40-67
1
2
S5938
Check and replace the O-ring (Item 1) [Figure 20-40-69]

S5936 before replacing the spool centering block.
Figure 20-40-70
[Figure 20-40-67].

Figure 20-40-68
1
S5939
Remove the tilt spool, centering spring, back-up washer

and spool seal [Figure 20-40-70].
S6602 Installation: Always use a new spool seal.
Remove the three bolts (Item 1) [Figure 20-40-68] from

the spool centering block and remove the spool centering
block.
Installation: Tighten the bolts to 10,5 - 11,5 N•m (95 -

105 in-lb) torque.
148 of 692 20-40-20

Figure 20-40-71 2 1
3
1 4
N-18944A
N-18942 3) and washer (Item 4) [Figure 20-40-73].
Figure 20-40-74
Put the linkage end of the spool in the vise [Figure 20-
40-71].
2

Install the spool tool (Item 1) [Figure 20-40-71] over the 1
centering spring.
Figure 20-40-72
1 1
S5940 N-18943
Remove the spool seal(s) (Item 1) and the back-up

Installation: Always use a new spool seal.

N-19014
Remove the bolt (Item 1) [Figure 20-40-72] holding the

centering spring to the spool.
Installation: Tighten the bolt to 10,5 - 11,5 N•m (95 - 105

in-lb) torque.
Remove spring tool from the spring assembly.
149 of 692 20-40-21

Auxiliary Spool Removal And Installation

procedure:
MEL 1278 - Detent Tool
MEL 1285 - Detent Spring Tool

1
2
Remove the end cap / spool lock block from the control
valve (See End Cap / Spool Lock Block Removal And
Figure 20-40-75 S5936

[Figure 20-40-77].
Figure 20-40-78
1

S5941
1
Remove the spacer (Item 1) [Figure 20-40-75] from the
auxiliary spool.
Figure 20-40-76
S6602
1 Remove the three bolts (Item 1) [Figure 20-40-78] from

the spool centering block and remove the spool centering
block.
Installation: Tighten the bolts to 10,5 - 11,5 N•m (95 -

105 in-lb) torque.
S3796
150 of 692 20-40-22

Auxiliary Spool Removal And Installation (Cont'd)
Figure 20-40-79
2 1
3
1
2
S5943
Remove the detent sleeve (Item 1), detent balls (Item 2)

S5938 and spring (Item 3) [Figure 20-40-81].
Figure 20-40-82
Check and replace the O-ring (Item 1) [Figure 20-40-79]
before replacing the spool centering block.

Figure 20-40-80
S5944
Remove the auxiliary spool assembly and seal (Item 1)

S5942 [Figure 20-40-82] from the control valve.

lost when the detent sleeve is removed.
151 of 692 20-40-23

Auxiliary Spool Removal And Installation (Cont'd) 2
Figure 20-40-83
1
3
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-85] over the

S5945 centering spring.
NOTE: Be careful when removing the detent adapter

Remove the auxiliary spool seal (Item 1) [Figure 20-40- (Item 2) [Figure 20-40-85] from the centering
83] from the linkage end of the valve. spring, as it is under spring pressure.

Figure 20-40-84 NOTE: The centering spring (Item 3) [Figure 20-40-85]
is white on all 700 series loaders.
Figure 20-40-86
P-8988
1
2
N-18916
40-84].
NOTE: Protect spool before clamping in vise. Put a rag around the detent assembly [Figure 20-40-86].
lost when the detent adapter is removed.
Remove the detent adapter with an Allen wrench.
Remove the back-up washer (Item 1) and spool seal

(Item 2) [Figure 20-40-86].
152 of 692 20-40-24


1
2
Figure 20-40-87
3
N-18919A
N-19004 3) and washer (Item 4) [Figure 20-40-89].
Figure 20-40-90
Remove the detent adapter (Item 1) [Figure 20-40-87]
from the spring assembly.

Figure 20-40-88
N-18918
Remove the stud from the end of the spool [Figure 20-
N-19009 40-90].
Remove spring tool (Item 1) [Figure 20-40-88] from the

spring assembly.
153 of 692 20-40-25

HYDRAULIC CONTROL VALVE (CONT’D) NOTE: Check the O-ring for damage. The auxiliary
spool will have an internal leak if there is
Auxiliary Spool Removal And Installation (Cont'd) damage to this O-ring. Always replace the O-
ring and recheck the auxiliary spool before
Figure 20-40-91 the control valve is replaced.
Figure 20-40-93
N-18920
Removal of the plastic plug: N-18963
Make a center point in the plug using a 1,6 mm (1/16 in)

Install the plastic plug and O-ring in the spool [Figure 20-
drill.
40-93].
Drill a hole all the way through the plug using a 2,8 mm
Figure 20-40-94
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-91] into the plug. O-ring
break the tap.
NOTE: DO NOT USE LOCTITE® ON THE STUD

THREADS.
Plastic
Figure 20-40-92 Plug
15,2 mm
(0.60 inch)
B-14712
2
1 Install the stud and tighten until the other end of the stud
is out about 15,2 mm (0.6 inch) from the spool [Figure
20-40-94].
N-18961

154 of 692 20-40-26

Figure 20-40-95
1
1
N-18968
Install the detent adapter to the collar [Figure 20-40-97].

N-18967
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
Clamp the collar (Item 1) [Figure 20-40-95] in a vise. to the auxiliary spool not the detent balls.
Hold the detent adapter and collar together to

Figure 20-40-96 prevent the detent balls and spring from
falling out.
Figure 20-40-98
2
1 3
2
N-18958
Apply grease on all the detent component surfaces

N-19004
before assembly [Figure 20-40-96].
Install the spring (Item 1) and detent balls (Item 2) into Install the spring tool (Item 1) [Figure 20-40-98] over the
the adapter (Item 3) [Figure 20-40-96] and compress washer, spring, collar and detent adapter.
with the detent pliers (Item 1) [Figure 20-40-97].
155 of 692 20-40-27

Figure 20-40-99
1 CD-15051
Install the detent balls and spring [Figure 20-40-101].

N-18917
Figure 20-40-102
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-99].

Figure 20-40-100
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-40-102].
N-19005
Install the spring assembly to the auxiliary spool hand

tight [Figure 20-40-100].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
Tighten the adapter to 10,5 - 11,5 N•m (95 - 105 in-lb)

torque.
NOTE: The adapter must fit in the center of the

156 of 692 20-40-28

HYDRAULIC CONTROL VALVE (CONT’D) Solenoid Removal And Installation
Auxiliary Spool Removal And Installation (Cont'd) Figure 20-40-104
Figure 20-40-103
1
S3787
N-19008
Remove the nut (Item 1) [Figure 20-40-104] from the
solenoid stem.
Install the detent sleeve (Item 1) [Figure 20-40-103] to
the detent adapter. Installation: Tighten the nut to 6 N•m (53 in-lb) torque.

Remove the solenoid coil (Item 2) [Figure 20-40-104].
Figure 20-40-105
N-18693A
Remove the O-rings (Item 1) [Figure 20-40-105] from

both ends of the solenoid coil.
Use an Ohm meter to measure the solenoid coil

resistance.
157 of 692 20-40-29

HYDRAULIC CONTROL VALVE (CONT’D) Lock Valve Removal And Installation
Solenoid Removal And Installation (Cont’d) Figure 20-40-108
Figure 20-40-106
1 2
1
S3787
S6603
Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-108] is for the lift
Remove the solenoid stem (Item 1) [Figure 20-40-106].
circuit.
Installation: Tighten the stem to 27 - 33 N•m (20 - 24 ft-

Figure 20-40-109
lb) torque.
Figure 20-40-107
1 1 1
3 2 2
S4193
S4187
Remove the lift lock valve (Item 1) [Figure 20-40-109]
from the back of the control valve.
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-40-107] from the cartridge. Installation: Tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any showing

excessive wear.
NOTE: The screen (Item 3) [Figure 20-40-107] can be

cleaned with solvent. If it is torn or worn it
needs to be replaced.
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
158 of 692 20-40-30

Lock Valve Removal And Installation (Cont’d)
Figure 20-40-110
1 2
1
1 1
1
S4191
2 2 2
Remove the lift spool lock solenoid (Item 1) [Figure 20-

S4194 40-112].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

Remove the O-rings (Item 1) and back-up rings (Item 2) 40-112].
[Figure 20-40-110] from the lift lock valve, and replace

with new ones. Installation: Lubricate the O-rings and tighten the spool
lock solenoids to 51 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-111
Figure 20-40-113
1
S3587
S5946
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-

111]. Remove the tilt lock valve (Item 1) [Figure 20-40-113]
from the front of the control valve.
159 of 692 20-40-31

HYDRAULIC CONTROL VALVE (CONT’D) Lift Arm Bypass Orifice Removal And Installation
Lock Valve Removal And Installation (Cont’d) Figure 20-40-115
Figure 20-40-114
1
1
1 1
2 2 2
S4191
S4194
valve.
[Figure 20-40-114] from the tilt lock valve, and replace Figure 20-40-116

with new ones.
P-51437
Inspect the lift arm bypass orifice (Item 1) [Figure 20-40-

116].
NOTE: This orifice is not removable from the valve

casting.
160 of 692 20-40-32

Main Relief Valve Removal And Installation
Figure 20-40-117
S4191
Remove the main relief valve (Item 1) [Figure 20-40-

117].

Figure 20-40-118
S4192
Remove the O-rings (Item 1) [Figure 20-40-118] from the

main relief valve.
Installation: Tighten main relief valve to 51 - 61 N•m (38

- 45 ft-lb) torque.
161 of 692 20-40-33

162 of 692
20-40-34
HYDRAULIC CONTROL VALVE (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
S10577
The hydraulic control valve is located inside the support. Replace if damaged.
mainframe on the right hand side, below the operators D-1009-0409

cab.
The hydraulic control valve [Figure 20-41-1] is the

hydraulic component that uses spools to direct the flow of
hydraulic fluid to the lift, tilt and auxiliary functions.
WARNING
The lift and tilt functions in the SJC hydraulic control valve Never work on a machine with the lift arms up unless
are operated using electronic control handles that send the lift arms are secured by an approved lift arm
an electronic signal to the electronic actuators to move support device. Failure to use an approved lift arm
the lift and tilt spools in the control valve. support device can allow the lift arms or attachment
The auxiliary function is operated by pilot pressure. W-2059-0598
There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handle/lever. The activated solenoid
sends pilot pressure oil to one side of the spool and
forces the spool to shift. IMPORTANT
The hydraulic control valve also contains a main relief When repairing hydrostatic and hydraulic systems,
valve which is adjustable. clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Lift and block the loader. (See Procedure on Page 10-10-

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

support device. (See Installing on Page 10-20-1.)
163 of 692 20-41-1

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-41-4
Raise the operator cab. (See Raising on Page 10-30-1.) 2
Clean the area around the control valve. 3

1
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the bucket position valve. (See Removal And

Figure 20-41-2
2 S10569
Disconnect and remove the tubeline (Item 1) [Figure 20-

1 41-4] from the control valve.

41-4] from the control valve.
3 3

control valve.
2
Figure 20-41-5
S9849
Disconnect the connector (Item 1) [Figure 20-41-2] from

the solenoid.
Cut the tie-strap (Item 2) [Figure 20-41-2].
Disconnect the two connectors (Item 3) [Figure 20-41-2] 2

from both auxiliary solenoids.
Figure 20-41-3
1 1
S10570
Remove the bolt and nut (Item 1) [Figure 20-41-5]

holding the tubeline clamp.
Remove the tubeline clamp (Item 2) [Figure 20-41-5].
S9850
Mark and disconnect the two connectors (Item 1) [Figure

20-41-3] from the lift and tilt actuators.
164 of 692 20-41-2

Removal And Installation (Cont'd)

1
Figure 20-41-6
1 1
1
2
1
S10573
3 Disconnect the three tubelines (Item 1) [Figure 20-41-8].

S10571
Figure 20-41-9
Disconnect the two auxiliary tubelines (Item 1) [Figure
20-41-6].

Disconnect the hose (Item 2) [Figure 20-41-6].
1
Disconnect and remove the tubelines (Item 3) [Figure
20-41-6].
1
Figure 20-41-7
1 S10574
Disconnect and remove the three tubelines (Item 1)

1 [Figure 20-41-9].
S10572
Disconnect the tubelines (Item 1) [Figure 20-41-7].
165 of 692 20-41-3

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Actuator Removal And Installation
Removal And Installation (Cont'd) Remove the hydraulic control valve from the loader (See
Removal And Installation on Page 20-41-1.).
Figure 20-41-10
Figure 20-41-11
1
1 1
S10575
S10578
Remove the two mounting bolts (Item 1) [Figure 20-41-

10] fastening the control valve to the loader. Remove the two mount bolts (Item 1) [Figure 20-41-11]

from the lift actuator.
Installation: Tighten bolt to 54 - 68 N•m (40 - 50 ft-lb)
torque. Installation: Tighten the mounting bolts to 10,5 - 11,5
N•m (95 - 105 in-lb) torque.
Remove the control valve from the loader.
Figure 20-41-12
S10579
Slide the actuator mount bracket (Item 1) [Figure 20-41-

12] away from the control valve.
Pull the lift actuator away from the control valve [Figure
20-41-12].
166 of 692 20-41-4

Actuator Removal And Installation (Cont’d)
Figure 20-41-13 1
S10582
1

S10580 15] from the tilt actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

Using a drift pin and a hammer, remove the actuator N•m (90 - 100 in-lb) torque.
linkage pin (Item 1) [Figure 20-41-13] from the actuator

and lift spool. Figure 20-41-16
Remove the lift actuator and linkage pin from the valve.
Figure 20-41-14
1
1
2
S10584
Slide the actuator mount bracket (Item 1) [Figure 20-41-

S10581 16] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
Inspect the O-ring (Item 1) [Figure 20-41-14] on the 41-16].
nose of the actuator, and replace if needed.
Inspect the linkage pin (Item 2) [Figure 20-41-14] and

replace if needed.
167 of 692 20-41-5

Actuator Removal And Installation (Cont’d)
Figure 20-41-17
1
3 2
3 S10583
1
NOTE: The two longer bolts (Item 1) are used to
S10585 mount the lift actuator and end cap (Item 2) to
the control valve.
The two shorter mount bolts (Item 3) are used
Using a drift pin and a hammer, remove the actuator to mount the tilt actuator (Item 4) [Figure 20-
linkage pin (Item 1) [Figure 20-41-17] from the actuator 41-19] to the end cap.

and the tilt spool.
Installation: Tighten the mounting bolts (Item 1) [Figure
Remove the actuator and linkage pin from the valve. 20-41-19] to 10,5 - 11,5 N•m (95 - 105 in-lb) torque.
Figure 20-41-18
S10581
Inspect the O-ring (Item 1) [Figure 20-41-18] on the

nose of the actuator, and replace as needed.
Inspect the linkage pin (Item 2) [Figure 20-41-18] and

replace as needed.
168 of 692 20-41-6

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)
Figure 20-41-20
C1 J1
H1 B1 MR
J3
E2
A1
H3 H2
E3
E1
C4 B2
A2
G1 G2
A3 C3 C2 B3 D1 F1
E1 D5
D2 D3 F2 D4
J4 J2 J5 J6

EM1017
ITEM S100 LOADER ITEM S100 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Lift Load Check G2 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function H1 BICS™ Valve Solenoid
C3 Load Check Valve Auxiliary Function H2 BICS™ Lock Valve (Tilt)
C4 Check Valve
H3 BICS™ Lock Valve (Lift)
D1 Anti-Cavitation Valve
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief / Anti-Cavitation Valve – 275 bar J2 Outlet Fluid Flow (Return to Tank)
(4000 psi) J3 Lift Arm Bypass Orifice
Lift (Base End) J4 Hydraulic Reservoir
D3 Port Relief / Anti-Cavitation Valve – 275 bar J5 Lift Arm Bypass Valve
(4000 psi)
J6 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 207 bar (3000 psi)
D4 Port Relief / Anti-Cavitation Valve – 275 bar
(4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
275 bar (4000 psi) (Optional)
169 of 692 20-41-7

BICS™ Load Check Valve Removal And Installation 1
Figure 20-41-21
2
S10588
Check for free movement of the BICS™ load check valve

S10586 (Item 1) [Figure 20-41-23].

check valve.

Remove the BICS™ load check valve (Item 2) [Figure
20-41-21].
Installation: Lubricate and tighten the valve to 74 - 88

Figure 20-41-22
S10587
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-41-22].
170 of 692 20-41-8

Load Check Valve Removal And Installation (Tilt And

Auxiliary)
4
Figure 20-41-24
1
3
2
1
P-51453
2

20-41-25].
S10592
Check the orifice (Item 3) [Figure 20-41-25] in the
poppet to be sure it is not plugged.
At the front side of the control valve locate the tilt section

load check valve (Item 1) [Figure 20-41-24]. Remove the O-ring (Item 4) [Figure 20-41-25] from the
plug.
At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-41-24].
Installation: Lightly lubricate and tighten the plug to 51 -

61 N•m (38 - 45 ft-lb) torque.
NOTE: The tilt and auxiliary load check valves are

interchangeable.
171 of 692 20-41-9

Anti-Cavitation Valve Removal And Installation (Lift,

Rod End)
4
Figure 20-41-26
1
3
2
1
P-51453

20-41-27].
S10593
Check the orifice (Item 3) [Figure 20-41-27] in the
poppet to be sure it is not plugged.
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-41-26]. Remove the O-ring (Item 4) [Figure 20-41-27] from the
plug.
Installation: Lightly lubricate and tighten the plug to 51 -
IMPORTANT
damage the system.
I-2003-0888
172 of 692 20-41-10

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End)
Installation (Lift, Base End) Figure 20-41-30
Figure 20-41-28
S10593
S10593
Remove the tilt port relief / anti-cavitation valve (Item 1)
[Figure 20-41-30] from the base end of the tilt section.
Loosen the lift circuit port relief / anti-cavitation valve

(Item 1) [Figure 20-41-28]. Installation: Lightly lubricate with oil and tighten to 51 -
Installation: Lightly lubricate with oil and tighten to 51 -
61 N•m (38 - 45 ft-lb) torque. Figure 20-41-31
Figure 20-41-29
1
1
S10595
S10594
173 of 692 20-41-11

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Port Relief / Anti-Cavitation Valve Removal And
Installation
Installation (Tilt, Rod End) Figure 20-41-34
Figure 20-41-32
S10593
S10593
Remove the port relief / anti-cavitation valve (Item 1)
[Figure 20-41-34] from the auxiliary circuit of the control
Remove the tilt port relief / anti-cavitation valve (Item 1) valve.

[Figure 20-41-32] from the rod end of the tilt section.
Installation: Lightly lubricate with oil and tighten to 51 -
Installation: Lightly lubricate with oil and tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-41-35
Figure 20-41-33
S10597
S10596

Remove the O-ring (Item 1) [Figure 20-41-33] from the port relief / anti-cavitation valve.
174 of 692 20-41-12

Plug Removal And Installation
Figure 20-41-36
1 1
S10701
Remove the plug (Item 1) [Figure 20-41-38] at the side

S10599 of the control valve.
Installation: Tighten the plug to 153 - 167 N•m (113 -

Remove the plug (Item 1) [Figure 20-41-36] at the side 123 ft-lb) torque.
of the control valve.

Figure 20-41-39
Installation: Tighten the plug to 54 N•m (40 ft-lb) torque.
Figure 20-41-37
S10700
S10700 Remove the O-ring (Item 1) [Figure 20-41-39].
Remove the O-ring (Item 1) [Figure 20-41-37].
175 of 692 20-41-13

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Lift Spool And Detent Removal And Installation
End Cap Block Removal And Installation The tool listed will be needed to do the following
procedure:
Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation on Page 20-41- MEL 1285 - Spring Tool
4.)
Remove the end cap block from the control valve. (See
Figure 20-41-40 End Cap Block Removal And Installation on Page 20-41-
14.)
Figure 20-41-42
1
S10702

Remove the two end cap block mount screws (Item 1)
S10704
[Figure 20-41-40].
Installation: Tighten the screws to 10,5 - 11,5 N•m (95 - Remove the O-ring (Item 1) [Figure 20-41-42].
105 in-lb) torque.
Figure 20-41-43
Figure 20-41-41
2
1
1
3
S10705A
S10703

Remove the end cap block (Item 1) [Figure 20-41-41] 20-41-43] from the lift spool.
[Figure 20-41-43].
176 of 692 20-41-14


(Cont'd)
Figure 20-41-44 1
S10708
1 Remove the lift spool assembly (Item 1) and seal (Item 2)

S10706
Figure 20-41-47
Remove the two screws (Item 1) [Figure 20-41-44] from

the lift spool end cap.
Installation: Lubricate the screws and tighten to 10,5 -

11,5 N•m (95 - 105 in-lb) torque.
Figure 20-41-45
S10709
1
Remove the lift spool seal (Item 1) [Figure 20-41-47]

from the linkage end of the valve.
S10707
Remove the lift spool end cap (Item 1) [Figure 20-41-45]

177 of 692 20-41-15


(Cont'd)
1
Figure 20-41-48
N-190146

centering spring to the spool.
P-51772
in-lb) torque.

41-48]. Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-51
Figure 20-41-49
3
4 1
1
P-51776
P-51773
centering spring.
178 of 692 20-41-16

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
Lift Spool And Detent Removal And Installation this O-ring. Always replace the O-ring and
(Cont'd) recheck the lift spool before the control valve
is replaced.
Figure 20-41-52
Figure 20-41-54
N-18920
P-74184
Removal of the plastic plug:

Make a center point in the plug using a 1,6 mm (1/16 in) Install the plastic plug and O-ring in the spool [Figure 20-
drill. 41-54].
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-41-52] into the plug.

break the tap.
NOTE: DO NOT USE LOCTITE® ON THE STUD

THREADS.
Figure 20-41-53
P-74183

179 of 692 20-41-17

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Installation: Tighten the screws to 10,5 - 11,5 N•m (95 -
105 in-lb) torque.
Tilt Spool Removal And Installation
Figure 20-41-57
procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve (See
End Cap Block Removal And Installation on Page 20-41- 2
14.).
Figure 20-41-55
S10712
Remove the spool centering block (Item 1) [Figure 20-


2
1 Figure 20-41-58
3 S10710A
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 2

1
20-41-55] from the tilt spool.

[Figure 20-41-55].
Figure 20-41-56
S10713
Remove the lift spool assembly (Item 1) and seal (Item 2)

1 1
S10711
Remove the three screws (Item 1) [Figure 20-41-56]

from the spool centering block.
180 of 692 20-41-18

Figure 20-41-59 1
N-19014
1

S10733 centering spring to the spool.

Remove the seal (Item 1) [Figure 20-41-59] from the in-lb) torque.
linkage end of the valve.

Remove spring tool from the spring assembly.
Figure 20-41-60
Figure 20-41-62
1
2 1
3
N-18942.
N-18944A
Put the linkage end of the spool in the vice [Figure 20-
41-60]. Inspect the adapter (Item 1), collar (Item 2), spring (Item
centering spring.
181 of 692 20-41-19

Auxiliary Spool Removal And Installation
Figure 20-41-63
S10714
1 1
Remove the spring (Item 1) and center spring retainer
S10711 (Item 2) [Figure 20-41-65] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

Remove the three screws (Item 1) [Figure 20-41-63] 20-41-65] must be replaced, replace the
from the spool centering block. retainer on the opposite end of the spool also.

Installation: Tighten the bolt to 10,5 - 11,5 N•m (95 - 105 Figure 20-41-66
in-lb) torque.
Figure 20-41-64
2
2
1
S10715
1
S10712 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-41-66] from the auxiliary spool.
Remove the spool centering block (Item 1) [Figure 20-

182 of 692 20-41-20

Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-67
1
2
S10718
1
Remove the auxiliary spool (Item 1) [Figure 20-41-69].

S10716
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-41-67] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure
20-41-67] must be replaced, replace the
retainer on the opposite end of the spool,
also.
Figure 20-41-68
1
S10717

20-41-68] from the auxiliary spool.
183 of 692 20-41-21

Auxiliary Solenoid Removal And Installation

2
Figure 20-41-70
1
S10721
1
Remove the two bolts (Item 1) [Figure 20-41-72] from
S10720 the solenoid.
Installation: Tighten the bolts to 5 - 8 N•m (48 - 72 in-lb)

Remove the two bolts (Item 1) [Figure 20-41-70] from torque.
the solenoid.

Remove the solenoid (Item 1) [Figure 20-41-72] from the
Installation: Tighten the bolts to 5 - 8 N•m (48 - 72 in-lb) hydraulic control valve.
torque.
Figure 20-41-73
hydraulic control valve.
Figure 20-41-71
2
S10722
2 Remove the O-rings (Item 1) and back-up rings (Item 2)

S10722 [Figure 20-41-73] from the solenoid.
Use an ohmmeter to measure the solenoid coil

Remove the O-rings (Item 1) and back-up rings (Item 2) resistance.
[Figure 20-41-71] from the solenoid.
Use an ohmmeter to measure the solenoid coil
resistance.
184 of 692 20-41-22

Solenoid Removal And Installation
Figure 20-41-74
1
1
S10724

S10723
Installation: Lubricate the O-rings and tighten the stem
to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-74] from the
solenoid stem. Figure 20-41-77

Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-74].

3
Figure 20-41-75 2
N-18694

[Figure 20-41-77] from the stem.
N-18693A Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any showing

Remove the O-rings (Item 1) [Figure 20-41-75] from both excessive wear.
ends of the solenoid coil.
NOTE: The screen (Item 3) [Figure 20-41-77] can be
Use an ohmmeter to measure the solenoid coil cleaned with solvent. If it is torn or worn it
resistance. needs to be replaced.
The correct resistance for the coil is 9.79 ± 0.29 ohm. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-75] and

[Figure 20-41-77] and new back-up rings (Item 2)
[Figure 20-41-77] on the solenoid stem.
185 of 692 20-41-23

Lock Valve Removal And Installation
Figure 20-41-78
1
1
1
1
2
1
2
2
2
P-51564

S10725 [Figure 20-41-80] from the lift lock valve, and replace
with new.
Locate the two BICS™ lock valves, (Item 1) is for the tilt Figure 20-41-81
circuit, and (Item 2) [Figure 20-41-78] is for the lift circuit.

Figure 20-41-79
S10727
S10726 Remove the tilt lock valve (Item 1) [Figure 20-41-81]

from the back of the control valve.
Remove the lift lock valve (Item 1) [Figure 20-41-79] Installation: Lightly lubricate the lock valve O-rings and
from the back of the control valve. tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.
Installation: Lightly lubricate the lock valve O-rings and

tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.
186 of 692 20-41-24

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Lift Arm Bypass Orifice Removal And Installation
Lock Valve Removal And Installation (Cont’d) Figure 20-41-83
Figure 20-41-82
1
1
1
1
1
2
2 S10728
2
P-51564
valve.
[Figure 20-41-82] from the tilt lock valve, and replace Figure 20-41-84

them.
S10729
Inspect the lift arm bypass orifice (Item 1) [Figure 20-41-

84].
NOTE: This orifice is not removable from the valve

casting.
187 of 692 20-41-25

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Check Valve Removal And Installation
Main Relief Valve Removal And Installation Figure 20-41-87
Figure 20-41-85
S10732
S10730
Remove the check valve fitting (Item 1) [Figure 20-41-
87] from the hydraulic control valve.
Remove the main relief valve (Item 1) [Figure 20-41-85].
Figure 20-41-88

Figure 20-41-86
1 1
1
P-68869
S10731
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

Remove the O-rings from the main relief valve (Item 1) 88] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
[Figure 20-41-86]. torque.
Installation: Always use new O-rings. Tighten to 51 - 61

188 of 692 20-41-26

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)
Check Valve Removal And Installation (Cont’d)
Figure 20-41-89
P-68870
Inspect the screen (Item 1) [Figure 20-41-89].
189 of 692 20-41-27

190 of 692
20-41-28
LIFT ARM BYPASS CONTROL VALVE Removal And Installation
Description
The lift arm bypass control valve is located on the right

side of the machine close to the engine speed control.
DANGER
The lift arm bypass control valve is manually operated by
pulling up on the Control Knob (Item 1) [Figure 20-50-1]
and turning the knob clockwise 90°. The valve releases
the hydraulic fluid from the base end of the lift cylinder(s)
which allows the lift arm to slowly lower to the transport
position.
Testing P-90328
Figure 20-50-1 AVOID DEATH

1 support. Replace if damaged.
D-1009-0409

WARNING
S4225
Raise the lift arms 2 m (6 feet) off the ground. Stop the
engine. Turn the Lift Arm bypass Control Knob (Item 1) W-2059-0598
[Figure 20-50-1] clockwise 90°. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower. Install jack stands under the rear corners of the loader.
The knob should return to its initial position. Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
10-20-1.)
191 of 692 20-50-1

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-4
Figure 20-50-2
1 2
S2910
Disconnect the base end lift tubeline (Item 1) [Figure 20-

S4225 50-4] from the Lift Arm Bypass valve.
Disconnect the motor case drain hose (Item 2) [Figure

Hold the Lift Arm Bypass Control knob (Item 1) [Figure 20-50-4].
20-50-2] and loosen the jam nut on the Lift Arm bypass

valve shaft. Figure 20-50-5
Figure 20-50-3
1 2
1
S4228
S4226
Remove the two mounting bolts / nuts (Item 1) [Figure

20-50-5].
Remove the Lift Arm Bypass Control knob (Item 1) and
the jam nut (Item 2) [Figure 20-50-3] from the Lift Arm Installation: Tighten the mounting bolts to 21 - 23 N•m
Bypass valve shaft. (15.5 - 17 ft-lb) torque.
192 of 692 20-50-2

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-50-7
Figure 20-50-6
2
1
2
1
S4229
S4229
Remove the bypass valve (Item 1) from the valve block
(Item 2) [Figure 20-50-7]. Inspect the bypass valve for
Remove the lift arm bypass control valve (Item 1) [Figure damage and replace if necessary.
20-50-6].

Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
Remove the rubber washer (Item 2) [Figure 20-50-6]. lb) torque.
Inspect the hydraulic fittings on the valve block for

damage and replace if necessary.
193 of 692 20-50-3

194 of 692
20-50-4
HYDRAULIC PUMP This procedure will require one operator in the cab and
one operator running the tester.
Description
Start the engine and run at low idle. Press the Front
The hydraulic gear pump is attached to the end of the Auxiliary button. Engage the front auxiliary with the
hydrostatic pumps and is located on the right side of the trigger on the right handle. Make sure the tester is
loader between the hydraulic control valve and the connected correctly. If no flow is indicated on the tester,
engine. the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
The hydraulic gear pump is a combination of gear pumps rpm.
that provide hydraulic flow to several hydraulic systems.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic gear pump has a dedicated charge pump. control clockwise on the tester so it reads about a 6,9
This supplies flow to the hydraulic fan motor and charge MPa (69 bar) (1000 psi).
pressure to the hydrostatic pump.
NOTE: DO NOT EXCEED 22,8 MPa (228 bar) (3300
A seal kit is available to service the hydraulic pump. If any psi).
of the main components of the pump are damaged, the
entire pump must be replaced. Turn the restrictor control (Item 2) [Figure 20-60-1] on
the tester counterclockwise to obtain free flow, the flow
Pump Test At Quick Couplers should be approximately 60,6 - 64,5 L/min (16 - 17 U.S.
gpm).
procedure: Start turning the restrictor clockwise, causing more

restriction on the flow. The GPM should drop off slightly
MEL10003 - Hydraulic Tester until the pressure reaches approximately 18,6 - 19,3 MPa
MEL10106 - Hydraulic Test Kit (186 - 193 bar) (2700 - 2800 psi).
Figure 20-60-1 At approximately 18,6 - 19,3 MPa (186 - 193 bar) (2700 -
2800 psi) the flow should start decreasing rapidly until
the pressure reaches 20,3 - 21,0 MPa (203 - 210 bar)
1 (2950 - 3050 psi).
At 20,3 - 21,0 MPa (203 - 210 bar) (2950 - 3050 psi) the
flow should be at 0 L/min (0 U.S. gpm). Turn the restrictor
(Item 2) [Figure 20-60-1] counterclockwise to free flow.
Shut the front auxiliary hydraulics off.
If flow and pressure specs are not obtained, go to Direct

Pump Testing. (See Direct Pump Test (Standard Section)
2 on Page 20-60-2.)
P-16903 S6029
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189 L/min (50 U.S. gpm).
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

the front auxiliary quick couplers.
195 of 692 20-60-1

HYDRAULIC PUMP (CONT’D) Figure 20-60-2
Direct Pump Test (Standard Section)

procedure:

MEL10106 - Hydraulic Test Kit
1 2
WARNING
S35965
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286 fitting on the control valve.
Figure 20-60-3

support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
1
WARNING
support device. Failure to use an approved lift arm S3780
W-2059-0598 Connect the INLET of the tester to the OUTLET hose
(Item 1) [Figure 20-60-2] and [Figure 20-60-3] of the
Raise the operator cab. (See Raising on Page 10-30-1.) pump.
Open the rear door of the loader. Connect the OUTLET hose (Item 2) [Figure 20-60-3]
from the tester to the fitting (Item 2) [Figure 20-60-2] on
Connect the remote start tool. (See Remote Start the control valve.
Procedure on Page 10-60-4.)
196 of 692 20-60-2

HYDRAULIC PUMP (CONT’D) Push the Maximum / Variable Flow switch (on the remote
start tool) to engage the front auxiliary hydraulics, the
Direct Pump Test (Standard Section) (Cont’d) light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (psi)
and flow (U.S. gpm). The high pressure flow must be at
least 80% of free flow.
IMPORTANT
% = HIGH PRESSURE FLOW (U.S. gpm) X 100
FREE FLOW (U.S. gpm)
position before you start the engine.
I-2024-0284
A low percentage can indicate a failed pump.
Figure 20-60-4
*(See Hydraulic System on Page SPEC-10-3.) for system
EXAMPLE: TESTER relief pressure and full rpm.
CONNECTION
Direct Pump Test (Charge Section)
Reservoir
procedure:


6661247 - Filter Assembly
Hydraulic Pump 17 KB 1212 - Elbow Fitting
15 KB 1212 - Straight Fitting
Out In Hydraulic Control 15 KB 0812 - Reducer Fitting
Valve
1
WARNING
BH-196

Sample tester connection shown [Figure 20-60-4]. of the frame before running the engine for service.
Start the engine and run at low idle rpm. Make sure the fall or move and cause injury or death.
tester is connected correctly. If no flow is indicated on the W-2017-0286
tester, the hoses are connected wrong. With the hoses
rpm*.
control (Item 1) [Figure 20-60-4] on the tester to about
6,9 MPa (68,95 bar) (1000 psi).
DO NOT exceed system relief pressure. Open the

restrictor control and record the free flow (U.S. gpm) at
full rpm*.
WARNING
W-2059-0598
197 of 692 20-60-3

Direct Pump Test (Charge Section) (Cont’d)
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
1
Tester, to prevent any contamination to the
Hydrostatic Pumps.

3
Connect the remote start tool. (See Remote Start 2
Procedure on Page 10-60-4.)
P-39248
Figure 20-60-5
Determine the proper direction of oil flow through the

2 filter housing (Item 1) [Figure 20-60-6] and [Figure 20-
60-7].
3 4 Install the fitting (15KB 1212-Straight Fitting) (Item 2)

[Figure 20-60-7] in the filter housing inlet.

1
Install the fitting (15KB 0812-Reducer Fitting) (Item 3)
[Figure 20-60-7] in the filter housing outlet.
Figure 20-60-8
P-39250
Assemble the filter assembly (Item 1), elbow fitting (Item

2), straight fitting (Item 3) and the reducer fitting (Item 4)
[Figure 20-60-5]. 1
Figure 20-60-6
EM1466
Disconnect the OUTLET hose (Item 1) [Figure 20-60-8]

from the charge pump.
1
1
P-39247
198 of 692 20-60-4

HYDRAULIC PUMP (CONT’D) Warm the fluid to 60°C. (140°F.) by turning the restrictor
Direct Pump Test (Charge Section) (Cont’d) 6,9 MPa (68,95 bar) (1000 psi). DO NOT exceed system
relief pressure. Open the restrictor control and record the
Figure 20-60-9 free flow (U.S. gpm) at full rpm*.
Turn the restrictor down to system operating pressure.

DO NOT EXCEED SYSTEM RELIEF PRESSURE. See
the Hydraulic Schematics for pressure. The high
pressure flow must be at least 80% of free flow.
% = HIGH PRESSURE FLOW (U.S. gpm) X 100
FREE FLOW (U.S. gpm)
1

relief pressure and full rpm.
**See the Hydraulic Schematics for pump flow and rpm.

EM1467
Connect the inlet hose from the hydraulic tester to the

outlet fitting (Item 1) [Figure 20-60-9] of the charge

pump.
Connect the outlet fitting on the hydraulic filter to the hose

that was removed from the charge pump.
Connect the outlet hose on the hydraulic tester to the

inlet fitting on the hydraulic filter assembly.
Figure 20-60-10
P-39255A
Be sure all connections are tight and that the hoses are
not touching any moving parts before starting the loader
[Figure 20-60-10].
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
rpm*.
199 of 692 20-60-5

Removal And Installation 2
DANGER
2
EM1468
P-90328
AVOID DEATH
Remove the bolts (Item 1) [Figure 20-60-11] and remove
the electrical cable from the hydraulic reservoir bracket.
Remove the hydraulic reservoir bracket by removing the
two screws (Item 2) [Figure 20-60-11].

Figure 20-60-12
D-1009-0409
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888
EM1469
Disconnect the two outlet tubelines (Item 1) [Figure 20-
Raise the lift arms and install an approved lift arm 60-12] from the hydraulic pump.
Page 10-20-1.)
Remove the hydraulic reservoir. (See Removal And

200 of 692 20-60-6

Removal And Installation (Cont’d) 25,4 mm 279,4 mm (11”)

(1”)
63,5 mm
(2.5”)
Figure 20-60-13 38,1 mm (1.5”)
I.S. Dia.
63,5 mm (2.5”)
O.S. Dia.
63,5 mm
(2.5”)
38,1 mm (1.5”) Square Tubing 6,35 mm
6,35 mm (0.25”) Wall Thickness (0.25”) (4)
Thick Gusset 25,4 mm
(1”) 406,4
1 mm
(16”)
50,8 mm (2”)
25,4 mm (1”)
25,4 mm
EM1470 (1”) 45° 228,6 mm (9”)
Disconnect the inlet tubeline (Item 1) [Figure 20-60-13]

from the hydraulic pump. 25,4 mm 4 in.

(1”)
Figure 20-60-14 25,4 mm (1”)

12,7
mm
(0.5”) 9,5 mm (0.375”)
Use two 3/8” x 1” Bolts for Drilled and Tapered Holes S5906
A tool needs to be fabricated to use in the removal

procedure. This tool allows the engine / hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
dimensions shown in [Figure 20-60-15] to make the
engine removal tool. (See Engine Removal And
1 1
Figure 20-60-16
EM1471
Remove the four engine mounts (Item 1) [Figure 20-60-

14].
Installation: Tighten the engine mount bolts to 95 N•m

(70 ft-lb) torque.
S2903
Install the chain on the engine as shown in [Figure 20-

60-16].
NOTE: You may need to adjust the chain which

fastens to the engine a couple of times to
reach the correct lifting position.
201 of 692 20-60-7


1
Figure 20-60-17
EM1473
Remove the hydraulic pump from the loader by removing

S2904 the two screws (Item 1) [Figure 20-60-19].

Lift the engine / hydrostatic pump assembly over a height
of approximately 0,5 mm (0.2 in) [Figure 20-60-17]. Hydraulic Pump Start Up

Push the engine / hydrostatic pump assembly to the side Ensure the hydraulic reservoir is filled to the correct level
to make sure there is enough space to remove the before starting the engine. (See Checking And Adding
hydraulic pump from the assembly. Fluid on Page 10-120-1.)
Figure 20-60-18
EM1472
Put a wooden block between the engine mount socket

(Item 1) [Figure 20-60-18] and the side of the frame to
make sure the engine / hydrostatic pump assembly will
stay in its place.
202 of 692 20-60-8

HYDRAULIC PUMP (CONT’D)
1. Bolt (8)
2. Washer
3. Shaft seal
4. Washer
5. Pump Flange Section
6. Plug
7. O-ring
8. Pre-Load Seal
9. Load Seal
10. Wear plate
11. Drive Gear
12. Key
13. Idler Gear
14. Hydraulic Pump Section
15. O-ring
16. Pump Center Section
17. O-ring
18. Drive Gear NOT AVAILABLE AT TIME
19. Idler Gear OF PRINTING
20. Pre-Load Seal
21. Load Seal
22. Wear plate

23. Charge Pump Section
24. O-ring
25. Pump End Section
S4746
203 of 692 20-60-9

Figure 20-60-20 1
1 3
1
S4209
Remove the pump flange section (Item 1) and the

S4208 hydraulic pump section (Item 2) from the pump center
section (Item 3) [Figure 20-60-21].
Mark the pump sections for correct assembly [Figure 20-
Remove both intermediate O-rings.
60-20].

Figure 20-60-22
Loosen the eight pump housing bolts (Item 1) [Figure 20-
60-20].
IMPORTANT
damage the system. S4749
I-2003-0888
Remove the shaft seal (Item 1) [Figure 20-60-22] from

the pump flange section.
204 of 692 20-60-10


1
Figure 20-60-23
2
S4212
Figure 20-60-26
S6033
Remove the wear plate (Item 1) and the bushings (Item

1
2) [Figure 20-60-23] from the pump end section and

check for wear. Replace if needed.
Figure 20-60-24
S4213
Remove the gear and axle (Item 1) [Figure 20-60-25]

and [Figure 20-60-26] from the pump center section.
Inspect the gear and axle (Item 1) [Figure 20-60-26].

Replace if needed.
S4748
Remove the load and preload seals (Item 1) [Figure 20-

60-24] from the wear plate.
205 of 692 20-60-11

Figure 20-60-27
1
S4216
Remove the bushings (Item 1) [Figure 20-60-29] from

S4214 the pump center section and check for wear. Replace if
needed.
Remove the pump center section (Item 1) [Figure 20-60- Figure 20-60-30
27] with drive gear and drive shaft by lifting it up.

Figure 20-60-28
1
1
S4217
3
Inspect the drive gear and drive shaft (Item 1) [Figure
S4215
20-60-30] for wear. Replace if needed.
Remove the section seal (Item 1) [Figure 20-60-28] from

the pump center section.
Remove the pin (Item 2) from the drive shaft (Item 3)

[Figure 20-60-28] and remove the drive shaft by pulling it
out of the bushing.
206 of 692 20-60-12


1
Figure 20-60-31
S4219
Figure 20-60-34
S4218
Remove the wear plate (Item 1) [Figure 20-60-31] from 1

the pump lower section.

Figure 20-60-32
S4213
Remove the gear and axle (Item 1) [Figure 20-60-33]

and [Figure 20-60-34] from the pump lower section.
Inspect the gear and axle (Item 1) [Figure 20-60-34] for

S4748 wear. Replace if needed.
Remove the load and preload seals (Item 1) [Figure 20-

60-32] onto the wear plate.
207 of 692 20-60-13

Figure 20-60-35
1
S4223
Remove the section seal (Item 1) [Figure 20-60-37] from

S4221 the pump end section
Figure 20-60-38
Remove the drive gear (Item 1) [Figure 20-60-35] from
the charge pump section.

Inspect the drive gear for wear and replace if needed.
Figure 20-60-36
S4224
Remove the bushings and check for wear. Replace if

needed [Figure 20-60-38].
S4222
Remove the charge pump section (Item 1) [Figure 20-

60-36] from the pump lower section by lifting it up.
208 of 692 20-60-14

HYDRAULIC PUMP (SJC) Start the engine and run at low idle rpm. Press the Front
Auxiliary button. Engage the front auxiliary with the
Description trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
The hydraulic gear pump is attached to the end of the the hoses are connected wrong. With the hoses
hydrostatic pumps and is located on the right side of the connected correctly, increase the engine speed to full
loader between the hydraulic control valve and the rpm*.
engine.
The hydraulic gear pump provides hydraulic flow to control clockwise on the tester so it reads about a 6,9
several hydraulic systems. MPa (69 bar) (1000 psi).
A seal kit is available to service the hydraulic pump. If any NOTE: DO NOT EXCEED 22,8 MPa (228 bar) (3300
of the main components of the pump are damaged, the psi).
entire pump must be replaced.
Turn the restrictor control (Item 2) [Figure 20-61-1] on
Pump Test At Quick Couplers the tester counterclockwise to obtain free flow, the flow
should be approximately 60,6 - 64,4 L/min (16 - 17 U.S.
The tools listed will be needed to do the following gpm). Start turning the restrictor clockwise, causing more
procedure: restriction on the flow. The L/min (U.S. gpm) should drop
off slightly until the pressure reaches approximately 18,6
MEL10003 - In-Line Hydraulic Tester - 19,3 MPa (186 - 193 bar) (2700 - 2800 psi).
MEL10006 - Flowmeter Fitting Kit
At approximately 18,6 - 19,3 MPa (186 - 193 bar) (2700 -

Figure 20-61-1 2800 psi) the flow should start decreasing rapidly until
the pressure reaches 20,3 - 21,0 MPa (203 - 210 bar)
(2950 - 3050 psi).
1
At 20,3 - 21,0 MPa (203 - 210 bar) (2950 - 3050 psi) the
flow should be at 0 L/min (0 U.S. gpm). Turn the restrictor
(Item 2) [Figure 20-61-1] counterclockwise to free flow.
Shut the front auxiliary hydraulics off.
If flow and pressure specs are not obtained, go to Direct

Pump Testing. (See Direct Pump Test (Standard Section)
on Page 20-61-2.).
2
P-16903 S6029
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).
Install a hydraulic tester (Item 1) [Figure 20-61-1] onto

the front auxiliary quick couplers.
This procedure will require a operator in the cab and one

operator running the tester.
209 of 692 20-61-1

HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-61-2
Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7217666 - Remote Start Tool

1 2
WARNING
S9846
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)

WARNING
support device. Failure to use an approved lift arm 2
support device can allow the lift arms or attachment 1
S9848
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-1.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
Open the rear door of the loader. of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-3] from the tester to the fitting (Item 2) [Figure 20-
Connect the remote start tool. (See Remote Start Tool - 61-2] on the control valve.
MEL1563 on Page 10-60-1.)
210 of 692 20-61-2

HYDRAULIC PUMP (SJC) (CONT'D) Removal And Installation
Direct Pump Test (Standard Section) (Cont'd) Remove the hydraulic fluid reservoir from the loader.
(See Removal And Installation on Page 20-80-1.)
Figure 20-61-4
Figure 20-61-5
EXAMPLE: TESTER
CONNECTION
Reservoir
1
Hydraulic Pump
2
Out In Hydraulic Control

Valve
S9834
1
Disconnect the tubeline (Item 1) [Figure 20-61-5].

BH-196 Disconnect the hose (Item 2) [Figure 20-61-5] from the
hydraulic pump by loosing the hose clamp.
Sample tester connection shown [Figure 20-61-4]. Figure 20-61-6

Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
rpm*.
1
69 bar (1000 psi). DO NOT exceed system relief
pressure. Open the restrictor control and record the free 1
flow (L/min [U.S. gpm]) at full rpm*.
Push the Maximum / Variable Flow switch (on the remote

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control S35956
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (bar
[psi]) and flow (L/min [U.S. gpm]). The high pressure flow Remove the four bolts (Item 1) [Figure 20-61-6] to
must be at least 80% of free flow. disconnect the hoses from the hydraulic pump.

lb) torque.
HIGH PRESSURE FLOW (U.S. gpm [L/min])
%= X 100
FREE FLOW (U.S. gpm [L/min])

211 of 692 20-61-3

HYDRAULIC PUMP (SJC) (CONT'D)
Figure 20-61-7
2 3
1
S9836
Remove the nut and bolt (Item 1) [Figure 20-61-7].

Installation: Tighten the bolt to 25 - 28 N•m (34 - 38 ft-lb)
torque.
Remove the two bolts (Item 2) [Figure 20-61-7].
Installation: Tighten the two bolts to 75 - 85 N•m (55 - 60

ft-lb) torque.
Remove the bracket (Item 3) [Figure 20-61-7].
Remove the hydraulic pump from the loader.
Hydraulic Pump Start Up
(See Hydraulic Pump Start Up on Page 20-61-4.) for the

SJC hydraulic pump start up procedure.
212 of 692 20-61-4

11 12
9 6 10 5
5 6 7
2 3 4

1
8 10
1. Shaft Seal
2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Drive Gear
8. Idler Gear
9. Pump Center Section
10. Pins
11. Pump End Section
12. Bolt (8)
EM1002
213 of 692 20-61-5

Clean the outside of the hydraulic pump before

disassembly.
Figure 20-61-8
S10556
Remove the pump end section [Figure 20-61-10].
Installation: Align the marks made during disassembly.
S10554 Figure 20-61-11

Mark the pump sections and fitting orientation for correct
assembly [Figure 20-61-8].
1 2
hydraulic pump.
Figure 20-61-9
1
S10557
Remove the O-ring (Item 1) and wear plate (Item 2)

[Figure 20-61-11] from the pump end section and check
for wear. Replace if needed.
S10555
Put the pump, mounting flange down, in a protected jaw

vise. Remove the eight assembly bolts (Item 1) [Figure
20-61-9].
214 of 692 20-61-6

Figure 20-61-12
1
1 1
S10560
Remove the pump center section (Item 1) [Figure 20-61-

S10558 14].
Installation: Align the marks made during disassembly.

Remove the bushings (Item 1) [Figure 20-61-12] from
the pump end section and check for wear. Replace if Figure 20-61-15

needed.
Figure 20-61-13
1
1
1
S10561
S10559 Remove the idler gear (Item 1) [Figure 20-61-15] from

the pump lower section.
Remove the guiding pins (Item 1) [Figure 20-61-13] from Inspect the idler gear. Replace if needed.
the pump center section.
NOTE: The drive gear and idler gear are not serviced
separately. These parts are matched sets
which are run in at the factory. If any part is
damaged, the entire section must be replaced.
215 of 692 20-61-7

Figure 20-61-16 1
S10564
Remove the load seal (Item 1) [Figure 20-61-18].

S10563
Figure 20-61-19
Remove the drive shaft and drive gear (Item 1) [Figure

20-61-16] from the pump lower section.

1
Inspect the drive shaft and drive gear. Replace if needed.
NOTE: The drive gear and idler gear are not serviced
separately. These parts are matched sets
which are run in at the factory. If any part is
damaged, the entire section must be replaced.
Figure 20-61-17
S10565
1
2
Remove the pre-load seal (Item 1) [Figure 20-61-19].
S10562
Remove the O-ring (Item 1) and wear plate (Item 2)

[Figure 20-61-17].
216 of 692 20-61-8

Figure 20-61-20
1
1
S10566
Remove the two bushings (Item 1) [Figure 20-61-20].

Figure 20-61-21
S10567
Remove the seal (Item 1) [Figure 20-61-21].
217 of 692 20-61-9

218 of 692
20-61-10
HYDRAULIC / HYDROSTATIC FILTERS Figure 20-70-2
Description Standard
The hydraulic / hydrostatic filters help to remove

contaminants from the hydraulic fluid when the hydraulic /
hydrostatic systems are operating.
1
The hydraulic / hydrostatic filter system consists of one 2
hydraulic / hydrostatic filter, one fan / charge pressure
filter and two case drain filters.
The hydraulic / hydrostatic filter removes contaminants

after the oil cooler.
The charge pressure filter removes contaminants after S10437

the hydraulic fan motor and before the oil enters the
hydrostatic pump.
Figure 20-70-3
Housing Removal And Installation
SJC
Drain the hydraulic fluid reservoir.

1
2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly S40482
damage the system.
I-2003-0888
Disconnect the hose (Item 1) [Figure 20-70-2] and
Figure 20-70-1 [Figure 20-70-3] from the hydraulic / hydrostatic filter.
Disconnect the hose (Item 2) [Figure 20-70-2] or

tubeline (Item 2) [Figure 20-70-3] from the hydraulic /
hydrostatic filter.
S10436
Disconnect the sensor wires (Item 1) [Figure 20-70-1]

from the hydraulic / hydrostatic filter.
219 of 692 20-70-1

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D) Charge Filter Housing Removal And Installation
Housing Removal And Installation (Cont’d) NOTE: The charge filter housing is installed in non-
SJC machines only.
Figure 20-70-4
Page 10-20-1.)
1
Figure 20-70-5
2
S10438
Remove the hydraulic / hydrostatic filter housing by

removing the two screws (Item 1) [Figure 20-70-4].

1
S10618
Remove tubeline (Item 1) and hose (Item 2) from the

charge pressure filter (Item 3) [Figure 20-70-5].
Figure 20-70-6
2
3
S5907

charge pressure filter.
Remove the nut (Item 2) [Figure 20-70-6] from the fitting.
Remove the charge pressure filter (Item 3) [Figure 20-

70-6].
220 of 692 20-70-2

HYDRAULIC FLUID RESERVOIR
Description
IMPORTANT
The hydraulic fluid reservoir is a storage container for the
loaders hydraulic / hydrostatic fluid. The reservoir When repairing hydrostatic and hydraulic systems,
contains a vented fill cap with a fluid screen to prevent clean the work area before disassembly and keep all
contaminants from entering the reservoir while adding parts clean. Always use caps and plugs on hoses,
fluid. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The hydraulic fluid reservoir is secured to the mainframe I-2003-0888
behind the operators cab.
Stop the engine.
THE LOADER on Page 10-10-1.) Figure 20-80-1
Start the engine. Raise the lift arms and install an

approved lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
DANGER

1
S10440
P-90328 Disconnect the hose (Item 1) [Figure 20-80-1] and drain

AVOID DEATH the hydraulic fluid reservoir. Make sure the reservoir is as
• Disconnecting or loosening any hydraulic empty as possible.
D-1009-0409
WARNING
W-2059-0598
221 of 692 20-80-1

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-4
Figure 20-80-2
1
Standard
2
2
1 S10441
Remove the bracket (Item 1) by removing the two screws

S10439 (Item 2) [Figure 20-80-4].
Installation: Tighten the screws to 20 - 27 N•m (15 - 20

Figure 20-80-3 ft-lb) torque.

SJC Remove the hydraulic reservoir.
S9843
Disconnect the hose (Item 1) [Figure 20-80-2] and

[Figure 20-80-3] from the hydraulic reservoir by
loosening the hose clamp.

hydraulic reservoir.
222 of 692 20-80-2

HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-6
Hydraulic Fluid Screen
Figure 20-80-5
S5917
Remove the hydraulic fluid screen (Item 1) [Figure 20-

S5916 80-6] from the reservoir.
Wash the screen in clean solvent and air dry, before

Remove the fill cap (Item 1) [Figure 20-80-5] from the installing.
223 of 692 20-80-3

224 of 692
20-80-4
OIL COOLER Figure 20-90-1
Description
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat 1
exchanger. The cooling fan forces air around the
passages cooling the oil.
The oil cooler is located underneath the rear grille.
IMPORTANT EM1412
When repairing hydrostatic and hydraulic systems, Disconnect the two connectors (Item 1) [Figure 20-90-1].
parts clean. Always use caps and plugs on hoses, Figure 20-90-2
damage the system.
I-2003-0888

Open the rear door of the loader. 2
Remove the rear grille. (See Removal And Installation on

Page 20-90-1.)
1
1
EM1457
Disconnect the two hydraulic tubelines (Item 1) [Figure

20-90-2] from the oil cooler.
Remove the oil cooler (and frame) by removing the five

screws (Item 2) [Figure 20-90-2].
225 of 692 20-90-1

OIL COOLER (CONT’D)
Figure 20-90-3
1 2
3
S4253
Figure 20-90-4

S6032
Remove the fans from the oil cooler frame by removing

the eight screws (Item 1) [Figure 20-90-3].
Remove the nuts (Item 2) [Figure 20-90-3] from the two

oil cooler fittings.
Remove the oil cooler [Figure 20-90-4] from the frame by

removing the bolts (Item 3) [Figure 20-90-3].
226 of 692 20-90-2

BUCKET POSITION VALVE Figure 20-100-2
Description
The Bucket Position Valve is an option that allows the

loader to meter the lift and tilt circuits. The metering of the 1
lift and tilt circuits allows the operator to hold the
attachment in the same relative position to the ground to
maximum lift height without using the tilt function.
The bucket position valve is located below the operator

cab below the left side of the control panel.
See Hydraulic Schematic for more circuit information.
Solenoid Removal And Installation S6636
Figure 20-100-1
Remove the solenoid stem (Item 1) [Figure 20-100-2]
from the bucket position valve.
1
Installation: Tighten the solenoid stem to 40,8 - 47,6
Figure 20-100-3

S3774
Disconnect the wire harness connector (Item 1) [Figure

2
20-100-1] from the bucket position shutoff solenoid.
S5910
Remove the solenoid nut (Item 2) [Figure 20-100-1].

Inspect the solenoid stem and replace the O-rings (Item
Installation: Tighten the solenoid nut to 6,78 N•m (60 in- 1) and back-up washers (Item 2) [Figure 20-100-3].
lb) torque.
Installation: Put oil on O-rings and back-up washers.
Remove the solenoid.
227 of 692 20-100-1

BUCKET POSITION VALVE (CONT’D)
Solenoid Testing
WARNING
Figure 20-100-4
W-2059-0598
Start the engine.

Stop the engine.

P9175
Use a test meter to measure coil resistance [Figure 20- Figure 20-100-5
100-4]. Coil wires do not have polarity. Correct resistance

for the coil is 9,7± 1 ohm @ 25,5° C (78° F).

1
DANGER
S35966

P-90328 hydraulic control valve by removing the nut.
AVOID DEATH
Installation: Tighten the solenoid nut to 6,78 N•m (60 in-
lb) torque.
D-1009-0409
228 of 692 20-100-2

BUCKET POSITION VALVE (CONT’D) Figure 20-100-8
Remove the steering linkages. (See Linkage Removal

And Installation on Page 50-100-6.)
NOTE: Before disconnecting the hydraulic tubelines

from the bucket position valve, first mark the
tubelines and the fittings of the bucket 1
position valve to make sure the tubelines will
be put on the right fitting while connecting the
tubelines.
Figure 20-100-6
S6639
Disconnect the hydraulic tubeline (Item 1) [Figure 20-

100-8] from the bucket position valve. Cap the tubeline
2 and the fitting after disconnection.
2
Figure 20-100-9

1
1
S6637
1
Remove the hydraulic tubeline (Item 1) by loosening the

nuts (Item 2) [Figure 20-100-6]. Cap the fittings and
tubeline after disconnection.
Figure 20-100-7
S6640
Disconnect the two hydraulic tubelines (Item 1) [Figure

20-100-9] from the bucket position valve. Cap the
tubelines and the fittings after disconnection.
2 2
S6638
Remove the hydraulic tubeline (Item 1) by loosening the

nuts (Item 2) [Figure 20-100-7]. Cap the tubeline and the
fittings after disconnection.
229 of 692 20-100-3

Removal And Installation (Cont’d) 1
Figure 20-100-10
1
1
3 S6642
Remove the bucket position valve from its support plate

S6641 by removing the two bolts (Item 1) [Figure 20-100-12].
Loosen the clamp (Item 1) and disconnect the hydraulic

tubeline (Item 2) from the bucket position valve by

loosening the nut (Item 3) [Figure 20-100-10]. After
disconnection, cap the fitting and the tubeline.
Figure 20-100-11
S4176
Remove the bucket position valve with its support plate

by removing the two bolts (Item 1) [Figure 20-100-11].
230 of 692 20-100-4


3
Figure 20-100-13
2
1 1
S5913
Remove the tilt cylinder check valve (Item 1), spring (Item
S5911 2) and plug (Item 3) [Figure 20-100-15]. Inspect for wear,
inspect O-ring and replace as needed.
Remove the solenoid stem (Item 1) [Figure 20-100-13]. Figure 20-100-16

Assembly: Tighten the solenoid stem to 40,8 - 47,6 N•m
Figure 20-100-14
2
1
1
S5914
Remove the plug (Item 1) and the flow control spool (Item
2) [Figure 20-100-16].
S5912
Inspect the flow control spool for wear, inspect the O-ring
on the plug and replace if needed.
Remove the plug and O-ring (Item 1) [Figure 20-100-14].
NOTE: Always install new O-rings before any parts

are installed into the valve. Inspect the parts
for wear or damage and replace as needed.
231 of 692 20-100-5

BUCKET POSITION VALVE (CONT’D)
Figure 20-100-17
S5915
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-17].

Inspect all parts and replace as needed. Install a new O-
ring on the plug before installing.
232 of 692 20-100-6

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Description
The front auxiliary hydraulic couplers supply hydraulic

flow for various attachments.
The front auxiliary hydraulic couplers are located at the

front of the machine on the left side arm.
IMPORTANT
damage the system.
I-2003-0888

Figure 20-110-1
1 2
S4044
Disconnect the auxiliary tubelines (Item 1) [Figure 20-

110-1] from the coupler frame.
Remove the mounting bolt (Item 2) [Figure 20-110-1].
Remove the front auxiliary hydraulic couplers.
233 of 692 20-110-1

234 of 692
20-110-2
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
(SJC)
Figure 20-111-2
Description
The front auxiliary hydraulic couplers supply hydraulic

1
flow for various attachments.
The front auxiliary hydraulic couplers are located at the

front of the machine on the left side arm.
2
4
3
IMPORTANT
P-34661
clean the work area before disassembly and keep all Figure 20-111-3
damage the system.
I-2003-0888 1

Figure 20-111-1
6
2
4
2 5 3
1
P-34760
3
Remove the male coupler (Item 1) [Figure 20-111-2] and

[Figure 20-111-3].
Installation: Tighten the male coupler (Item 1) [Figure

P-43215
20-111-2] and [Figure 20-111-3] to 80 N•m (59 ft-lb)
torque.
Disconnect the auxiliary tubelines (Item 1) and drain Remove the drain coupler (Item 2) [Figure 20-111-2] and
tubeline (Item 2) [Figure 20-111-1] from the coupler [Figure 20-111-3].
block. Installation: Tighten the drain coupler (Item 2) [Figure
Remove the two mounting bolts (Item 3) [Figure 20-111- torque.
1].
Remove the female coupler (Item 3) [Figure 20-111-2]
and [Figure 20-111-3].
Installation: Tighten the female coupler (Item 3) [Figure

torque.
Remove the fittings (Item 4), inspect the O-rings (Item 5)

[Figure 20-111-3] and replace as needed.
Remove the springs (Item 6) [Figure 20-111-3].
235 of 692 20-111-1

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-111-6
(SJC) (CONT’D)

1
Figure 20-111-4
1
2
P-34665
Inspect the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-111-6] for damage and replace as needed.
P-34663
Figure 20-111-7
Inspect the O-ring (Item 1) [Figure 20-111-4] for damage

and replace as needed. 1
Figure 20-111-5
P-34664
Inspect the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-111-7] for damage and replace as needed.
P-34701
Press center of male couplers down and inspect the O-

ring (Item 1) [Figure 20-111-5] for damage and replace
as needed.
236 of 692 20-111-2

AUXILIARY HYDRAULIC INTERLOCK VALVE Figure 20-120-1
Description
2
The auxiliary hydraulic interlock valve is installed in non-
SJC machines only.
The auxiliary hydraulic interlock valve has a single

solenoid stem that is normally closed. The operation of 3
the valve is controlled by an electric solenoid.
1
The auxiliary hydraulic interlock valve prevents or allows
hydraulic fluid to flow to the auxiliary couplers.
The auxiliary hydraulic interlock valve is located on the

left side of the frame just above the battery. S9837

Disconnect the electrical connector (Item 1) [Figure 20-
Open the rear door. 120-1] from the auxiliary hydraulic interlock valve.
Disconnect the tubelines (Item 2) [Figure 20-120-1] from

the auxiliary hydraulic interlock valve.
WARNING

Remove the two mounting bolts and nuts (Item 3) [Figure
20-120-1] securing the auxiliary hydraulic interlock valve
AVOID INJURY OR DEATH to the frame.
sparks or lighted tobacco away from fuel and oil. Remove the auxiliary hydraulic interlock valve.
explosion or fire.
W-2103-0508
IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning
repairs. Use plugs and caps to cover open ports. Dirt
can quickly damage the system.
I-2173-0598
237 of 692 20-120-1

AUXILIARY HYDRAULIC INTERLOCK VALVE Figure 20-120-4
(CONT’D)
Figure 20-120-2
1
S9840
S9838 Installation: Tighten the solenoid stem to 41 - 47 N•m

Remove the two straight fittings (Item 1) [Figure 20-120- Figure 20-120-5

2].
Figure 20-120-3
1
1
2 2
S9841
S9839 Remove the O-rings (Item 1) and back-up washers (Item

2) [Figure 20-120-5].
Remove the solenoid nut (Item 1) and coil (Item 2)

[Figure 20-120-3].
Installation: Tighten the nut to 7 N•m (62 in-lb) torque.
238 of 692 20-120-2

BOB-TACH (POWER) BLOCK
Description
The Power Bob-Tach block is an option that allows the

IMPORTANT
operator to hydraulically control the Bob-Tach levers for
mounting and dismounting the attachments. When repairing hydrostatic and hydraulic systems,
The Power Bob-Tach block is operated by a switch on the parts clean. Always use caps and plugs on hoses,
front console. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The Power Bob-Tach block is mounted on the front right
side of the machine.
Removal And Installation THE LOADER on Page 10-10-1.)

Page 10-20-1.)
WARNING Raise the operator cab. (See Raising on Page 10-30-1.)
Drain the hydraulic reservoir.

Remove the steering linkages.
Remove the bucket position valve. (See Removal And
W-2059-0598
Figure 20-130-1
DANGER
1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure EM1134

• Keep out of this area when lift arms are raised Disconnect the Power Bob-Tach harness from the
unless supported by an approved lift arm solenoid connectors (Item 1) [Figure 20-130-1].
D-1009-0409
239 of 692 20-130-1

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-130-4

1
Figure 20-130-2
EM1137
Disconnect the two hoses (Item 1) [Figure 20-130-4]

1
EM1135 from the Power Bob-Tach block.
Figure 20-130-5
Disconnect the hydraulic tubeline (Item 1) [Figure 20-
130-2] from the Power Bob-Tach block.

Figure 20-130-3
1 EM1163
Remove the four mounting bolts (Item 1) [Figure 20-130-

EM1136 5].
Installation: Tighten the mounting bolts to 34 - 38 N•m

Disconnect the hose (Item 1) [Figure 20-130-3] from the (25 - 28 ft-lb) torque.
Power Bob-Tach block.
Remove the Power Bob-Tach block.
240 of 692 20-130-2

Figure 20-130-6
1
3
4
1 2
EM1145
2
Remove the spring guide (Item 1), spring (Item 2) and the
EM1144 spool (Item 3) [Figure 20-130-7].
Check the O-ring (Item 4) [Figure 20-130-7] on the plug

Clean the block (Item 1) [Figure 20-130-6] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-130-8
Remove the plug (Item 2) [Figure 20-130-6].
Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-

lb) torque.
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, 1
EM1146
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage can occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-8].
Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.
241 of 692 20-130-3

Figure 20-130-9
1 1 EM1148
Do not remove the plugs (Item 1) [Figure 20-130-11].

EM1146
NOTE: Do not remove the plugs. If the plugs are
removed the internal pressure relieving
Remove the check valve (Item 1) [Figure 20-130-9]. spring setting will be altered.

Installation: Oil the check valve and O-rings and tighten Figure 20-130-12
the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.
Figure 20-130-10
2
1
EM1153
3 EM1147 Remove the plug (Item 1) [Figure 20-130-12], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-130-
(Item 2) [Figure 20-130-10]. 12] to 16,3 - 19 N•m (12 - 14 ft-lb) torque.
Check the O-rings and back-up washers (Item 3) [Figure

20-130-10] on the check valve and piston assembly and
replace as needed.
242 of 692 20-130-4

Figure 20-130-13
1 2
1
2
EM1149
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-130-15].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 1) located behind the ease of installation.

Figure 20-130-16
Installation: Tighten the orifice screw (Item 2) [Figure
20-130-13] to 8,1 - 10,8 N•m (71.7 - 95.5 in-lb) torque.
Figure 20-130-14
1
1
EM1150

EM1148
Installation: Tighten the solenoid stem to 27,1 - 34 N•m
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage can occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-130-14].
Remove the solenoid nut (Item 2) [Figure 20-130-14].
Installation: Tighten the solenoid valve stem nut to 1,7 -

5,1 N•m (15 - 45 in-lb) torque.
243 of 692 20-130-5

Figure 20-130-17
EM1152
1
Remove the screened orifice plug (Item 1) [Figure 20-
EM1151 130-19].
Installation: Tighten the screened orifice plug to 14,9 -

Remove the armature rod assembly (Item 1) [Figure 20- 16,3 N•m (11 - 12 ft-lb) torque.
130-17].

Figure 20-130-20
Figure 20-130-18
2
2
1
1
S4394
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 130-20] for damage and replace if needed. If the
(Item 2) and the spool (Item 3) [Figure 20-130-18] for screened orifice plug is blocked replace with a new plug.
damage.
Check the O-ring (Item 2) [Figure 20-130-20] and
NOTE: If the solenoid stem is damaged (Item 1) check replace if needed.
the armature assembly (Item 2) for damage.
The armature assembly and spool (Item 3)
[Figure 20-130-18] are non-serviceable parts.
If they are damaged, order a new power Bob-
Tach block assembly from Bobcat parts.
244 of 692 20-130-6

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-40-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-11
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-2
Hydrostatic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-5
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-24
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-27
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

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


HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of a tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.
IMPORTANT
damage the system.

I-2003-0888
247 of 692 30-10-1

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Troubleshooting
WARNING
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If the service code appears in the left instrument panel,

see to the Electrical Service Manual for the probable
cause.
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side, in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9

1. The hydrostatic pump replenishing valves are not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump is damaged.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
248 of 692 30-10-2

HYDROSTATIC MOTOR
Description
WARNING
The hydrostatic motors are driven by high pressure from
the hydrostatic pumps.
In this system there is a case drain filter for each motor to
filter the excess low pressure oil before the oil enters the
explosion or fire.
W-2103-0508
The hydrostatic motors do not have an internal brake.
Removing And Replacing Oil Lift and block the loader. (See LIFTING AND BLOCKING
The hydrostatic motor carrier requires no maintenance.
See your Bobcat dealer for track and motor carrier support device. (See Installing on Page 10-20-1.)
lubricant replacement.
Stop the engine.
Figure 30-20-1
DANGER

1
P-90328
AVOID DEATH
tubeline, hose, fitting, component or a part failure S4499
unless supported by an approved lift arm Remove the back wheel / tire assemblies by removing
support. Replace if damaged. the eight bolts (Item 1) [Figure 30-20-1].
D-1009-0409
WARNING
W-2059-0598
249 of 692 30-20-1

HYDROSTATIC MOTOR (CONT’D) Figure 30-20-4
Figure 30-20-2
1 S4231
1
Remove the hydrostatic motor from the loader by
S4372 removing the four mounting bolts (Item 1) [Figure 30-20-
4] and pulling it out of the loader.
Remove the cover by removing the four bolts (Item 1) Installation: Tighten the four hydrostatic motor mounting
[Figure 30-20-2]. bolts 122 - 136 N•m (90 - 100 ft-lb) torque.

Figure 30-20-3
S4230
Disconnect the three hydraulic tubelines (Item 1) [Figure

30-20-3] from the hydrostatic motor.
250 of 692 30-20-2

HYDROSTATIC MOTOR (CONT’D)
1. Plug
2. O-ring
3. Bolt 1
4. Housing 2
5. Sleeve
6. Spring
7. Poppet
8. Piston
9. Snap Ring 3
10. Seal Outer
11. Valve 4
12. Plate, Valve
13. Geroler® Assy
14. Drive Valve
15. Drive Shaft
16. Bearing Housing 1 2 5
17. Seal Shaft Face 6
7
18. Bearing And Shaft Assy 2
19. Retainer Front

1 8
20. Exclusion Seal
21. Seal Inner 7 6
5 1
9
21
6
14
2 10
2
11
2
12 2
2 15
13
2
16 17
18
2
6
3 20
19
P-82626
251 of 692 30-20-3

Figure 30-20-5
1
2
1
S4259
Remove the valve (Item 1) and valve plate (Item 2)

S4257 [Figure 30-20-7] from the hydrostatic motor.
Figure 30-20-8
Remove the end cap (Item 1) from the hydrostatic motor
by removing the four bolts (Item 2) [Figure 30-20-5].

Installation: Tighten the bolts to 406,7 N•m (300 ft-lb)
torque.
2
Figure 30-20-6 1
S4260
Remove the valve (Item 1) and check the O-ring (Item 2)

[Figure 30-20-8] for wear. Replace if needed.
S4258

end cap and check for wear. Replace if needed.
252 of 692 30-20-4

Figure 30-20-9
S4497
Installation: Install the inner and outer seals as shown in

S4495 [Figure 30-20-11]. Apply grease on the inner and outer
seals.
Installation: The motor needs proper timing when Figure 30-20-12

reassembling. The timing alignment should be as shown

above [Figure 30-20-9]. Wrong timing results in reverse
rotation of the motor.
Figure 30-20-10
1
1 2
2 S4262
Remove the balance ring (Item 1) from the valve (Item 2)

[Figure 30-20-12].
S4261
Remove both inner and outer seals (Items 1 and 2) and

the two springs (Item 3) [Figure 30-20-10] from the
valve.
253 of 692 30-20-5

Figure 30-20-13
1
S4274
Remove the drive shaft (Item 1) [Figure 30-20-15] from

S4271 the hydrostatic motor.
Turn the hydrostatic motor upside down.

Remove the drive shaft (Item 1) [Figure 30-20-13] from
the hydrostatic motor. Figure 30-20-16

Remove the gerotor section (Item 2) [Figure 30-20-13]
from the hydrostatic motor. 3
Figure 30-20-14
2
1
1
2
S4275
Remove the plate from the drive shaft by removing the

eight bolts (Item 1) [Figure 30-20-16].
S4272
Remove the O-ring (Item 2) [Figure 30-20-16] and
inspect for wear. Replace if needed.
NOTE: Do not disassemble the gerotor section (Item
1) [Figure 30-20-14]. Installation: Pretighten the eight bolts to 6 N•m (53 in-lb)
torque, then torque screws to 34 N•m (25 ft-lb) torque.
Installation: Align the drain hole (Item 2) [Figure 30-20-
14] with other sections on hydrostatic motor. Remove the drive shaft (Item 3) [Figure 30-20-16] from
Apply grease on all seals. the motor housing.
254 of 692 30-20-6

Figure 30-20-17
S4279
Remove the spacer (Item 1) [Figure 30-20-19] that is

S4277 situated between the two bearings.
Remove the lower bearing (Item 2) [Figure 30-20-19]

Installation: Use a hydraulic press to install the drive from the drive shaft by pulling it back.
shaft in the housing [Figure 30-20-17].

Figure 30-20-20
Figure 30-20-18
2
3
S4280
S4278
Installation: Use a hydraulic press to install the two

Remove the seal (Item 1) [Figure 30-20-18] from the bearings and the ring on the drive shaft [Figure 30-20-
drive shaft and inspect for wear. Replace if needed. 20].

the drive shaft.
Remove the upper bearing (Item 3) [Figure 30-20-18]

from the drive shaft by pulling it back.
255 of 692 30-20-7

256 of 692
30-20-8
CHARGE PRESSURE
Description
Charge pressure is a supply of oil to the hydrostatic

WARNING
pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
W-2059-0598
Charge pressure is obtained from the standard section
on the hydraulic gear pump.
Figure 30-30-2
Charge pressure is also used to operate other hydraulic
functions, such as shifting the auxiliary spool in the main
1
hydraulic control valve.
The charge pressure sender is located on the charge

filter housing mounted next to the blower housing.
Charge pressure alarm settings are pre-programmed into
the main controller and are based on loader type and
options installed.
3
2

Testing
Figure 30-30-1
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-30-2].
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to

the adapter fitting. Tighten all connections.
2
Put the loader on jackstands. (See LIFTING AND
3 BLOCKING THE LOADER on Page 10-10-1.)
1
Raise the loader lift arms and install an approved lift arm
P-43196A

The tools needed to check charge pressure, hydraulic
hose (Item 1), Hydraulic gauge 6895 kPa (69 bar) (1000
psi) (Item 2) and adapter fitting (P/N 93F-5) (Item 3)
[Figure 30-30-1].
257 of 692 30-30-1

CHARGE PRESSURE (CONT’D) Sender Removal And Installation
Testing (Cont’d) Figure 30-30-4
Figure 30-30-3
S5907
1
S5907
Disconnect the charge pressure sender connector (Item
1) [Figure 30-30-4] from the sender.
Remove the cap (Item 1) [Figure 30-30-3] from the
fitting. Remove the sender (Item 2) [Figure 30-30-4] from the

adapter fitting.
Install the hose that is attached to the pressure gauge, to
the fitting, where the cap was removed. Installation: Tighten the charge pressure sender to 10 -
11 N•m (7.4 - 8.1 ft-lb) torque.
Tighten the hydraulic fittings.
Start the loader and warm the hydraulic fluid to 60°C

(140°F).
The charge pressure at high idle, with the fluid

temperature of 60°C (140°F) and with the pump in neutral
is 1999 kPa (20 bar) (290 psi) for manually controlled
machines and 2399 kPa (24 bar) (348 psi) for SJC
controlled machines.
258 of 692 30-30-2

CHARGE PRESSURE (CONT’D) SJC Machines
Adjusting
Non SJC Machines

IMPORTANT
IMPORTANT clean the work area before disassembly and keep all
When repairing hydrostatic and hydraulic systems, damage the system.
clean the work area before disassembly and keep all I-2003-0888
Figure 30-30-6
damage the system.
I-2003-0888
Figure 30-30-5

1
S9833
The charge relief valve (Item 1) [Figure 30-30-6] is

S35966 located on the front of the hydrostatic pump.
If the charge pressure is not correct remove the charge

The charge relief valve is located inside the left hand relief valve (Item 1) [Figure 30-30-6].
machine side hydrostatic pump (Item 1) [Figure 30-30-
5]. (See [Figure 30-40-15] on Page 30-40-7.) for Assembly: Always use a new O-ring. Tighten the charge
disassembly of the charge inlet relief valve. relief valve to 70 N•m (52 ft-lb) torque.
The charge inlet relief valve cannot be adjusted.
259 of 692 30-30-3

CHARGE PRESSURE (CONT’D) Figure 30-30-8
Adjusting (Cont’d)
SJC Machines (Cont’d)

3 4
2
Figure 30-30-7 1 5
P-64435
Remove the poppet (Item 1) and the mating seat (Item 2)

[Figure 30-30-8] for damage or foreign material. Ensure
the poppet moves freely in its bore.
P-64435
Inspect the sealing ring (Item 3) [Figure 30-30-8] and the
mating seat in the pump housing for damage or foreign

Check and replace the O-ring (Item 1) [Figure 30-30-7]. material.
Inspect the spring (Item 4) and the charge relief valve

shims (Item 5) [Figure 30-30-8].
NOTE: 0,254 mm (0.01 in) is 55 kPa (0,55 bar) (8 psi)

in pressure change. Adding shims increases
charge pressure. Removing shims decreases
charge pressure.
The charge pressure should be set at 2,40 MPa (24 bar)

(248 psi).
260 of 692 30-30-4

HYDROSTATIC PUMP Figure 30-40-2
Description
The hydrostatic pump is composed of two hydrostatic 1

piston pumps connected together. The pumps provide bi-
directional flow to two separate hydrostatic drive motors.
The pump flow and direction are controlled by two hand
levers, one for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the 2
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure S4152
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump contains the charge pressure Remove the replenishing / high pressure relief valve
relief. The charge pressure relief is adjustable with shims. (Item 1) [Figure 30-40-2] from the pump.
The hydrostatic pump is located in the center of the Assembly: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)
mainframe mounted to the engine flywheel housing. torque.

Replenishing / High Pressure Relief Valve Removal Check for damage and replace as needed.
And Installation
Check O-ring (Item 2) [Figure 30-40-2] for damage and
Figure 30-40-1 replace as needed.
If the replenishing / high pressure relief valve must be

replaced, it must be replaced as a complete unit.
The pressure setting for a new replenishing / high

pressure relief valve is 27,58 MPa (276 bar) (4000 psi).
1
EM1450
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-40-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two are located at the bottom of the pumps.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.
261 of 692 30-40-1

HYDROSTATIC PUMP (CONT’D) Figure 30-40-4
2
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
EM1451
Remove the engine / hydrostatic pump assembly from
the loader. (See Removal And Installation on Page 30-
40-2.) Loosen the drive belt (Item 1) by pulling the tension
wheel (Item 2) [Figure 30-40-4] upward with a handle.
Figure 30-40-3
Remove the drive belt by pulling it back from the pulleys.
Figure 30-40-5

1
1 1
S4109
Remove the cover on the left side of the engine by EM1452

removing the two brackets (Item 1) [Figure 30-40-3].
Remove the bolt and washer (Item 1) [Figure 30-40-5] by

screwing them loose.
Installation: Apply Loctite® #242 and tighten the

mounting bolt to 24 - 26 N•m (18 - 19 ft-lb) torque.
262 of 692 30-40-2

Figure 30-40-6
2 2
1
2
1 1
EM1455
1
Remove the black cover from the pump assembly by

EM1453 removing the six screws (Item 1) and loosening the two
bolts (Item 2) [Figure 30-40-8].
Install the puller (Item 1) on the hydrostatic pump drive Figure 30-40-9
pulley. Remove the drive pulley (Item 2) [Figure 30-40-6]

from the pump shaft.
Installation: Install the key in the hydrostatic pump shaft

before installing the pump drive pulley.
Figure 30-40-7 1
EM1450
1 Remove the hydraulic pump from the pump assembly by

removing the two screws (Item 1) [Figure 30-40-9].
1 Installation: Tighten to 74,6 - 81,3 N•m (55 - 60 ft-lb)

EM1454 torque.
Remove the three hydrostatic pump mounting bolts (Item

1) [Figure 30-40-7] from the pump and drive belt
housing. The pump assembly (one hydraulic and two
hydrostatic) is now loose from the drive belt housing.
Installation: Tighten to 125 - 135 N•m (90 - 100 ft-lb)

torque.
263 of 692 30-40-3

HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Ensure the hydrostatic reservoir is filled to the correct
level before starting the engine. (See Checking And
Figure 30-40-10 Adding Fluid on Page 10-120-1.)
NOTE: Because the hydraulic reservoir is above the

inlet of the hydraulic pump, hydraulic fluid will
always be available for the hydraulic pump
when starting. No other special precautions
need to be made.
1
EM1456
Separate the two hydrostatic pumps by removing the two


Installation: Tighten to 125 - 135 N•m (90 - 100 ft-lb)
torque.
WARNING
explosion or fire.
W-2103-0508
264 of 692 30-40-4

HYDROSTATIC PUMP (CONT’D)
1. Bolt (2)
2. Washer
3. O-ring
4. Coupler
5. O-ring
6. Replenishing/High Pressure Relief Valve
7. Pin
8. Bearing
9. Valve Plate
10. Gasket
11. Block
12. Wear Plate
13. Swash plate
14. Tapered Roller Bearing
15. Plug
16. O-ring
17. Housing
18. O-ring
19. Bearing Race
20. Cover
21. Washer
22. Bolt (6)

23. Bearing
24. Crush Ring
25. Seal
26. Cover
27. Shaft (For Left Pump)
28. Key
29. Retainer Ring
30. Bearing Thrust
31. Bearing
32. Washer
33. Seal
34. Retainer Ring
35. Shaft (For Right Pump)
36. O-ring
37. Charge Pressure Relief Valve Housing
38. Piston
39. Spring
40. Washer
41. Retainer Ring
42. Pin
43. End Cap
S4747
265 of 692 30-40-5

Disassembly
1
Figure 30-40-11
1
S4151
1
Screw the two replenishing / high pressure valves (Item
1 S4149 1) [Figure 30-40-13] out of the end cap.
NOTE: While removing the valves, oil can be spilled.

Remove the four bolts (Item 1) [Figure 30-40-11] from
the pump housing to separate the hydrostatic pump into Figure 30-40-14

left and right.
Figure 30-40-12
1
3
1
2 S4152
S4150 Remove the spring washer (Item 1) [Figure 30-40-14] to

disassemble the valve.
Remove the valve plate (Item 1) [Figure 30-40-12] and

gasket from the smallest hydrostatic pump part. Check
the valve plate for wear (both sides).
Check the valve plate locating pin (Item 2) [Figure 30-40-

12] for wear and replace if needed.
Check the needle bearing (Item 3) [Figure 30-40-12] for

wear and replace if needed.
266 of 692 30-40-6

Disassembly (Cont’d)
Figure 30-40-15
S4157
Remove the block and piston assembly (Item 1) [Figure

S4155 30-40-17] from the pump by pulling it back.
Figure 30-40-18
Remove the charge inlet relief valve (Item 1) [Figure 30-
40-15].

Figure 30-40-16
1
2
2
6 5 4 3 1
S4158
Pull the ring (Item 1) and pistons (Item 2) [Figure 30-40-

S4156 18] out of the cylinder block.
Check all the pistons for wear and replace if needed.

Remove the snap ring (Item 1) [Figure 30-40-16].
NOTE: Remove the retaining ring very carefully

because of the expanding spring.
Successively pull the washer (Item 3), spring (Item 4) and

piston (Item 5) out of the valve housing (Item 2) [Figure
30-40-16].
267 of 692 30-40-7

Figure 30-40-19
1
2 7
5 6
1 3 4
8 S4160
S4159 Remove the retaining ring (Item 1) [Figure 30-40-20]

from the back of the pump to remove the pump shaft out
of the pump housing.
Pull the snap ring (Item 1) out of the cylinder block (Item
2) [Figure 30-40-19]. Figure 30-40-21

NOTE: Remove the retaining ring carefully because
of the expanding spring.
Pull the two washers (Items 3 and 4) and the spring (Item 1 2 3 4 5 4
5) [Figure 30-40-19] out of the cylinder block. 6
Remove the ball guide retainer (Item 6) [Figure 30-40-

19] from the cylinder block.
Check the ball guide retainer for wear and replace if

needed.
Pull the retainer (Item 7) out of the cylinder block and

S4161
remove the three pins (Item 8) [Figure 30-40-19].
Check the cylinder block for wear and replace if needed.

Remove the seal ring (Item 1) and the washer (Item 2)
Check the three pins to see if they are all the same [Figure 30-40-21] from the pump shaft.
length.
the pump shaft.
Remove the two thrust bearings (Items 4) and the

bearing (Item 5) from the pump shaft. Also remove the
retaining ring (Item 6) [Figure 30-40-21].
268 of 692 30-40-8

Figure 30-40-22
2
1 3
S4164
Remove the O-ring (Item 1), the crush ring (Item 2) and
S4162
the bearing race (Item 3) [Figure 30-40-24] from the
cover. Inspect them and replace if needed.
Remove the bearing (Item 1) [Figure 30-40-22] from the
Figure 30-40-25
pump housing.

Figure 30-40-23
1
1
1
1
S4165
S4163
Remove the lower cover from the pump housing by
removing the three bolts (Item 1) [Figure 30-40-25].
Remove the cover from the pump housing by removing
the three bolts (Item 1) [Figure 30-40-23].
269 of 692 30-40-9

Figure 30-40-26
1
1
S4168
Remove the wear plate (Item 1) [Figure 30-40-28] from

S4166 the swash plate.
Slide the swash plate from side to side and remove the
lower tapered roller bearing (Item 1) [Figure 30-40-26]

from the swash plate shaft.
Figure 30-40-27
S4167
Tilt the swash plate (Item 1) [Figure 30-40-27] and

remove the swash plate with upper tapered roller bearing
from the pump housing.
270 of 692 30-40-10

Assembly
Figure 30-40-29
1
S4165
Install the lower cover on the pump housing and tighten

S4168 the bolts (Item 1) [Figure 30-40-31] to 39,3 N•m (29 ft-lb)
torque.
Install the wear plate (Item 1) [Figure 30-40-29] onto the Figure 30-40-32
swash plate.

Figure 30-40-30
2
1 3
S4164
S4166
Install the O-ring (Item 1), the crush ring (Item 2) and the
bearing race (Item 3) [Figure 30-40-32] on the cover.
Install the swash plate and the upper tapered roller
bearing into the pump housing [Figure 30-40-30].
271 of 692 30-40-11

Assembly (Cont’d)
Figure 30-40-33
1 2 3 4 5 4 6
1
1
1
S4161
Install the snap ring (Item 6), the two thrust bearings
S4163 (Item 4) and the bearing (Item 5) [Figure 30-40-35] onto
the pump shaft.
Install the cover on the pump housing and tighten the Install the snap ring (Item 3) [Figure 30-40-35] onto the
bolts (Item 1) [Figure 30-40-33] to 39,3 N•m (29 ft-lb) pump shaft.

torque.
Install the washer (Item 2) and the seal ring (Item 1)
Figure 30-40-34 [Figure 30-40-35] onto the pump shaft.
Figure 30-40-36
1
1
S4162
Install the bearing (Item 1) [Figure 30-40-34] into the S4160

pump housing.
Install the pump shaft into the pump housing and install
the snap ring (Item 1) [Figure 30-40-36].
272 of 692 30-40-12

Assembly (Cont’d)
Figure 30-40-37
2 7
5 6
1 3 4
S4157
8
Install the rotating group into the pump as shown in

S4159 [Figure 30-40-39].
Figure 30-40-40
Install the two washers (Items 3 and 4) and the spring
(Item 5) [Figure 30-40-37] into the cylinder block.

Install the snap ring (Item 1) [Figure 30-40-37] into the
cylinder block.
2
Install the three pins (Item 8) into the cylinder block and 6 5 4 3 1
put the tension ring (Item 7) [Figure 30-40-37] in its
place.
Install the ball guide retainer (Item 6) [Figure 30-40-37]

into the cylinder block.
Figure 30-40-38
S4156
Install the piston (Item 5), the spring (Item 4), the washer
(Item 3) and the snap ring (Item 1) into the valve housing
(Item 2) [Figure 30-40-40].
Install the O-ring (Item 6) [Figure 30-40-40] on the valve

housing.
S4158
Install the ring and pistons into the cylinder block [Figure
30-40-38].
273 of 692 30-40-13

Assembly (Cont’d)
Figure 30-40-41
S4152
Assemble the parts shown in [Figure 30-40-42] to

S4155 become the part shown in [Figure 30-40-43].
Figure 30-40-44
Screw the charge inlet relief valve (Item 1) [Figure 30-40-
41] into the end cap.

1
Figure 30-40-42
1
S4151
Install the two valves (Item 1) [Figure 30-40-44] into the

S4153 end cap and tighten to 128,8 - 142,4 N•m (95 - 105 ft-lb)
torque.
274 of 692 30-40-14

Assembly (Cont’d)
Figure 30-40-45 1
1 1
1 S4149
Assemble the two pump parts by means of the four bolts

S4150
(Item 1) [Figure 30-40-47].
Tighten the bolts to 25 N•m (19 ft-lb) torque.

Coat the backside of the valve plate (Item 1) [Figure 30-
40-45] with petroleum jelly to hold it in position and install

the valve plate onto the end cap.
Figure 30-40-46
S6017
Install the two pins (Items 5) and gasket (Item 3) [Figure

30-40-46] onto the pump part.
275 of 692 30-40-15

276 of 692
30-40-16
HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casting. The end caps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on top of the pump
that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port

MG Gauge Port For Charge Pressure
EM1015
277 of 692 30-41-1

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
High Pressure Relief And Bypass Valve
Figure 30-41-1
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-41-3]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-3] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-41-1] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-1].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 27,58 MPa (276 bar)
Figure 30-41-2 (4000 psi).
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-2], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-41-2]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-41-2] to

ensure it is not broken or flattened.
278 of 692 30-41-2

IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
S10447
the loader. (See Engine Removal And Installation on
Page 70-10-8.) Loosen the drive belt (Item 1) by pulling the tension
wheel (Item 2) [Figure 30-41-5] upward with a handle.
Figure 30-41-4
Figure 30-41-6

1
1
1 S4109
Remove the cover on the left side of the engine by S10448

removing the two brackets (Item 1) [Figure 30-41-4].
Remove the nut and washer (Item 1) [Figure 30-41-6] by

screwing them loose.
Installation: Apply Loctite® #242 and tighten the bolt to

24 - 26 N•m (18 - 19 ft-lb) torque.
279 of 692 30-41-3

HYDROSTATIC PUMP (SJC) (CONT’D) Figure 30-41-9
Figure 30-41-7
2
3
2
1
EM1020
1
Remove the nut and bolt (Item 1) [Figure 30-41-9].
EM1018
Installation: Tighten the bolt to 25 - 28 N•m (34 - 38 ft-lb)
torque.
Install the puller (Item 1) on the hydrostatic pump drive
pulley. Remove the drive pulley (Item 2) [Figure 30-41-7] Remove the two bolts (Item 2) [Figure 30-41-9].

from the pump shaft.
Installation: Tighten the two bolts to 75 - 85 N•m (55 - 60
Installation: Install the key in the hydrostatic pump shaft ft-lb) torque.
before installing the pump drive pulley.
Figure 30-41-8
Figure 30-41-10
1
EM1019
EM1021
Put a strap around the hydrostatic pump assembly and

support it by means of a hoist [Figure 30-41-8]. Remove the two bolts and nuts (Item 1) [Figure 30-41-
10] and remove the hydraulic / hydrostatic pump
assembly from the engine.
Installation: Tighten the bolts and nuts to 125 - 135 N•m

280 of 692 30-41-4

HYDROSTATIC PUMP (SJC) (CONT’D) Hydrostatic Pump Start Up
Removal And Installation (Cont’d) Before putting a hydrostatic pump back into operation,
the hydrostatic pump should be filled with hydrostatic
Figure 30-41-11 fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
1
Starting a hydrostatic pump dry can cause premature
2 wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before start up.
3
EM1022 Figure 30-41-12
Disconnect the tubeline (Item 1) [Figure 30-41-11] from

the hydraulic pump.

41-11] from the hydrostatic pump.
Remove the hydraulic pump (Item 3) [Figure 30-41-11]

from the hydrostatic pump by sliding it off. 1
P-64458
Remove the air bleed plugs (Item 1) [Figure 30-41-12].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.
281 of 692 30-41-5

Hydraulic Controller Removal And Installation
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Remove the hydrostatic pump. (See Removal And

Installation on Page 30-41-3.) 1
Figure 30-41-13
1
P-64426
Remove the four mount bolts (Item 1) [Figure 30-41-14]

from the hydraulic controller.
Installation: Alternately tighten bolts to 10,4 N•m (92 in-

lb) torque. Ensure bolts are tight to specifications.

P-64425
Locate the two hydraulic controllers (Item 1) [Figure 30-

41-13] on the hydrostatic pumps.
IMPORTANT
damage the system.
I-2003-0888
282 of 692 30-41-6

Hydraulic Controller Removal And Installation

(Cont'd)
Figure 30-41-15 1
1
2
2 P-64444
3
Installation: Be sure the feedback lever (Item 3) [Figure
30-41-15] is in the center of the servo piston groove (Item
P-64427 1) [Figure 30-41-16].
Use a small amount of grease on a new gasket and

Remove the controller (Item 1) [Figure 30-41-15] from
install the gasket on the hydraulic controller (Item 1)
the pump.

[Figure 30-41-15].
Remove the controller gaskets (Item 2) [Figure 30-41-
Be sure the pump surface is clean.
15] from the pump.
Figure 30-41-17
NOTE: When a hydraulic controller is replaced, the
hydrostatic pumps must be calibrated (See
Hydraulic Controller Neutral Adjustment on
Page 30-41-27.).
P-64978
Installation: With the engine running and the loader on

jack stands: Bleed the trapped air in the controller by
loosening the small set screw (Item 1) [Figure 30-41-17]
a maximum of two turns. Leave the screw loose until oil
comes dripping out of the set screw. Tighten set screw to
2 N•m (18 in-lb) torque.
Repeat the bleeding procedure for all of the solenoids.
283 of 692 30-41-7

HYDROSTATIC PUMP (SJC) (CONT'D)
3 1
1. O-ring 5 4
2. Bolt
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer / Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt 14
15
16
19 17
21
24 23 22 26

20
25
18
26
18
27
32 19 29
28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
6 22. Plug
2
7 23. Screen
24. Plug
25. Orifice
30 26. Dowel Pin
27. Charge Pressure Relief
4 28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
B25010
284 of 692 30-41-8

Remove the hydraulic controllers. (See Hydraulic

Controller Removal And Installation on Page 30-41-6.).
1
Figure 30-41-18
2
2
1 1 1
EM1013
Remove the mounting bolts and washers for the swash

plate angle sensor (Item 1) [Figure 30-41-20].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

EM1011
Figure 30-41-21

Swash plate angle sensors (Item 1) are mounted on top
of the hydrostatic pump. They are protected by a steel
cover (Item 2) [Figure 30-41-18].
1
Note the connectors facing each other.
Note the steel cover facing direction.

2
Figure 30-41-19
EM1014
Assembly: Note the slotted portion (Item 1) of the

1 positioning pin tightly fits the machined section on the
swash plate angle sensor shaft (Item 2) [Figure 30-41-
21].
Note the machined section of the swash plate angle

sensor shaft faces the center of the hydrostatic pump.
EM1012
Remove the steel cover mounting bolts (Item 1) [Figure

30-41-19] (Both Sides.)
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.
Remove the steel cover.
285 of 692 30-41-9

HYDROSTATIC PUMP (SJC) (CONT'D) Left End Housing
Disassembly And Assembly (Cont'd) Figure 30-41-24
Figure 30-41-22 3 1
1 2
P-64447
P-64453
Remove the four mount bolts (Item 1) securing the end
housing (Item 2) to the main case housing (Item 3)
NOTE: Improperly installing the swash plate angle [Figure 30-41-23] and [Figure 30-41-24].
sensor, with the shaft facing toward the

outside of the hydrostatic pump, will make it Assembly: Alternately, tighten mount bolts to 130 N•m
hard to install the sensor mounting bolts and (96 ft-lb) torque.
also destroy the seal (Item 1) [Figure 30-41-
22]. Figure 30-41-25
Right End Housing
Figure 30-41-23
3
1
P-64464
1
Pull the end housings from the case housing [Figure 30-
P-64445 41-25].
286 of 692 30-41-10

Disassembly And Assembly (Cont'd)
Figure 30-41-26
1 2 1
P-64466
Assembly: Ensure servo follower (Item 2) [Figure 30-

P-64463 41-27] is swung out for proper engagement with the
notch in the servo piston (Item 1) [Figure 30-41-28].
Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-41-26] before

tightening screws.
Figure 30-41-27
1
2
P-64465
287 of 692 30-41-11


LEFT SIDE
Figure 30-41-29
RIGHT SIDE 1
1 2
P-64501
2
Remove valve plate (Item 1) [Figure 30-41-29] and
P-64454 [Figure 30-41-30] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.

NOTE: Pay attention to the notches (Item 2) [Figure
30-41-29] and [Figure 30-41-30] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.
288 of 692 30-41-12

Disassembly And Assembly (Cont'd) RIGHT SIDE

Figure 30-41-31
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-41-34
P-64455
LEFT SIDE
Figure 30-41-32 1
2

LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64502 31] and [Figure 30-41-32] in the case housing with the
notch (Item 1) [Figure 30-41-33] and [Figure 30-41-34]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-41-31] and [Figure 30-41-32] with the beveled edge
on the valve plate (Item 2) [Figure 30-41-33] and [Figure
30-41-34].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.
289 of 692 30-41-13

Figure 30-41-35
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-37].

B25012
Figure 30-41-38
Right Side Rotating Group [Figure 30-41-35].

Figure 30-41-36
1
P-64475
Remove the pistons (Item 1) [Figure 30-41-38] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-41-36].
290 of 692 30-41-14


1
Figure 30-41-39
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64476 41].
Figure 30-41-42
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-41-39] in the
1

slippers, are not plugged.
Figure 30-41-40
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-42]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-41-40].
291 of 692 30-41-15


3
Figure 30-41-43
1
1
P-64479
Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-41-45].
Remove the swash plate from the end cap housing (Item
Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-41-45].
1) [Figure 30-41-43].

Remove the slide ring (Item 3) [Figure 30-41-45], ensure
Figure 30-41-44 it pivots freely.
Figure 30-41-46
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-44] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in end cap housing (Item 2) [Figure 30-41-46].
Visually ensure spring (Item 2) and circlip (Item 3)
[Figure 30-41-44] are not bent or damaged.
292 of 692 30-41-16

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-41-47
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64481 49].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-41-49] on them. The edges face toward the
swash plate (Item 1) [Figure 30-41-47]. outside of the end cap housing

Figure 30-41-48 Inspect bearing surfaces for scratches or scoring.
Figure 30-41-50
2
1
2
P-64482
P-64484
Remove the shell bearing (Item 1) [Figure 30-41-48].
Inspect individual roller bearings and machined surfaces Remove the snap ring (Item 1) from the positioning pin
(Item 2) [Figure 30-41-48] on swash plate. (Item 2) [Figure 30-41-50].
293 of 692 30-41-17

Disassembly And Assembly (Cont'd) RIGHT SIDE

Figure 30-41-51 1
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-41-52] and

P-64485 [Figure 30-41-53] from the end housing.
Figure 30-41-54
Pull the positioning pin from the end housing.

Inspect wear surfaces (Item 2) [Figure 30-41-51] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
Figure 30-41-52
LEFT SIDE 1
P-64524
1
The pump seal (Item 1) [Figure 30-41-54] is removed by
inserting a screw into the seal and prying out.
P-64486
294 of 692 30-41-18

Figure 30-41-55
P-64490
Measure and record servo piston depth at the adjustment

P-64488 screw [Figure 30-41-57].
The drive shaft can be tapped out of the end housing with Figure 30-41-58
a rubber mallet.

Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-41-55] and remove
bearing.
1 1
Figure 30-41-56
P-64489
Remove servo piston mounting bolts (Item 1) [Figure 30-

41-58].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
B25013
Servo Piston Assembly [Figure 30-41-56].
The Servo Piston Assembly [Figure 30-41-56] cannot be

removed unless the hydraulic controller and rotating
group is removed first.
295 of 692 30-41-19

Figure 30-41-59
P-64467
Figure 30-41-62
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-41-59].
1

Figure 30-41-60
P-64466
Assembly: Align the servo piston so the guide slot

(Item 1) [Figure 30-41-62] is parallel to the driveshaft
center line. Measure with a straight-edge [Figure 30-41-
61].
P-64492
Slide the servo piston assembly out of the bore. [Figure

30-41-60].
296 of 692 30-41-20

Figure 30-41-63
2
1
1
2
P-64495
Remove the lock nut (Item 1) [Figure 30-41-65] from the

P-64493 servo piston.
Assembly: Tighten lock nut to 30 N•m (22 ft-lb) torque.

Remove the bushings (Item 1), seals and O-rings (Item 2)
[Figure 30-41-63] from the pump housing. Figure 30-41-66

Figure 30-41-64
3 P-64496
P-64494
Remove the servo cover (Item 1) [Figure 30-41-66] from
the servo piston.
Each servo has a pair of bushings (Item 1), O-rings (Item
2) and square-cut seals (Item 3) [Figure 30-41-64].
297 of 692 30-41-21

Figure 30-41-67
2 1
P-64461
1
Remove the plug (Item 1) from the top center of the case
P-64497 housing. Replace O-ring (Item 2) [Figure 30-41-69].
Assembly: Tighten plug to 10 N•m (7.4 ft-lb) torque.

Remove snap ring (Item 1) [Figure 30-41-67] from the
servo piston. Remove internal screen (Item 3) [Figure 30-41-69].

Figure 30-41-68 Assembly: Tighten internal screen to 62 N•m (45 ft-lb)
torque.
1
2 Figure 30-41-70
P-64498
Remove the piston stop adjustment mechanism (Item 1)

P-64462
[Figure 30-41-68] from the servo piston.
Inspect mechanism for broken parts. Ensure screen is clean [Figure 30-41-70].
Replace O-ring (Item 2) [Figure 30-41-68]
298 of 692 30-41-22

HYDROSTATIC PUMP (SJC) (CONT'D)

WARNING
Figure 30-41-71
Hydraulic fluid escaping under pressure can have
immediately.
1 W-2145-EN-0210
1
P-64499
Remove the four plugs (Item 1) [Figure 30-41-71] at the

top of the case housing.

Replace O-rings on plugs.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.
Figure 30-41-72
2
1
P-64502
Bearings (Item 1) [Figure 30-41-72] in case housing are

replaced by using a press and bearing driver.
Inspect center coupler (Item 2) [Figure 30-41-72].
299 of 692 30-41-23

Mechanical Neutral Adjustment
The pump mechanical neutral adjustment sets the

position of the servo piston and pump swash plate
relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.
Place the loader on jackstands. (See Procedure on Page

10-10-1.).
S35961
WARNING
Move the tube and hose out assembly of the way for
Put jackstands under the front axles and rear corners better access to the hydrostatic pumps [Figure 30-41-
of the frame before running the engine for service. 74].
fall or move and cause injury or death. Figure 30-41-75
W-2017-0286
1

Raise the lift arms, and install an approved lift arm
1
support device. (See Installing on Page 10-20-1.).
Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to P-64973
find an accessible connector to disconnect.
Figure 30-41-73 Connect a hydraulic hose (Item 1) [Figure 30-41-75]

between port X1 and port X2 on each side of the
hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
S10533
Remove the bolt (Item 1) [Figure 30-41-73].
300 of 692 30-41-24

Mechanical Neutral Adjustment (Cont’d) 1
Figure 30-41-76
1
1
1
EM1003
Remove drive hoses from the A and B ports (Item 1)

P-64425 [Figure 30-41-78]. Plug the ports with metal caps. The
caps must be able to handle at least 51,71 MPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
Remove the plugs (Item 1) [Figure 30-41-76] from the leakage at the drive motors from causing errors in the
MB ports on the front side of the pump, and install 51,71 pump mechanical neutral setting.

MPa (517 bar) (7500 psi) pressure gauges.
Figure 30-41-79
Figure 30-41-77
P-64457
P-64438
Loosen the pump neutral adjustment lock nut (Item 1)

Remove the plugs (Item 1) [Figure 30-41-77] from the [Figure 30-41-79].
MA ports on the bottom of the pump, and install 51,71
MPa (517 bar) (7500 psi) pressure gauges. Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
301 of 692 30-41-25

Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-80
P-64457
1
Turn the adjustment screw (Item 1) [Figure 30-41-82]
P-64457
clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-41-83

in system pressure. Mark the position of the adjustment
screw.
Figure 30-41-81
P-64457
1 While holding the adjustment screw (Item 1) in position,

tighten the lock nut (Item 2) [Figure 30-41-83] to 30 N•m
P-64457 (22 ft-lb) torque.
Shut loader OFF.

counterclockwise, until the other gauge registers an Remove the hydraulic hose from the X1 and X2 ports on
increase in system pressure. Mark the position of the the pump. Install the plugs and tighten to 25 N•m (18 ft-
adjustment screw. lb) torque.
Remove the pressure gauges from the MA and MB ports

on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
NOTE: The Hydraulic Controller Neutral Adjustment

must be performed whenever the Mechanical
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41-
27.)
302 of 692 30-41-26

Hydraulic Controller Neutral Adjustment
The hydraulic controller neutral adjustment, aligns the

pump swash plate and the control spool so that a zero
angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
1
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
NOTE: Procedure is shown for the left side hydraulic

controller. Procedure is the same for the right S10533
side hydraulic controller, except you
disconnect the electrical connectors for the
right side hydraulic controller and connect Remove the bolt (Item 1) [Figure 30-41-84].
pressure gauges in the X1 and X2 ports on the
right side of the pump. Figure 30-41-85
Place the loader on jack stands. (See Procedure on Page

10-10-1.)

WARNING
W-2017-0286
S35961
Raise the lift arms, and install an approved lift arm
Move the tube and hose out assembly of the way for
Raise the operator cab. (See Raising on Page 10-30-1.) better access to the hydrostatic pumps [Figure 30-41-
85].
Connect the remote start tool. (See REMOTE START
TOOL KIT-MEL1563 on Page 10-60-1.)
WARNING
Hydraulic fluid escaping under pressure can have
immediately.
W-2145-EN-0210
303 of 692 30-41-27

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-86
1
P-64975
Install 3,45 MPa (34 bar) (500 psi) pressure gauges in

EM1006 the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting [Figure 30-41-88].
Disconnect the hydraulic controller connectors (Item 1) Figure 30-41-89

[Figure 30-41-86] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-41-87
1
1
P-64459
Loosen the locking screw (Item 1) [Figure 30-41-89].

P-64458
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-41-87] pertaining to the side of the Read and note down the system pressure at the gauges.
hydrostatic pump you are adjusting.
Shut down the engine and let it cool down.
WARNING
W-2276-1297
304 of 692 30-41-28

Figure 30-41-90
P-64459
With engine off and cold, turn the adjustment screw (Item
P-64459 1) [Figure 30-41-91] counterclockwise for 90°.
Start the loader using the remote start tool and run at an
When engine is cold, turn the adjustment screw (Item 1) idle.
[Figure 30-41-90] clockwise for 90°.

Again read the system pressure at the gauges, shut
Start the loader using the remote start tool and run at an down the engine and let it cool down.
idle.
Repeat these steps until the other gauge registers an
Again read the system pressure at the gauges, shut increase in system pressure. Mark the position of the
down the engine and let it cool down. adjustment screw (when engine is cold).
Repeat these steps until one of the gauges registers an

increase in system pressure. Mark the position of the
adjustment screw (when engine is cold).
WARNING
AVOID INJURY
WARNING DO NOT go into these areas with the engine running.
Avoid hot and rotating parts.
W-2148-1092
AVOID INJURY
DO NOT go into these areas with the engine running.
Avoid hot and rotating parts.
W-2148-1092
WARNING
WARNING W-2276-1297

W-2276-1297
305 of 692 30-41-29


2
Figure 30-41-92
P-64459
When engine is cold, hold the adjustment screw (Item 1)

P-64459 in position and tighten the locking screw (Item 2) [Figure
30-41-93] to 6,1 N•m (54 in-lb) torque.
With engine off and cold, turn the adjustment screw (Item Remove the pressure gauges from the X1 and X2 ports
1) [Figure 30-41-92] clockwise, to a position halfway on the pump. Install the plugs and tighten to 25 N•m (18

between the recorded positions. ft-lb) torque.
Start the loader using the remote start tool and run at an Connect the hydraulic controller wire connectors to the
idle. loader wiring harness.
The pressure gauges should read equal pressures. Perform a controller calibration procedure. (See
CALIBRATION on Page 60-140-1.)
Shut down the engine and let it cool down.
306 of 692 30-41-30

DRIVE BELT Adjusting
Description Figure 30-50-2
The drive belt makes the mechanical connection from the

engine flywheel to the hydrostatic pump pulley.
The belt is a cord-reinforced rubber design. 1
Constant tension is applied to the drive belt by the use of

a spring-loaded belt tensioner.
The drive belt is protected by a plastic shield fastened to

the flywheel housing by metal clips. The shield is also in
place to protect the operator.
Shield Removal And Installation

EM1449
Figure 30-50-1
The adjustment of the drive belt is done automatically by

means of a spring loaded tensioner pulley (Item 1)
1 [Figure 30-50-2].

S4232
Remove the two drive belt shield mounting clips (Item 1)

[Figure 30-50-1].
Remove the belt shield.
307 of 692 30-50-1

DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
Belt Removal And Installation Remove the drive belt from the engine. (See Belt
Removal And Installation on Page 30-50-2.)
Figure 30-50-4
Remove the negative (-) cable from the battery. The
battery can be removed for additional working clearance.
1
Remove the belt shield. (See Shield Removal And
Figure 30-50-3
1 EM1449
Remove the tensioner pulley from the engine by

removing the screw (Item 1) [Figure 30-50-4].
Tensioner Pulley Disassembly And Assembly
EM1449 Figure 30-50-5
Loosen the drive belt (Item 1) by pulling the tension

wheel (Item 2) [Figure 30-50-3] upward with a socket
wrench.
Install a new drive belt. 1
Reinstall the belt shield and connect the negative (-)

cable to the battery.
S4234
Remove the bolt (Item 1) [Figure 30-50-5] from the

tensioner pulley and remove the black cover.
308 of 692 30-50-2

CASE DRAIN FILTER Figure 30-60-3
Description
The case drain filter is an external filter assembly in the

case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete 1
assembly or disassembled to replace the element with an
element kit and / or the spring kit purchased from Bobcat
Parts.
Remove the case drain filter(s) from the machine. (See

Removing And Replacing Case Drain Filters on Page 10-
120-4.) P-76218
Figure 30-60-1
Remove the filter element and spring assembly (Item 1)
[Figure 30-60-3]
NOTE: Remember the orientation of the filter element

and spring assembly for correct assembly.

Figure 30-60-4
1 3
P-76212
1
Remove the filter housing nut (Item 1) from the filter

housing (Item 2) [Figure 30-60-1]. 2
Figure 30-60-2
P-76216
The larger taper spring (Item 1) slides over the end of the
2 filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-60-4] slides into the filter element.
P-76214
Remove the packing (Item 1) and O-ring (Item 2) [Figure

30-60-2] from the filter housing nut.
309 of 692 20-60-1

310 of 692
20-60-2
DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2


BRAKE Disc Removal And Installation
Description Raise the lift arms and install an approved lift arm
Figure 40-10-1
WARNING
W-2059-0598
1 Raise the operator cab. (See Raising on Page 10-30-1.)

EM1448
Remove the center chaincase cover. (See Center Cover
The brake is used to hold the machine in place. The
Figure 40-10-2
brake is operated by a switch (Item 1) [Figure 40-10-1]

located on the front accessory panel.
The brake is applied by a spring-loaded wedge that drops

into two notched brake discs. An electric solenoid is
getting power from a relay to pull the wedge away from
the discs. A signal from the main Bobcat controller holds
1
the wedge away from the discs.
The hold signal will be interrupted and the wedge will

drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
For more information on the brake. (See TRACTION

LOCK on Page 60-110-1.) 1 S0364
The parking brake discs (Item 1) [Figure 40-10-2] are

located beneath the center chaincase cover.
313 of 692 40-10-1

BRAKE (CONT’D) Figure 40-10-4
Disc Removal And Installation (Cont’d)
Figure 40-10-3
2
P-54222
1
Snap ring pliers with 90° tips is necessary for removing
N-19105 the parking brake discs.
Remove the snap ring (Item 1) from the end of the

Inspect the traction lock guides (Item 1) [Figure 40-10-3] sprocket (Item 2) [Figure 40-10-4].
and the brake discs for damage or wear and replace if

necessary. Slide the disc (Item 3) [Figure 40-10-4] off the sprocket
and remove the disc.
Reverse the removal procedure to install the disc in the

loader.
314 of 692 40-10-2

DRIVE COMPONENTS
Description

S4265
The drive components consist of a chaincase, drive

chains, sprockets, axleshafts, hubs and a brake.
The chaincase is partially filled with hydraulic fluid to

lubricate the chains and bearings.
A cover is located on the bottom of the chaincase for

access to the fuel tank drain plug.
315 of 692 40-20-1

DRIVE COMPONENTS (CONT’D) Figure 40-20-2
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool

2
MEL1399 - Seal Driver Tool
MEL1242 - Power Ram (can be used if desired)
Figure 40-20-1
P-4159
2
Install the puller tool (Item 1) [Figure 40-20-2] on the

axle hub.
1
A driver tool (Item 2) [Figure 40-20-2] can be used for
centering the threaded rod of the puller.
2

P-4157
Before lifting and blocking the loader, loosen the hub

WARNING
mounting bolt (Item 1) [Figure 40-20-1]. NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
NOTE: If the axle and bearings are being replaced, tapered fit on the axle end and can come off the axle
also loosen the sprocket mounting bolt inside with great force and cause serious injury.
the chaincase before lifting and blocking the W-2186-0395
loader. (See Axle, Sprocket And Bearings
Use a wrench with the puller and remove the axle hub
Lift and block the loader. (See LIFTING AND BLOCKING from the axle tube. A spacer and a power ram MEL 1242
THE LOADER on Page 10-10-1.) can be used between the axle and the tool if available,
instead of the wrench, threaded rod and driver tool.
Remove the front tire / wheel assembly.
Remove the hub mounting bolt (Item 1) [Figure 40-20-1]

and washer from the axle.
Installation: Tighten the hub mounting bolt to 983 - 1085

Remove two of the wheel mounting studs (Item 2)

[Figure 40-20-1].
Use a wheel mounting nut on both studs and remove the

two studs with a hammer.
Installation: Support the flange of the axle hub and

install the two studs with a hammer. A hydraulic press
can also be used to install the studs.
316 of 692 40-20-2

Axle Seal Removal And Installation (Cont’d)
Figure 40-20-3
P-4160
1 Installation: MEL1399 seal driver tool is necessary for

P-4161 the following procedure:
Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair

Figure 40-20-4 sleeve kit is available from Bobcat Parts.
Place the new axle seal over the axle and into the axle
tube.
Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].
Hit the seal driver tool with a hammer until the tool is
flush with the edge of the axle tube [Figure 40-20-5].
1 Reverse removal procedure to install the axle hub and

wheel assembly.
P-4181
Drill a small hole in the axle seal.
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end in the axle seal.
Remove the axle seal.
317 of 692 40-20-3

Axle, Sprocket And Bearings Removal And

Installation
The tools listed are needed for the following procedure:
MEL1242 - Power Ram

MEL1202B - Axle Bearing Service Set
NOTE: The procedure shown is for removing the

front axle, bearings and sprocket. This
procedure can also be used for the rear axle,
bearings and sprocket.
1
Use jackstands to support the rear of the loader. (The P-4147A
loader wheels should remain on the ground.)
Loosen the axle sprocket mounting bolt (Item 1) [Figure

40-20-6].
WARNING Remove the axle hub. (See Axle Seal Removal And

the lift arms are secured by an approved lift arm Remove the sprocket mounting bolt (Item 1) [Figure 40-
support device. Failure to use an approved lift arm 20-6].
to fall and cause injury or death. Installation: Tighten the sprocket mounting bolt to 407 -
W-2059-0598 447 N•m (300 - 330 ft-lb) torque.

Remove the fluid from the chaincase.
Remove the cover from the chaincase. (See Front Cover

318 of 692 40-20-4


Installation (Cont’d)
Figure 40-20-7 1
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed for

1 the following procedure.
P-4158A
Put the axle / outer bearing assembly in the bearing
Install the MEL1242 power ram (Item 1) [Figure 40-20-7] puller as shown and put in the hydraulic press [Figure
between the two sprockets. 40-20-9].

Put a spacer between the power ram and axle. Push the Figure 40-20-10
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure
until the axle is free from the sprocket and inner bearing.
Figure 40-20-8
P-4171
2
1 Be sure the bearing puller makes good contact with the
inner race of the bearing and press the bearing off the
mounting surface of the axle.
P-4162A
Be sure to hold on to the axle during removal as it will

Remove the drive chain from the sprocket (Item 1) slide freely along the axle shaft after removal from the
[Figure 40-20-8] and remove the sprocket from the bearing mounting surface and until the bearing contacts
chaincase. the spline on the shaft.
Remove the inner bearing (Item 2) [Figure 40-20-8]. Press the splined end of the axle free from the bearing
[Figure 40-20-10].
Installation: Pack both axle bearings with grease before
installing them.
Remove the axle / outer bearing assembly from the axle

tube.
319 of 692 40-20-5


Figure 40-20-11
4
3
P-4175
2
Installation: When the bearing reaches the bearing
mounting surface, continue the installation until the
P-4169 bearing is fully seated [Figure 40-20-12].
Figure 40-20-13
Installation: A piece of round tubing (Item 1) [Figure 40-

20-11] is needed to install the bearing on the axle shaft.
The tubing needs to measure approximately 12,7 mm

(0.5 in) to 25,4 mm (1.0 in) in length. The inside diameter
of the tubing should not be under 53,3 mm (2.1 in) and
the outside diameter should not be over 60 mm (2.4 in).
A bearing puller (Item 2) [Figure 40-20-11] is also

needed to install the bearing on the axle.
Put the tubing (Item 1) on the bearing puller (Item 2)

[Figure 40-20-11]
Put the bearing (Item 3) [Figure 40-20-11] on the tube as P-4172

shown.
Put the spline end of the axle shaft (Item 4) [Figure 40- Use the tools provided in the MEL1202B Axle Bearing
20-11] in the bearing and press the bearing onto the axle. Service Set for bearing cup removal and installation. A
slide hammer is also necessary for this procedure.
Be sure to hold on to the axle during installation, as it will
slide freely along the axle shaft after the spline end has Use the long rod and the bearing cup tool to remove the
passed through the bearing and until it reaches the inner bearing cup [Figure 40-20-13].
bearing mounting surface on the axle.
Hit the long rod with a hammer to remove the inner
bearing cup from the axle tube [Figure 40-20-13].
320 of 692 40-20-6


Installation (Cont’d) 1
2
Figure 40-20-14
P-4174A
2
1
Figure 40-20-17
P-4179
1
To remove the outer bearing cup, place the bearing cup

tool (Item 1) [Figure 40-20-14] on the slide hammer.
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-14].
After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-14] on the tool. 2
Figure 40-20-15 P-4164
Installation: Use the bearing cup installation tools (Item

1) [Figure 40-20-16] and [Figure 40-20-17] and the long
threaded rod (Item 2) [Figure 40-20-17] from the service
set to install the inner and outer bearing cups.
Put the inner bearing cup (Item 2) [Figure 40-20-16] in

the axle tube.
Put the installation tool (Item 1) [Figure 40-20-16] in the

axle tube.
Install the long threaded rod into the axle tube and
P-4180 through the installation tool [Figure 40-20-16].
Secure the tool to the threaded rod with a nut (Item 3)

Use the slide hammer and remove the bearing cup from [Figure 40-20-16].
the axle tube [Figure 40-20-15].
Put the installation tool (Item 1) [Figure 40-20-17] in the
axle tube with the threaded rod through the hole in the
tool.
321 of 692 40-20-7

DRIVE COMPONENTS (CONT’D) Chain Removal And Installation

Secure the tool to the threaded rod with a nut [Figure 40-
20-17].
WARNING
Hold the inside nut with a wrench and tighten the outside
nut as shown in photo [Figure 40-20-17].
Tighten the nut until the bearing cup is seated.
W-2059-0598
Figure 40-20-18

Page 10-20-1.)
Raise the loader operator cab. (See Raising on Page 10-

30-1.)

Drain the fluid from the chaincase.
Remove the center chaincase cover. (See Center Cover

P-4173
Remove the front chaincase cover. (See Front Cover

Installation: To install the outer bearing cup, use the Removal And Installation on Page 40-30-1.)
short rod and the bearing cup tool used for removing the
bearing cups. Remove the front axle and sprocket. (See Axle, Sprocket
And Bearings Removal And Installation on Page 40-20-
Put the bearing cup tool on the short rod. 4.)
Put the bearing cup in the axle tube and put the tool into
the tube over the bearing cup [Figure 40-20-18].
Hit the short rod with a hammer until the bearing cup is
seated inside the axle tube.
322 of 692 40-20-8

DRIVE COMPONENTS (CONT’D) Remove the front drive chain from the chaincase.
Chain Removal And Installation (Cont’d) Figure 40-20-21
Figure 40-20-19
B-13504A
S0463
The tool listed is needed for the following procedure:
Remove the parking brake disc (Item 1) [Figure 40-20-
MEL1037 - Chain Link Tool
19]. (See Disc Removal And Installation on Page 40-10-

1.)
Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
Remove the six mounting bolts (Item 2) [Figure 40-20-
19] from inside the chaincase.
Use MEL1037 Chain Link Tool and #80 chain adapter.
Installation: Tighten the mounting bolts to 170 - 190
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-21].
Figure 40-20-20
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-21].
Tighten the threaded rod of the chain link tool to 176 N•m
(130 ft-lb) torque.
1
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
P-54226 W-2233-0307
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain from the sprocket.
NOTE: It can be necessary to tie the front drive chain

up as shown in [Figure 40-20-20], so the motor
assembly can be moved enough to free the
rear drive chain (Item 1) [Figure 40-20-20] from
the sprocket.
323 of 692 40-20-9

324 of 692
40-20-10
CHAINCASE Figure 40-30-1
Description
The chaincase contains the drive components.

1
Front Cover Removal And Installation
DANGER S2912
Remove the 12 front chaincase cover mounting screws

(Item 1) [Figure 40-30-1].
Remove the front chaincase cover from the loader.
Installation: Apply polyurethane sealant to mating

surfaces. Polyurethane sealant should be applied to the
P-90328 screw threads to stop oil leakage.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598
325 of 692 40-30-1

CHAINCASE (CONT’D) Figure 40-30-3
Center Cover Removal And Installation
WARNING
2
W-2059-0598
S4239
If loader is equipped with SJC, skip to [Figure 40-30-5].
Remove the side bracket (Item 1) by removing the screw
Remove the control panel (See Removal And Installation (Item 2) [Figure 40-30-3].
on Page 50-100-2.) (for standard machines) or (See
Removal And Installation on Page 50-101-1.) (for SJC Figure 40-30-4

machines).
Remove the hydraulic control valve (See Removal And

Installation on Page 20-40-1.) (for standard control 1
machines) or (See Removal And Installation on Page 20-
41-1.) (for SJC machines).
Figure 40-30-2
2
1
S4240
Remove the side bracket (Item 1) by removing the screw

(Item 2) [Figure 40-30-4].
S4236
Disconnect the electrical connector (Item 1) [Figure 40-

30-2] from the traction lock solenoid.
Remove the solenoid stem (Item 1) [Figure 40-30-2]

from the Bob-Tach block.
326 of 692 40-30-2

CHAINCASE (CONT’D) Figure 40-30-7
Center Cover Removal And Installation (Cont’d) CORRECT

INCORRECT
Figure 40-30-5 3
N-19106 N-19105
1
Installation: Install the traction lock guides (Item 1) to
S4241 the chaincase cover (Item 2) [Figure 40-30-7] using the
four screws. Do not tighten at this time.
Remove the center chaincase cover by removing the Install the traction wedge assembly (Item 3) into the
chaincase cover mounting screws (Item 1) [Figure 40- solenoid traction lock guides (Item 1) [Figure 40-30-7].

30-5]. Tighten the four bolts and check to make sure the shaft
assembly is moving freely in the guides.
Figure 40-30-6
Apply polyurethane sealant to mating surfaces.
Polyurethane sealant should be applied to the screw
threads to stop oil leakage.
3 1
2
S4242
Remove the traction lock assembly (Item 1) [Figure 40-

30-6] from the center chaincase cover.
Remove the traction lock solenoid by removing the two

Remove the traction lock guides (Item 3) [Figure 40-30-

6] from the center chaincase cover by removing the four
screws.
Thoroughly clean the polyurethane from the chaincase

cover, screws and traction lock guides and dry.
327 of 692 40-30-3

328 of 692
40-30-4
MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1

Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2

Lower Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-5
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Pintle Arm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-7
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-2
Joystick Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-3
WINDOWS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

WINDOWS (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
WINDOWS (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1

WINDOWS (CAB DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123-1

Removal (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123-1
Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123-2
Removal And Installation (Special Applications Window) . . . . . . . . . . . . . . . . . . . . 50-123-3
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-3
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-3


SEAT BAR Figure 50-10-3
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
1
The seat bar is located in the operator cab.
Figure 50-10-1
N-18572
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-3] (both sides).
1
Installation: Tighten the nuts to 38 N•m (28 ft-lb) torque.

2.)
Figure 50-10-4
P-43383
Raise the seat bar (Item 1) [Figure 50-10-1].

1
Figure 50-10-2
1 S4010
Remove the seat bar (Item 1) [Figure 50-10-4] from the

operator cab.
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

from the cab harness.
Lower the seat bar.
333 of 692 50-10-1

SEAT BAR (CONT’D) Figure 50-10-7

5
Figure 50-10-5 4 6
4 3
6
5
7
2 7
3
2 9 8
10 1
1 N-19340
Figure 50-10-8
N-19383
4
5
Figure 50-10-6
3 6
2

4
5 9 8 7
3 1
6
2 10
7
1
N-19220
Assemble the parts as shown for the right side of the

N-19219
seat bar pivot assembly [Figure 50-10-7] and [Figure
50-10-8]. Note the direction of the mounting bolt
Assemble the parts as shown for the left side of the seat (Item 7).
bar pivot assembly [Figure 50-10-5] and [Figure 50-10-
6]. Note the direction of the mounting bolt (Item 2). Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Seat Bar Mount (Item 1) Pivot Bushing (Item 3)
Seat Bar Mounting Bolt (Item 2) Spacer Bushing (Item 4)
Keyed Plastic Bushing (Item 3) Seat Bar (Item 5)
Seat Bar (Item 4) Keyed Plastic Bushing (Item 6)
Magnetic Bushing Assembly (Item 5) Mounting Bolt (Item 7)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7) Installation: Tighten the seat bar mounting bolt (Item 7)
Sensor Mounting Nut (Item 8) [Figure 50-10-9] and [Figure 50-10-10] to 33,9 - 38 N•m
Sensor Mounting Bolt (Item 9) (25 - 28 ft-lb) torque.
Seat Bar Mounting Nut (Item 10)
Installation: Tighten the seat bar mounting bolt (Item 2)

[Figure 50-10-7] and [Figure 50-10-8] to 33,9 - 38 N•m
(25 - 28 ft-lb) torque. Tighten the sensor mounting bolt
(Item 9) to 5,6 - 7,9 N•m (50 - 70 in-lb) torque.
334 of 692 50-10-2

SEAT BAR (CONT’D) Figure 50-10-10
Compression Spring Disassembly And Assembly

2
Figure 50-10-9
6 7
3 3
5
4 6 1
P109169
3
2
Turn the bolt (Item 1) [Figure 50-10-9] and [Figure 50-
1
10-10] out of the clevis.
N-19384
Assembly: Apply Loctite® #518 adhesive to the bolt

Disassemble and assemble the seat bar compression threads. Adjust the compression spring by turning the
spring and parts as shown in Fig. [Figure 50-10-9]. bolt in past the end of the clevis three turns (Item 2)
[Figure 50-10-10], or the dimension 109,2 mm (4.3 in)

Bolt (Item 1) (Item 3) [Figure 50-10-10].
Bushing (Item 2)
Spring (Item 3) NOTE: For procedures requiring the use of Loctite®
Clevis (Item 4) #518 adhesive, thoroughly clean and dry
Retaining Pin (Item 5) affected parts before the application of
Pin (Item 6) Loctite® #518.
Bushing (Item 7)
335 of 692 50-10-3

336 of 692
50-10-4
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING 1
Cylinder contains high pressure gas. Do not open.

Opening cylinder can release rod and cause injury or
death.
W-2113-0288
WARNING P1518 P1528
Remove the cab nut and holddown plate (Item 1) [Figure

Never work on a machine with the lift arms up unless 50-20-2] (both sides).
support device. Failure to use an approved lift arm Installation: Tighten the nut to 54 - 68 N•m (40 - 50 ft-lb)
support device can allow the lift arms or attachment torque.
W-2059-0598

Figure 50-20-3
Figure 50-20-1 1
N-20617D
P-54018
Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Remove the operator cab stop (Item 1) (both sides)
[Figure 50-20-1]. Raise the operator cab. (See Raising on Page 10-30-1.),
to release the tension on the gas cylinder.
337 of 692 50-20-1

Gas Cylinder Removal And Installation (Cont’d)
Figure 50-20-4
SINGLE GAS CYLINDER
2 1
P-48587
Rotate the mounting bracket forward to relieve any

N-20631 remaining tension on the gas cylinder(s) [Figure 50-20-
6].
Figure 50-20-5 Remove the front screw (Item 1) [Figure 50-20-6] from
the gas cylinder mounting bracket.

DUAL GAS CYLINDER
Installation: Tighten the screws to 11,3 - 14,7 N•m (100
- 130 in-lb) torque.
1 2
P-43354
Loosen the front screw (Item 1) and remove the rear

screw (Item 2) [Figure 50-20-4] and [Figure 50-20-5]
from the gas cylinder mounting bracket.
338 of 692 50-20-2

OPERATOR CAB (CONT’D) Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont’d) Figure 50-20-9
Figure 50-20-7
SINGLE GAS CYLINDER
2
1
1
P1008
2
P-66830
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.

DUAL GAS CYLINDER
Assembly: Install a replacement cylinder inside the
cylinder housing.
Figure 50-20-10
1
P-68819
Remove the retaining pin(s) (Item 1) [Figure 50-20-7]

and [Figure 50-20-8] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-7]

P1006
and [Figure 50-20-8] from the operator cab.
Assembly: Apply a small amount of Loctite® #242 on

the threads of the cylinder rod [Figure 50-20-10].
Reinstall the washer and clevis on the cylinder rod.
339 of 692 50-20-3


1
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796 EM1447
Figure 50-20-11
Disconnect the cab harness connector (Item 1) [Figure
50-20-12].
1
Installation: Tighten connector screw to 3,4 - 4 N•m (30
- 35 in-lb) torque.

Lower the cab. (See Lowering on Page 10-30-2.)
Figure 50-20-13
N-20617D
1 2
Remove the operator cab gas cylinder(s). (See Gas
Cylinder Removal And Installation on Page 50-20-1.)
Remove the heater unit from the cab (if equipped).
Use the hoist connected to the operator cab grab handles

to lower or (raise) the operator cab when the gas P-54021
cylinders are disconnected [Figure 50-20-11].

Remove the rear mounting bolts (Item 1) and nuts (Item
2) [Figure 50-20-13] (both sides) from the operator cab.

35 ft-lb) torque.
340 of 692 50-20-4

OPERATOR CAB (CONT’D)
Figure 50-20-14

3
N-20627A S4299
Connect the slings (Items 1, 2, and 3) [Figure 50-20-14]

to a chain hoist.
Remove the operator cab from the loader.
341 of 692 50-20-5

342 of 692
50-20-6
OPERATOR SEAT Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
Figure 50-30-1
1 1
1
2
1 1
N-20729A
N-20729
Raise the operator cab. (See Raising on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation
(Items 1 and 2) [Figure 50-30-3] and peel back or cut

Remove the four seat mounting nuts (Item 1) [Figure 50- insulation to gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Installation: Tighten the mounting nuts to 27 N•m (20 ft-

lb) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2 N-20655
Remove the two nuts (Items 1 and 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) to 73 N•m (54 ft-lb)

torque. Tighten nut (Item 2) [Figure 50-30-4] to 46 N•m
P10564 P10563 (34 ft-lb) torque.
Repeat for other half of seat belt and guide.

Lower the cab and install one of the plates and nuts
[Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Remove the seat.
343 of 692 50-30-1

344 of 692
50-30-2
OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Figure 50-31-1
1 1
1
1 1
S4352
Figure 50-31-4
S4355

2

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 27 N•m (20 ft-

lb) torque. 1
Figure 50-31-2
S4351
NOTE: Assure seat tethers are securely fastened to

the seatbelt studs (Item 1) [Figure 50-31-3]
and the seat rail studs (Item 2) [Figure 50-31-
4].
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P10564 P10563
Lower the cab and install one of the mounting washers

and a nut [Figure 50-31-2].
NOTE: With the seat removed, the cab will raise.
Remove the operator seat.
345 of 692 50-31-1

OPERATOR SEAT (SUSPENSION) (CONT’D) Seat Belt Removal And Installation
Slide Rail Removal And Installation Figure 50-31-6
Figure 50-31-5
1
1
2
2
1
1
1
S4352
S4351
Remove the operator seat. (See Removal And
Installation on Page 50-31-1.) Remove the nut (Item 1) [Figure 50-31-6] from the seat

belt mount.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5]. Remove the seat belt.
Remove the slide rail (Item 2) [Figure 50-31-5] from the Installation: Tighten the mounting nuts to 78,6 - 84 N•m
bottom of the seat frame. (58 - 62 ft-lb) torque.
346 of 692 50-31-2

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Removal And Installation Figure 50-31-9
Figure 50-31-7
1
N-18583
S4353
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-9] and tilt the seat back all the way forward.
Remove the retainer clips (Item 1) [Figure 50-31-7] and
lift the seat cushion. Figure 50-31-10

Figure 50-31-8
1 1
N-18578
S4354
Remove the two mounting screws (Item 1) [Figure 50-
31-10] from the seat back and remove the back.
Inspect the seat ride adjustment [Figure 50-31-8].
347 of 692 50-31-3

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-31-11
Figure 50-31-12
2
1 1
3
P-43118
P16285

Remove the mounting nut (Item 1) [Figure 50-31-12].

Remove the end release buckle (Item 2) [Figure 50-31-
Remove the seat shock mounting bolts (Item 1) (Both
12].
ends) [Figure 50-31-11].
Installation: Be sure the tether strap (Item 3) [Figure 50-
Remove the seat shock (Item 2) [Figure 50-31-11].
31-12] is on the seat belt stud behind the end release
buckle.
Figure 50-31-13
P16284
Remove the mounting nut (Item 1) [Figure 50-31-13].
Remove the seat belt retractor (Item 2) [Figure 50-31-

13].
Installation: Be sure the tether strap (Item 3) [Figure 50-

31-13] is on the seat belt stud behind the seat belt
retractor.
348 of 692 50-31-4

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)
Figure 50-31-14 1 2
P16126
1
INSIDE OF CAB
P16128
OUTSIDE OF CAB Remove the shoulder harness retractor (Item 1) [Figure

P16131 50-31-15].
Installation: Line up the bolt (Item 1) [Figure 50-31-14]

Remove the mounting bolt (Item 1) [Figure 50-31-14]. with the mounting bracket (Item 2) [Figure 50-31-15] on
the inside of the cab.
349 of 692 50-31-5

350 of 692
50-31-6
BOB-TACH (HAND LEVER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Bob-Tach uses two manually
operated, spring assisted, locking wedge and lever
assemblies to secure the attachment to the Bob-tach.
The Bob-Tach is located on the front of the loader and is

connected to the lift arms.
S4304
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks [Figure 50-40-1] approximately 3 inches thick
under each side of the Bob-Tach. Lower the Bob-Tach
onto the blocks.

Figure 50-40-2
S4309
Remove the retainer nut (Item 1) and bolt (Item 2)

[Figure 50-40-2] from the pivot pin (Both sides).
Installation: Tighten the retainer bolt to 34 - 38 N•m (25 -

28 ft-lb) torque.
Remove the rod end pivot pin (Item 3) [Figure 50-40-2]

(Both sides).
351 of 692 50-40-1

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-4
Figure 50-40-3
2
1
1 S4316
2 Remove the seal dust cup (Item 1) [Figure 50-40-4].

S4313
Remove the rubber seal (Item 2) [Figure 50-40-4].
NOTE: Removal procedure is shown for the right side. Remove the pivot pin (Item 3) [Figure 50-40-4] from the
Left side procedure is the same. Bob-Tach frame.

Remove the grease fitting (Item 1) [Figure 50-40-3] from Check for wear and damage. Replace the pivot pins as
the Bob-Tach frame for the pivot pin (Both sides). needed.
NOTE: The grease fitting (Item 1) [Figure 50-40-3] Installation: Push the pivot pin (Item 3) [Figure 50-40-4]
must be removed to prevent the pivot pin from into the Bob-Tach frame. Position the end of the pin flush
being locked in the Bob-Tach frame. with the end of the Bob-Tach bushing.
Loosen the bolt (Item 2) [Figure 50-40-3] at the Bob-
Tach pivot pin.
Strike the head of the bolt (Item 2) [Figure 50-40-3] to

push the pivot pin into the Bob-Tach frame.
Remove the bolt (Item 2) [Figure 50-40-3] and use a

punch to push the pivot pin all the way into the Bob-Tach
frame.
Installation: A longer bolt will be needed to temporarily

reach through the lift arms into the pins to seat them into
the lift arms. Once seated, reinstall the original bolts.
NOTE: Use tapered ream MEL 1233 to clean the

tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
Slowly back the loader away to remove the Bob-Tach

frame.
352 of 692 50-40-2

BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-7
Lever And Wedge Disassembly And Assembly
Figure 50-40-5
S5991
1
Remove the Bob-Tach lever (Item 1) [Figure 50-40-7].
S5989
Figure 50-40-8
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-5], spring and

wedge.
1
Figure 50-40-6
S5992
Use a punch and hammer, remove the roll pin (Item 1)

[Figure 50-40-8] from the Bob-Tach wedge and spring,
2 1
bolt and clevis assembly.
S5990
Remove the lever mounting bolt and nut (Item 1) and

spring (Item 2) [Figure 50-40-6].
353 of 692 50-40-3

BOB-TACH (HAND LEVER) (CONT’D)

(Cont’d)
Figure 50-40-9
S5993
Remove the spring, bolt and clevis assembly (Item 1)

[Figure 50-40-9].

Remove the wedge (Item 2) [Figure 50-40-9] from the
Bob-Tach frame.
Always replace bent or broken wedges.
Figure 50-40-10
2
1
4
3
S5994
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
or clevis (Item 4) are damaged, put the assembly in the
vise. Loosen and remove the bolt (Item 1) [Figure 50-40-
10] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Assembly: Clean threads and apply Loctite® 242 to the

bolt (Item 1) [Figure 50-40-10], tighten to 88 - 95 N•m
Reverse the removal procedure to install the Bob-Tach

Lever and Wedge.
354 of 692 50-40-4

BOB-TACH (HAND LEVER) (CONT’D) Pivot Pin Bushing And Seal Removal And Installation
Bob-Tach Stops Figure 50-40-12
Figure 50-40-11
S4316
P-3914
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.).
Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-11] (both sides) if worn or damaged.

NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-11]
Installation: Use a new seal when assembling.
must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
Figure 50-40-13
available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
S5995
Remove the bushing (Item 1) [Figure 50-40-13] with a

slide hammer.
Installation: Install the bushing with a driver tool and

hammer.
355 of 692 50-40-5

356 of 692
50-40-6
BOB-TACH (POWER) Figure 50-41-2
Description
The Bob-tach is the section of the loader lift arm that

attachments mount to. The Power Bob-tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-tach.
1
The hydraulically operated Power Bob-tach has a
hydraulic cylinder that opens and closes both wedge and 3
lever assemblies by pressing a switch on the front
accessory panel. The switch activates the Power Bob- 2
tach block to allow flow into or out of the hydraulic 4
cylinder connected to the levers on the Bob-tach. S4309
The Power Bob-tach block is located under the cab, on

the front left side, below the Bucket Positioning Valve (if Remove the retainer bolt (Item 1) and nut (Item 2)
equipped). [Figure 50-41-2] from the tilt cylinder rod end pin.
The Bob-tach is located on the front of the loader Installation: Tighten the retainer bolt and nut to 34 - 38
connected to the loader lift arms. N•m (25 - 28 ft-lb) torque.

Removal And Installation Remove the pivot pin (Item 3) [Figure 50-41-2] from the
tilt cylinder rod end.
Figure 50-41-1
Remove the tilt cylinder rod end (Item 4) [Figure 50-41-
2] from the Bob-Tach.
2 1 2
S5919
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-41-1].
Lower the Bob-Tach onto the blocks.
Remove the hoses on the cylinder fittings (Item 1)

[Figure 50-41-1].
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the Bob-Tach lever to
secure the clamp.
357 of 692 50-41-1

BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-3
2
1
1 S4316
2 Remove the dust cup (Item 1) [Figure 50-41-4] (Both

S4313 sides) when the Bob-Tach is free from the loader.
Remove the rubber seal (Item 2) [Figure 50-41-4] (Both

Remove the grease fitting (Item 1) [Figure 50-41-3] sides).
(Both sides). This allows grease to come out in the next

step. Not letting grease escape will prevent the pin from Installation: Use a new seal when assembling.
going into the Bob-Tach far enough to remove the Bob-
Tach from the lift arms. Remove the Bob-Tach pivot pin (Item 3) [Figure 50-41-4]
(Both sides).
Loosen the bolt (Item 2) [Figure 50-41-3] at the Bob-
Tach pivot pin. (Both sides) Check for wear and damage on the pins and the Bob-
Tach bushings. Replace as needed.
Strike the head of the bolt (Item 2) [Figure 50-41-3] to
push the pivot pin into the Bob-Tach frame. (Both sides) Reverse the removal procedure to install the Bob-Tach.
Remove the bolt. (Both sides)
Installation: A longer bolt will be needed to temporarily

reach through the lift arms into the pins to seat them into
the lift arms. Once seated, reinstall the original bolts.
Use a punch to push the pivot pins all the way inside the
Bob-Tach frame.
Remove the Bob-Tach from the lift arms.
358 of 692 50-41-2

Remove the Power Bob-Tach cylinder. (See Removal

1
Figure 50-41-5
S5997
Remove the wedge (Item 1) [Figure 50-41-7].
1 Always replace bent or broken wedges.
S5919 Figure 50-41-8

Use the following procedure to remove and install the
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and 2
wedge. 1
3
Figure 50-41-6
1
5
S5998
Remove the washer and bolt (Item 1) [Figure 50-41-8].

lb) torque.
S5996
Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the bottom
Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-41-8].
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis. Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].
Installation: Tighten the nut to 34 - 38 N•m (25 - 28 ft-lb)

torque.
359 of 692 50-41-3

BOB-TACH (POWER) (CONT’D) Bob-Tach Stops
Lever And Wedge Disassembly And Assembly Figure 50-41-11

(Cont’d)
Figure 50-41-9
4 1
1
3 2 P-3914
N-20625 Remove and replace the Bob-Tach stop (Item 1) [Figure

50-41-11] (both sides) if worn or damaged.
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) NOTE: The Bob-Tach stop (Item 1) [Figure 50-41-11]

or clevis (Item 4) [Figure 50-41-9] are damaged, put the must contact the lift arm at the same time the
assembly in a vise. tilt cylinder reaches full extension. Use
available shims to adjust the Bob-Tach stop
Remove the bolt and replace the damaged parts as and tilt cylinder sequence as closely as
needed. possible.
Installation: Clean the bolt threads and apply Loctite®.

Tighten the bolt to 107,1 - 118,0 N•m (79 - 87 ft-lb)
torque.
Figure 50-41-10
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-41-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge.
360 of 692 50-41-4

Pivot Pin Bushing And Seal Removal And Installation
Figure 50-41-12
S5995
Remove the bushing (Item 1) [Figure 50-41-13] with a

S4316
slide hammer.
Installation: Install the bushing with a driver tool and

Remove the Bob-Tach. (See Removal And Installation on hammer.
Page 50-41-1.)

Installation: Use a new seal when assembling.
361 of 692 50-41-5

362 of 692
50-41-6
LIFT ARMS Left Side
Removal And Installation Figure 50-50-2
Figure 50-50-1
S4044
S4297
Remove the front auxiliary block mounting bolt (Item 1)
[Figure 50-50-2].
Remove the Bob-Tach frame from the lift arms. (See
Removal And Installation on Page 50-41-1.) Figure 50-50-3

Install jackstands under the rear of the loader [Figure 50-
50-1].
1
2
1
S5954
Remove the tubeline clamps (Item 1) [Figure 50-50-3]

under the lift arms.
Pull the tubelines (Item 2) [Figure 50-50-3] down.
363 of 692 50-50-1

LIFT ARMS (CONT’D) Figure 50-50-6
Right Side
Figure 50-50-4
1
S4312
Remove the lift arm support device mounting bolt (Item 1)

1 [Figure 50-50-6] spacer and nut.
S4325 Installation: Tighten the mounting bolt and nut to 34 - 38


Remove the mounting bolt (Item 1) [Figure 50-50-4] from Remove the retainer bolt (Item 2) [Figure 50-50-6] and
the tilt tubeline clamp. nut from the lift cylinder rod end pivot pin.
Figure 50-50-5 Installation: Tighten the mounting bolt and nut to 34 - 38

1
1
S5955
Remove the tubeline clamps (Item 1) [Figure 50-50-5]

under the lift arms.
364 of 692 50-50-2

Figure 50-50-7
2 1
1 2
1
S5986
Wrap one of the 2 m (7 ft) lifting straps around the lift arm
S5983 crossmember as shown [Figure 50-50-9].
Both loops of the lifting strap should be supported by the

Raise the operator cab. (See Raising on Page 10-30-1.) chain hoist [Figure 50-50-9].

Remove the right side lift cylinder pivot pin (Item 1) Use a chain hoist and lifting strap to raise the lift arms
[Figure 50-50-7]. enough to remove the tilt cylinder base end pivot pin
[Figure 50-50-9].
NOTE: Put a piece of cardboard under the rod end of
the lift cylinders to protect the fender from Figure 50-50-10
scratches.
Remove the lift arm support device (Item 2) [Figure 50-

2
50-7].
Figure 50-50-8
1 S5985
Remove the tilt cylinder (Both sides) (Item 1) from the lift
arm crossmember by removing the bolts and nuts (Item
2) [Figure 50-50-10] and removing the pivot pins.
S5984
Remove the left side lift cylinder pivot pin (Item 1) [Figure
50-50-8].
365 of 692 50-50-3

Figure 50-50-11
1 3
1
S4323
2
Remove the upright pivot pin mounting bolt (Item 1) and
S5987
nut (Item 2) [Figure 50-50-13] (Both sides.)
Put the middle of the second lifting strap (Item 1) [Figure Tighten the pivot pin mounting bolt and nut to 34 - 38
50-50-11] up into the lift arm as shown. N•m (25 - 28 ft-lb) torque.

Install the lift cylinder pivot pin (Item 2) [Figure 50-50-11] Remove the upright pivot pin (Item 3) [Figure 50-50-13].
and secure the pin with the mounting bolt and nut. (Both sides.)
Wrap both ends of the strap around the top of the lift arm Figure 50-50-14
and down the back of the lift arm [Figure 50-50-11].
Figure 50-50-12
S5956
S5987
Raise the lift arms with the chain hoist so the lift arms are
Continue to wrap the lifting strap around the lift arm a free from the loader [Figure 50-50-14].
second time [Figure 50-50-12].
Fasten both loops of the lifting strap to a second chain

attached to the chain hoist.
Use the wrapping procedure on the third strap which

would be installed on the right side lift arm.
Use the chain hoist and lower the lift arms so they rest on
the blocking.
366 of 692 50-50-4

LIFT ARMS (CONT’D)
Figure 50-50-15
S5953

Pull the lift arms away from the loader [Figure 50-50-15].
Lower the lift arms slowly and put on the floor.
Reverse the removal procedure to install the lift arms on

the loader.
367 of 692 50-50-5

368 of 692
50-50-6
REAR GRILLE Figure 50-60-3
Open the rear door.
Figure 50-60-1
1
P-48130
Installation: Line up the tab (Item 1) on the grille with the

slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
S4331

Figure 50-60-2
S4082
Lift the rear grille (Item 1) [Figure 50-60-1] and [Figure

50-60-2].
Pull the rear grille away from the loader.
369 of 692 50-60-1

370 of 692
50-60-2
REAR DOOR Figure 50-70-3

1
Figure 50-70-1
1
P-43360
Remove the top and bottom door hinge mounting bolts

EM1446 (Item 1) [Figure 50-70-3] and nuts.
Installation: Tighten the mounting bolts and nuts to 34 -

Disconnect the light harness connector (Item 1) [Figure 38 N•m (25 - 28 ft-lb) torque.
50-70-1] from the engine harness.

NOTE: Install the door stop (Item 2) and the door stop
Remove both rear lights from the door. (See Rear retainer (Item 3) [Figure 50-70-3] in the top
Removal And Installation on Page 60-60-1.) hinge as shown.
Figure 50-70-2 Lift the door away from the loader frame and put the door
flat on the floor.
2
P-34588
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.
371 of 692 50-70-1

REAR DOOR (CONT’D) Striker Disassembly And Assembly
Striker Removal And Installation Earlier Models
Earlier Models Figure 50-70-6
Figure 50-70-4
2 2
3
4
1
1
P-31320
P-31126
Remove the lock nut (Item 1) [Figure 50-70-6].
Remove the rollers (Item 2) and the spacer (Item 3) from

Later Models the bolt (Item 4) [Figure 50-70-6].
Figure 50-70-5 Check the parts for wear and replace as needed.

28 ft-lb) torque.
1
Later Models
Figure 50-70-7
2
3
P-76970A
4
1
Remove the two striker mount bolts (Item 1) [Figure 50-
70-4] and [Figure 50-70-5].
Remove the striker assembly from the loader.

P-31320A
Remove the lock nut (Item 1) [Figure 50-70-7].
Remove the roller (Item 2) and the spacer (Item 3) from

the bolt (Item 4) [Figure 50-70-7].
Check the parts for wear and replace as needed.

28 ft-lb) torque.
372 of 692 50-70-2

REAR DOOR (TAILGATE) (CONT’D) NOTE: Tighten the striker assembly, top mount bolt
only, until it will hold the striker assembly in
Striker (Adjusting) the center of the mounting slots.
Close the rear door. (This will align the striker assembly
to the correct position.)
WARNING Open the door.
Installation: Tighten the mounting bolts (Item 1) [Figure
Never service or adjust the machine when the engine
50-70-8] and [Figure 50-70-9] to 125 - 135 N•m (90 -
is running unless instructed to do so in the manual.
W-2012-0497
100 ft-lb) torque.

Earlier Models
Tighten both striker mount bolts (Item 1) [Figure 50-70-
Figure 50-70-8 8] to 125 - 135 N•m (90 - 100 ft-lb) torque.

1
P-31126
Later Models
Figure 50-70-9
P-76970A
Loosen the striker assembly mount bolts (Item 1) [Figure

50-70-8] and [Figure 50-70-9].
Align the striker assembly in the center of the mounting

holes.
373 of 692 50-70-3

REAR DOOR (CONT’D) Figure 50-70-12
Latch Removal And Installation
Figure 50-70-10
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-12] from

P-31125 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-10] from

the rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-10] from
the latch.
Figure 50-70-11
P-31127
Remove the spring (Item 1) [Figure 50-70-11] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-11] from

the door handle.
374 of 692 50-70-4

FUEL TANK Figure 50-80-3

4
Figure 50-80-1
1
2
3
3 5
S4243
Disconnect the fuel fill hose (Item 1) and the vent hose
P1616 (Item 2) [Figure 50-80-3] from the fuel tank.
Remove the fuel supply and return hoses (Item 3)

Remove the cover (Item 1) [Figure 50-80-1] which is [Figure 50-80-3].
installed over the fuel drain.

Disconnect the fuel sender connector (Item 4) [Figure
Installation: Tighten the cover mounting bolts to 20 - 27 50-80-3] from the fuel tank.
Lift the fuel tank (Item 5) [Figure 50-80-3] and remove it
Figure 50-80-2 from the loader.
P1619A
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].

Page 70-10-8.)
375 of 692 50-80-1

FUEL TANK (CONT’D) Figure 50-80-6
Fuel Level Sender Removal And Installation

30-1.)
Figure 50-80-4
S5959
1 Remove the fuel inlet screen (Item 1) [Figure 50-80-6].

Clean and dry the screen. Check the screen for damage
and replace if necessary.
2
S5980 Fuel Pickup Screen

Figure 50-80-7
Disconnect the harness (Item 1) and loosen the fuel level
sender (Item 2) [Figure 50-80-4] with a wrench.
Pull the fuel level sender (Item 2) [Figure 50-80-4] out

and remove it from the fuel tank. Check the fuel level
sender for damage and replace if necessary.
Installation: Tighten the fuel level sender to 5,7 - 6,8

Fuel Fill Screen Removal And Installation
Figure 50-80-5
1
S5981
Disconnect the fuel hose (Item 1) [Figure 50-80-7] from

the fitting.
Remove the fitting and grommet from the fuel tank.
Remove the fuel supply screen from the hose and check
the screen for damage. Replace if needed.
S5981
Disconnect the fuel fill hose (Item 1) [Figure 50-80-5]

from the fuel tank.
376 of 692 50-80-2

CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
The control pedals and linkages are connected to the 1

control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operator’s feet.
Pedal Removal And Installation
WARNING S2907

the lift arms are secured by an approved lift arm Remove the bolt (Item 1) [Figure 50-90-1] and nut from
support device. Failure to use an approved lift arm the pedal linkage.
to fall and cause injury or death. Installation: Tighten the bolt and nut to 34 - 38 N•m (25 -
W-2059-0598 28 ft-lb) torque.

Check the rubber bushing in the pedal for wear and
replace as needed.
Figure 50-90-2
DANGER 1
P-90328
P-28909
AVOID DEATH
tubeline, hose, fitting, component or a part failure Remove the two mounting bolts (Item 1) [Figure 50-90-2]
can cause lift arms to drop. from the pedal mounting bracket.
unless supported by an approved lift arm Remove the pedal assembly from the loader.
D-1009-0409
377 of 692 50-90-1

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
P-28909
Loosen the two mounting bolts (Item 1) [Figure 50-90-5]

S2907
from the pedal mounting bracket.
Figure 50-90-6
Disconnect the linkage from the pedal by removing the
bolt and nut (Item 1) [Figure 50-90-3].

1 2
Figure 50-90-4
S2907
Loosen the bolt (Item 2) [Figure 50-90-6] and nut on the

pedal linkage.
S2908
Check the rubber bushing in the pedal for wear and
replace as needed.
Disconnect the linkage from the hydraulic control valve by
removing the bolt and nut (Item 1) [Figure 50-90-4].
Tilt the pedal back and forth until an acceptable “neutral”
angle is achieved on the pedal.
Remove the linkage.
Tighten the two mounting bolts (Item 1) and pivot bolt
Pedal (Adjusting)
(Item 2) [Figure 50-90-6] on the pedal assembly to
standard torque.
After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
spool must travel full stroke without the pedal hitting the
floor panel.
The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
378 of 692 50-90-2

CONTROL PANEL
Description
Figure 50-100-1

EM5318
The steering system [Figure 50-100-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. The returning force of the torsion bushings.
bellcranks have grease fittings.
NOTE: Torsion bushings need to be replaced if torn
The forward travel is adjusted by drift adjustment bolts. or rotating in the housing. Loosen torsion
bushing bolts slightly before adjustments are
The bellcranks are attached to steering linkage bars with made. Do not fully tighten torsion bushing
rubber torsion bushings pressed into the bellcranks. bolts again until all steering adjustments have
Bellcranks mount to the control panel. been made first.
Steering linkage bars are a two-piece design. Steering Sequence of steering adjustments:
linkage bars are adjustable in length for “full travel
adjustment”. 1. Set neutral of pintle arms, “creep”
2. Set linkage travel at steering linkage bars
Steering linkage bars attach to the pintle arms where a 3. Set drift at drift adjustment bolts
rubber torsion bushing is pressed into the pintle arms.
379 of 692 50-100-1

CONTROL PANEL (CONT'D) Figure 50-100-2
DANGER
S4225
P-90328
AVOID DEATH Loosen the jam nut from the bypass control knob (Item 1)
• Disconnecting or loosening any hydraulic [Figure 50-100-2].
can cause lift arms to drop. Figure 50-100-3

D-1009-0409
2
1
3
WARNING
W-2059-0598 S6040
Remove the control knob (Item 1), jam nut (Item 2) and
rubber washer (Item 3) [Figure 50-100-3].
WARNING
W-2017-0286

Remove the engine speed control. (See Removal And

380 of 692 50-100-2

Figure 50-100-4
1
1
1
S3765
Scribe a mark across the top of the steering linkage bars

S2862 which are connected to the steering shaft on the control
panel.
Disconnect the control harness connector (Item 1) Remove the four steering linkage mounting bolts (Item 1)
[Figure 50-100-4] from the control levers. [Figure 50-100-6].

Figure 50-100-5 Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5
- 54,2 N•m (35 - 40 ft-lb) torque.
S3766
Remove the shocks. (See Shock Removal And

Remove the linkage (Item 1) [Figure 50-100-5] by

disconnecting it from the control valve and the shaft.
381 of 692 50-100-3

Figure 50-100-7
1
1
1
P-
263
29
1
1
S4387 S2858
Remove the control panel mounting bolts (Item 1)

S2856 [Figure 50-100-9] from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to

Figure 50-100-8 20 - 27 N•m (15 - 20 ft-lb) torque.

Remove the control panel from the loader.
1 S2857
Remove the control panel mounting bolts (Item 1)

[Figure 50-100-7] and [Figure 50-100-8] from both sides
of the control panel.
Installation: Tighten the control panel mounting bolts to

20 - 27 N•m (15 - 20 ft-lb) torque.
382 of 692 50-100-4

CONTROL PANEL (CONT'D) Remove the steering shaft from the control panel.
Shaft Removal And Installation Figure 50-100-12
NOTE: The steering shaft can be removed without

removing the control panel from the loader.
1
Figure 50-100-10
1
1
S2857
1
To remove the steering shaft mounting bracket, remove
the three mounting bolts (Item 1) [Figure 50-100-12]
from the front of the control panel.
S3766
Remove the steering shaft mounting bracket.

Installation on Page 50-100-6.) Installation: Tighten the mounting bolts to 20 - 27 N•m
Remove the linkage (Item 1) [Figure 50-100-10] by
disconnecting it from the control valve and the shaft. Shaft Disassembly And Assembly
Remove the steering linkages. (See Linkage Removal Figure 50-100-13

Figure 50-100-11
1
2
2
1 P-4154
Disassemble the right and left steering bellcranks

S4227 (Item 1) [Figure 50-100-13] from the cross shaft
assembly.
Remove Control Handle Lever. (See Lever Removal And
Installation on Page 50-110-1.) Assembly: Install new nylon bushings (Item 2) [Figure
50-100-13] as needed when assembling the steering
Remove the steering shaft pivot bolt (Item 1) [Figure 50- shaft. Be sure to apply grease on the cross shaft before
100-11] from both sides of the control panel. installing the right and left bellcranks.
Installation: Tighten the pivot bolts to 34 - 38 N•m (25 - NOTE: The bellcranks should pivot freely on the
28 ft-lb) torque. cross shaft when assembled correctly.
383 of 692 50-100-5

CONTROL PANEL (CONT'D) Linkage Removal And Installation
Shock Removal And Installation
WARNING
WARNING Never work on a machine with the lift arms up unless
Never work on a machine with the lift arms up unless support device. Failure to use an approved lift arm
the lift arms are secured by an approved lift arm support device can allow the lift arms or attachment
support device. Failure to use an approved lift arm to fall and cause injury or death.
support device can allow the lift arms or attachment W-2059-0598
W-2059-0598
WARNING
WARNING Put jackstands under the front axles and rear corners
Put jackstands under the front axles and rear corners Failure to use jackstands can allow the machine to
of the frame before running the engine for service. fall or move and cause injury or death.
Failure to use jackstands can allow the machine to W-2017-0286

W-2017-0286
THE LOADER on Page 10-10-1.) Raise the lift arms and install an approved lift arm
Raise the lift arms and install an approved lift arm Page 10-20-1.)
Page 10-20-1.)
Raise the operator cab. (See Raising on Page 10-30-1.) Installation on Page 50-100-6.)
Figure 50-100-14 Figure 50-100-15
1 1
1 P-90636 EM1442
Remove the steering linkage mounting bolts and nuts

Remove the nuts (Item 1) [Figure 50-100-14] and
(Item 1) [Figure 50-100-15].
remove the shocks from the steering linkages.
Installation: Tighten the steering linkage mounting bolts
to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
384 of 692 50-100-6

CONTROL PANEL (CONT'D) Pintle Arm Removal And Installation
Linkage Removal And Installation (Cont’d) NOTE: The hydrostatic pump assembly has been
removed from the loader for photo clarity.
Figure 50-100-16
Figure 50-100-17
S35909
2
P-48631
Remove the steering linkage mounting bolts and nuts

(Item 1) [Figure 50-100-16]. Remove the nut (Item 1) from the end of the centering

spring shoulder bolt (Item 2) [Figure 50-100-17].
Installation: Tighten the steering linkage mounting bolts
to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque. Remove the bolt / spring assembly.
Remove the steering linkages from the loader. Installation: Tighten the centering spring bolt and a
NEW lock nut to 34 - 38 N•m (25 - 28 ft-lb) torque.
NOTE: After removal and installation of the linkage,
the linkage neutral adjustment procedure Figure 50-100-18
must be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-11.)
S35910
Slide the centering plate (Item 1) [Figure 50-100-18] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator seat.
385 of 692 50-100-7

CONTROL PANEL (CONT'D) If the centering blocks need replacement, remove the
bolts (Item 2) [Figure 50-100-20]. Remove the centering
Pintle Arm Removal And Installation (Cont’d) blocks.
Figure 50-100-19 Installation: Tighten the centering block bolts to 47,5 -

54,2 N•m (35 - 40 ft-lb) torque.
7 NOTE: The washers go between the bolts and the
6 8
centering plate.
3 1 4
NOTE: If the centering blocks are worn, they can be
removed and rotated 180° and reinstalled. If
the solid cams are worn, they can be loosened
and rotated 90° and reinstalled.
Figure 50-100-21
2
5
2
2
P-48630
1
The centering plate / centering spring assembly consists
of the following parts [Figure 50-100-19]: 3
3

ITEM DESCRIPTION 6
2 5
1 Bolt
2 Bushings 1
4
3 Washer
4 Bushing Spacer S35911
5 Spring
6 Lock Nut If the surface of any of the four solid pintle cams (Item 1)
7 Centering Plate are worn, loosen the bolt (Item 2) [Figure 50-100-21]
and rotate the cams 90°.
8 Guide Bushings
Remove the bolts and washers (Item 3) [Figure 50-100-
Figure 50-100-20 21] from the pintle.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.
2
Loosen the creep adjustment bolt (Item 4) [Figure 50-
100-21].
Remove the pintle arm (Item 5) from the pintle base (Item
1 1 6) [Figure 50-100-21].
P-48629
Inspect the wear on the centering blocks (Item 1) [Figure

50-100-20].
386 of 692 50-100-8

Pintle Arm Removal And Installation (Cont’d)
Figure 50-100-22
2
2
3
4
3 1
P-48659
2
1 Installation: Install the pintle base (Item 1) onto the

S35912 pump shaft (Item 2) [Figure 50-100-24]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the bolt and nut (Item 1) [Figure 50-100-22].
NOTE: When installing the pintle base (Item 1) onto

Inspect the washers (Item 2), pintle arm (Item 3) and the the pump shaft, the cutouts on the pump shaft
steering linkage bar (Item 4) [Figure 50-100-22] for will not line up with the bolt (Item 3) [Figure
damage and replace as needed. 50-100-24].
NOTE: The washers (Item 2) [Figure 50-100-22] are NOTE: After installing the linkage onto the
hardened, and should only be replaced hydrostatic pumps the linkage neutral
through Bobcat Parts. adjustment procedure must be performed.
(See Linkage Neutral (Adjusting) on Page 50-
Figure 50-100-23 100-11.)
Figure 50-100-25
2
2
1
P-54615
1
P-54625
Loosen the bolt (Item 1) and remove the pintle base (Item
2) [Figure 50-100-23].
Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-25] and inspect the pintle solid cams
for damage or excessive wear.
Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40

ft-lb) torque.
387 of 692 50-100-9

Pintle Arm Disassembly And Assembly
Figure 50-100-26
4 1 3
2
2
P-48619
3
Using a bushing driver (Item 1). Remove the torsion

P-54626 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) [Figure 50-
100-27] to catch the torsion bushing.
Remove the retaining bolt (Item 2), adjusting screw (Item
3) and neoprene dampener (Item 4) from the base pintle Installation: Install the torsion bushing (Item 2) [Figure
(Item 1) [Figure 50-100-26]. 50-100-27] into the pintle arm using the same procedure

as the removal.
Inspect parts for wear and damage, replace as needed.
NOTE: When the torsion bushing is installed, the
NOTE: Anti-seize should be used on the adjusting amount of bushing on each side of the pintle
screw to prevent corrosion and allow free arm should be the same.
movement while adjusting.
388 of 692 50-100-10

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
MEL1563 - Remote Start Tool Kit
Connect the remote start tool to the engine harness.

(See Remote Start Procedure on Page 10-60-4.) 1

Figure 50-100-28 S2855
3
Loosen the bolt / nut (Item 1) [Figure 50-100-29] only

until the tension is released from the torsion bushing.
2
1

Figure 50-100-30
P-48450
Tool that can assist in the neutral adjustment [Figure 50-

2
100-28].
To make this tool use a locking grip C-Clamp and grind

one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-28] to a small rounded edge.
S35913
A steering centering block (Item 3) [Figure 50-100-28] is
also needed. The centering block can be placed as
shown and welded to the C-clamp if desired. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-100-30].
NOTE: The bolt must be loose enough to allow the

torsion bushing (Item 2) [Figure 50-100-30] to
WARNING turn freely between the torsion bushing and
the steering linkage bar.
W-2017-0286
389 of 692 50-100-11

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-31
2
1
2 P16121
Using the remote start tool, turn the key switch (Item 1)
EM1444 [Figure 50-100-33] to the RUN position.
Move the Traction Lock Override switch (Item 2) [Figure

Loosen the two bolts (Item 1) holding the right centering 50-100-33] so the traction function is unlocked. (The
block. Move the right hand centering block (Item 2) Traction Lock Override switch light will be ON.) On a

[Figure 50-100-31] until both pintle cams contact the standard loader the wedge brake will unlock.
centering block.
NOTE: When the engine is started, the wheels /
NOTE: The left centering block is not adjustable. By tracks can begin to move.
adjusting the right centering block the left
centering block will also become aligned NOTE: In loaders equipped with manual steering and
properly. hydraulic brake, the steering levers may have
to be moved during engine startup to reduce
Figure 50-100-32 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key switch (Item 1)
[Figure 50-100-33] and start the engine and run at low
idle.
Tighten bolts (Item 3) [Figure 50-100-32] to 47,5 - 54,2

NOTE: Check for play between centering blocks and

pintle cams. If there is excessive play repeat
2 above steps [Figure 50-100-31] and [Figure
S5975 50-100-32].
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-28] can be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-100-
32] around both centering blocks.
Lock the C-Clamp in place.
390 of 692 50-100-12

Linkage Neutral (Adjusting) (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-34
2 1
1
S35914
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
S35910 NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
Loosen the left pump pintle adjustment lock bolts neutral adjustment.
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-34].) Loosen the bolts enough to Turn the adjustment screw (Item 1) [Figure 50-100-35]
allow free movement between the pintle arm and the counterclockwise until forward creep is seen.
pintle base.
NOTE: If the bolts are too loose or too tight, the counterclockwise to a point between forward and reverse
neutral adjustment can be affected. where there is zero creep.
Stroke the left steering lever to forward and allow the

lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw
(if necessary) until zero creep is obtained.
391 of 692 50-100-13

CONTROL PANEL (CONT'D) Linkage Travel (Adjusting)
Linkage Neutral (Adjusting) (Cont’d) NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
Figure 50-100-36 adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.
2 1
2 1
WARNING
S35910 W-2059-0598
Torque the left pump pintle adjustment lock bolts (Item 1) Lift and block the loader. (See LIFTING AND BLOCKING
[Figure 50-100-36] to 47,5 - 54,2 N•m (35 - 40 ft-lb) THE LOADER on Page 10-10-1.)

torque.
Repeat the adjustment procedure for the right pump. support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Torque the right pump pintle adjustment lock bolts (Item
2) [Figure 50-100-36] to 47,5 - 54,2 N•m (35 - 40 ft-lb)
torque.
Test both levers by moving them backward and forward WARNING

and letting them return to neutral by the return spring
force. Put jackstands under the front axles and rear corners
If the levers do not return to neutral and the wheels do Failure to use jackstands can allow the machine to
not come to a complete stop, repeat the adjustment fall or move and cause injury or death.
procedure again. W-2017-0286
Stop the engine.

Remove one pintle adjustment bolt (Item 1) [Figure 50-
Pre-load tension in the torsion bushings must be
100-36] at a time and apply Loctite® 242 or equivalent
removed before adjusting the steering linkage.
thread locker to the bolt and re-install the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque. Repeat for
the three remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre-applied
Loctite®.
Remove the loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-14.)
392 of 692 50-100-14

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-37
1
S35908
Remove access plug from the top of the control panel.

S2855
Loosen the jamb nut (Item 1) (Both Sides), turn the
control lever drift adjustment bolts (one on each control
Remove the shocks. (See Shock Removal And lever) in or out, and re-tighten the jamb nut (Item 1)
Installation on Page 50-100-6.) [Figure 50-100-39] (Both Sides).

Loosen the nut (Item 1) three to four turns, then loosen The distance between the bottom of the control lever drift
the bolt (Item 2) [Figure 50-100-37]. The bolt must be adjustment bolt and the bottom of the jamb nut (Item 1)
loose enough to allow the torsion bushing to turn freely [Figure 50-100-39] must be 8,9 mm (0.350 in).
between the steering bellcrank and the linkage bar.
Figure 50-100-40
Figure 50-100-38
3 2
2
4
1
P-51173
S35913
Move the right side steering lever to the rear and install a
Loosen the bolt (Item 1) only until the tension is released 10 mm (0.375 in) thick spacer (Item 1) between the pintle
from the torsion bushing (Item 2) [Figure 50-100-38]. arm cam (Item 2) and the centering block (Item 3)
[Figure 50-100-40].
The bolt must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-38] to turn freely
between the torsion bushing and the linkage bar.
393 of 692 50-100-15

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-41
2
2
1
S35915
1 3 4
Before adjusting the linkage, check that the base pintle

P-51174 arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-42] are tightened to
48 - 54 N•m (35 - 40 ft-lb) torque. There should be no
Move the right side steering lever forward and install a play between the pintle arm and the square pump shaft.
28,57 mm (1,125 in) thick spacer (Item 1) between the

center plate (Item 2) and the mounting plate (Item 3) Also check that the cam mounting nuts or bolts (Item 4)
[Figure 50-100-41]. [Figure 50-100-40] are tight, 48 - 54 N•m (35 - 40 ft-lb)
torque.
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
speed.
Remove the 10 mm (0.375 in) thick spacer (Item 4)

[Figure 50-100-41].
394 of 692 50-100-16

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-43
1
1 1
P-51175
EM1445
Remove the spacer (Item 1) [Figure 50-100-44].
Disconnect the remote start tool. (See Remote Start

Loosen the two bolts and nuts (Item 1) [Figure 50-100- Procedure on Page 10-60-4.)
43] on each steering linkage bar.
Figure 50-100-45

Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm 2
is rotated to the front as far as possible. Use a locking
plier, clamp the two linkage bars together.
Installation: Tighten the nuts and bolts to 48 - 54 N•m

Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
1
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the
right side linkage.
S35913
Tighten the two bolts (Item 1) and nuts (Item 2) [Figure

50-100-45] to 48 - 54 N•m (35 - 40 ft-lb) torque.
395 of 692 50-100-17

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-46
1
S35908
Push the control lever to full stroke, loosen the jamb nut
S2855 (Item 1) [Figure 50-100-47] and turn drift adjustment bolt
in until it touches the U-bolt holding the control lever.
Tighten the two bolts and nuts (Item 1) [Figure 50-100- Re-tighten the jamb nut (Item 1) [Figure 50-100-47].
46] to 48 - 54 N•m (35 - 40 ft-lb) torque at the steering

bell cranks. Repeat steps on the other control lever.
Reinstall the shocks. (See Shock Removal And Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3,05 m (10
ft) of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-47] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Install the plug in the drift bolt access hole after

adjustment.
396 of 692 50-100-18

CONTROL PANEL (SJC)
Description
WARNING
With the option of SJC you receive a control panel that
has two electronic handles that control the steering, lift
and tilt functions. There is no mechanical linkages
connecting to the hydrostatic pumps or the control valve.
The control panel is connected to the lower mainframe
and wraps around and underneath the operator seat. W-2059-0598

WARNING Raise the operator cab. (See Raising on Page 10-30-1.).
Remove the Bobcat Drive controller. (See Removal And

Put jackstands under the front axles and rear corners Installation on Page 60-73-4.)
Failure to use jackstands can allow the machine to Figure 50-101-1
W-2017-0286

3
DANGER 2
2 1
S9828
P-90328
AVOID DEATH Remove the lift arm bypass control knob and rubber
• Disconnecting or loosening any hydraulic washer (Item 1) [Figure 50-101-1].
can cause lift arms to drop. Remove the bolts from the speed control bracket (Item 2)
• Keep out of this area when lift arms are raised [Figure 50-101-1].
support. Replace if damaged. Installation: Tighten the bolts to 20 - 27 N•m (15 - 20 ft-
D-1009-0409 lb) torque.
Remove the bolts from the speed control lever (Item 3)

[Figure 50-101-1].
Installation: Tighten the two bolts evenly until the speed

control lever moves back and forth at a comfortable
tension.
397 of 692 50-101-1

CONTROL PANEL (SJC) (CONT’D) Figure 50-101-4
Figure 50-101-2
S9977
1 Disconnect the right joystick wire harness connectors

S9829 (Item 1) [Figure 50-101-4].
Remove the control panel from the loader.

Remove the control panel mount screws (Item 1) [Figure
50-101-2] from the both sides of the control panel.

Installation: Tighten the control panel mounting screws
to 20 - 27 N•m (15 - 20 ft-lb) torque.
Figure 50-101-3
S9976
Disconnect the left joystick wire harness connectors

(Item 1) [Figure 50-101-3].
398 of 692 50-101-2

CONTROL HANDLE / LEVER (STANDARD) Boot Removal And Installation
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted onto the control

panel.
Lever Removal And Installation 2
Figure 50-110-1
P-28845
1 2
To replace the rubber boot (Item 1) [Figure 50-110-2] on
the control panel, remove the control lever (See Lever

Drill out the four rivets (Item 2) [Figure 50-110-2] located
on the flange of the rubber boot and remove the old boot.
1 S6644 Use a new boot for installation.
Remove the nuts from the two U-bolts (Item 1) [Figure

50-110-1] used to mount the control lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 2) [Figure 50-110-1] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-2] on the front of the control panel.
Installation: Tighten the U-bolts so the lever cannot be

moved right or left when seated in the operator seat. Be
sure the control lever does not interfere with the operator
cab when lowering or raising the cab.
399 of 692 50-110-1

400 of 692
50-110-2
CONTROL HANDLE / LEVER (SJC) Figure 50-111-3
Description
The control handles / levers are used to control the 1
forward and reverse travel and the lift and tilt functions.
The control handles / levers are mounted to the control
panel.
Joystick Testing 3
Figure 50-111-1
2
P-28312
Disconnect the joystick harness connector (Item 1) from

the loader wiring harness (Item 2) [Figure 50-111-3].
Install the test harness (Item 3) [Figure 50-111-3]

between the two connectors.

Turn the remote start key switch to ON position without
starting the loader.
P-28301
Check the voltage between pin 3 and pin 5 on the joystick

The tools listed will be needed to do the following test harness (Item 3) [Figure 50-111-3].
procedure:
MEL1608-Joystick Test Harness [Figure 50-111-1]. The voltage should be between 2.45 and 2.55 volt.
MEL1563 or 7217666-Remote Start Tool Kit.
Figure 50-111-4
Raise the operator cab. (See Raising on Page 10-30-1.).
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60-1.)
Figure 50-111-2
S9977
1
Repeat the procedure at the right joystick wiring harness

connector (Item 1) [Figure 50-111-4]. (If needed.)
S9976
At the back side of the control panel, locate the left

joystick wire connector (Item 1) [Figure 50-111-2].
401 of 692 50-111-1

CONTROL HANDLE / LEVER (SJC) (CONT’D) Figure 50-111-7
Joystick Removal And Installation
Figure 50-111-5
1 S10466
Disconnect the joystick connector (Item 1) [Figure 50-

S9978 111-7] from the harness connector.
Lift the rubber boot (Item 1) [Figure 50-111-5].

Figure 50-111-6
1
1
S9979
Remove the four screws (Item 1) [Figure 50-111-6] to lift

the joystick control from the base.
Installation: Tighten screws (Item 1) [Figure 50-111-6]

to 4,0 - 4,5 N•m (35 - 40 in-lb) torque.
402 of 692 50-111-2

CONTROL HANDLE / LEVER (SJC) (CONT’D) Figure 50-111-10
Joystick Mount Removal And Installation
Figure 50-111-8
1
1
1
S10478
Remove the four bolts (Item 1) [Figure 50-111-10] to

S9976 remove the control lever from the loader.
Figure 50-111-9

1
S9977
Disconnect both of the electrical harness connectors

from the loader harness (Item 1) [Figure 50-111-8] and
[Figure 50-111-9].
403 of 692 50-111-3

404 of 692
50-111-4
WINDOWS (REAR) Figure 50-120-3
Removal
Figure 50-120-1
P16015A
Apply liquid soap on the rubber cord to make installation

P-64994 easier. Install the rubber cord (Item 1) [Figure 50-120-3]
into the molding on the inside of the operator cab.
Pull on the tag (Item 1) [Figure 50-120-1] on the rear
window to remove the rubber cord. Install the safety tag in the top center of the cord.

Using gloves, push the rear window out the rear of the Figure 50-120-4
operator cab.
NOTE: If rear window was broken, remove all glass

fragments from the rubber molding before
installing a new window.
Installation
Clean the area before installing the rubber molding.

1
Figure 50-120-2
P-64997
Apply liquid soap in the rubber molding (Item 1) [Figure

50-120-4] to make installation easier.
Install the window from the outside of the operator cab.
1 Install a lower corner of the rear window into the corner of

the molding. [Figure 50-120-4].
Align the other lower corner of the window in the molding.

P16014
Work the window downward until the window is fully

Install the rubber molding (Item 1) [Figure 50-120-2] seated in the lower portion of the molding.
around the edge of the rear opening in the operator cab.
NOTE: Before installing the rubber molding, cut off

excess molding.
405 of 692 50-120-1

WINDOWS (REAR) (CONT’D) Figure 50-120-6
Figure 50-120-5
1
P16013
Use the plastic stick (Item 1) [Figure 50-120-6] to

P-64998 position the locking tab into the groove to secure the
window in the molding.
Use a plastic stick (Item 1) [Figure 50-120-5] under the Tapping the window corners will help seat the window in
molding lip to guide the window into the molding groove. the molding.
406 of 692 50-120-2

WINDOWS (TOP) Figure 50-121-2
Figure 50-121-1
1 1
1
1
P-24378
1
1
Remove the bolts (Item 1) [Figure 50-121-2], lift the
N-20950 window and remove the bushings.
Installation: Install the bolts (Item 1) [Figure 50-121-2]

Loosen the knobs (Item 1) [Figure 50-121-1]. through the window grommets, the nylon bushings and
through the cab holes.

Installation: Do not overtighten the knobs. This can
damage the window.
407 of 692 50-121-1

408 of 692
50-121-2
WINDOWS (SIDE) Figure 50-122-3
Figure 50-122-1
2
N-20814
From inside the operator cab, loosen the knobs (Item 1)

P-66024 [Figure 50-122-2] and [Figure 50-122-3] on the window
slide rail bolts.
Release the latch (Item 1) [Figure 50-122-1] and slide Move the window slide rail using the two thumb pads
the front window back toward the rear of the operator (Item 2) [Figure 50-122-2] and [Figure 50-122-3] toward

cab. the rear of the operator cab and then down toward the
bottom of the operator cab.
Figure 50-122-2
NOTE: The top of the window should come out of the
top slide rail at this time. Make sure the
window is secured and does not fall. Make
sure the slide rails are in alignment and the
window is positioned in the top track during
1 1 installation.
Remove the front side window from the operator cab.
Figure 50-122-4
2 2
P-66019 2
1
P-66021
Installation: When installing the window make sure the

slide rail (Item 1) adjoins the front stationary slide rail
(Item 2) [Figure 50-122-4].
409 of 692 50-122-1

WINDOWS (SIDE) (CONT’D)
Figure 50-122-5
P-66020
The rear side window sets in a recessed groove.

NOTE: The window should be secured to prevent
damage when the bolt (Item 1) [Figure 50-122-
5] is loosened.
Loosen the bolt (Item 1) [Figure 50-122-5] on the rear

side window.
Remove the rear side window.
410 of 692 50-122-2

WINDOWS (CAB DOOR) Figure 50-123-3
Removal (Standard Window)
Figure 50-123-1
3 1
2
1
1
1 S0366
Push the window out at any corner of the window (Item 1)

P-66051 [Figure 50-123-3].
NOTE: The window can fall when pushing on the

Remove the wiper arm assembly (Item 1) [Figure 50- corners. Have a second technician assist you
123-1]. during the removal of the window.

Remove the two screws (Item 2) and the nut (Item 3)
[Figure 50-123-1].
Secure the wiper motor inside the cab.
Figure 50-123-2
N-20171
Pull the plastic loop (Item 1) [Figure 50-123-2] at the top

of the window to remove the rubber cord.
411 of 692 50-123-1

WINDOWS (CAB DOOR) (CONT’D) Figure 50-123-6
Installation (Standard Window)
Clean the area before installing the rubber molding.
Figure 50-123-4
1
P-66059
Apply liquid soap in the rubber molding to make

installation easier.
P-66058 Install the window from the outside of the door frame.
Install a lower corner of the rear window (Item 1) [Figure

Install the rubber molding (Item 1) [Figure 50-123-4] 50-123-6] into the corner of the molding.
around the edge of the front door frame starting at the
bottom of the door frame. Align the other lower corner of the window in the molding.
NOTE: Before replacing the rubber molding, cut off Work the window downward until the window is fully
the excess molding. seated in the lower portion of the molding.
Figure 50-123-5 Figure 50-123-7
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-123-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-123-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.
412 of 692 50-123-2

WINDOWS (CAB DOOR) (CONT’D) Removal And Installation (Special Applications
Window)
Installation (Standard Window) (Cont’d)
Replace the polycarbonate glazing under the following
Figure 50-123-8 conditions:
• When the glazing is four years old;
• When the glazing becomes yellow or hazed;
• Is scratched on either side with scratches that can be

felt with the fingernail;
• Has cracks coming from the edges or mounting holes.

1 or fine cracks on the surface area;
• Has contacted any fluids that have caused

cloudiness.
P-66049A Figure 50-123-10
Use the plastic stick (Item 1) [Figure 50-123-8] to

position the locking tab into the groove to secure the

window in the molding. 1
Tapping the window corners will help seat the window in

the molding.
Figure 50-123-9
1
P-66101
Remove window from loader.
NOTE: The Special Applications window is held on by

2 the brackets only, it does not sit in the rubber
molding. During Removal the window can fall
as the mounting bolts are loosened.
P-66051 Remove the five mounting brackets and bolts (Item 1)

[Figure 50-123-10].
Install the wiper motor (Item 1) and wiper arm assembly

(Item 2) [Figure 50-123-9].
413 of 692 50-123-3

414 of 692
50-123-4
CAB DOOR Figure 50-130-2
Description
The standard cab door is available as an option or dealer

installed kit. The Special Application Kit Door or Forestry
Door kit are available for use with certain attachments.
Figure 50-130-1
3
2

P-76520
1
P-76526
Open the cab door.
Remove the gas spring (Item 1) [Figure 50-130-1] from Lift the door (Item 1) [Figure 50-130-2] off the hinges.
the threshold.
Disconnect the electrical harnesses (Items 2 and 3)

[Figure 50-130-1].
Disconnect the washer bottle hose (Item 4) [Figure 50-

130-1].
415 of 692 50-130-1

CAB DOOR (CONT’D) Aligning
Removal And Installation (Cont’d) Figure 50-130-4
Figure 50-130-3 WRONG WRONG
2 1
P-76523B P-76524A
Figure 50-130-5
CORRECT CORRECT

1
2
N-20132
1
1
Remove the four bolts and nuts (Item 2) [Figure 50-130-
3] from the cab.
P-76522B P-76525A
Remove the hinges (Item 1) [Figure 50-130-3] from the

cab.
When the striker or latch is NOT adjusted properly there
Installation: Install the hinges (Item 1) on the cab and will be a gap (Item 1) [Figure 50-130-4] between the
use the bolts and nuts (Item 2) [Figure 50-130-3] to door and the cab or the striker and the latch.
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 94.7 in-
lb) torque. If adjustment is needed. (See Adjusting on Page 50-130-
3.)
When the striker or latch is adjusted properly there will be

no gap (Item 1) [Figure 50-130-5] between the door and
the cab or the striker and the latch.
After verifying alignment check for proper operation (See

Checking Operation on Page 50-130-3.)
416 of 692 50-130-2

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-130-8
Figure 50-130-6
1
1
EM1026
P-76521A
Sit in operator’s seat. Turn key switch ON. (Standard Key
Panel), press RUN / ENTER button (Deluxe
Loosen the two bolts (Item 1) [Figure 50-130-6] and Instrumentation Panel), lower seat bar and close the
adjust the latch as needed. door. Press the PRESS TO OPERATE LOADER button

(Item 1) [Figure 50-130-8].
NOTE: For the initial adjustment, position the latch
toward the bottom of the door. Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-130-8] will flash, an audible tone will sound,
Figure 50-130-7 and the message [door] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-130-8] will go out and the display will return to
machine hours.
P-76516
Loosen the striker and adjust as needed (Item 1) [Figure

50-130-7].
NOTE: For the initial adjustment, position the striker

toward the front of the machine.
After adjusting the striker and latch recheck the alignment

of the door sensor. (See Aligning on Page 50-130-2.)
417 of 692 50-130-3

418 of 692
50-130-4
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR) Figure 50-131-2
Description
The Special Application Kit Door or Forestry Door kit are

available for use with certain attachments.
Figure 50-131-1
3
2

P-76520
Open the cab door.
Remove the gas spring (Item 1) [Figure 50-131-1] from

the threshold. P-64982
Disconnect the electrical harnesses (Items 2 and 3)

[Figure 50-131-1]. Lift the door (Item 1) [Figure 50-131-2] off the hinges.
Disconnect the washer bottle hose (Item 4) [Figure 50-

131-1].

CAB DOOR (SPECIAL APPLICATIONS KIT DOOR) Aligning
(CONT’D)
Figure 50-131-4
WRONG WRONG
Figure 50-131-3
2 1
P-76523B P-76524A
Figure 50-131-5
CORRECT CORRECT

1
2
N-20132
1
1
Remove the four bolts and nuts (Item 2) [Figure 50-131-
3] from the cab. P-76522B P-76525A
Remove the hinges (Item 1) [Figure 50-131-3] from the

cab. When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-131-4] between the
Installation: Install the hinges (Item 1) on the cab and door and the cab or the striker and the latch.
use the bolts and nuts (Item 2) [Figure 50-131-3] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (7.1 - 7.9 ft- If adjustment is needed. (See Adjusting on Page 50-131-
lb) torque. 3.)
When the striker or latch is adjusted properly there will be

no gap (Item 1) [Figure 50-131-5] between the door and
the cab or the striker and the latch.
After verifying alignment check for proper operation. (See

Checking Operation on Page 50-131-3.)

CAB DOOR (SPECIAL APPLICATIONS KIT DOOR) Checking Operation
(CONT’D)
Figure 50-131-8
Adjusting
Figure 50-131-6
1 1
EM1026
P-76521A Sit in operator’s seat. Turn key switch ON. (Standard Key
Panel), press RUN / ENTER button (Deluxe
Instrumentation Panel), lower seat bar and close the
Loosen the two bolts (Item 1) [Figure 50-131-6] and door. Press the PRESS TO OPERATE LOADER button

adjust the latch as needed. (Item 1) [Figure 50-131-8].
NOTE: For the initial adjustment, position the latch Open the door. The LIFT & TILT VALVE light (Item 2)
toward the bottom of the door. [Figure 50-131-8] will flash, an audible tone will sound,
and the message [door] will appear in the display.
Figure 50-131-7
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-131-8] will go out and the display will return to
machine hours.
P-76516
Loosen the striker and adjust as needed (Item 1) [Figure

50-131-7].
NOTE: For the initial adjustment, position the striker

toward the front of the machine.
After adjusting the striker and latch recheck the alignment

of the door sensor. (See Aligning on Page 50-130-2.)


ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2

Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Standard Key Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Keyless Start Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Deluxe Instrumentation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Front Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Removal And Installation (Left And Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2

BOBCAT CONTROLLER (GATEWAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (AUXILIARY) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
BOBCAT CONTROLLER (ACS) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
BOBCAT CONTROLLER (DRIVE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting Deactivation Of Lift And Tilt Functions (SJC) . . . . . . . . . . . . . . . . . . . . . 60-90-2
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-100-6
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-5
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-5
STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Attachment Control Information (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . 60-160-2

PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . . 60-170-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Troubleshooting (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-3
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-4
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-4


3600
3610
3520 3520 3520
3210 3210
3200 3200
8250 8250
1010 1020
8200 8200
1800
2380
4380
2370
4370
2430
4440
3110
3100
2410
4410
2010
1800 1800
3110
3100
3930
3410
3420
8060 8040
2510
2500
8800
4200
4370
4410
4440
4380
3200
2860
3910
2430
2410 2900
2380 2235
8020 8010 2370 2780 2900
8250 2510
2820
3600 2500 2110
7000 7000 2090
2760
1210 2730 2240
3010 7010 7010
2810 8080 8080 8080 2770 2790 2765
2810 3920 3920 2745
2790
3900 3900 2780
9350 9350 2730
9210 9200 9200 2600

3300 2830
9110 9100 9100 2390
3310 2000
1130 2810
1450 1450
1110 2710
2745 2200
9500
3430 3430
2765 2120
9600
6100
9800
7030 7022
2740
Dealer Copy -- Not for Resale 3610
8200
1120
9620
9520
3520
2720
2120
2770
2760
3210
3910
9370
3310 3010
9360
9380
6210
6320
8000
6230
6330
8210
8150
8110
4110
9370
8510
4150
8050
3410
8550 9380 3110
9360
1800
2200 2200 1400
4200 4200 1410
4100 1370
1780 1700 1700
1720 1710 1710
1770
4220
4275
1720
2720
4550
6010 6010
4550
6515 6500
4275
6415 6400
9520
6510
6410
9620
8100 8120 4220
8800
2800 2830 1740
2600
2090 7100
6330
6410
1120 6510
6200
6310 6310
8200
6200
6210
8000
6230
1400
4150
4110
8050
GLOW
8110
8550
8210
8510
8150
1370
2000
REAR
8500
1410
1120
HVAC
6320
6340
PLUG
6100
LIGHT
1730
9600
1160
9800
9500
2710
4100
8120
1050
2010
SWITCH FUEL TRACTION

PULL PULL STARTER
POWER
8000
1740
1350
1360
1330
1070
1060
1030
1320
1140
1520
2040 2050 2060 1500 2020
2070 2070 2030 2030
1780
1300
1730
1770
1310
1740
1410
1160
1340
1430 1175 1170

1235
2235
1040
2240
1060
1070
1310
1010 1030
1050
1340
427 of 692 1300
1430
ELECTRICAL SCHEMATIC
DELUXE CAB
S100 (S/N A8ET20001 AND ABOVE) C635
F
C483 E
C482 BLK C 2110 2130 C BLK
POTENTIOMETER B
C408 SEATBAR WHT 7220 7220 D WHT HEATER
(TEMP CONTROL
MAINFRAME CONN SENSOR DBL A 1550 1530 A RED VALVE
SWITCH)
45 3910 A GND 1540 B
46 3920 B SIG S3
HEADLIGHT
44 3900 C PWR 1 C 7040 BLOWER
LEFT
C434
1500
C630 2110 6 5 SWITCH
28 2765 2750 B 3 3 C611 BLOWER
A 3100 2130 4 1 2OFF
6110 A S4 1520 A 14.00 Amps High MOTOR
C 2310 2100
AC SWITCH 1510 B 7.50 Amps Med
HEADLIGHT
B 7020 2740
25 6100 6120 A 7030 C 5.00 Amps Low
RIGHT
C435
2760 B THERMOSTAT 2740 D
34 7020
22 2745
21 1500
10 7010
9 7000
2 1 SW5
3 POWER
4 BOBTACH
5 6 SWITCH
1380 1330
26 1410 1360
15 6010 T3
1330 X
6 SW3
6010 L
FLASHER
4 5 HAZARD
C479 6450 CONN
D2 3 2 SWITCH 6000
29 6400 6400 6430
1
6440 (PINS 3 & 6
C479 6550 D1 INTERNALLY
INSULATED)
36 6500 6500 6530
6540
2810
30 2780 2725
6 5
4
1 2 C479
6700
SW2
2800
3 LEFT PANEL 11 8 10 5 2 7 9 1 3 4 12 6
BEACON
C670
SWITCH BLACK CONN
6450
6550
9320
4500
1790
1440
9120
2910
4730
9220
9150
9250
F B A C D E EXTERIOR
DLX CAB HARNESS 7139311 CAB CONN
120
OHM
D2 D1
STROBE T2
LEFT RIGHT
BUZZER (-) C500
BLINKER BLINKER BEACON
RIGHT PANEL CONN
T1
9110
9210
BUZZER (+) 9250 K
1940 H
9150
8 9200 9230 B
7 A
TO MAINFRAME 41
9100
1450
9130
1420 E
HARNESS 4 9360 9360 J
40 9350 9350 D
1940
1790 C
C499 1780 1780 F
2 4 3 1 2960 G
PTOL CONN
4500
3 2
1820
1775 1775
1 9380 1
2930
1730 1730 4 5
37 9370 6
43 1770 1810
4730
SW9 SW1
TRVL CTRL 5 6 BRAKE
1785
SWITCH 4 SWITCH
2940 2910 2 3
9310
31 2900 2700 1 C480
13 1710 2830 2930 2 12 6 3 4 5 8 1 9 10 11 7 LEFT PANEL
2960 GRAY CONN
SW6 25
1785
4710
9310
Bucket Position
SWITCH 3 14 6
35 7022
C667
SW4 DOOR KIT CONN
2 1 HAND/FOOT (ACS)
3 4275 3 C250
5
H/ISO (SJC, AWS) DOOR SWITCH DOOR SWITCH HARNESS 7104465
4550 5 6 SWITCH
HARN CONN
4 4710 4 4710 1 4720 1 C253
SENSOR SHOWN
2 4235 1810 6 1810 2 1810 2 DOOR
WITH DOOR OPEN
2720 2735 2735 2 2735 SENSOR
33 2730 2820
1 C212 2715
2795
POWER
1470 2 + SOCKET
1390
C209 C129
ACCESSORY
A DOME LIGHT
24 2790 CONN
2710 B B
2820 C
23 1370 1480 1480 A C251
32 1700 1800 1800 B WIPER CONN
1750 1760 1760 5 1760 C PARK
SW8 REAR 1 A WIPER
1740
7210 7210 POWER

FRONT WIPER WIPER 2755 B MOTOR
T5 1 GROUND
SWITCH MOTOR
2 1 1720 1 2 C252
3 SW7 3 WASHER CONN
5 4 REAR 4 5 7230 T6 1
6 6 2745 X GROUND
WIPER
7310
7210
SWITCH WASHER
7310 3 7310 L POWER MOTOR
WIPER HARNESS 7117322

428 of 692
429 of 692
WIRING SCHEMATIC SSL 7-PIN
CAN CONNECTOR D F C E A B G
C426 To Mainframe
Harness
OPTIONS SWITCH 6661150
87A 87
NO
C B A
C220B
30
A B C
C220B
TO BRAKE LIGHT For Manual, ACS & TO BRAKE LIGHT
9800
1160
1710
9500
9600
2710
9700
1730 6600
HARNESS 7151691 HARNESS 7151691
S100 (S/N A8ET20001 AND ABOVE) AHC Models Only
NC
C474
TO SJC HARNESS 4210 2730
C705
85
86
KEY "RUN" D 9800 PUR J1 - 8-PIN
(PRINTED SEPTEMBER 2009) UNSW POWER 2 1160 RED/WHT 2720 H GROUND
TO MAINFRAM ADDITIONAL
V-1372 HARNESS CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
BRAKE LIGHT HARNESS 7151696 POWER / GROUND
SW POWER 1 1730 RNG 1720 B SW POWER ACD
(FOR SJC MODELS ONLY) (ACCESSORY POWER) SOURCE FOR KITS Machine
BOOM HARNESS 7152108 C489A C220A C489B CAN LOW B 9620 PUR 9610 E CAN LOW
Connector
(For Vertical Path Loaders)
TO MAINFRAME A B C B A A B CAN HIGH A 9520 PUR 9510 D CAN HIGH
RIGHT HEAD LIGHT BOOM HARNESS 7151706 GROUND 3 2730 BLK C OPEN
7100 C (For Radial Path Loaders)
2230
1520
6700
7-PIN A OPEN
2 2 A A
C666 ATTACHMENT
1500
2200
2650 6810 6800 7210
1510
2210
F
6 6 B B TO TO CONNECTOR G OPEN
C103
6600 G LIGHT 2130 2130 2310
C170A
BACK-UP SIDE MARKER 5 5 6830 6830 C C 7230 MAINFRAM TAILGATE J
6410 E BOOM-MOUNTED
ALARM 4 4 6820 6820 D D 7270 TO HARNESS HARNESS N ACD CONNECTORS
6310 A BLINKER
TAILGATE SW POWER K 1740
6700
6510 D 3 3 OPEN OPEN E E OPEN
C103A C103B
6200 H 1 1 OPEN OPEN F F OPEN
HARNESS BRAKE LIGHT
HARNESS (For HARNESS 7151691
A B C D E F G H A B C D E F G H
GROUND B 2740 C703 J2 - 10-PIN BLACK
C407A All Models E OUTPUT E 5100 5100 C E OUTPUT

2600 B Except SJC)
A F H
C407
F OUTPUT 5350 5350 F OUTPUT
6320 A A 6320
A
OPEN
OPEN
OPEN
6530
6000
2000
7100
6210
6110
6010
6000
2010
7100
6230
6130
6320
A C230A G OUTPUT G 5400 5400 J G OUTPUT
2620
H OUTPUT H 5050 5050 B H OUTPUT ACD
2610
6610
6320
A
6620
6410
6330
2640
6510
F OPEN Output
C OUTPUT C 5300 5300 G C OUTPUT
Connector
6430
E OPEN
2670
6340
6500
D OUTPUT D 5150 5150 D D OUTPUT
C260
E F C A B D F E D C B A 2630 6210 D 2320
A OUTPUT A 5250 5250 F A OUTPUT
C 7200 7210 A A 6420
M OUTPUT M 5200 5200 E B OUTPUT
C602 C603 LEFT WORK RIGHT WORK
B A B 7260 2300 B B 2110
E F C A B D F E D C B A ID (K TO L) L 5910 5000 A J OUTPUT
C170
C800 A 7240 7220 C C 6220
ID (K TO P) P 5510 5450 K K OUTPUT
B A 7250 D D 6440
7200 E E 6510 6530 C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
DELUXE TAILGATE REAR LIGHT HARNESS (2) OPEN F F OPEN CONNECTOR
5900 J ID #1
7152344
To Ground
HARNESS - 7139785 (Not Used on All Models)
7210 A A 6330
5500 A ID #2
STOP TURN TAIL STOP REGISTRATION B ID #3

TAIL TURN ACD
LEFT TAILLIGHT RIGHT TAILLIGHT LAMP 2300 B B 2120
C ID #4 Input
C180
A 7240 7220 C C 6120
D ID #0 Connector
B 7260 7250 D D 6340 6320
E OPEN
C270
C 7200 7200 E E 6520
F OPEN
BACK-UP TO MAINFRAME D 2320 OPEN F F OPEN
ALARM G OPEN
E OPEN 7 / 14 PIN ATTACHMENT CONTROL
6310
2030
6410
2020
7100 C H OPEN
F OPEN
K
2650
F
TO HARNESS – 6729380 (For SJC Models) OPEN
C103
G
87A 87 86 87A 87 86 TAILGATE
E
HARNESS
6310 A
D A 2 6810 6800 A A 7210 A B
HARNESS 7153090
6200 H LIGHT B 6 2130 2130 B B 2310 30 85 30 85
C180A
SIDE MARKER C 5 6830 6830 C C 7230
6340
2670
2600 B
GROUNDS
BLINKER D 4 6820 6820 D D 7270
6300
6400
2010
E 3 OPEN OPEN E E OPEN
C412
B 2750 87A 87 86
2620
1010
1400
1020
1410
2000 2020
2610
6320
6330
2640
F 1 OPEN OPEN F F OPEN

2030 A 1730
LEFT HEAD LIGHT BOOM HARNESS 7152108
(For Vertical Path Loaders) LICENCE LIGHT 30 85
1 2 2 1 2630 6210 A B A B
ROAD LIGHTS
C402 C490
BOOM HARNESS 7151706 B 2740
2770
2760
C604 C605 LEFT WORK RIGHT WORK
(For Radial Path Loaders) To Starter "B" Terminal
A
1 2 2 1 (EUROPE ONLY) 1010
Left Marker Fuse 10A Right Marker Fuse 10A
1740
A 1720
HARNESS 7141369
B 2720
STANDARD TAILGATE
LEFT TAILLIGHT RIGHT TAILLIGHT
HARNESS - 7109403 C 7200
C427
ATTACHMENT CONTROLS HARNESS - 6710300 Rev. A LIFT ARM HARNESS - 6710299 No
Rev.
B 6415
A 6515
TO OPTIONS TO BOOM TO PWM ATTACHMENT TO OPTIONS
(K TO P DIVERTER HARNESS) 50E 50E B 6000
BLK B B BLK B
C426 Dealer Copy -- Not for Resale 57J 57J C OPEN
C401
USED
To Mainframe A J J J
NOT
LGN LGN LGN
SSL 7-PIN D 6410
Harness 57N 57N
CAN CONNECTOR D F C E A B G TO TO C PNK PNK N N PNK N
57P 57P E OPEN
ATTACHMENT DIODE MODULE B WHT WHT P P WHT P
57BA 57BB 57BB A 6510
K K LBL 14 LBL C C LBL C
6410
56BA
9800
1160
1710
9500
9600
2710
10
9700
56BAA 56BAA
E E YEL YEL H H YEL H
6510
C507
56RA 12 56RAA 56RAA
C506
D D DGN DGN G G DGN G
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN C C
57BC
YEL/WHT R R 87A 87 86
C509
56BBA 11 56BBB 56BBB 87A 87 86
UNSW POWER F 1160 RED/WHT 2720 H GROUND B B DBL DBL F F DBL F
56RBA 13 56RBB
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD A A RNG/WHT RNG/WHT56RBB E E RNG/WHT E
57RRB 6 57RRC 57RRC 30 85
SW POWER E 1730 RNG 1720 B SW POWER ACD F F BRN BRN D D BRN D 30 85
9 Machine 57RRD 57RRD
CAN LOW B 9620 PUR 9610 E CAN LOW H H RED A A RED A
2780
Connector to
6020
57RRE 57CB 57CB
14 G G WHT RNG/DBL L L RNG/DBL L
6010
2790
CAN HIGH A 9520 PUR 9510 D CAN HIGH Engine 57RRF 56S 56S
GROUND G 2730 BLK 13 C OPEN Compartment J J BRN/YEL DGN M M DGN M
7-PIN 12C 12C
Connector A OPEN RNG K K RNG K
on Loader C666 ATTACHMENT
CONNECTOR G OPEN
Boom
J
N
BOOM-MOUNTED
ACD CONNECTORS
SJC HORN / BLINKER
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK
HARNESS - 7152661
E OUTPUT E 5100 5100 C E OUTPUT
F OUTPUT F 5350 5350 H F OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT TO CONTROLS
(LEFT HANDLE)
H OUTPUT H 5050 5050 B H OUTPUT ACD
RELAY 1 - TO
C461
Output 56BB
C OUTPUT C 5300 5300 G C OUTPUT (EXAMPLE - ANGLE BROOM POWER) DBL B MAINFRAME
Connector to 56RB
C404
D OUTPUT D 5150 5150 D D OUTPUT 87 B
Engine WHT A
A 7100 A
A OUTPUT A 5250 5250 F A OUTPUT Compartment
M OUTPUT M 5200 5200 E B OUTPUT 19 30 87 57RRD TO CONTROLS
RED/WHT RED (AUXILIARY RELIEF)
ID (K TO L) L 5910 5000 A J OUTPUT BACK-UP ALARM
USED
12 86 85 SWITCHES
BLK 50B
NOT
57RRE WHT 9 56A
ID (K TO P) P 5510 5450 K K OUTPUT DGN/YEL A 7110 TO
11 MAINFRAME
B
C506
C489-A
14-PIN
Connector
ATTACHMENT
CONNECTOR
C704 J3 - 10-PIN GRAY 1740 1720 A
on Loader 5900 J ID #1 2720 B
Boom 5500 A ID #2 TO WATER KIT TO CONTROLS
(RIGHT
BACK-UP ALARM
C505
50W
B ID #3
ACD B BLK HANDLE) ADDITIONAL POWER
RELAY 2 - 56W SWITCHES HARNESS - CONNECTOR
C489-B
C ID #4 Input (EXAMPLE - FRONT/REAR AUXILIARY - BASE END) A LGN/WHT B
Connector to B
D ID #0 87
57RB E 7174471
C409
Engine 1730 A
7 / 14 PIN ATTACHMENT E OPEN
Compartment
A YEL/RED BLK
50Z
56B
F
F OPEN 57BC 30 87 57BBA YEL D
CONTROL HARNESS – G OPEN
YEL/WHT LGN
DGN
56R
C
86 85 16 7 12
BLK 50C 57C
6732730 (FOR SJC MODELS) H
K
OPEN
OPEN
RNG/DBL RNG A
Rev. none
ADDITIONAL POWER CONNECTOR RELAY 3 - TO CONTROLS TO RIGHT HANDLE

LEFT RIGHT (EXAMPLE - FRONT/REAR AUXILIARY - ROD END) STROBE OR
FLASHER FLASHER
1740 A 57RB C
BEACON
USED
C497
87 YEL/RED B
NOT
LIGHT LIGHT 2740 B 57RR YEL/ 57RR B
A YEL/LGN C 12E
LGN A RNG
12A
57RRF 30 87 57BBB 15 RNG A TO
TO MAINFRAME BRN/YEL LGN 2 1 ENGINE
12D 12A
(ACCESSORY CONNECTOR) 6
C498
86 85 A RNG RNG A
C133
TO OPTIONS
1730 1720 A BLK 50D 57CA RNG/DBL C609 10
2790
2795
C402
(EXTERIOR CAB) B BLK B

2 1 TO
2720 B
6440 1 STROBE/BEACON
TO CONTROLS TO RIGHT HANDLE
C669
2785 2 (LEFT HANDLE) TO OPTIONS

ALARM 12A TO
6540 3 6700 E
C668 OR C670
TO HANDLE CONNECT0R RNG A ENGINE
C410
HORN
2775
RELAY 4 - 57B A 10
C132
C412
4 WAY FLASHER 2730

7200
B
A
(EXAMPLE - STUMP GRINDER)
YEL/RED
YEL/LGN
57RRA
B
C
TO OPTIONS
(4 WAY FLASHER) C 6
BLK
RNG
12
B
A
87
HARNESS - 6718873 56SA 2 2785 2780 D
C669
A DGN
TO CONTROLS 1 6440 F
FRONT HORN HARNESS - 6719151 57BBC 30
LGN
87 (USED WITH HIGH FLOW
MACHINES ONLY)
3 6540 B
TO LEFT HANDLE
USED
86 85 56SG
BLK 50A EXTERIOR CAB HARNESS - TO HORN
NOT
56SG DGN DGN A 12B
6
C620
C131
B A 64 RNG
SSL 7-PIN 12B 6718872
C133
CAN CONNECTOR RNG A B RNG/DBL

D 50
KEY "RUN" 9800 D BLK B
19
C132
UNSW POWER 2 1160 F RED/WHT A

TO ENGINE
CAN SHIELD C 9700 C B RED = RED
RNG = ORANGE B
C621
SW POWER 1 1710 E To Mainframe 12C
TO ENGINE BLK = BLACK A RNG
Harness LBL = LIGHT BLUE
CAN LOW B 9600 A C
WIRES CONNECT BY DBL = DARK BLUE
CAN HIGH A 9500 B LGN = LIGHT GREEN TO LEFT HANDLE
LETTER ACROSS
GROUND 3 2700 G DGN = DARK GREEN
BATTERY FEED 1000-1999 RED, RED/WHT, RNG CONNECTORS
Connector
7-PIN
GROUND 2000-2999 BLK A B
YEL = YELLOW
POWER HARNESS
on Loader C666
ATTACHMENT
CONNECTOR C426 MONITORING 3000-3999 LBL
B A
PNK = PINK
WHT = WHITE
Boom HYDRAULIC 4000-4999 LGN
BRN = BROWN 6706816 Rev. B
430 of 692 7 PIN ATTACHMENT CONTROL
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK SOME CONNECTOR TAN = TAN
PUR = PURPLE
ACCESSORIES 7000-7999 WHT BODIES NOT SHOWN
ENGINE 8000-8999 TAN GRY = GRAY
HARNESS – 6718426 (For SJC Models) COMMUNICATION 9000-9999 PUR
FOR DRAWING CLARITY
V-1372 (9-15-09)
Printed In Belgium
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting two harnesses together or represent an component that is
C107
3520 C C 3520
3510 B B 3510
a harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example:
three pin connectors shown). The LIGHT -
C107 connector pins can be numbered
3500
A A
3500 alphabetical (shown) or numerical (1,
C C
3520
B B
3520 2, 3 etc.). The harness wires numbers
3510 3510
are called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
- positions will be specified depending
NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.
431 of 692 60-10-1

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
STAR T
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch to
warn personnel.
BUZZER - Audible alarm. Sounds at a

1 SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)
432 of 692 60-10-2

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A SPEED SENSOR - magnetic pickup -

detects rpm.
B
433 of 692 60-10-3

Standard Cab Harness Connectors
Figure 60-10-1
C 212
C 434
C 482
408 C 499
C 479

C 129 C 480
C 209 S1
S2
T3
SW1
C 435
C 500
C 408
MS2660
434 of 692 60-10-4

Deluxe Cab Harness Connectors
Figure 60-10-2
1. Flasher Connection T3
2. Beacon Switch
3. Hazard Switch
4. Blower Switch
5. Temp Control Switch
6. Rear Wiper Switch
7. Front Wiper Switch
8. Travel Control Switch
S35207
435 of 692 60-10-5

Mainframe Harness Connectors
Figure 60-10-3
C607
C608
C404
C489
C411
C408 C423
SP21 D3
SP22
SP30
SP31
C300
C490 C421
C422
C425
C492
C493

T4
C420
C426 T3
C105
SP32
C108
C112
C554
C103
C106
SP10
SP9
T6 SP2
T8 SP12
C101 J1A
J1B
T1 C113
D2 P7
SP26
SP6 SP3
S9982
436 of 692 60-10-6

Description
Figure 60-10-4
P-13849
P100083
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by

fuses located in the engine compartment and a 100 amp
master fuse (Inset) [Figure 60-10-4] located under the
air cleaner. The fuses will protect the electrical system
when there is an electrical overload. The reason for the
overload must be found before starting the engine again.
437 of 692 60-10-7

Troubleshooting
WARNING
assistance in locating and correcting BICS™ system AVOID INJURY OR DEATH
problems. It is recommended that these procedures be Instructions are necessary before operating or
done by authorized Bobcat Service Personnel only. servicing machine. Read and understand the
W-2003-0807
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.
438 of 692 60-10-8

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-6
Fuse And Relay Location / Identification 11

1 9 13 15 17
5
Figure 60-10-5
2 6 18
3 7 19
8 16 20
4 10 12 14
7159779
P-90154A
The electrical system is protected from overload by fuses

and relays under the fuse panel cover (Item 1) [Figure

60-10-5]. A decal is inside the cover to show location and
amp ratings. N-19660
Remove the cover to check or replace the fuses [Figure

60-10-5]. The location and sizes are shown below and [Figure 60-
10-6].
REF DESCRIPTION AMP REF DESCRIPTION AMP

1 Unswitched 25 11 Front And Marker R
Horn Lights
2 ACS/AWS/SJC 5 12 Fuel Shutoff R
Switched
3 Alternator & 25 13 Rear Lights R
Accessories
Back-up Alarm
4 Attachments 25 14 Traction R
5 Heater And Air 25 15 Glow Plugs R
Conditioning
6 Front And Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Traction 30
8 Bobcat Controller 25 18 Fuel Shutoff 30
9 Heater And Air R 19 Power Plug 15
Conditioning
10 Switch Power R 20 ACS/AWS/SJC 25
Unswitched
R - Relay
439 of 692 60-10-9

Solenoid Testing
Figure 60-10-7
P9175
Use a test meter to measure coil resistance [Figure 60-

10-7]. Coil wires do not have polarity. Correct resistance

for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
440 of 692 60-10-10

BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P09589 P09590
and wash eye with clean, cool water for at least 15
minutes. Always clean the battery terminals and cable ends when
installing a new or used battery [Figure 60-20-2].
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get NOTE: Always connect the negative (-) cable last and
prompt medical attention. remove it first to prevent sparks.
W-2065-0807

Install and tighten the battery hold down clamp.
Open the rear door.
Connect and tighten the battery cables.
Figure 60-20-1
2
1
P-90157
Disconnect the negative (-) battery cable (Item 1) [Figure

60-20-1].
Remove the battery hold down clamp (Item 2) [Figure

60-20-1].
Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.
Remove the battery from the loader.
NOTE: When removing or installing the battery in the

loader, do not touch any metal parts with the
battery terminals.
441 of 692 60-20-1

BATTERY (CONT’D)
Servicing
Figure 60-20-3
P09589 P09590
The battery cables must be clean and tight [Figure 60-

20-3]. Check electrolyte level in the battery. Add distilled

water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Battery Saver (6988074) or grease on the battery

terminals and cable ends to prevent corrosion.
WARNING

In case of eye contact get prompt medical attention
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
442 of 692 60-20-2

BATTERY (CONT’D) Figure 60-20-4
Using A Booster Battery (Jump Starting)

2
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
4
operator’s seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF or the STOP button must be

pressed. The booster battery must be 12 volt.
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
1
Do not jump start or charge a frozen or damaged 3

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910
P-31860B
Connect the end of the first cable (Item 1) [Figure 60-20-

4] to the positive (+) terminal of the booster battery.
IMPORTANT Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.
Damage to the alternator can occur if:
Connect the end of the second cable (Item 3) [Figure 60-
• Engine is operated with battery cables
20-4] to the negative terminal of the booster battery.
disconnected.
Connect the other end of the same cable (Item 4) [Figure
• Battery cables are connected when using a fast
60-20-4] to the engine.
charger or when welding on the loader. (Remove
both cables from the battery.)
Keep cables away from moving parts. Start the engine.
• Extra battery cables (booster cables) are
(See the Operation & Maintenance Manual for the correct
connected wrong.
procedure.)
I-2023-1285
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
the positive terminal (Item 2) [Figure 60-20-4].
443 of 692 60-20-3

444 of 692
60-20-4
ALTERNATOR Belt Replacement
Belt Adjustment Stop the engine and open the rear door.
Stop the engine and open the rear door. Loosen the alternator mounting and adjustment bolts
(Items 1 and 2) [Figure 60-30-1] and loosen the belt all
Figure 60-30-1 the way.
Remove the belt and install a new belt.
Move the alternator until the belt has 7,63 - 8,18 mm

(0.300 - 0.322 in) movement with 40 N (9 lbf) of force at
the middle of the belt span.
Tighten the adjustment bolt and mounting bolt.
P107110

2
P-90164
Loosen the alternator mounting bolt (Item 1) [Figure 60-

30-1].
Loosen the adjustment bolt (Item 2) [Figure 60-30-1].
Move the alternator until the belt has 8,81 - 9,54 mm

(0.347 - 0.376 in) movement with 40 N (9 lbf) of force at
the middle of the belt span.
Tighten the adjustment bolt and mounting bolt.
445 of 692 60-30-1

ALTERNATOR (CONT’D) Figure 60-30-2
Charging System Inspection

2
WARNING 1


S5960
In case of eye contact get prompt medical attention
minutes.
If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities Check the condition and tension of the alternator belt.
of water or milk! DO NOT induce vomiting. Get (See Belt Adjustment on Page 60-30-1.) Replace the belt
prompt medical attention. if worn or deteriorated.
W-2065-0807
Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
WARNING Inspect the fuse for the alternator in the fuse panel. If
fuse is burned, find the cause and repair / replace. If fuse
is in doubt, remove it and check for continuity.
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH Check the electrolyte level in the battery. Add distilled
Keep arcs, sparks, flames and lighted tobacco away water as needed. (Does not apply to maintenance free
from batteries. When jumping from booster battery batteries.)
make final connection (negative) at machine frame.
Verify the charge of the battery. Make sure battery is fully
Do not jump start or charge a frozen or damaged charged.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before Disconnect the battery cables (negative first, then
connecting or disconnecting cables to battery. Never positive). Inspect the cable clamps and battery posts for
lean over battery while boosting, testing or charging. corrosion. Remove acid or corrosion from the battery and
W-2066-0910 cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Connect the cable to the positive
terminal.
With the key off, connect a test light between the negative
IMPORTANT battery post and the disconnected negative cable clamp.
1. If the test light does not light up, reattach the clamp
Damage to the alternator can occur if: and proceed to alternator voltage test. (See Below.)
disconnected. 2. If the test light lights up, there is a short (drain) in the
• Battery cables are connected when using a fast electrical system of the loader. The short must be
charger or when welding on the loader. (Remove repaired before the charging system can be checked.
• Extra battery cables (booster cables) are 3. Disconnect the alternator B+ terminal (Item 1) and L
connected wrong. & S terminal connector (Item 2) [Figure 60-30-2] and
I-2023-1285 if the test light goes out, the alternator is faulty. If the
test light stays on, find the short in the system and
repair it.
446 of 692 60-30-2

ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-4
Figure 60-30-3
1
1
EM1431
EM1430
Turn engine OFF and remove the L&S-terminal
connector (Item 1) [Figure 60-30-4] from the alternator.
Open the rear door.
Turn the remote start tool key switch to the ON position.

Connect the remote start tool to the loader. (See Remote
Start Procedure on Page 10-60-4.) Figure 60-30-5
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+-
terminal (Item 1) and ground (Item 2) [Figure 60-30-3] at
the starter.
The voltage must be higher than 13.5 volt but lower than 1
14.7 volt at 21°C (70°F) (Alternator temperature).
If the voltage is higher than 14.7 volt, proceed to the

following high voltage test.
If the voltage is lower than 13.5 volt, run the engine at

high idle and recheck the voltage. If the voltage is still
below 13.5 volt, proceed with the following low voltage 2 S5971
test.
Check the voltage across the L&S-terminal (Item 1) and a

good ground source (Item 2) [Figure 60-30-5]. The
voltage should be what the battery voltage is. If not,
check wire harness, relay and fuses.
If the wire harness, relay and fuses are good then

remove the alternator for replacement or repair. To repair,
(See Alternator Voltage Testing on Page 60-30-3.) for
further component testing.
447 of 692 60-30-3

ALTERNATOR (CONT’D) Removal And Installation
High Voltage Testing Place jackstands under the rear corners of the loader.
Figure 60-30-6
DANGER
1
P-90328
AVOID DEATH
EM1431 • Disconnecting or loosening any hydraulic
Turn engine OFF and remove the L&S-terminal • Keep out of this area when lift arms are raised
connector (Item 1) [Figure 60-30-6] from the alternator. unless supported by an approved lift arm

NOTE: Check the continuity between the "S" terminal D-1009-0409
and the positive (+) terminal on the battery or
starter. There should be continuity. If no
continuity, replace wire harness.
Turn the remote start tool key switch to the ON position.

WARNING
If the voltage is still above 14.7 volt at 21°C (70°F) Never work on a machine with the lift arms up unless
(Alternator Temperature), then remove alternator for the lift arms are secured by an approved lift arm
replacement or repair. To repair, (See Alternator Voltage support device. Failure to use an approved lift arm
Testing on Page 60-30-3.) for further component testing. support device can allow the lift arms or attachment
W-2059-0598
IMPORTANT
Damage to the alternator can occur if:
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

Page 10-20-1.)
448 of 692 60-30-4

ALTERNATOR (CONT’D) Figure 60-30-8
Disconnect the negative (-) cable from the battery.

1
Figure 60-30-7
S4248
2
Remove the adjustment bolt (Item 1) [Figure 60-30-8]

from the mounting bracket.
1
Remove the alternator belt (Item 2) [Figure 60-30-8]
from the alternator pulley.
S5972

Figure 60-30-9
Remove the nut (Item 1) and disconnect the two red

cables [Figure 60-30-7] from the alternator.
Disconnect the wiring harness connector (Item 2)

[Figure 60-30-7] from the alternator.
Installation: Tighten nut (Item 1) [Figure 60-30-7] to 13 -

17 N•m (8.75 - 12.58 ft-lb) torque.
EM1432
449 of 692 60-30-5

ALTERNATOR (CONT’D)
1. Alternator 11. Bearing

2. Nut 12. Stator
3. Pulley 13. Housing 7
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Housing 16. Rectifier 1
7. Bolt 17. Cover
8. Bearing 18. Spacer 6
9. Retainer 19. Nut
10. Rotor
14
13
4 7
3
2 12 5
11

10
9
8
19
18
17
15 16
C-3529B
450 of 692 60-30-6

STARTER Figure 60-40-3
Testing
Figure 60-40-1 2
Bat
S 1
M
Cranking
Motor
EM1424
Disconnect the negative cable from the battery. (See

A-1992 Removal And Installation on Page 60-20-1.)
The key switch must be in the OFF position. Disconnect the S-terminal on the starter (Item 1) [Figure
60-40-3].
The battery must be fully charged.

Hold-In Test: Use circuit tester, attach one probe to the
The cable connections on the battery must be clean and L&S-terminal (Item 1) and one probe to the mounting bolt
tight. (Item 2) [Figure 60-40-3] on the magnetic switch
(solenoid). If there is no continuity replace the magnetic
Connect a jumper wire between L&S-terminal and BAT- switch (solenoid).
terminal [Figure 60-40-1].
Figure 60-40-4
If the starter turns but the engine does not turn, the
starter drive has a defect. 2
Figure 60-40-2
1
P-34675
Bat 1
S
M
2
Cranking
Motor
EM1425
Disconnect the negative (-) cable from the battery. (See

A-1991 Removal And Installation on Page 60-20-1.)
Connect a jumper wire (of at least four gauge in size) Disconnect the L&S-terminal on the starter (Item 1)
between the M terminal and the BAT terminal [Figure 60- [Figure 60-40-4].
40-2].
Pull-In Test: Use circuit tester, touch one probe to the
If the starter turns, the defect is in the solenoid. L&S-terminal (Item 1) and one probe to the starter motor
terminal (Item 2) [Figure 60-40-4]. If there is no
If the starter does not turn, the starter is defective. continuity replace the magnetic switch (solenoid).
451 of 692 60-40-1

STARTER (CONT’D) Figure 60-40-6

1
Remove the negative (-) and then the positive (+) cable
from the battery.
Figure 60-40-5
3 4 1
EM1427
1
Remove the starter from the engine by removing the two
bolts (Item 1) [Figure 60-40-6].
2
1 2 Installation: Tighten the mounting bolts to 34 - 38 N•m

EM1426
Remove the red and black covering (Item 1) and nuts

(Item 2) [Figure 60-40-5].
Disconnect the brown wire (Item 3) [Figure 60-40-5] from

the starter.
Disconnect the engine harness power wire and positive

(+) battery cable from the starter solenoid terminal (Item
4) [Figure 60-40-5].
452 of 692 60-40-2

STARTER (CONT’D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
21
32 7*
15
37
14

16 20
17
19 18
5 8
12
14
6
29
1 4
3
28
2
27
25. Holder
35 26. Bracket
27. Ring
28. Bolt
22 26
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
24 36. Bracket
37. Bearing
* Not serviceable parts B-16488
453 of 692 60-40-3

454 of 692
60-40-4
INSTRUMENT PANELS
Left Panel
Figure 60-50-1
3 12
2
7 16
1
13
4
8 10 11 15
6 9
14
5

17 20
18 19
21 22
23
P-76459C
The left instrument panel [Figure 60-50-1] is the same The table on the next page shows the DESCRIPTION
for both Standard Key Panel and Deluxe Instrumentation and FUNCTION / OPERATION for each of the
Panel equipped machines. components of the left panel.
455 of 692 60-50-1

INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected. (Available with SJC controls only)
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT AND TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right turn signals are ON.
13 SHOULDER BELT Not used.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)

15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED
will light.) Press a second time to add REAR work lights. (Left and right
green LEDs will light.) Press a third time to turn all lights off. (Left and
right green LEDs will be off.)
Press and hold 5 seconds to display software version in display screen.
18 HIGH-FLOW Not used.
19 AUXILIARY HYDRAULICS Press once to engage the auxiliary hydraulics. (left green LED will
light.) Press a second time to disengage.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine rpm
• Battery voltage
• Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
or joystick(s) to move the loader forward or backward when using the
backhoe attachment or for service. (See TRACTION LOCK OVERRIDE
in this manual.) Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ System when the seat bar is down and
operator is seated in operating position. Button will light.
Press and hold 3 seconds to engage Drive Response and Steering
Drift Compensation. (See DRIVE RESPONSE and STEERING DRIFT
COMPENSATION in this manual.)
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.
* For further description on Service Codes (See DIAGNOSTIC SERVICE CODES on PAGE 60-80-1.)
456 of 692 60-50-2

INSTRUMENT PANELS (CONT’D) Keyless Start Panel
Standard Key Panel Figure 60-50-3
Figure 60-50-2
2 3
4
5
6
P-90816A
S4498
This machine can be equipped with a Keyless Start Panel
[Figure 60-50-3].
This machine can be equipped with a Standard Key
Panel [Figure 60-50-2]. 1. Keypad (keys 1 through 0): Used to enter a number

code (password) to allow starting the engine. An
The Standard Key Panel is used to turn the loader asterisk will show in the left panel display screen for
electrical system on and off, and to start and stop the each key press.
engine.
2. LOCK Key: Used to lock keypad. The lock key will
display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-171-1.)
3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-171-1.)
4. START Button: Used to start the engine.
5. STOP Button: Used to stop the engine and shut

down the loader electrical system.
6. RUN Button: Used to turn on the loader electrical

system.
457 of 692 60-50-3

INSTRUMENT PANELS (CONT’D) 9. Keypad: The numeric keypad has two functions:
- To enter a number code (password) to allow starting
Deluxe Instrumentation Panel
the engine.
Figure 60-50-4 - To enter a number as directed for further use of the
Display Screen.
10. Start Button: Used to start the engine.
11. Run / Enter Button: Used to turn on the loader
electrical system.
1 7 Figure 60-50-5
4
5
2 3 6
ENTER PASSWORD
8 LANGUAGES

B-16165
The first screen you will see on your new loader will be as
10 11 B-15553N shown in [Figure 60-50-5].
When this screen is on the display you can enter the

This machine can be equipped with a Deluxe
password and start the engine or change the Display
Instrumentation Panel [Figure 60-50-4].
Screen setup features.
1. Display Screen: The Display Screen is where all
NOTE: Your new loader (with Deluxe Instrumentation
system setup, monitoring, troubleshooting and error
Panel) will have an Owner Password. Your
conditions are displayed.
dealer will provide you with this password.
2. Bobcat Main Controller Error: Indicates Change the password to one that you will
communication error between Bobcat Main Controller easily remember to prevent unauthorized use
and Deluxe Instrumentation Panel. (See of your loader. (See Changing The Owner
DIAGNOSTIC SERVICE CODES on Page 60-80-1.) Password on Page 60-170-1.) Keep your
3. Display Error: Indicates communication error password in a safe place for future needs.
between instrument panel and Bobcat controller.
(See DIAGNOSTIC SERVICE CODES on Page 60- Change Language: Press the Selection button at the end
80-1.) of the arrow [Figure 60-50-5] to go to the next screen.
4. BobCARE PMSM Icon: Indicates planned Use the Keypad to select the number of the language.
maintenance is due.
Press EXIT. The screen will return to [Figure 60-50-5].
5. Engine Air Filter Icon: Indicates engine air filter
You can then enter the password and start the engine.
requires service.
6. Hydraulic Filter Icon: Indicates hydraulic filter See CONTROL PANEL SETUP for further description of
requires service. screens to setup the system for your use. (See
7. Selection Buttons: The four Selection buttons allow CONTROL PANEL SETUP on Page 60-160-1.)
you to select items from the Display Screen and scroll
through screens. NOTE: Pressing the EXIT key will go to the previous
8. Stop Button: Used to stop the engine and shut down screen and you can continue pressing until
the loader electrical system. you get to the initial (home) screen.
SHORTCUT: Press the “0” (zero) key to get to
the home screen immediately.
458 of 692 60-50-4

INSTRUMENT PANELS (CONT’D) Front Panel
Side Panel Figure 60-50-7
Figure 60-50-6 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9
B-15993R
S1819
NOTE: Parking Brake (Item 4) [Figure 60-50-7] is
standard on all loaders.
REF. REF.
DESCRIPTION FUNCTION / OPERATION DESCRIPTION FUNCTION / OPERATION
NO. NO.
1 POWER PORT Provides a 12 volt receptacle 1 SELECTABLE Press the top to select ‘ISO’
for accessories. JOYSTICK Control Pattern; bottom to
2 TRAVEL LOCK Press the top of the switch to CONTROLS select ‘H’ Control Pattern.
lock the lift and tilt hydraulic (SJC) (Option)
functions for travel. Press the 2 NOT USED Covered by decal if equipped
bottom of the switch to turn with SJC.

travel lock OFF.
3 POWER BOB- Press and hold the up arrow to
3 FRONT WIPER Press the bottom of the switch TACH (Option) disengage the Bob-Tach
(Option) to start the front wiper (press wedges. Press and hold the
and hold for washer fluid). down arrow to engage the
Press the top of the switch to wedges into the mounting
stop the wiper. frame holes.
4 REAR WIPER Press the bottom of the switch 4 PARKING BRAKE Press the top to engage the
(Option) to start the rear wiper (press (Standard on all PARKING BRAKE; bottom to
and hold for washer fluid). loaders) disengage.
Press the top of the switch to
stop the wiper. 5 HYDRAULIC Press the top to engage
BUCKET Hydraulic Bucket Positioning;
5 NOT USED --- POSITIONING bottom to disengage.
6 NOT USED --- (Option)
7 FAN MOTOR Turn clockwise to increase fan 6 HAZARD LIGHTS Press the top to turn the
(Option) speed; anticlockwise to (Option) HAZARD LIGHTS ON; bottom
decrease. There are four to turn OFF.
positions; OFF-1-2-3. 7 ROTATING Press the top to turn the light
8 NOT USED --- BEACON (Option) ON; bottom to turn OFF.
9 TEMPERATURE Turn clockwise to increase the or
CONTROL temperature; anticlockwise to STROBE LIGHT
(Option) decrease. (Option)
8 NOT USED ---
459 of 692 60-50-5

INSTRUMENT PANELS (CONT’D) Removal And Installation (Left And Right)
Front Panel Removal And Installation Figure 60-50-10
Figure 60-50-8
1 1
S4369
S0366
Remove the three mounting bolts (Item 1) [Figure 60-50-
10].
8]. Installation: Be careful to not overtighten the instrument

panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the front holes in the panels.
accessory panel mounting bolts to prevent damage to the
plastic panel. Figure 60-50-11
Figure 60-50-9
1
3
2 1
S4334
S5979
Pull the right instrument panel down and disconnect the
key switch wiring harness connector (Item 1) [Figure 60-
Pull the front accessory panel down and disconnect the 50-11] from the panel.
wire harness connector(s) (Items 1, 2, and 3) [Figure 60-
50-9] from the switches. Remove the panel from the loader cab.
Remove the panel.
460 of 692 60-50-6

INSTRUMENT PANELS (CONT’D) Key Switch Removal And Installation
Removal And Installation (Left And Right) (Cont’d) Remove the right instrument panel from the loader. (See
Removal And Installation (Left And Right) on Page 60-50-
Figure 60-50-12 6.)
Figure 60-50-14
1
2
EM1026
S4498
12].

Remove the ignition key (Item 1) from the switch.
Installation: Be careful to not overtighten the instrument Remove the ignition switch retaining nut (Item 2) [Figure
panel mounting bolts to prevent stripping of the threaded 60-50-14] from the switch.
holes in the panels.
Figure 60-50-15
Figure 60-50-13
3
2
1
S5977
S5976
Remove the ignition switch (Item 1) [Figure 60-50-15]

Pull the left instrument panel down and disconnect the
from the control panel.
two connectors (Item 1) [Figure 60-50-13] from the
loader alarm.
Disconnect the two wire harness connectors (Item 2)

[Figure 60-50-13] from the loader instrument panel.
Disconnect the connector (Item 3) [Figure 60-50-13]

from the loader instrument panel.
Remove the instrument panel from the loader.
461 of 692 60-50-7

INSTRUMENT PANELS (CONT’D)
Alarm Removal And Installation
Figure 60-50-16
S5978
Remove the left side instrument panel. (See Removal

And Installation (Left And Right) on Page 60-50-6.)

Remove the retaining nut (Item 1) [Figure 60-50-16] from
the alarm.
Remove the alarm from the loader instrument panel.
462 of 692 60-50-8

LIGHTS Rear Removal And Installation
Front Removal And Installation Figure 60-60-2
Figure 60-60-1
S4326
S4339
Gently press the rear light through the light housing
[Figure 60-60-2].
Open the rear door.
Figure 60-60-3

Disconnect the negative (-) cable from the battery. (See
Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.
Remove the bulb assembly (Item 2) [Figure 60-60-1]

from the light housing by turning bulb assembly 90°.
Remove the bulb from the socket.
S4327
With 120° turn, twist the light bulb out [Figure 60-60-3].
Reverse this procedure for installation.
463 of 692 60-60-1

LIGHTS (CONT’D) Figure 60-60-5
Cab Light Removal And Installation
Figure 60-60-4 1
1
1
P-66222
Remove the bulb (Item 1) [Figure 60-60-5] from the light

P-66221
housing.
Remove the screws (Items 1) [Figure 60-60-4] from the

light cover.

NOTE: The wires for the switch will hold the light
cover. Do not pull the light cover too far away
from the light housing to prevent damage to
the wires.
Move the light cover to allow access to the bulb.
464 of 692 60-60-2

BOBCAT CONTROLLER (GATEWAY)
Description
The Gateway controller provides information to all other

controllers. All loaders have a Gateway controller.
The Gateway controller is located behind the rear door, in

the engine compartment, on the right side.
465 of 692 60-70-1

BOBCAT CONTROLLER (GATEWAY) (CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624
466 of 692 60-70-2

Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL LOCK SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 8080 TAN FAN RELAY SIGNAL
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 OPEN NA NA

12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENDER SIGNAL
16 OPEN NA NA
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 OPEN NA NA
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8050 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 OPEN NA NA
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER
26 2430 BLACK AUX HYD LOCK SOLENOID GROUND
27 OPEN NA NA
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS
467 of 692 60-70-3

J1B
WIRE
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL

12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 OPEN NA NA
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3930 LBL HYDRAULIC CHARGE PRESSURE
24 3900 LBL SEATBAR SENSOR POWER
25 OPEN NA NA
26 4440 LGN AUX HYD SOLENOID SIGNAL
468 of 692 60-70-4

WARNING
W-2059-0598
Open the rear door.
Figure 60-70-1

2
3
2
1 EM1423
Remove the connectors (Item 1) [Figure 60-70-1].
NOTE: The connectors are keyed and will only plug

in one direction.
Remove the mounting bolts (Item 2) [Figure 60-70-1]

from the Bobcat controller.
Installation: Tighten the bolts to 16,3 - 19 N•m (12 - 14

ft-lb) torque.
Remove the Bobcat controller (Item 3) [Figure 60-70-1].
469 of 692 60-70-5

470 of 692
60-70-6
BOBCAT CONTROLLER (AUXILIARY) (SJC)
Description
The Auxiliary controller is on loaders equipped with the

SJC option. This controller provides information to all
other controllers.
The Auxiliary controller is located under the cab, right

under the operator’s seat.
471 of 692 60-71-1

BOBCAT CONTROLLERS (AUXILIARY) (SJC)
(CONT’D)
Auxiliary Controller
1 1
34 26
J2A J2B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645
472 of 692 60-71-2

(CONT’D)
J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 OPEN NA NA
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 OPEN NA NA
11 OPEN NA NA

12 OPEN NA NA
13 OPEN NA NA
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 OPEN NA NA
21 OPEN NA NA
22 OPEN NA NA
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 OPEN NA NA
27 OPEN NA NA
28 OPEN NA NA
29 OPEN NA NA
30 OPEN NA NA
31 OPEN NA NA
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA
473 of 692 60-71-3

(CONT’D)
J2B
WIRE
NUMBER
1 OPEN NA NA
4 OPEN NA NA
5 OPEN NA NA
6 OPEN NA NA
7 OPEN NA NA
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA

12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 OPEN NA NA
18 OPEN NA NA
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 OPEN NA NA
22 1560 RNG SWITCHED INPUT POWER
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 OPEN NA NA
474 of 692 60-71-4

BOBCAT CONTROLLERS (AUXILIARY) (SJC) Figure 60-71-1
(CONT’D)
Removal And Installation 2
WARNING
1
support device. Failure to use an approved lift arm 2
W-2059-0598
S10479
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.). Disconnect the harness connectors (Item 1) [Figure 60-
71-1] from the Bobcat controller.
support device. (See Installing on Page 10-20-1.). NOTE: The connectors are keyed and will only plug
in one way.
Stop the engine. Raise the seat bar.

Raise the operator cab. (See Raising on Page 10-30-1.). 1].

ft-lb) torque.
Remove the Bobcat controller from the machine.
Reverse the above procedure to install the system

controller.
475 of 692 60-71-5

476 of 692
60-71-6
BOBCAT CONTROLLER (ACS) (SJC)
Description
The ACS controller is on loaders equipped with the SJC

option. This controller processes information for the lift
and tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.
The ACS controller is located under the cab, on the back

of the control panel.
477 of 692 60-72-1

BOBCAT CONTROLLER (ACS) (SJC) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D J3
B
C G H
F J
K J2
F E
G D A
E H B
A C
B J2
D
J1
C
J3
J1 J2

P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A +5V SUPPLY Light Green A TILT ACTUATOR FORWARD
Orange B SWITCHED BATTERY 12V Red/White B UNSWITCHED BATTERY
Green C OPEN Red/White C UNSWITCHED BATTERY
Purple/White D CAN SIGNAL HIGH ACS Light Green D LIFT ACTUATOR MOTOR NEG
Purple E CAN SIGNAL LOW ACS E OPEN
Purple F OPEN Light Green F LIFT ACTUATOR MOTOR PWR
Black G ACS GROUND G OPEN
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Light Green K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Light Green E TILT ACTUATOR POSITION
F OPEN
G OPEN
Light Green H LIFT ACTUATOR POSITION
J OPEN
K OPEN
478 of 692 60-72-2

BOBCAT CONTROLLER (ACS) (SJC) (CONT’D) Figure 60-72-2

1
WARNING
W-2059-0598
S10489
Remove the Bobcat auxiliary controller. (See Removal
Loosen the sound insulation (Item 1) [Figure 60-72-2]
Figure 60-72-1 from the control panel and fold it toward the front of the
machine.
Figure 60-72-3

1
1
2
S10488
Cut the two tie-straps (Item 1) [Figure 60-72-1]. S10490

3].

ft-lb) torque.
479 of 692 60-72-3

BOBCAT CONTROLLER (ACS) (SJC) (CONT’D) Figure 60-72-5
Figure 60-72-4
1
1
S10492
Remove the four mounting bolts (Item 1) [Figure 60-72-

S10491 5].

Disconnect the three harness connectors (Item 1) ft-lb) torque.
[Figure 60-72-4] from the Bobcat controller.

Remove the controller from the loader.
NOTE: The calibration procedure must be followed

when replacing actuator or ACS Controller.
(See CALIBRATION on Page 60-140-1.)
480 of 692 60-72-4

BOBCAT CONTROLLER (DRIVE) (SJC) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The hydrostatic drive pump is a Rexroth A22 unit. It has
drive functions. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller is located under the cab, on the back forward and reverse outputs of the pump to the drive
of the control panel. motors. The Rexroth pump is equipped with position
sensors mounted to the bottom of the swash plates to
The drive controller monitors the position of the left provide feedback to the controllers to sense
joystick and pump swash plate angles. uncommanded swash plate movement.
The drive controller works along with the ACS controller

and communicates with the Gateway controller in an SJC
system. All these controllers are capable of software
upgrades.
RIGHT DRIVE
HAND CONTROL
PANEL
ACS

CONTROL
LIFT / TILT
ACTUATORS
INTERNAL CAN BUS
GEAR ENGINE
SERIAL TT BUS
PUMP
RIGHT
JOYSTICK
ISO
SWITCH FWD / REV
SWASH PLATE
SENSORS
LEFT
JOYSTICK
AUXILIARY DRIVE
LEFT PUMP
CONTROL
HAND
PANEL
EXTERNAL
CAN BUS ACD
GATEWAY CONTROL
CONTROL
EM5346
481 of 692 60-73-1

BOBCAT CONTROLLER (DRIVE) (SJC) (CONT’D)
P-64295
482 of 692 60-73-2

BOBCAT CONTROLLER (DRIVE) (SJC) (CONT’D)
Connector Identification (Cont'd)
S10734
483 of 692 60-73-3

BOBCAT CONTROLLER (DRIVE) (SJC) (CONT’D) Figure 60-73-2

1
WARNING
W-2059-0598
S10489
Remove the Bobcat auxiliary controller. (See Removal
Loosen the sound insulation (Item 1) [Figure 60-73-2]
Figure 60-73-1 from the control panel and fold it toward the front of the
machine.
Figure 60-73-3

1
1
S10488
2
Cut the two tie-straps (Item 1) [Figure 60-73-1].

S10490

3].

ft-lb) torque.
484 of 692 60-73-4

BOBCAT CONTROLLER (DRIVE) (SJC) (CONT’D) Figure 60-73-5
Figure 60-73-4
S10553
1

S10552 5].

Remove the screw (Item 1) [Figure 60-73-4] and remove ft-lb) torque.
the wire harness from the controller.

Set the Bobcat ACS controller and bracket aside to
Installation: Tighten the connector screw to 3,39 - 3,96 provide clearance for easy removal of Bobcat drive
N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN! controller.
Installation: Tighten the bolt to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.
Remove the Bobcat drive controller from the machine.
485 of 692 60-73-5

486 of 692
60-73-6
DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes.
The Service Codes will aid your dealer in diagnosing
conditions which can damage your machine. Figure 60-80-2
Figure 60-80-1
Press TOOL / SETUP
2 B-16163
Press OWNER UTILITIES
B-24288
Enter PASSWORD (owner or

master)
1 P-76455G on Keypad
then press ENTER
to Continue
B-24290
Press the INFORMATION button (Item 1) to cycle the

DATA DISPLAY (Item 2) [Figure 60-80-1] until the
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the Press SERVICE CODES
DATA DISPLAY.
B-24291
NOTE: Corroded or loose grounds can cause
multiple service codes and / or abnormal
symptoms. All instrument panel lights Press NEXT to view the
flashing, alarm sounding, headlights and next 8 Service Codes.
taillights flashing, could indicate a bad (A total of 40 Codes can be
ground. The same symptoms could apply if stored.)
B-24298
the voltage is low, such as loose or corroded
battery cables. If you observe these
symptoms, check grounds and positive leads
first. The Display Panel will list the Code Number, (CODE)
hourmeter reading when the error occurred (HOUR), and
the User (USER) who was logged in to operate the
machine when the error occurred [Figure 60-80-2].
A total of 40 Codes can be stored. When more than 40

codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.
487 of 692 60-80-1

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-80-3 The following word errors can be displayed:
2 [REPLY] One or both instrument panel(s) not

1
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
P-76461H only.)
P-76461P
P-76455G
[SHTDN] A shutdown condition exists.
Service Codes can be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-80-3]. functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A0618 Wheel speed out of range A8406 ACD output ‘E’ short to ground

A3623 ACD not programmed A8407 ACD output ‘E’ open circuit
A4621 Sensor supply 2 out of range high A8432 ACD output ‘E’ overcurrent
A4622 Sensor supply 2 out of range low A8502 ACD output ‘F’ error ON
A4721 Sensor supply 1 out of range high A8503 ACD output ‘F’ error OFF
A4722 Sensor supply 1 out of range low A8505 ACD output ‘F’ short to battery
A8002 ACD output ‘A’ error ON A8506 ACD output ‘F’ short to ground
A8003 ACD output ‘A’ error OFF A8507 ACD output ‘F’ open circuit
A8005 ACD output ‘A’ short to battery A8532 ACD output ‘F’ overcurrent
A8006 ACD output ‘A’ short to ground A8602 ACD output ‘G’ error ON
A8007 ACD output ‘A’ open circuit A8603 ACD output ‘G’ error OFF
A8032 ACD output ‘A’ overcurrent A8605 ACD output ‘G’ short to battery
A8102 ACD output ‘B’ error ON A8606 ACD output ‘G’ short to ground
A8103 ACD output ‘B’ error OFF A8607 ACD output ‘G’ open circuit
A8105 ACD output ‘B’ short to battery A8702 ACD output ‘H’ error ON
A8106 ACD output ‘B’ short to ground A8703 ACD output ‘H’ error OFF
A8107 ACD output ‘B’ open circuit A8705 ACD output ‘H’ short to battery
A8132 ACD output ‘B’ overcurrent A8706 ACD output ‘H’ short to ground
A8202 ACD output ‘C’ error ON A8707 ACD output ‘H’ open circuit
A8203 ACD output ‘C’ error OFF A8802 Reverse solenoid error ON
A8205 ACD output ‘C’ short to battery A8803 Reverse solenoid error OFF
A8206 ACD output ‘C’ short to ground
A8207 ACD output ‘C’ open circuit D3905 Left joystick X-axis not in neutral
A8232 ACD output ‘C’ overcurrent D3907 Left joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D4007 Right joystick Y-axis not in neutral
A8303 ACD output ‘D’ error OFF D7501 CAN joystick communication error
A8305 ACD output ‘D’ short to battery D7504 No communication from drive controller
A8306 ACD output ‘D’ short to ground D7505 Left joystick X-axis not in neutral
A8307 ACD output ‘D’ open circuit D7507 Left joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7508 Right joystick Y-axis not in neutral
A8402 ACD output ‘E’ error ON D7509 Operating mode switch short to ground or battery
A8403 ACD output ‘E’ error OFF D7510 Improper joysticks installed
A8405 ACD output ‘E’ short to battery D7511 Left speed sensor not connected
488 of 692 60-80-2

Service Codes List (Cont’d)

D7512 Right speed sensor not connected D7564 Left rear steer retract short to ground
D7513 Right front wheel angle sensor stuck D7565 Steer pressure short to ground
D7514 Left front wheel angle sensor stuck D7566 Back-up alarm error OFF
D7515 Right rear wheel angle sensor stuck D7567 No communication from Gateway controller
D7516 Left rear wheel angle sensor stuck D7568 Angle sensors not calibrated
D7517 Left swash plate not in neutral D7569 Battery voltage out of range high
D7518 Right swash plate not in neutral D7570 Interrupted power (also occurs after software update)
D7519 Left joystick X-axis out of range high D7571 Battery voltage out of range low
D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery

D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535 Right rear wheel angle sensor out of range low D7585 Sensor supply 1 out of range high
D7536 Left rear wheel angle sensor out of range low D7586 Sensor supply 2 out of range high
D7537 Sensor supply 1 out of range low D7587 Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF
D7540 Left swash plate sensor out of range low D7590 Drive calibration performed
D7541 Right swash plate sensor out of range high D7591 Left swash plate sensor reversed
D7542 Right swash plate sensor out of range low D7592 Right swash plate sensor reversed
D7543 Left forward drive solenoid error ON D7593 Right speed sensor unresponsive
D7544 Left reverse drive solenoid error ON D7594 Left speed sensor unresponsive
D7545 Right forward drive solenoid error ON D7595 Left speed sensor reversed
D7546 Right reverse drive solenoid error ON D7596 Right speed sensor reversed
D7547 Right front steer extend short to battery D7597 Controller programmed
D7548 Left front steer extend short to battery D7598 In drive calibration mode
D7549 Right rear steer extend short to battery D7599 In angle calibration mode
D7550 Left rear steer extend short to battery
D7551 Steer pressure short to battery H1121 Boost Sensor out of range high
D7552 Back-up alarm error ON H1122 Boost Sensor out of range low
D7553 Left forward drive solenoid error OFF H1221 Right Primary out of range high
D7554 Left reverse drive solenoid error OFF H1222 Right Primary out of range low
D7555 Right forward drive solenoid error OFF H1224 Right Primary not in neutral
D7556 Right reverse drive solenoid error OFF H1321 Left Primary out of range high
D7557 Right front steer extend short to ground H1322 Left Primary out of range low
D7558 Right front steer retract short to ground H1324 Left Primary not in neutral
D7559 Left front steer extend short to ground H2005 Boost solenoid short to battery
D7560 Left front steer retract short to ground H2006 Boost solenoid short to ground
D7561 Right rear steer extend short to ground H2007 Boost solenoid open circuit
D7562 Right rear steer retract short to ground H2032 Boost solenoid overcurrent
D7563 Left rear steer extend short to ground H2205 Pressure control solenoid short to battery
489 of 692 60-80-3


H2206 Pressure control solenoid short to ground H7328 Remote control no signal
H2207 Pressure control solenoid open circuit H7404 Main controller no communication
H2232 Pressure control solenoid overcurrent H7604 Left hand panel no communication
H2305 Rear base solenoid short to battery
H2306 Rear base solenoid short to ground L0102 Left panel button 1 error ON
H2307 Rear base solenoid open circuit L0202 Left panel button 2 error ON
H2332 Rear base solenoid overcurrent L0302 Left panel button 3 error ON
H2405 Rear rod solenoid short to battery L0402 Left panel button 4 error ON
H2406 Rear rod solenoid short to ground L7404 Left panel main controller no communication
H2407 Rear rod solenoid open circuit L7672 Left panel programming error
H2432 Rear rod solenoid overcurrent
H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic/Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high

H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807 Diverter rod solenoid open circuit M0422 Engine oil pressure out of range low
H2905 High-flow solenoid short to battery M0509 Hydraulic charge pressure low
H2906 High-flow solenoid short to ground M0510 Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely low
H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128 Interrupted power failure M0521 Hydraulic charge pressure out of range high
H3648 ACD multiple M0522 Hydraulic charge pressure out of range low
H3913 Left joystick grip no communication M0610 Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928 Left joystick failure M0613 Engine speed no signal
H3948 Left joystick multiple M0615 Engine speed shutdown
H4013 Right joystick grip no communication M0618 Engine speed out of range
H4016 Right joystick not connected M0634 Engine speed invalid data from ECU
H4028 Right joystick failure M0710 Hydraulic oil temperature high
H4048 Right joystick multiple M0711 Hydraulic oil temperature extremely high
H4302 Horn error ON M0715 Hydraulic oil temperature shutdown
H4303 Horn error OFF M0721 Hydraulic oil temperature out of range high
H4423 Auxiliary not programmed M0722 Hydraulic oil temperature out of range low
H4502 Right signal error ON M0810 Engine coolant temperature high
H4503 Right signal error OFF M0811 Engine coolant temperature extremely high
H4602 Left signal error ON M0815 Engine coolant temperature shutdown
H4603 Left signal error OFF M0821 Engine coolant temperature out of range high
H4721 Sensor supply 1 out of range high M0822 Engine coolant temperature out of range low
H4722 Sensor supply 1 out of range low M0909 Fuel level low
H7314 Remote control failure M0921 Fuel level out of range high
490 of 692 60-80-4


M0922 Fuel level out of range low M2821 Throttle secondary out of range high
M1016 Hydraulic charge filter not connected M2822 Throttle secondary out of range low
M1017 Hydraulic charge filter plugged M3128 Interrupted power failure
M1121 Seat bar sensor out of range high M3204 Workgroup no communication
M1122 Seat bar sensor out of range low M3304 Deluxe panel no communication
M1128 Seat bar sensor failure M3404 Deluxe panel no communication
M1305 Fuel hold solenoid short to battery M3505 Hydraulic fan short to battery
M1306 Fuel hold solenoid short to ground M3506 Hydraulic fan short to ground
M1307 Fuel hold solenoid open circuit M3507 Hydraulic fan open circuit
M1402 Fuel pull output error ON M3532 Hydraulic fan overcurrent
M1403 Fuel pull output error OFF M3705 Two-speed secondary short to battery
M1407 Fuel pull output open circuit M3706 Two-speed secondary short to ground
M1428 Fuel pull output failure M3707 Two-speed secondary open circuit
M1502 Traction lock pull output error ON M3732 Two-speed secondary overcurrent
M1503 Traction lock pull output error OFF M3805 Auxiliary hydraulic lock short to battery
M1507 Traction lock pull output open circuit M3806 Auxiliary hydraulic lock short to ground
M1528 Traction lock pull output failure M3807 Auxiliary hydraulic lock open circuit
M1605 Traction lock hold solenoid short to battery M3832 Auxiliary hydraulic lock overcurrent

M1606 Traction lock hold solenoid short to ground M4109 Alternator low
M1607 Traction lock hold solenoid open circuit M4110 Alternator high
M1705 Hydraulic lock valve solenoid short to battery M4304 Keyless panel no communication
M1706 Hydraulic lock valve solenoid short to ground M4404 Auxiliary no communication
M1707 Hydraulic lock valve solenoid open circuit M4521 Water in fuel sensor out of range high
M1732 Hydraulic lock valve solenoid overcurrent M4522 Water in fuel sensor out of range low
M1805 Lift spool lock short to battery M4530 Water in fuel sensor fault
M1806 Lift spool lock short to ground M4621 5 volt sensor supply out of range high
M1807 Lift spool lock open circuit M4622 5 volt sensor supply out of range low
M1832 Lift spool lock overcurrent M4721 8 volt sensor supply out of range high
M2005 Two-speed primary short to battery M4722 8 volt sensor supply out of range low
M2006 Two-speed primary short to ground M4802 Front light relay error ON
M2007 Two-speed primary open circuit M4803 Front light relay error OFF
M2032 Two-speed primary overcurrent M4807 Front light relay open circuit
M2102 Glow plug output error ON M4902 Rear light relay error ON
M2103 Glow plug output error OFF M4903 Rear light relay error OFF
M2107 Glow plug output open circuit M4907 Rear light relay open circuit
M2128 Glow plug output failure M5002 Front light output error ON
M2202 Starter output error ON M5003 Front light output error OFF
M2203 Starter output error OFF M5007 Front light output open circuit
M2207 Starter output open circuit M5028 Front light output failure
M2228 Starter output failure M5102 Rear light output error ON
M2302 Starter relay error ON M5103 Rear light output error OFF
M2303 Starter relay error OFF M5107 Rear light output open circuit
M2402 Fuel pull relay error ON M5128 Rear light output failure
M2403 Fuel pull relay error OFF M5202 PTOL switch error ON
M2502 Traction pull relay error ON M5221 PTOL switch out of range high
M2503 Traction pull relay error OFF M5222 PTOL switch out of range low
M2602 Glow plug relay error ON M5305 PTOL LED short to battery
M2603 Glow plug relay error OFF M5306 PTOL LED short to ground
M2721 Throttle primary out of range high M5405 Tilt spool lock short to battery
M2722 Throttle primary out of range low M5406 Tilt spool lock short to ground
491 of 692 60-80-5


M5407 Tilt spool lock open circuit M8615 Engine speed derate shutdown
M5432 Tilt spool lock overcurrent M8625 Engine speed derate unresponsive
M5902 DPF force regeneration switch error ON M8715 Torque derate shutdown
M5948 DPF switch multiple M8725 Torque derate unresponsive
M6002 DPF inhibit regeneration switch error ON
M6402 Switched power relay error ON W3223 ACS calibration required
M6403 Switched power relay error OFF W3224 ACS calibration performed
M6505 EEC power short to battery W3225 ACS calibration failed
M6506 EEC power short to ground W3231 Tilt actuator fault
M6507 EEC power open circuit W3232 Tilt actuator wiring fault
M6604 EEC power no communications W3233 Tilt handle wiring fault
M6702 HVAC output error ON W3234 Tilt actuator not in neutral
M6703 HVAC output error OFF W3235 Tilt handle / pedal not in neutral
M6707 HVAC output open circuit W3236 Lift actuator fault
M6728 HVAC output failure W3237 Lift actuator wiring fault
M6802 HVAC relay error ON W3238 Lift handle wiring fault
M6803 HVAC relay error OFF W3239 Lift actuator not in neutral
M7002 Switched power output error ON W3240 Lift handle / pedal not in neutral

M7003 Switched power output error OFF W3241 No communication
M7007 Switched power output open circuit W3249 Lift actuator short to ground
M7028 Switched power output failure W3250 Tilt actuator short to ground
M7102 Electric fan 1 output error ON W3251 Lift actuator short to battery
M7103 Electric fan 1 output error OFF W3252 Tilt actuator short to battery
M7128 Electric fan 1 output failure W3253 Lift handle / pedal short to ground
M7202 Electric fan 1 relay error ON W3254 Tilt handle / pedal short to ground
M7203 Electric fan 1 relay error OFF W3255 Lift handle / pedal short to battery
M7207 Electric fan 1 relay open circuit W3256 Tilt handle / pedal short to battery
M7304 Remote control no communication W3257 Lift actuator reduced performance
M7316 Remote control not connected W3258 Tilt actuator reduced performance
M7423 Main controller not programmed W3259 Lift actuator wrong direction
M7472 Main controller in boot code W3260 Tilt actuator wrong direction
M7497 Main controller software updated W3261 Handle lock short to ground
M7504 Drive no communication W3262 Handle lock short to battery
M7604 Left display panel no communication W3263 Pedal lock short to ground
M7748 Key switch multiple W3264 Pedal lock short to battery
M7839 Hourmeter changed W3265 Sensor supply voltage out of range
M7974 Door open W3266 Battery voltage out of range
M8541 DPF automatic regeneration active W3267 Handle/pedal switch flipped while operating
M8542 DPF automatic regeneration active W3268 Lift handle information error
M8543 DPF regeneration required W3270 Right hand drive short to ground
M8550 DPF service regeneration required W3271 Right hand drive short to battery
M8551 DPF regeneration required but inhibited W3274 Left joystick X-axis out of range
M8552 DPF regeneration required but inhibited W3275 Interrupted unswitched power
M8553 DPF service regeneration required W3276 CAN joystick information error
M8554 DPF service regeneration required W3277 Remote control information error
M8560 DPF service regeneration active W3297 Controller programmed
M8561 DPF service regeneration active W3905 Left joystick X-axis not in neutral
M8562 DPF service regeneration active W4005 Right joystick X-axis not in neutral
M8563 DPF service regeneration active W4007 Right joystick Y-axis not in neutral
M8564 DPF service regeneration active
492 of 692 60-80-6

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Description
Figure 60-90-1
EM1026
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system

consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel [Figure

60-90-1] of the loader cab.
The Press To Operate button activates the system and

allows the operator to function the loader.
If any of these indicator lights illuminates (except the

Press To Operate button) the loader will not function.
493 of 692 60-90-1

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The Traction Lock (Engine RUNNING)
(CONT’D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS™ (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers or joystick(s)
Figure 60-90-2 slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
1 2 3 PRESS TO OPERATE LOADER button.
7. Engage parking brake and move steering levers or

joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.
6 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
5 brake is disengaged.
4
Inspecting The Lift Arm Bypass Control
8. Raise the lift arms 2 m (6 ft) off the ground. Stop

P-76459A engine. Turn lift arm bypass control knob clockwise
90°. Pull up and hold lift arm bypass control knob until

1. Sit in operator’s seat. Turn key switch to RUN or press lift arms slowly lower.
RUN button. Lower seat bar and disengage parking
Inspecting Deactivation Of Lift And Tilt Functions
brake. Press the PRESS TO OPERATE LOADER
(SJC)
button (Item 4). Two BICS™ lights (Items 1 and 2)
[Figure 60-90-2] [SEAT BAR AND LIFT & TILT 9. Sit in operator’s seat and fasten seat belt. Lower seat
VALVE] on left instrument panel must be OFF. The bar, start engine and press the PRESS TO OPERATE
PRESS TO OPERATE LOADER button will light. LOADER button.
2. Raise seat bar fully. All three BICS™ lights (Items 1, 10. Raise lift arms about 2 m (6 ft) off the ground.
2 and 3) [Figure 60-90-2] [SEAT BAR, LIFT & TILT
VALVE AND PARKING BRAKE] on left instrument 11. Turn key switch OFF or press STOP button, and wait
panel must be ON. The PRESS TO OPERATE for the engine to come to a complete stop.
LOADER button light will turn OFF.
12. Turn key switch ON or press RUN button. Press the
Inspecting Deactivation Of The Auxiliary Hydraulics PRESS TO OPERATE LOADER button, move the
System (Engine STOPPED - Key ON) control (foot pedal, hand control or joystick) to lower
the lift arms. Lift arms must not lower.
3. Sit in operator’s seat, lower seat bar and press the
PRESS TO OPERATE LOADER button (Item 4). 13. Move the control (foot pedal, hand control or joystick)
Press the Auxiliary Hydraulics button (Item 5). The to tilt the bucket (or attachment) forward. The bucket
auxiliary hydraulics light (Item 6) [Figure 60-90-2] will (or attachment) must not tilt forward.
be ON. Raise the seat bar. The light must be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt.
WARNING
5. Start engine and operate at low idle. Press the The Bobcat Interlock Control System (BICS™) must
PRESS TO OPERATE LOADER button. While raising deactivate the lift, tilt and traction drive functions. If it
the lift arms, raise the seat bar fully. The lift arms must does not, contact your dealer for service. DO NOT
stop. Repeat using the tilt function. modify the system.
W-2151-1111
494 of 692 60-90-2

(CONT’D)
Troubleshooting WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. See the BICS™ troubleshooting chart (See Troubleshooting (Cont’d) on Page 60-90-4.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
495 of 692 60-90-3

(CONT’D)
Troubleshooting (Cont’d)
The following list shows the probable causes when the BICS™ system lights are off or flashing and the associated service
codes. (See DIAGNOSTIC SERVICE CODES on Page 60-80-1.)
INDICATOR EFFECT ON OPERATION OF SERVICE

LIGHT OFF LIGHT ON FLASHES
LIGHT LOADER WHEN LIGHT IS ON CODE
PRESS TO PRESS TO Lift and tilt functions will operate. Continuous Flashing M-52-02
TRACTION
LOCK OVERRIDE
OPERATE OPERATE Loader can be moved forward Continuous Flashing M-52-21
LOADER button LOADER and backward. Continuous Flashing M-52-22
is NOT pressed. button IS
PRESS TO
OPERATE
pressed.
LOADER
1
Seat Bar is down. Seat Bar is Lift and tilt functions will not Continuous Flashing M-11-21
up. operate. Continuous Flashing M-11-22
2
Control valve can Control valve Lift and tilt functions will not
Continuous Flashing M-17-05

be used. cannot be operate. Continuous Flashing M-17-06
used. Continuous Flashing M-17-07
3 Continuous Flashing M-18-07
Solid (battery) Icon M-03-09
Loader can be Loader cannot Loader cannot be moved forward Continuous Flashing M-15-02
moved forward be moved and backward. Continuous Flashing M-15-03
and backward forward and Continuous Flashing M-16-05
backward. Continuous Flashing M-16-06
4 Continuous Flashing M-25-02
496 of 692 60-90-4

SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The seat bar sensor is part of the BICS™ system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the done by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.
The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.

2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
497 of 692 60-100-1

SEAT BAR SENSOR (CONT’D) Figure 60-100-3
Testing
Figure 60-100-1
1
P-4698
If there is no power light (Item 1) [Figure 60-100-3] on

N-18463 the sensor tester, check the tester or wiring harness.
Figure 60-100-4
Use a Sensor Tester (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:

Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-100-1].
Figure 60-100-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1
[Figure 60-100-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-100-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-100-2]
inline to the seat bar sensor connectors. [Figure 60-100-
Replace the Seat Bar Sensor. (See Removal And
2].
Turn the key switch to the ON position. DO NOT START
If the above test passes, run the seat bar sensor BICS™
THE ENGINE.
circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-100-6.)
The toggle switch (Item 2) [Figure 60-100-3] can be in
either the Absent or Present position.
498 of 692 60-100-2

SEAT BAR SENSOR (CONT’D) Figure 60-100-7
NOTE: This procedure is performed with the seat bar

in the raised position and the technician in the 3
operators seat.
Figure 60-100-5
1 2
P100745
Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-100-7]. Remove the seat bar mounting bolt
and nut (Item 3) [Figure 60-100-7].
2
P100742

Remove the sensor mounting bolt and nut (Item 1)
[Figure 60-100-5]. Disconnect the sensor wiring
connector (Item 2) [Figure 60-100-5].
Figure 60-100-6
P100743
P100759
Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-100-6].
NOTE: Approximately 4 turns of the clevis bolt

should be adequate to release the spring
tension. When tension is released, the clevis
pin can easily be rotated using the retaining
pin.
499 of 692 60-100-3

SEAT BAR SENSOR (CONT'D) Remove and save the metal pivot bushing (Item 6)
[Figure 60-100-9].
Figure 60-100-10
Figure 60-100-8
3
1
4
P100748
P100746
Install the new keyed bushing (Item 1), magnet bushing

Pull the front of the seat bar down slightly from the top of
(Item 2) and seat bar sensor (Item 3) [Figure 60-100-10].
the cab, while raising the sensor end of the seat bar up,
Reinstall the metal pivot bushing (Item 4) [Figure 60-
away from the mount [Figure 60-100-8].
100-10].

NOTE: The sensor end of the seat bar will raise easily
NOTE: The sensor must be centered on the metal
ONLY if the front of the seat bar is pulled
pivot bushing. When centered, the assembly
slightly down from the top of the cab.
will slide freely into the mount.
Figure 60-100-9
Figure 60-100-11
5
3
3
1
6 1
2
2
P100747
P100749
Place a soft jaw locking pliers (Item 1) [Figure 60-100-9]

on the cab side screen to hold the seat bar above the Position the clevis (Item 1) over the mount (Item 2) and
mount. lower the end of the seat bar until the mounting bolt (Item
3) [Figure 60-100-11] is resting on the top of the mount.
Remove the clevis pin bushing (Item 2) [Figure 60-100-
9]. Apply grease to the shoulder of the bushing to help Remove the nut from the mounting bolt. Remove the
retain it during assembly. Reinstall the clevis pin bushing. mounting bolt and lower the seat bar until the seat bar
and mount holes align and the clevis is over the clevis pin
Remove and dispose of the keyed bushing (Item 3), bushing. Reinstall the seat bar mounting bolt. Apply
magnet bushing (Item 4), and seat bar sensor (Item 5) Loctite® 243 to the nut threads. Install the nut and tighten
[Figure 60-100-9]. to 33,9 - 38 N•m (25 - 28 ft-lb) torque.
500 of 692 60-100-4

SEAT BAR SENSOR (CONT'D)
Figure 60-100-12
1
2

P100751
P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-100-12].
Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.
Reconnect the sensor wiring connector (Item 2) [Figure

60-100-5].
Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-100-5] and tighten the mounting bolt to 6,8
N•m (60 in-lb) torque.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS™) inspection as described in the loader Operation
& Maintenance Manual.
501 of 692 60-100-5

SEAT BAR SENSOR (CONT’D) When the power light (Item 2) [Figure 60-100-14] is
illuminated and the seat bar is up, the sensor test light
Bobcat Interlock Control System (BICS™) Circuit (Item 4) [Figure 60-100-14] should be off.
Test
NOTE: The sensor test light (Item 4) [Figure 60-100-
Figure 60-100-13 14] is only activated by the seat bar. It will be
on with the seat bar down or off with the seat
bar up.
When the power light (Item 2) is illuminated, move the

toggle switch (Item 3) [Figure 60-100-14] on the sensor
tester to the Present position.
Figure 60-100-15
P-85653
1
Use the Sensor Tester (MEL1428) and seat bar sensor

tester adapter (MEL1567) for the following procedure:
Connect the seat bar sensor tester adapter to the sensor

tester.
P-85413
Disconnect the seat bar sensor connector (Item 1)

[Figure 60-100-13]. The BICS™ seat bar indicator light (Item 1) [Figure 60-
100-15] should turn OFF.
Figure 60-100-14
Figure 60-100-16
1 3
1
P-4703
P-4699
Connect the Sensor Tester (Item 1) [Figure 60-100-14]

Move the toggle switch (Item 1) [Figure 60-100-16] on
inline to the seat bar sensor connectors.
the sensor tester to the Absent position.
Turn the key switch to the ON position. DO NOT START The BICS™ seat bar indicator light (Item 1) [Figure 60-
THE ENGINE. 100-15] should illuminate.
When the power light (Item 2) [Figure 60-100-14] is not If the above test fails, there is a problem with the Bobcat
illuminated, check the tester or wiring harness. controller or the wiring harness.
502 of 692 60-100-6

TRACTION LOCK Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The Traction Lock Control System will lock the traction problems. It is recommended that these procedures be
drive system when the engine stops. The Traction Lock done by authorized Bobcat Service Personnel only.
Control System is incorporated into the BICS™ System.
WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock. 8, 9, 10, 11

1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it has not released, check the brake 30 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses.
5. To test the solenoid, the pull coil should be about 0.3 ohm and the hold coil should be about 10.9 ohm.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check flywheel rpm sensor and wiring.
12. Check the Display Panel for an error code.
13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volt.
503 of 692 60-110-1

TRACTION LOCK (CONT’D) Figure 60-110-2
WARNING 2
AVOID INJURY OR DEATH 1

Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat S5965
Company parts if repair is necessary.
W-2165-0100
Remove the two bolts (Item 1) and remove the bracket
(Item 2) [Figure 60-110-2] from the chaincase cover.
30-1.) Installation: Apply Loctite® 243 or equivalent to the
bolts threads and tighten the mounting bolts to 34 - 38
Remove the shocks. (See Shock Removal And N•m (25 - 28 ft-lb) torque.

NOTE: Be sure the solenoid mounting bracket is
Figure 60-110-1 installed in the same position. The solenoid
mounting surface has a slight angle which
tips the top of the solenoid toward the rear of
the loader when installed correctly. See inset
photo [Figure 60-110-1].
Figure 60-110-3
2
P-4712
1 2
S5964
NOTE: The loader control panel and linkage crossbar

have been removed for photo clarity. The
traction lock can be removed without
removing the control panel.
S5966
Remove the two mounting screws (Item 1) [Figure 60-

110-1] from the electric solenoid mounting bracket. Remove the traction lock assembly (Item 1) [Figure 60-
110-3] from the chaincase.
Installation: Tighten the mounting screws to 9 - 10 N•m
(80 - 90 in-lb) torque. Inspect gasket (Item 2) [Figure 60-110-3], replace if
necessary.
Remove the electric solenoid (Item 2) from the chaincase
cover [Figure 60-110-1].
504 of 692 60-110-2

TRACTION LOCK (CONT'D) Figure 60-110-5

4 5
Figure 60-110-4
3
2
1
4 1
3 2
P-68144
Remove the shaft mounting bolt (Item 1), spring (Item 2),
P-68143 washer (Item 3) and wedge (Item 4) from the assembly
shaft (Item 5) [Figure 60-110-5]. Inspect all parts for
damage or wear. Replace if necessary.
Remove and inspect the compression spring (Item 1) and
spring cap washer (Item 2) [Figure 60-110-4] for wear or Installation: Thoroughly clean and dry the shaft

damage. Replace if necessary. The spring can also stay mounting bolt (Item 1), shaft (Item 5) and wedge (Item 4)
with the shaft when the electric solenoid and bracket are [Figure 60-110-5]. Use Loctite® 243 or equivalent when
removed from the chaincase. assembling these parts to the traction lock assembly.
Installation: Install the compression spring (Item 1) Figure 60-110-6

[Figure 60-110-4] on the collar located on the electric
solenoid.
Inspect the shaft (Item 3) and wedge (Item 4) [Figure 60-

110-4] for scoring and deep scratches. Replace if
necessary.
S5967
Inspect the guides (Item 1) [Figure 60-110-6] for wear or

damage. Replace if necessary.
If replacement is necessary, remove the center

chaincase cover. (See Center Cover Removal And
505 of 692 60-110-3

Removal And Installation (Cont'd) INCORRECT CORRECT

Figure 60-110-7
1 2
2 2 1
N-19106 N-19105
Installation: Install the traction lock guides (Item 1) to

S5968 the chaincase cover (Item 2) [Figure 60-110-9] using the
four bolts (removed earlier).
NOTE: Notice the direction of the groove (Item 1) Do not tighten at this time.
[Figure 60-110-7] in the traction lock guides.

Figure 60-110-10
To remove the traction lock guides remove the four bolts
(Item 2) [Figure 60-110-7].
1
Installation: Thoroughly clean the polyurethane from the
chaincase cover, traction lock guides (Item 1) and bolts
(Item 2) [Figure 60-110-7] and dry.
Figure 60-110-8
S5970
Installation: Install the traction wedge assembly (Item 1)

into the solenoid and traction lock guides (Item 2) [Figure
60-110-10].
After the bolts have been tightened recheck to make sure

P11333 the shaft assembly is moving freely in the guides.
Remove the wedge assembly (Item 1) [Figure 60-110-

Installation: Apply a bead of polyurethane on the 10].
traction lock guides and bolts [Figure 60-110-8].
NOTE: The wedge assembly must slide freely in the
grooves of the guides. Tighten the four guide
bolts to 123 - 135 N•m (90 - 100 ft-lb) torque.
506 of 692 60-110-4

Lower operator cab. (See Lowering on Page 10-30-2.)

1
Perform the BICS™ inspection procedure. (See
Inspecting The BICS™ (Engine STOPPED - Key ON) on
Page 60-90-2.)
Inspecting
Figure 60-110-11
EM1421
2
Check the wire connections at the engine flywheel rpm
speed sensor (Item 1) [Figure 60-110-12].
NOTE: When the Traction Lock Override button is

activated, the Traction Lock Override Control
1 System will NOT engage the Traction Lock if

the engine stops.
For Flywheel rpm sensor adjustment. (See Adjusting on

Page 60-150-1.)
EM1026
Fasten the seat belt, disengage the parking brake pedal,
press the green PRESS TO OPERATE button and raise
the Seat Bar fully. Move the control levers slowly forward
Fasten the seat belt, disengage the Parking Brake button,
and backward. The Traction lock should be engaged.
press the PRESS TO OPERATE LOADER button (Item
Lower the Seat Bar. Press the green PRESS TO
1) [Figure 60-110-11] and raise the Seat Bar fully. Move
OPERATE button.
the steering levers slowly forward and backward. The
TRACTION lock (Item 2) [Figure 60-110-11] should be
Engage the parking brake pedal and move the control
engaged. Lower the Seat Bar. Press the PRESS TO
levers slowly forward and backward. The Traction Lock
OPERATE LOADER button (Item 1) [Figure 60-110-11].
should be engaged.
Engage the parking brake pedal and move the steering
levers slowly forward and backward. The TRACTION lock
should be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
button is pressed and the parking brake is
disengaged.
507 of 692 60-110-5

508 of 692
60-110-6
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
RIGHT HAND
17 18
2 1
6
10
1. Front Aux.
2. Front Aux.
11 3. Auxiliary Detent
7 6. Right Ski (Up) 3
16 7. Right Ski (Down)
10. Right Blink
11. Left Blink

16. Float (Yellow in Color)
P-24802 17. Future Function
18. Future Function P-73298
LEFT HAND
4. Left Ski (Up)

5. Left Ski (Down)
8. Future Function
9. Future Function
12. Speed Control (High)
19 20 13. Speed Control (Low)
8 9 14. Horn
15. Inching Control
(Grey in Color)
12
19. Future Function
4 20. Future Function
13 5
14
15
P-24820
P-73297
509 of 692 60-120-1

ELECTRICAL/HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart (Cont’d)
ATTACHMENT
SWITCH SOLENOID
LEFT SIDE CONTROL HARNESS RIGHT SIDE CONTROL
NUMBER NUMBER
HANDLE SWITCHES TERMINAL HANDLE SWITCHES
ACTIVATED
ACTIVATED
6
1 1 K
4
2 2 K
3 1 K 7
1
2
4 1 K, E
5 5 1 K, F
6 1 K, G
3
7 1 K, H
Attachment Harness Connector

Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader. 1
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If equipped as a dealer installed kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
* If harness terminals K and L are jumped together, switches 4 through 7 will function the same as switch 1 and 2.
* Terminal K is activated with Key switch ON.
510 of 692 60-120-2

ELECTRICAL/HYDRAULIC CONTROLS (SJC) (CONT’D)
Identification Chart (Cont’d)
Solenoid Hydraulic Wiring

S100 Number Coupler Number
1 Front 4340
Female
(Base)
2 Front 4330
Male
(Rod)
2 1
Hydraulic Control Valve
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in

at the front auxiliary block.
511 of 692 60-120-3

512 of 692
60-120-4
SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-130-2
Figure 60-130-1
1 2
2
3
1
P-76450
P16119
procedure:
procedure: Order from Bobcat Parts P/N: 7217666 - Remote Start

Tool (Service Tool) Kit
MEL1563 or 7217666 - Remote Start Tool
MEL1565 - Service Tool Harness Control Kit Includes:
MEL1566 - Service Tool Harness Communicator
(Computer Interface) 7022042 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
NOTE: Make all connections with the key switch in 6689746 - Computer Service Tool Harness
the OFF position. 6689745 - BOSS® Service Tool Harness
The Service PC (Item 1) with the Remote Start Tool (Item NOTE: Make all connections with the key switch in
2) [Figure 60-130-1]. When connected to the loader, the the OFF position.
Service PC is used to monitor, conduct diagnostics, and
upgrade software. The Service PC (Item 1) with the Remote Start Tool
(Service Tool) (Item 2) [Figure 60-130-2]. When
Connect the Service Tool Harness Communicator connected to the loader, the Service PC is used to
(MEL1566) (Item 3) [Figure 60-130-1] to the designated monitor, conduct diagnostics, and upgrade software.
serial port on the Service PC.
Connect the Remote Start Tool (Service Tool) Computer
NOTE: The recommended serial cable length should Service Tool Harness (Item 3) [Figure 60-130-2] to the
not exceed 4,57 m (15 ft). A serial cable longer designated serial port on the Service PC.
than 4,57 m (15 ft) will create a degraded
signal causing communication errors. NOTE: The recommended serial cable length should
not exceed 4,57 m (15 ft). A serial cable longer
Connect the other end to the connector on the Remote than 4,57 m (15 ft) will create a degraded
Start Tool. signal causing communication errors.
Connect the remote start tool to the loader. (See Remote Connect the other end to the connector on the Remote
Start Procedure on Page 10-60-4.) Start Tool (Service Tool).
Connect the Remote Start Tool (Service Tool) to the

loader. (See Remote Start Procedure on Page 10-61-5.)
513 of 692 60-130-1

514 of 692
60-130-2
CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, pump controller, hydrostatic pump, or
hydrostatic motor. Failure to calibrate after component
replacement can result in poor performance or reduced
life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

CONTROL VALVE ACTUATORS
preferred method of actuator and valve spool S10576
calibration.
The Lift and Tilt Calibration (SJC) provides set points to [Figure 60-140-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (SJC) should be used if reduced misaligned. Misalignment can reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting

controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Hydrostatic Pump Calibration (SJC) provides set valve spool misalignment.
points to the Drive controller to actuate the hydrostatic
controller that directs flow to a servo piston. Hydrostatic Connect the Service PC. (See SERVICE PC (LAPTOP
Pump Calibration (SJC) should be performed when a COMPUTER) on Page 60-130-1.)
desired travel path cannot be attained or replacing the
hydrostatic pump, hydrostatic motor, or controller. After If a Service PC is not available. (See Lift And Tilt
Performing a Hydrostatic Pump Calibration (SJC), Calibration (SJC) on Page 60-140-3.)
Steering Drift Compensation can be used to fine tune the
hydrostatic pump control. NOTE: Warm the hydraulic oil to room temperature
22°C (72°F), stop the engine and clear all
For more information on Steering Drift Compensation. active service codes before running the test.
(See STEERING DRIFT COMPENSATION on Page 60-
141-1.) Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the test
NOTE: The Actuator Test is the only test that uses a will be performed and the results can be viewed on the
Service PC. The Lift and Tilt Calibration (SJC) Service PC (Laptop) monitor.
does not need to be performed if the Actuator
Testing is being performed with the Service
PC. The Hydrostatic Pump Calibration does
not need to be performed with the Actuator
Test or Lift and Tilt Calibration (SJC).
515 of 692 60-140-1

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-140-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause can be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
The pin can be too large. Oversized pins exceeding 6,30
• Actuator did not fully extend/retract. During the test, mm (0.248 in) in diameter should be replaced.
the spool was not able to fully stroke in both
directions. If the Actuator Test failed due to a slow return to neutral
after checking the probable causes in Column 1 [Figure
• Actuator out of neutral. The spool did not return to the 60-140-2], check the following probable causes in
neutral window during the test. Column 2 [Figure 60-140-2].

NOTE: A time out will occur if the test cannot be • Contamination in the spool.
completed within 8 seconds. If this happens,
retry the test. • The spool end cap can be defective or the centering
spring can be broken. Inspect the end cap and the
Figure 60-140-2 centering spring, replace if necessary.
Run Actuator Test
• The wire harness or connectors can have an
intermittent short. Check the connections and wire
Pass Fail harnesses.
Retest With Warm Hydraulic Oil • The controller can be defective, replace the controller.
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
If the initial Actuator Test results in a fail mode due to a

slow return to neutral, follow the troubleshooting tree to
pinpoint the probable cause [Figure 60-140-2].
516 of 692 60-140-2

CALIBRATION (CONT’D) Lift And Tilt Calibration (SJC)
Actuator Testing (Cont’d) The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
If the initial Actuator Test results in the fail mode actuator stroke (full flow) while preventing over stroke (loading) of
did not fully extend / retract, check the following. the actuator and resets the calibration points in the
controller.
• The actuator connectors can be reversed between
the lift and tilt actuator. Reverse the connectors and NOTE: The Actuator Test is the preferred method to
rerun the Actuator Test. calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-140-1.)
• The actuator can be weak, replace the actuator.
NOTE: This calibration procedure must be followed
• The spool end cap can be defective or the centering when replacing the hydraulic control valve, lift
spring can be broken. Inspect the end cap and the or tilt actuator, or drive controller. Failure to
centering spring, replace if necessary. calibrate after component replacement can
result in poor performance or reduced life of
• Contamination in the spool. actuator(s).
If the initial Actuator Test results in the fail mode actuator Figure 60-140-3
out of neutral, check the following.
• The actuator can be defective, replace the actuator.

• The spool end cap can be defective or the centering
spring can be broken. Inspect the end cap and the
centering spring, replace if necessary.
1
• Contamination in the spool.
S35986
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern switch (Item 1) [Figure

60-140-3] in the ISO position.
517 of 692 60-140-3

CALIBRATION (CONT’D) Figure 60-140-6
Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-140-4
1
B-19874
P-76683
At the left panel, press the PRESS TO OPERATE button

P-28063 (Item 1) [Figure 60-140-6] while holding the right joystick
in position.
Move the right joystick to the forward-right corner position Release the joystick.
[Figure 60-140-4] and hold in position.

NOTE: During the calibration cycle, the system will
Figure 60-140-5 beep three times. Once the calibration is
complete code W3224 (Calibration
Performed) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
1
1
P-76601 P-76597A
With the seat bar down, turn the ignition key switch ON
(Deluxe Instrumentation Panel press RUN / ENTER)
[Figure 60-140-5].
NOTE: Do not start the engine.
The loader Control Pattern switch (Item 1) [Figure 60-

140-5] will start flashing and will continue to flash until the
calibration procedure is completed.
518 of 692 60-140-4

CALIBRATION (CONT'D) Figure 60-140-8
Hydrostatic Pump Calibration (SJC)
WARNING
Failure to use jackstands can allow the machine to 1
fall or move and cause injury or death. 1
W-2017-0286
P-76601 P-76597A
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
With the seat bar down, turn the Ignition key switch ON
Operator must be in the seat and the seat bar down. (Deluxe Instrumentation Panel press RUN / ENTER)
[Figure 60-140-8].
Figure 60-140-7
NOTE: Do not start the engine.

1
S35987
Close the cab door (If loader is equipped).
Place the loader Control Pattern switch (Item 1) [Figure

60-140-7] in the ISO position.
Verify the parking brake (Item 2) [Figure 60-140-7] is

OFF.
519 of 692 60-140-5

Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-140-9
P-76683
Press the PRESS TO OPERATE LOADER button (Item

S35987 1) [Figure 60-140-11] while holding the left joystick in
position.
The Control Pattern ISO switch (Item 1) [Figure 60-140- Three audible beeps will sound.
9] will start flashing.

Figure 60-140-12
Figure 60-140-10
B-19873
B-19873
P-26476
P-26476
Move the left joystick to the reverse-right corner position

Move the left joystick to the forward-left corner position [Figure 60-140-12] and hold in position.
[Figure 60-140-10] and hold in position.
520 of 692 60-140-6

Figure 60-140-13
P-76683
1
P-76683 1) [Figure 60-140-15].
Three audible beeps will sound.

1) [Figure 60-140-13] while holding the left joystick in Start the engine from the RUN, RUN / ENTER position.

position. DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
Three audible beeps will sound. repeated.
Figure 60-140-14 Figure 60-140-16
P-26474 S35987
Allow the left joystick to go to the neutral position [Figure The Control Pattern ISO switch (Item 1) [Figure 60-140-
60-140-14]. 16] will stop flashing, and will remain ON for the rest of
the calibration procedure.
521 of 692 60-140-7

Figure 60-140-17
B-19873
P-26482
1
Move and hold the left joystick to the forward position

S9832 [Figure 60-140-18] until the forward calibration is
completed.
Move the throttle (Item 1) [Figure 60-140-17] to high idle. Figure 60-140-19

NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key switch
OFF, lift the seat bar, or return the joystick to
1
the neutral position.
The calibration procedure will stop.
To return to calibration mode, the operator

must start the complete procedure from the
beginning.
WARNING S35272
Put jackstands under the front axles and rear corners The loader will “stair step” the speed (Item 1) [Figure 60-
of the frame before running the engine for service. 140-19] until it reaches full speed and then come to a
Failure to use jackstands can allow the machine to stop.
W-2017-0286
Continue to hold the left joystick in the forward position
until the loader wheels or tracks come to a stop and an
audible beep is heard.
Forward calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
522 of 692 60-140-8

CALIBRATION (CONT'D) There will be an audible beep and the TRACTION lights
will go out. The PRESS TO OPERATE LOADER, SEAT
Hydrostatic Pump Calibration (SJC) (Cont'd) BAR and LIFT AND TILT lights will remain on. The 75-98
error code will clear. There should be no other codes in
Figure 60-140-20 the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
neutral.
Press the PRESS TO OPERATE LOADER button. Move

the left joystick to forward position [Figure 60-140-18 on
Page 8] and check for normal forward wheel or track
rotation.
B-19873
Move the left joystick to the reverse position [Figure 60-
140-20] and check for normal reverse wheel or track
P-26483 rotation.
Stop the engine, and remove the loader from jackstands.

Move and hold the left joystick to the reverse position
[Figure 60-140-20] until the reverse calibration is The calibration procedure is completed.

completed.
After calibration is complete, use Steering Drift
Figure 60-140-21 Compensation for fine tuning or if an acceptable line of
drift cannot be achieved (See STEERING DRIFT
COMPENSATION on Page 60-141-1.).
1 If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-r10]
or [S-L10], see the electrical and hydrostatic
troubleshooting (See Troubleshooting on Page 30-10-2.)
or (See Troubleshooting on Page 60-10-8.).
S35272
The loader will “stair step” the speed (Item 1) [Figure 60-
140-21] until it reaches full speed and then come to a
stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Reverse in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
523 of 692 60-140-9

524 of 692
60-140-10
STEERING DRIFT COMPENSATION Operation
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to activate the BICS™.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
• To compensate for normal variations such as tire 3. Place joysticks in neutral position.
inflation pressure, track tension, tire wear and track
wear. 4. Start the engine.
• Using side shift attachments such as trenchers, 5. Press the PRESS TO OPERATE LOADER button.
planers and silt fence installers.
6. Current drive response setting will be displayed briefly
• Driving on uneven terrain such as crowned road in the data display.
surfaces.
NOTE: Raising the seat bar or changing control
Figure 60-141-1 mode (ISO / H) will cause the machine to

disengage from steering drift compensation.
STEERING DRIFT COMPENSATION
The last displayed setting will remain in effect
[S-L10] [S----] [S-R10] until the STOP button is pressed or the key
switch is turned OFF.
[S-L10] [S----] [S-R10]
B-23580A
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-141-1].
525 of 692 60-141-1

STEERING DRIFT COMPENSATION (CONT’D) Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
Operation (Cont’d) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-141-2 to appear in the data display (Item 2) [Figure 60-141-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-141-3
1 2
3 4 5
P-76456F
P-76461L
P-76461N 1 2
P-76461M

Left Joystick Right Joystick
3 4
P-76456F
P-76461K
P-76461O
6 7
P-24820B P-24802B Saving The Steering Drift Compensation Setting:
The current steering drift compensation setting can be

Press and hold the PRESS TO OPERATE LOADER
saved by pressing and holding the PRESS TO OPERATE
button (Item 1) for 3 seconds to enter the drive response
LOADER button (Item 1) for 3 seconds. [SET] (Item 3)
adjustment menu. Press the PRESS TO OPERATE
will appear in the data display (Item 2) [Figure 60-141-3]
LOADER button (Item 1) again to adjust the loader
and the machine will exit from the steering drift
steering drift compensation setting. The current steering
compensation adjustment menu.
drift compensation setting will appear in the data display
(Item 2) [Figure 60-141-2].
OR
Press the upper left button (Item 6) on the left joystick to
Press the PRESS TO OPERATE LOADER button to exit
adjust the machine left. [S-L01] (Item 3) through a
from the steering drift compensation adjustment menu
maximum of [S-L10] will appear in the data display (Item
without saving the current setting. [DONE] (Item 4) will
2) [Figure 60-141-2]. The number will increase by one
appear in the data display (Item 2) [Figure 60-141-3] and
each time you press the button. The higher the number,
the upper left and upper right buttons on the left joystick
the greater the amount of steering drift compensation to
will no longer make changes to steering drift
the left. Adjustments to steering drift compensation will
compensation.
be effective immediately.
NOTE: The last displayed steering drift
compensation setting will remain in effect
until the STOP button is pressed or the key
switch is turned OFF. The machine will revert
back to the last saved setting the next time it
is started.
526 of 692 60-141-2

FLYWHEEL RPM SENSOR Figure 60-150-2
Description
The flywheel rpm sensor has a magnet located on the

end of the sensor which senses breaks between the ring
gear teeth. The sensor relays this information back to the
main Bobcat controller which registers the rpm of the
engine.
The flywheel rpm sensor is located just above the starter

on the left side of the engine.
1
Code 06-13 will occur if the main Bobcat controller loses
the signal for the flywheel rpm sensor. 2
EM1422
The inability to unlock the traction lock (brake) is a
symptom of losing the flywheel rpm sensor signal. Not
being able to read engine speed on the service tool is Turn the rpm sensor and the jam nut out from the
also a symptom of losing the flywheel rpm sensor signal flywheel. Set a clearance of 1,27 mm (0.050 in) between
the jam nut and the housing with a feeler gauge (Item 1)
Adjusting [Figure 60-150-2].
Figure 60-150-1 NOTE: New rpm sensors have a plastic tip which is

used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
Tighten the jam nut (Item 2) [Figure 60-150-2] to 16 - 23

N•m (12 - 17 ft-lb) torque, while holding the sensor from
turning.
2 1
EM1421
When installing the rpm sensor, turn the rpm sensor

(Item 1) [Figure 60-150-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 60-150-1] until it

contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the rpm sensor when the
sensor is turned back out for adjustment.
527 of 692 60-150-1

528 of 692
60-150-2
CONTROL PANEL SETUP Examples
Right Panel Setup (Deluxe Instrumentation Panel) Figure 60-160-2

Icon Identification
Figure 60-160-1
Press
TOOL / SETUP
SELECTION
EXAMPLE
BUTTONS
Press
B-16162
LOADER FEATURES
Make selection by pressing the SELECTION button

adjacent to the icon [Figure 60-160-1].
ICON DESCRIPTION

LOCK / UNLOCK: Allows machine to be Press
locked / unlocked. You must lock machine to DISPLAY OPTIONS
activate security system.
When system is unlocked, the user can press
RUN / ENTER then press START to begin
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL / SETUP: Access system options.
Use to set clock, check system warnings,
select language, set passwords, etc. Press
? HELP: Access help on current menu item. ADJUST CONTRAST
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or lock
0.0 job clock; TOOL / SETUP to set time.
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one screen.
Press
OUTLINE ARROWS: No screen available UP OR DOWN
(backward / forward). Arrow to
change
contrast
SELECTION ARROW: Use to select menu
item. Press EXIT to
NEXT Goes to the NEXT screen in series. return to
previous level
EXAMPLE: the next Active Warning screen. menu
INFO Goes to more information about attachments.
B-16163/B-24288/B-16161A/B-16166/B-16167
YES / NO Answer yes / no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.
529 of 692 60-160-1

CONTROL PANEL SETUP (CONT’D) Attachment Control Information (Deluxe
Instrumentation Panel)
Right Panel Setup (Deluxe Instrumentation Panel)
(Cont’d) The Deluxe Instrumentation Panel allows the user to view
information concerning the operation of Bobcat
More Examples attachments.
Clocks Figure 60-160-3
Press . . .
TOOL / SETUP Press
LOADER FEATURES
DISPLAY OPTIONS TOOL / SETUP
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press
Press EXIT to return to previous level menu.
LOADER FEATURES
RESET JOB CLOCK (Password required)
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK / UNLOCK to unlock.

Enter Password and press RUN / ENTER.
Press
Languages
ATTACHMENTS
Press . . .
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES Press
Select the language, press RUN / ENTER. RUN / ENTER BUTTON
Press EXIT to return to previous level menu.
on keypad
Vitals (Monitor the engine, hydraulic / hydrostatic,
electrical functions when engine is running.)
Press
UP OR DOWN
Press . . .
Arrow to
TOOL / SETUP scroll through
LOADER FEATURES. attachments
VITALS
Press SELECTION ARROW to select METRIC or
ENGLISH (M / E) readouts
Press
You can monitor real-time readouts of: the keypad number
of a switch to view
Engine Oil Pressure a description of the
Engine Coolant Temperature attachment function
Hydraulic Charge Pressure of the switch
Hydraulic Oil Temperature
System Voltage
Engine Speed B-16163/B-24288/B-16161A/B-15753A/B-15754A/B-15755A
The Deluxe Instrumentation Panel is easy to use.

Continue to set your own preferences for running / Attachments are listed alphabetically [Figure 60-160-3].
monitoring your Bobcat loader. Press the Exit button to return one screen or press the “0”
(zero) key to return to the home screen immediately.
530 of 692 60-160-2

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Figure 60-170-1
Password Setup is available on machines with a Deluxe
Instrumentation Panel.
Press TOOL / SETUP
Password Description
All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start Press OWNER UTILITIES
the engine.
For security purposes, your dealer may change the

password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password: Enter PASSWORD (owner or master)

on Keypad
then press ENTER
A permanent, randomly selected password set at the to Continue
factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Press PASSWORD UTILITIES
password.

Owner Password:
Allows for full use of the loader and to setup the

Deluxe Instrumentation Panel. There is only one Press MODIFY OWNER
owner password. It must be used to change the owner
or user passwords. Owner should change the
password as soon as possible for security of the
loader.
User Password:
Enter new OWNER
PASSWORD on Keypad
Allows starting and operating the loader; cannot then press ENTER
change password or any of the other setup features. to Continue
For the procedures to change passwords (See Changing

The Owner Password on Page 60-170-1.) (See Changing
The User Passwords on Page 60-170-2.) Re-Enter new OWNER
PASSWORD on Keypad
then press ENTER
to Continue
OWNER PASSWORD procedure

is now complete
B-16163/B-24288/B-24290/B-24291/B-16171/B-24292/B-24293/B-24294

PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
This feature allows the owner to unlock the password
Changing The User Passwords feature so that a password does not need to be used
every time the engine is started.
Figure 60-170-2
Figure 60-170-3
Press TOOL / SETUP

Press
LOCK / UNLOCK
Press OWNER UTILITIES
Enter OWNER
Enter PASSWORD (owner or PASSWORD
master) on Keypad then press on Keypad
ENTER to Continue then press ENTER
to Continue

Press PASSWORD UTILITIES
Press
Press MODIFY USER UNLOCK MACHINE
Enter USER number

on Keypad (There can be up to 8
different Users, each with their
own password)
then press ENTER to Continue
Press
EXIT
Enter USER PASSWORD
on Keypad
then press ENTER to Continue
Machine is now
UNLOCKED and
USER PASSWORD procedure can be started
is now complete. Enter without using a
another USER number password
OR
Press EXIT
B-16163/P-76075/P-76076/P-76076A/P-76077
B-16163/B-24288/B-24290/B-24291/B-16171/B-24295/B-24296/B-24297A

PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Press the RUN button to turn on the loader electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-171-2
Allows for full use of the loader. It must be used to

change the owner password.
Changing The Owner Password
Press the RUN button to turn on the loader electrical

system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.

Figure 60-171-1
1 2
P-90816B
Press the unlock key (Item 2) [Figure 60-171-2].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2 The loader can now be started without using a password.
P-90816B NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-171-1] keys for two seconds. Press the RUN button to turn on the loader electrical
system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-171-2].
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.


MAINTENANCE CLOCK This message will remain for 10 seconds before reverting
back to the previous screen and will appear for 10
Description seconds every time the machine is started until the
maintenance clock is reset.
The Maintenance Clock alerts the operator when the next
service interval is due. EXAMPLE: The Maintenance Figure 60-180-3
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.
Figure 60-180-1
1 B-16163A
3
The Deluxe Instrumentation Panel, if equipped, will
P-76461R display a wrench icon (Item 1) [Figure 60-180-3] alerting
the operator to service the machine. This icon will remain
During machine operation, a two beep alarm will sound on the display until the maintenance clock is reset.

when there are less than 10 hours until the next planned
maintenance. NOTE: Loaders equipped with a Standard Key Panel
or Keyless Start Panel will not display the
The remaining hours before maintenance is required will BobCARESM PM message or wrench icon on
appear in the data display (Item 1) for five seconds while the right panel.
the service icon (Item 3) and hourmeter icon (Item 2)
[Figure 60-180-1] flash.
NOTE: The display will show negative numbers after

counting down to zero.
The display will then revert back to the previous display

and will appear for five seconds every time the machine
is started until the maintenance clock is reset.
Figure 60-180-2
1
P-76122
The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-180-2] alerting
the operator to service the machine.
535 of 692 60-180-1

MAINTENANCE CLOCK (CONT’D) Figure 60-180-6
Setup
Figure 60-180-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-180-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-180-4] to Figure 60-180-7
view the next analyzer screen.

Figure 60-180-5
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-180-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-180-5] the information is now stored. This will
be displayed on Deluxe Instrumentation Panel equipped
loaders when the maintenance clock is less than 10
hours until next planned maintenance.
536 of 692 60-180-2

Setup (Cont’d)
Figure 60-180-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-180-10] to scroll
P-76114 through the tabs.
Figure 60-180-11
A green COMPLETE (Item 1) [Figure 60-180-8]

message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-180-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-180-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-180-11] to

view the maintenance clock screen.
Click ON/OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-180-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-180-9]. new interval. Click SET/RESET (Item 4) [Figure 60-180-
11] to reset and set the maintenance clock.
537 of 692 60-180-3

Setup (Cont’d)
Figure 60-180-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-180-14] to

P-76111 view the maintenance clock.
Figure 60-180-15
The current maintenance clock Length (Interval) and

Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-180-12].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.
P-64244A
Figure 60-180-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-180-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-180-13] to return to the

main menu.
538 of 692 60-180-4

MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-180-16
P-76455H
Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-180-16] shows the
maintenance clock.

Press and hold the information button (Item 2) for 7
seconds until [RESET] appears in the display screen
(Item 1) [Figure 60-180-16].
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-180-11] in service analyzer.
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.
539 of 692 60-180-5

540 of 692
60-180-6
BACK-UP ALARM SYSTEM Inspect the back-up alarm electrical connections (Item 1)
[Figure 60-190-2], wire harness (Item 2) [Figure 60-190-
Description 2] and back-up alarm switches (if equipped) (Item 2)
[Figure 60-190-3] for tightness and damage. Repair or
This machine can be equipped with a back-up alarm replace any damaged components.
system. The back-up alarm will sound when the operator
moves both steering levers or joystick(s) in the reverse If the back-up alarm switches require adjustment, (See
position. Slight movement of the steering levers in the Adjusting Switch Position on Page 60-190-1.)
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound. Adjusting Switch Position
Inspecting NOTE: Joystick equipped machines do not have

back-up alarm switches and cannot be
Figure 60-190-1
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound.
1 Standard Controls (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-190-3

1 1
P-76108
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-190-1]. Replace if required. 2
2
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER Switch Roller contacting Bellcrank
button. Disengage the parking brake. S35967
Move both steering levers or joystick(s) into the reverse

position. The back-up alarm must sound when all wheels Place the steering levers in the neutral position.
or both tracks are moving in reverse.
Loosen the screws (Item 1) [Figure 60-190-3] securing
The back-up alarm is located on the inside of the rear the back-up alarm switches.
door.
Position the back-up alarm switch rollers so that they just
Figure 60-190-2 make contact with bellcranks without compressing the
switch springs [Figure 60-190-3]. Torque the screws
(Item 1) [Figure 60-190-3] securing the switches to the
bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Lower the operator cab (See Lowering on Page 10-30-2.)

1 and inspect back-up alarm system for proper function.
(See Inspecting on Page 60-190-1.)
P-69346
541 of 692 60-190-1

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Standard)
WARNING
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers in the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The alarm or back-up switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.
542 of 692 60-190-2

Troubleshooting (Joystick)
WARNING
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) in the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.
543 of 692 60-190-3

BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches and cannot be
Stop the engine and open the tailgate. adjusted.
Figure 60-190-4 Standard Controls
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)
Figure 60-190-6
1
1
1
P-69346
2 2
Mark the wires for ease of assembly. Disconnect the
wires (Item 1) [Figure 60-190-4] from the alarm.

Installation: Make sure the wire harness ends do not S35968
touch the mounting bolts during assembly.
Figure 60-190-5 Place the steering levers in the neutral position.
Loosen the screws (Item 1) securing the back-up alarm

switches. Slide the switch assemblies (Item 2) [Figure
1 60-190-6] off the mounting bracket.
1
Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjusting the switches (See
Adjusting Switch Position on Page 60-190-1.) and
inspecting back-up alarm operation (See Inspecting on
Page 60-190-1.) are required.
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-190-5]. Remove the alarm from the
mounting bracket.
544 of 692 60-190-4

Switch Removal And Installation (Cont’d)
Standard Controls (Cont’d)
Figure 60-190-7
1
3
2
3
P-62917

Mark the wires for ease of assembly.
Disconnect the Orange wire from the common terminal

(Item 1) [Figure 60-190-7].
Disconnect the White wire from the normally open

terminal (Item 2) [Figure 60-190-7].
Disconnect the remaining White wires to the other switch

terminals (Item 3) [Figure 60-190-7].
Remove the switches.
545 of 692 60-190-5

546 of 692
60-190-6
ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-8
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-20
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-21
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-2
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Governor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Glow Plug - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-10
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Cylinder Bore Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6

Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Idler Gear And Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2

ENGINE INFORMATION
Description
Figure 70-10-1
P-82620
The S100 has a Kubota V1505-E2B diesel engine

[Figure 70-10-1] with a displacement of 1,50 L (91.4

in³). The engine is rated at an SAE Net 25,0 kW (33.5 hp)
and has a closed crankcase ventilation system.
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol/water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fans are driven by electric
motors. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic/hydrostatic
fluid temperature sensor.
549 of 692 70-10-1

ENGINE INFORMATION (CONT’D)
Specifications
Fuel Injection Nozzles
Opening Pressure 13734 - 14707 kPa (137 - 147 bar) (1992 - 2133 psi)
Fuel Tightness Nozzle Seat Dry Nozzle at 12748 kPa (127 bar) (1849 psi)
Fuel Injection Pump
Fuel Tightness Plunger 10 sec.: initial pressure

12,7 - 13,7 MPa (127,5 - 137,3 bar) (1849 - 1991 psi)
Allowable Limit 5 seconds 13727 kPa (137,3 bar) (1991 psi)
Injection Timing 17 - 19 degrees B.T.D.C.
High Idle 3220 rpm
Low Idle 1225-1275 rpm
Cylinder Head
Cylinder Head Surface Distortion 0,05 mm (0.002 in)

Top Clearance (Piston to Head) 0,55 - 0,70 mm (0.0217 - 0.0276 in)

Compression 28,4 - 32,3 bar (412 - 469 psi)
Allowable Limit 2255 kPa (23 bar) (327 psi)
Allowable Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake and Exhaust) 2,12 mm (0.0835 in)

O.D. of Valve Stems 6,960 - 6,975 mm (0.2741 - 0.2746 in)
I.D. of Valve Guides 7,010 - 7,025 mm (0.2760 - 0.2765 in)
Clearance Between Valve Stem and Guide 0,035 - 0,065 mm (0.0014 - 0.0025 in)
Allowable Limit 0,1 mm (0.0039 in)
Valve Clearance (Cold) 0,145 - 0,185 mm (0.00571 - 0.00728 in)
Valve Recessing (Protrusion) 0,05 mm (0.0020 in)
(Recess) 0,25 mm (0.0098 in)
Allowable Limit (Recess) 0,4 mm (0.0157 in)
Valve Seat Angle (Int.) 60 degrees
Valve Seat Angle (Exh.) 45 degrees
550 of 692 70-10-2

Specifications (Cont’d)
Valve Springs
Free Length 37 - 37,5 mm (1.457 - 1.476 in)

Fitted Length 31 mm (1.220 in)
Compress to Fitted Length 117,4 N (26.4 lbf)
Allowable Limit 100 N (22.5 lbf)
Inclination Allowable Limit 1 mm (0.039 in)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.

(Close) 36 degrees A.B.D.C.
Exhaust Valve (Open) 45 degrees B.B.D.C.
(Close) 17 degrees A.T.D.C.
Rocker Arms

O.D. of Rocker Arm Shaft 11,973 - 11,984 mm (0.4714 - 0.4718 in)
I.D. of Rocker Arm 12 - 12,018 mm (0.4724 - 0.4731 in)
Clearance Between Rocker Arm and Shaft 0,02 - 0,05 mm (0.0006 - 0.0018 in)
Camshaft
Journal O.D. 35,934 - 35,950 mm (1.4147 - 1.4153 in)

Cylinder Block Bore I.D. 36 - 36,025 mm (1.4173 - 1.4183 in)
Oil Clearance 0,05 - 0,091 mm (0.00197 - 0.00358 in)
Alignment Allowable Limit 0,01 mm (0.0004 in)
Cam Lobe Height (IN.) 28,8 mm (1.1339 in)
Allowable Limit (IN.) 28,75 mm (1.1319 in)
Cam Lobe Height (EX.) 29 mm (1.1417 in)
Allowable Limit (EX.) 28,95 mm (1.1398 in)
End Clearance 0,07 - 0,22 mm (0.0028 - 0.0087 in)
Tappet
Clearance Between Tappet and Guide 0,02 - 0,062 mm (0.0008 - 0.0024 in)
Tappet O.D. 19,959 - 19,980 mm (0.7858 - 0.7866 in)
Tappet Guide I.D. 20 - 20,021 mm (0.7874 - 0.7882 in)
551 of 692 70-10-3

Cylinders
Cylinder Bore I.D. (Standard) 78 - 78,019 mm (3.0709 - 3.0716 in)

Allowable Limit (Standard) +0,15 mm (+0.006 in)
Cylinder Bore I.D. (Oversize) 78,5 - 78,519 mm (3.0906 - 3.0913 in)
Allowable Limit (Oversize) +0,15 mm (+0.006 in)
Piston Rings
Ring Gap (Top) 0,25 - 0,40 mm (0.0098 - 0.0157 in)

Ring Gap (2nd Ring) 0,35 - 0,50 mm (0.0138 - 0.0197 in)
Ring Gap (Oil Ring) 0,20 - 0,40 mm (0.0079-0.0157 in)
Allowable Limit (All Rings) 1,25 mm (0.0492 in)
Side Clearance of Ring Groove:
2nd Ring 0,085 - 0,112 mm (0.0033 - 0.0044 in)
Oil Ring 0,02 - 0,055 mm (0.008 - 0.0021 in)

Pistons
Piston Pin Bore 22 - 22,013 mm (0.8661 - 0.8667 in)

Connecting Rods
Piston Pin O.D. 22,002 - 22,011 mm (0.8662 - 0.8666 in)

Small End Bushing I.D. 22,025 - 22,040 mm (0.8671 - 0.8677 in)
Clearance Between Piston Pin and Small End Bushing 0,014 - 0,038 mm (0.0006 - 0.0015 in)
Connecting Rod Alignment Allowable Limit 0,05 mm (0.002 in)
Oil Pump
Oil Pressure at Rated rpm 0,20 - 0,44 MPa (2,0 - 4,4 bar) (28.5 - 64 psi)
Allowable Limit 0,15 MPa (1,5 bar) (21.3 psi)
Idle Speed Allowable Limit 0,05 MPa (0,5 bar) (7 psi)
Clearance Between Inner Rotor and Outer Rotor 0,06 - 0,18 mm (0.0024 - 0.0071 in)
Clearance Between Outer Rotor and Pump Body 0,1 - 0,180 mm (0.0039 - 0.0071 in)
End Clearance Between Inner Rotor and Cover 0,025 - 0,075 mm (0.0010 - 0.0030 in)
552 of 692 70-10-4

Crankshaft
Crankshaft Alignment Allowable Limit 0,02 mm (0.0008 in)

Oil Clearance Between Journal and Bearing #1 0,034 -0,114 mm (0.0013 - 0.0045 in)
Journal O.D. #1 47,934 - 47,950 mm (1.8872 - 1.8878 in)
Bearing I.D. #1 47,984 - 48,048 mm (1.8891 - 1.8917 in)
Oil Clearance Between Journal and Bearing #2 0,034 - 0,095 mm (0.0013 - 0.0037 in)
Journal O.D. #2 47,934 - 47,950 mm (1.8872 - 1.8878 in)
Bearing I.D. #2 47,984 - 48,029 mm (1.8891 - 1.8909 in)
Oil Clearance Between Crank Pin and Bearing 0,029 - 0,091 mm (0.0011 - 0.0036 in)
Crank Pin O.D. 30,059 - 39,975 mm (1.5732 - 1.5738 in)
Crank Pin Bearing I.D. 40,004 - 40,500 mm (1.5750 - 1.5768 in)

Crankshaft Side Clearance 0,15 - 0,35 mm (0.0059 - 0.0122 in)
Timing Gear
Timing Gear Backlash:

Crank Gear - Idle Gear 0,032 - 0,115 mm (0.0013 - 0.0045 in)
Idle Gear - Cam Gear 0,036 - 0,114 mm (0.0014 - 0.0045 in)
Idle Gear - Injection Pump Gear 0,034 - 0,116 mm (0.0013 - 0.0046 in)
0.0016-0.0043 (0,042-0,109) Crank Gear - Oil Pump Gear
Clearance Between Idle Gear Shaft and Idle Gear Bushing 0,020 - 0,054 mm (0.0008 - 0.0021 in)
Idler Gear Side Clearance 0,20 - 0,51 mm (0.0079 - 0.0201 in)
Thermostat
Valve Opening Temperature 69,5 - 72,5°C (157.1 - 162.5 °F)

Valve Fully Open 85°C (185°F)
553 of 692 70-10-5

Torque Values
Kubota Metric Engine Bolts
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 to 5 N•m
(3 to 4 ft-lb)
M6 x 1.0 8 to 9 N•m 8 to 12 N•m
(6 to 7 ft-lb) (6 to 9 ft-lb)
M8 x 1.25 8 to 12 N•m 15 to 22 N•m 24 to 34 N•m
(6 to 9 ft-lb) (11 to 16 ft-lb) (18 to 25 ft-lb)
M10 x 1.25 18 to 24 N•m 30 to 41 N•m 49 to 68 N•m
M12 x 1.25 30 to 41 N•m 54 to 73 N•m 94 to 118 N•m
M14 x 1.5 49 to 68 N•m 79 to 108 N•m 157 to 186 N•m

Tightening Torques For General Use Screws, Bolts And Nuts
Grade Standard Screw and Bolt Special Screw and Bolt (7)
Nominal Unit (4)

Diameter N•m kgfm ft-lb N•m kgfm ft-lb
M6 7,9 - 9,3 0.80 - 0.95 5.8 - 6.9 9,8 - 11,3 1.00 - 1.15 7.23 - 8.32
M8 17,7 - 20,6 1.8 - 2.1 13.0 - 15.2 23,5 - 27,5 2.4 - 2.8 17.4 - 20.3
M10 39,2 - 45,1 4.0 - 4.6 28.9 - 33.3 49,0 - 55,9 5.0 - 5.7 36.2 - 41.2
M12 62,8 - 72,6 6.4 - 7.4 46.3 - 53.5 77,5 - 90,2 7.9 - 9.2 57.1 - 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening,
be sure to check out the numbers as shown below.
Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS400, S20C
7 Special screw and bolt S43C, S48C (Refined)
554 of 692 70-10-6

Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53

Start and stop 9, 10, 11

1. Battery capacity low 28. Worn valves and seat
2. Bad electrical connections 29. Broken or worn piston rings
3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores
555 of 692 70-10-7

ENGINE INFORMATION (CONT’D) Figure 70-10-1
Engine Removal And Installation
DANGER
1 1
S10509
P-90328
AVOID DEATH
Cut the four tie-straps (Item 1) [Figure 70-10-1].
Figure 70-10-2

D-1009-0409
WARNING
S10510
W-2059-0598
Disconnect the connector (Item 1) [Figure 70-10-2].

NOTE: Put jackstands under the rear and front
corners of the loader. Make sure the loader is
well supported so it will not topple over when
removing the engine or lifting the operator
cab (or lift arms). This can cause serious
injuries.

Page 10-20-1.)
Open the rear door at the back of the loader.
Remove the muffler. (See Removal And Installation on

Page 70-30-1.)
Remove the battery. (See Removal And Installation on

Page 60-20-1.)
556 of 692 70-10-8

Engine Removal And Installation (Cont’d)
Figure 70-10-3
1
2
1
S10513
1 Disconnect the stop solenoid connector (Item 1) [Figure

1 S10511 70-10-5].
Figure 70-10-6
Remove the red and black covering (Item 1) and loosen
the three nuts (Item 2) [Figure 70-10-3] to release the

wires and cables from the starter.
Figure 70-10-4
S10514
1
Release the wire from the glow plug lead by removing the
nut (Item 1) [Figure 70-10-6].
S10512
Disconnect the connector (Item 1) [Figure 70-10-4] from

rpm sensor.
Remove the bolt (Item 2) [Figure 70-10-4] to release the

two black cables from the engine.
557 of 692 70-10-9

Figure 70-10-7
1
1
S10517
2
S10515
Figure 70-10-10
Remove the bolt and nut (Item 1) [Figure 70-10-7] to

remove the cable support from the engine.

Remove the bolt (Item 2) [Figure 70-10-7] to release the
two black cables from the engine. 1
Figure 70-10-8
S10518
Remove the bolt (Item 1) [Figure 70-10-10] to release

the cable and wires from the alternator.
1 1
S10516
Remove the two bolts (Item 1) [Figure 70-10-8] to

remove the cables supports from the engine.
558 of 692 70-10-10

Figure 70-10-11
1
S10521
Remove the wire (Item 1) [Figure 70-10-13] from the

S10519 engine.
Figure 70-10-14
Remove the bolt (Item 1) [Figure 70-10-11] to remove
the cable support from the alternator.

Figure 70-10-12
1 S10522
Remove the exhaust by removing the four bolts (Item 1)

1
S10520 [Figure 70-10-14] that secure it to the engine.
Remove the black covering and remove the nut (Item 1)

[Figure 70-10-12] to release the cables from the
alternator.
Disconnect the connector (Item 2) [Figure 70-10-12]

from the alternator.
Installation: Tighten the nut (Item 1) [Figure 70-10-12]

to 13 - 17 N•m (8.75 - 12.58 ft-lb) torque.
559 of 692 70-10-11

Figure 70-10-15
1 1
S10525
2
First drain the engine coolant by opening the valve on the
S10523 back of the engine. Also open the coolant filler cap. The
engine coolant will flow through the hose (Item 1) [Figure
70-10-17] that is situated on the bottom of the engine
Remove air cleaner hose (Item 1) from the engine by storage room.
loosening the screw (Item 2) [Figure 70-10-15].

NOTE: While performing the following steps, engine
Figure 70-10-16 coolant can still be in the hoses. Make sure
you are able to catch the engine coolant in a
reservoir.
Figure 70-10-18
S10524
Drain the hydraulic reservoir.

S10526
Disconnect the cooling hose (Item 1) [Figure 70-10-18]
from the thermostat by loosening the hose clamp.
560 of 692 70-10-12

Figure 70-10-19
S10529
Disconnect the fuel return line (Item 1) [Figure 70-10-21]

S10527 from the engine by loosening the hose clamp.
NOTE: While performing the following steps, fuel can

Disconnect the cooling hose (Item 1) [Figure 70-10-19] be spilled. Make sure you are able to catch the
from the engine by loosening the hose clamp. fuel in a reservoir.

NOTE: While performing the following steps, fuel can Figure 70-10-22
still be in the lines and hoses. Make sure you
are able to catch the fuel in a reservoir.
Figure 70-10-20
1 1
S10530
Disconnect the two hoses (Item 1) [Figure 70-10-22] by

S10528 loosening the hose clamps.
Disconnect the fuel line (Item 1) [Figure 70-10-20] from

the engine by loosening the hose clamp.
561 of 692 70-10-13

Figure 70-10-23
S10533
Remove the bolt (Item 1) [Figure 70-10-25] on the side

S10531 of the engine and put the complete frame with fuel filter
and engine speed control cable aside.
Remove the bolt and nut (Item 1) [Figure 70-10-23] from Figure 70-10-26
the frame.

Figure 70-10-24
S10534
1 S10532 Disconnect the two connectors (Item 1) [Figure 70-10-

26].
Remove the two bolts (Item 1) that secure the frame to

the engine. Also remove the nut (Item 2) [Figure 70-10-
24] to release the engine speed control cable from the
engine.
Remove the complete frame with fuel filter and engine

speed control cable from the engine.
562 of 692 70-10-14

Figure 70-10-27
1
2
S10536
S4139
Remove the hose (Item 1) [Figure 70-10-29] from the

S10535
S10535 hydraulic pump by loosening the hose clamp.
Disconnect the tubeline (Item 2) [Figure 70-10-29] from

Remove the two fans by removing the eight screws (Item the hydraulic pump.
1) [Figure 70-10-27] after disconnecting the plugs.

Figure 70-10-30
Figure 70-10-28
1 1 1
S10537
S35909
S4139
S4139
Remove the tubeline (Item 1) [Figure 70-10-30] from the

If loader is equipped with SJC, skip to [Figure 70-10-33]. hydrostatic pump.
Disconnect the steering linkages from the pumps by
removing the bolts and nuts (Item 1) [Figure 70-10-28].
563 of 692 70-10-15

Figure 70-10-31
1
1
EM1003
If loader is not equipped with SJC, skip to [Figure 70-10-

S10538 41].
S4139
Disconnect the four hoses (Item 1) [Figure 70-10-33]

Remove the two hoses (Item 1) [Figure 70-10-31] from from the hydrostatic pump.
the hydrostatic pump.

Figure 70-10-34
Figure 70-10-32
S35956
S10539
S4139

Remove the hose (Item 1) [Figure 70-10-32] from the disconnect the two hoses.
hydrostatic pump.
Disconnect the six hydraulic tubelines between the lb) torque.
engine and the pump assembly.
564 of 692 70-10-16

Figure 70-10-35
1
1
3
3
2
1
2
EM1006
Disconnect the two connectors (Item 1) [Figure 70-10-

EM1004 37] from the swash plate angle sensors.
Cut the tie-straps (Item 2) and disconnect the two

Disconnect the hose (Item 1) [Figure 70-10-35] from the connectors (Item 3) [Figure 70-10-37].
hydrostatic pump.

Figure 70-10-38
Figure 70-10-36
1 1
1
2
EM1007
EM1005
Cut the tie-straps (Item 1) [Figure 70-10-38].

hydraulic pump by loosening the hose clamp. Remove the two bolts (Item 2) [Figure 70-10-38] to
disconnect the harness from the hydrostatic pump.
565 of 692 70-10-17

Figure 70-10-39
1
1
1
1
S4107
Remove the screw and nut (Item 1) [Figure 70-10-41] to

EM1008 release the engine from its foot support.
Installation: Tighten to 95 N•m (70 ft-lb) torque.

Cut the two tie-straps (Item 1) [Figure 70-10-39].
Repeat the previous step for the three other foot supports

Figure 70-10-40 (total: four foot supports: two on the front and two on the
back of the engine).
1
1
EM1009 EM1010
Disconnect the connectors (Item 1) [Figure 70-10-40]

from the hydraulic controllers.
566 of 692 70-10-18

ENGINE INFORMATION (CONT’D) NOTE: You may need to adjust the chain which
fastens to the engine a couple of times to
Engine Removal And Installation (Cont’d) reach the correct lifting position.
Figure 70-10-42 Figure 70-10-44

279,4 mm
(11”)
63,5 mm
(2.5”)
38,1 mm (1.5”) I.S. Dia.
63,5 mm (2.5”) O.S. Dia.
63,5 mm
6,35 mm (1/4”) (4) (2.5”)
38,1 mm (1.5”) Square Tubing Thick Gusset
6,35 mm (1/4”) Wall Thickness
25,4 mm
(1”) 406,4
mm (16”)
50,8 mm (2”)
25,4 mm
(1”)
25,4 mm
(1”) 45° 228,6 mm
(9”)

25,4 mm 101,6 mm (4”)
(1”)
25,4 mm
12,7 mm (1”)
(0.5”)
9,5 mm (0.375”)
Use two 3/8”x1” Bolts for Drilled and Tapered Holes S5906
S2904
A tool needs to be fabricated to use in the removal

procedure. This tool allows the engine / pump assembly Remove the engine / pump assembly from the loader
to be lifted evenly for easier removal. Use the dimensions [Figure 70-10-44].
shown in [Figure 70-10-42] to make the engine removal
tool. Figure 70-10-45
Figure 70-10-43
S4109
S2903
NOTE: After lifting the engine out of the loader, put

Install the chain on the engine as shown in [Figure 70- the engine on a safe place and make sure it is
10-43]. well supported [Figure 70-10-45].
567 of 692 70-10-19

Engine Mount Replacement

2
Figure 70-10-46 5
4
1
2 3
1
3
S4285
Installation: Tighten the mounting bolts to 95 N•m (70 ft-

5 S4284 lb) torque.
Use the following procedure to install engine mounts:
• Remove the existing mount from the engine. See

engine removal and installation for engine mount
locations.
• Replace all four engine mounts two front and two rear.
• Use the parts shown to install the new engine mounts

[Figure 70-10-46] and [Figure 70-10-47]:
• Hex Nut (Item 1).
• Engine Mount (Item 2).
• Tube Spacer (Item 3).
• Tube (Item 4).
• Mounting Bolt (Item 5).
568 of 692 70-10-20

Compression - Checking

procedure:
MEL10630 - Engine Compression Kit

MEL 1352 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs.
Figure 70-10-48

S10495
Install the correct compression adapter into the cylinder

head [Figure 70-10-48].
Connect the compression gauge [Figure 70-10-48].
Make sure the speed control lever is at low engine idle.
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200 - 300 rpm.
Compression Pressure 3730 - 4116 kPa

(37 - 41 bar)
(412 - 469 psi)
Allowable Limit 2255 kPa
(minimum) (22,5 bar)
(327 psi)
The compression must be no lower than the allowable

limit, with no more than 10% variance among cylinders.
Connect the fuel stop solenoid.
569 of 692 70-10-21

570 of 692
70-10-22
ENGINE SPEED CONTROL Figure 70-20-1
DANGER
1 1
P-48565
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic Raise the lift arms and install an approved lift arm device.
tubeline, hose, fitting, component or a part failure (See Installing on Page 10-20-1.)
• Keep out of this area when lift arms are raised Raise the operator cab. (See Raising on Page 10-30-1.)
support. Replace if damaged. Remove the two mounting screws (Item 1) [Figure 70-

D-1009-0409 20-1] from the speed control mounting bracket.
Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)

torque.
WARNING Installation: Tighten the mounting bolts (Item 2) [Figure

70-20-1] evenly until the speed control lever moves back
and forth at a comfortable tension.
the lift arms are secured by an approved lift arm Figure 70-20-2
W-2059-0598
P-4072
Pull the speed control away from the loader frame and
disconnect the speed control rod (Item 1) [Figure 70-20-
2] from the control.
Installation: Be sure to install the speed control rod in

the bottom hole of the speed control lever.
571 of 692 70-20-1

ENGINE SPEED CONTROL (CONT’D)
Figure 70-20-3
P-34156
Installation: Install the stop bracket (Item 1) [Figure 70-

20-3] in the same location. It is necessary for the front

and rear stop on the bracket to be located correctly.
Reverse the removal procedure to install the engine

speed control.
572 of 692 70-20-2

ENGINE SPEED CONTROL (SJC) Figure 70-21-3

Figure 70-21-1
P-64313
1 Disconnect the foot speed control linkage (Item 1)

[Figure 70-21-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.

S9971
Remove the two mounting bolts (Item 1) [Figure 70-21-1]

from the right side foot rest.
Remove the foot rest from the loader.
Figure 70-21-2
S9972
Remove the two screws from the mount (Item 1) [Figure

70-21-2].
Remove the rubber grommet (Item 2) [Figure 70-21-2].
Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)

torque.
573 of 692 70-21-1

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-6

1
Figure 70-21-4 2 4 4
1 3 5 3
P-34654A
The parts that go into the pivot arm (Item 1) are the bolt
P-34550 (Item 2), washers (Items 3), fiber washers (Items 4), and
spacer (Item 5) [Figure 70-21-6].
Remove the bolt and nut (Item 1) [Figure 70-21-4] from Figure 70-21-7
the hand speed control pivot arm.

Figure 70-21-5
1
1
S9973
P-34549 Remove the two screws (Item 1) [Figure 70-21-7] from

the hand speed control lever assembly.
Remove the keeper and pin (Item 1) [Figure 70-21-5] Installation: Tighten screws to 20 - 27 N•m (15 - 20 ft-lb)
that attaches the pivot arm to the speed control cable. torque.
Remove the speed control pivot arm from the loader.
574 of 692 70-21-2

ENGINE SPEED CONTROL (SJC) (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 70-21-10
Figure 70-21-8
1
1
P-64305
S9974
foot speed control assembly.
At the bottom side of the control panel, move the speed
control linkage toward the rear of the loader. Figure 70-21-11

Slide the hand speed control lever (Item 1) [Figure 70-
21-8] forward and lift, and disconnect the assembly from
the speed control rod clevis.
Figure 70-21-9
P-64305A
2
1 Remove the bushing / nut (Item 1) [Figure 70-21-11]
from the pedal lever.
S9975
Installation: When installing the hand speed control, be

sure the speed control lever and pin (Item 1) fit in the
notch (Item 2) [Figure 70-21-9] of the speed control rod
clevis.
575 of 692 70-21-3

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-14
Figure 70-21-12 1
P-34659
1
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
P-34657 the speed control.
Figure 70-21-15
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing / nut.

Remove the foot pedal lever (Item 2) and linkage rod
(Item 3) [Figure 70-21-12].
Figure 70-21-13
P-64307
1
The pivot assembly shown disassembled [Figure 70-21-

15].
NOTE: No lubrication is necessary or recommended

P-34658 on the engine speed control.
Reverse the disassembly procedure to assemble the

Remove the fiber washer (Item 1) and washer (Item 2) (SJC) speed control.
[Figure 70-21-13] from the pivot bolt.
576 of 692 70-21-4

MUFFLER Figure 70-30-2

1 1

Page 50-60-1.)
Figure 70-30-1
EM1420
1 Remove the two mounting bolts (Item 1) [Figure 70-30-2]

from the muffler.
Installation: Tighten the muffler mounting bolts to 34 -


EM1419 Remove the muffler from the loader.
Remove the exhaust pipe clamp (Item 1) [Figure 70-30-

1] from the muffler.
Disconnect the exhaust pipe from the muffler.
577 of 692 70-30-1

578 of 692
70-30-2
AIR CLEANER Figure 70-40-3
Open the rear door of the loader. 1

Figure 70-40-1
1 EM1418
Remove the two bolts (Item 1) [Figure 70-40-3] from the

air cleaner bracket.
EM1416 Installation: Tighten to 20 - 27 N•m (15 - 20 ft-lb) torque.
Remove the air cleaner and intake hose assembly.

Loosen the clamp (Item 1) [Figure 70-40-1] and remove
the hose from the engine.
NOTE: Plug the intake manifold hole to prevent any

contamination from getting into the engine.
Figure 70-40-2
EM1417
Remove the hose (Item 1) [Figure 70-40-2] of the air

filter condition indicator from the air cleaner.
579 of 692 70-40-1

580 of 692
70-40-2
ENGINE COOLING SYSTEM Figure 70-50-3
Radiator Removal And Installation

Page 50-60-1.)
2
Drain the coolant from the radiator. (See Removing And
Replacing Coolant on Page 10-90-2.) 1
Figure 70-50-1
P-82638
1 Loosen the clamp (Item 1) and disconnect the hose (Item

2) [Figure 70-50-3] from the radiator.
Figure 70-50-4
1 1

EM1410 EM1411
1
Remove the two hoses (Item 1) [Figure 70-50-1] from

the radiator by loosening the clamps.
Figure 70-50-2
S4287
1
Remove the three bolts (Item 1) [Figure 70-50-4] to
remove the overflow bottle from the top of the radiator.
P-82637
Loosen the clamp (Item 1) and disconnect the overflow

hose (Item 2) [Figure 70-50-2] from the radiator.
581 of 692 70-50-1

ENGINE COOLING SYSTEM (CONT’D) Fan Removal And Installation
Radiator Removal And Installation (Cont’d) Figure 70-50-6
Figure 70-50-5
1 1
EM1412
S4288
Disconnect the two fan electrical connectors (Item 1)
[Figure 70-50-6].
remove the engine cooler from the loader. Figure 70-50-7

2 2
2
1
1
EM1413
Remove the fans (Item 1) from the oil cooler frame by

removing the eight screws (Item 2) [Figure 70-50-7].
582 of 692 70-50-2

ENGINE COOLING SYSTEM (CONT’D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-9
Drain the radiator. (See Removing And Replacing

Coolant on Page 10-90-2.)
Remove the alternator. (See Removal And Installation on

Page 60-30-4.)
2 4
1 3
Figure 70-50-8
2 B-14859B
2
Put the water pump in a vise.
2 Remove the pulley (Item 1) and press the shaft (Item 2)

[Figure 70-50-9] out of the pulley side of the water pump.

1
P13265 Remove the seal (Item 3) and impeller (Item 4) [Figure
70-50-9].
Loosen the clamps and disconnect the hoses (Item 1) Install a new seal when assembling the water pump.
[Figure 70-50-8] from the water pump.
Remove the seven mounting bolts (Item 2) [Figure 70-

50-8] from the water pump.
NOTE: The bolts can vary in length. Keep the bolts in

their original location.
Remove the water pump from the engine.
Installation: Always use a new gasket when installing

the water pump.
583 of 692 70-50-3

ENGINE COOLING SYSTEM (CONT’D) Thermostat - Checking
Thermostat Housing Removal And Installation Figure 70-50-12
Drain the coolant. (See Removing And Replacing

Coolant on Page 10-90-2.)
Figure 70-50-10
1
1
P-37172
2
Hang the thermostats in a suitable container filled with

coolant [Figure 70-50-12].
EM1414
Heat the coolant gradually. Use a thermometer to check

the temperature when it starts to open and when it's fully
Remove the two bolts (Item 1) and remove the open.
thermostat housing (Item 2) [Figure 70-50-10].
If the thermostats do not operate correctly they must be
Figure 70-50-11 replaced.
1
2
EM1415
Remove the thermostat (Item 1) and the thermostat

housing gasket (Item 2) [Figure 70-50-11].
Installation: Make sure all gasket surfaces are clean.

Replace the gasket (Item 2) [Figure 70-50-11] before
installing the thermostat housing. Apply a liquid gasket
(Three Bond 1215 or equivalent) only at the thermostat
cover side of the gasket.
584 of 692 70-50-4

LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Figure 70-60-3
Remove the engine and hydrostatic pump assembly from

Page 70-10-8.)
The engine will have to be on an engine stand or

suspended in the air safely to remove the oil pan. 1
Figure 70-60-1
1
1
1 P13272
Remove the timing gear case cover. See [Figure 70-60-

3].
Remove the mounting bolts (Item 1) [Figure 70-60-3].

P-66843 N•m (70 - 113 in-lb) torque.
Remove the rear cover (Item 2) [Figure 70-60-3].

Remove oil pan bolts securing oil pan. Slightly tapping on
the oil pan with a soft mallet will break loose the oil pan
Figure 70-60-4
from the engine block.
Installation: Apply a liquid gasket adhesive to the oil pan

side of the oil pan gasket (Item 1) [Figure 70-60-1].
Tighten oil pan bolts to 39 - 75 N•m (29 - 33 ft-lb) torque.
Figure 70-60-2
1
1
2
P13273
Remove the oil pump rotor assembly (Item 1) [Figure 70-

60-4] and check for wear.
P-66844
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.
585 of 692 70-60-1

LUBRICATION SYSTEM (CONT’D) Figure 70-60-7
Oil Pump Inspection
Figure 70-60-5
P13273
Put a strip of plastigauge (Item 1) [Figure 70-60-7] onto

P13317 the rotor face.
Figure 70-60-8
Measure the clearance between the lobes of the inner
rotor and the outer rotor with a feeler gauge [Figure 70-

60-5].
Clearance 0,06 - 0,18 mm

(0.0024 - 0.0071 in)
Figure 70-60-6 1
P13272
Install the oil pump cover (Item 1) [Figure 70-60-8] and

tighten the bolts to 7,9 - 12,8 N•m (70 - 113 in-lb) torque.
P13316
Measure the clearance between the outer rotor and the

pump body with a feeler gauge [Figure 70-60-6].
Clearance 0,100 - 0,180 mm

(0.0039 - 0.0071 in)
586 of 692 70-60-2

LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure - Testing
Oil Pump Inspection (Cont’d) Remove the oil pressure sender.
Figure 70-60-9 Figure 70-60-10
P13273 PI-10010
Remove the cover and measure the width of the pressed Install a pressure gauge [Figure 70-60-10].
plastigauge (Item 1) [Figure 70-60-9].

Start the engine and run until it is at operating
End Clearance 0,025 - 0,075 mm temperature.
(0.0010 - 0.0030 in)
If the oil pressure is less than the allowable limit, check
the following Items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod and Mainbearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable Limit 50 kPa (0,50 bar)(7 psi)

At Rated Speed 196 - 441 kPa
(1,96 - 4,41 bar) (28 - 64 psi)
Allowable Limit 147 kPa (1,47 bar) (21 psi)
587 of 692 70-60-3

588 of 692
70-60-4
FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Solenoid - Checking Stop the engine and open the rear door.
Figure 70-70-1 Disconnect the negative (-) cable from the battery.
Figure 70-70-3
EM1408
1
S6006

Disconnect the electrical connector (Item 1) [Figure 70- Disconnect the electrical connector (Item 1) [Figure 70-
70-1] from the fuel shutoff solenoid. 70-3] from the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid. Figure 70-70-4
Figure 70-70-2
C B
A
S6007
S6673
that secure the fuel shutoff solenoid.
The reading between electrical connector terminal C
(black wire) and terminal A (red wire) must be between Remove the fuel shutoff solenoid.
approximately 15.6 ohm [Figure 70-70-2].
Reverse the above procedure to install the fuel shutoff
The reading between electrical connector terminal C solenoid.
(black wire) and terminal B (white wire) must be between
approximately 0.35 - 0.4 ohm.
589 of 692 70-70-1

Fuel Injection Pump - Checking
The injection pump contains parts which have a very

close tolerance and its operation has a direct effect on
the performance of the engine.
1
WARNING
AVOID INJURY OR DEATH 2
penetrate skin or eyes, causing serious injury or B-8235
not use your bare hand. Wear safety goggles. If fluid Connect the adapter fuel line (Item 1) to the fitting and
enters skin or eyes, get immediate medical attention connect the pressure gauge (Item 2) [Figure 70-70-5].
W-2072-EN-0909 Move the speed control lever to the high engine idle
position.

Turn the flywheel to increase the pressure. If the pressure
procedure:
cannot reach the allowable limit, replace the injection
pump assembly.
MEL 1237 - Adapter Fuel Line
MEL 1173-1 Pressure Gauge Fuel Tightness of Pump 13,73 MPa (137 bar)
Element Allowable Limit (1991 psi)
To check the discharge pressure at the fuel injection
pump, use the following procedure: With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 13,7
Disconnect a high pressure fuel line from the injection MPa (137,3 bar) (1991 psi).
pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting. Turn the flywheel back approximately 180° Keep the
flywheel at this position, and measure the time it takes
the pressure to decrease from 12,75 MPa (127 bar)
(1849 psi).
Fuel Tightness of Delivery 5 Seconds

Valve Allowable Limit
590 of 692 70-70-2

Fuel Injection Pump Removal And Installation
IMPORTANT
2
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289 1
Clean the area around the injection pump thoroughly.

S6004
Figure 70-70-6
Remove and cap the fuel inlet hose (Item 1) and the fuel
return hose (Item 2) [Figure 70-70-7] from the injection
pump vent.
1
Remove the high pressure fuel lines (Item 3) [Figure 70-
70-7] from the injection pump.

Installation: Tighten the high pressure fuel line nuts to
24 - 33 N•m (18 - 25 ft-lb) torque.
Figure 70-70-8
S6003
Disconnect the high pressure fuel lines (Item 1) [Figure 1

70-70-6] from the fuel injectors.
2
24 - 33 N•m (18 - 25 ft-lb) torque.
1
1
S6005
Remove the eight mounting bolts (Item 1) from the intake

manifold (Item 2) [Figure 70-70-8].
Remove the intake manifold from the engine.
Installation: Replace the manifold gasket if it is worn or

damaged.
591 of 692 70-70-3

Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 70-70-9
1 2
1
1 1
P-69916
1 Disconnect the starter spring (Item 1) from the thrust

lever (Item 2) [Figure 70-70-11].
P-62659
Figure 70-70-12
Remove the six mounting bolts (Item 1) [Figure 70-70-9]

from the injection pump.
3
1
Figure 70-70-10
2
2
P-69914
Align the control rack pin (Item 1) with the notch (Item 2)
and remove the pump (Item 3) [Figure 70-70-12].
1 P-69915
Remove the speed control plate (Item 1) and the

governor spring (Item 2) [Figure 70-70-10] from the
injection pump.
Installation: Apply a liquid gasket to both sides of the

solenoid cover gasket and control plate gasket.
NOTE: Be careful not to drop the governor springs

into the crankcase.
592 of 692 70-70-4

FUEL SYSTEM (CONT’D) Governor Disassembly And Assembly
Fuel Injection Pump Removal And Installation The governor serves to keep the engine speed constant
(Cont’d) by automatically adjusting the amount of fuel supplied to
the engine according to changes in the engine load.
Figure 70-70-13
Figure 70-70-14
1
3 2
4
P-69917
P-69859
Installation: Use the same number of gasket shims, or

new gasket shims with the same thickness. Remove the external snap ring (Item 1) [Figure 70-70-
14] from the governor shaft.
Installation: When installing the injection pump, insert
the control rack pin (Item 1) [Figure 70-70-12 on Page 4] NOTE: When replacing the ball bearing from the
firmly into the groove (Item 1) [Figure 70-70-13] of the governor shaft (Item 2), securely install the
fork thrust lever. ball bearing (Item 3) to the crankcase, apply
liquid adhesive (Loctite®) to the set screw
(Item 4) [Figure 70-70-14] and fasten the screw
until its tapered parts contacts the
circumferential end of the ball bearing.
593 of 692 70-70-5

FUEL SYSTEM (CONT’D) Fuel Camshaft Removal And Installation
Governor Disassembly And Assembly (Cont’d) Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Figure 70-70-15 100-1.)
4 Remove the idler gear. (See Idler Gear And Shaft

5
Figure 70-70-17
2
3 3
1
1 P-69860
1. Flyweight
2. Fork Lever Shaft

3. Maximum Torque Limitation
P-69858
4. Start Spring
5. Governor Spring
Remove the fuel camshaft stopper (Item 1) [Figure 70-
Figure 70-70-16 70-17].
Remove the fuel camshaft gear and fuel camshaft (Item 2

and 3) [Figure 70-70-17].
5
Installation: Apply a thin layer of engine oil to the fuel
2 camshaft before installation.
3
P-69861
1. For Lever Shaft

2. Fork Lever 1
3. Fork Lever 2
4. Floating Lever
5. Torque Pin
Check all the parts for wear or damage and replace as

needed.
594 of 692 70-70-6

Fuel Injection Pump - Timing
WARNING
P-55324
W-2072-EN-0909
Install a short plastic tube (Item 1) [Figure 70-70-18] in

the number one cylinder port of the injection pump. The
tube should fit securely in the port and point upward.
IMPORTANT Move the fuel lever on the injection pump to full fuel
position (or full throttle).

when removing or installing them. Turn the engine counterclockwise until fuel flows out of
I-2029-0289 the injection pumps number 1 cylinder nozzle. (Install a
tool on the crankshaft at the front of the engine to turn the
engine.)
Timing the injection pump is done by changing the
number of shims between the injection pump and the
NOTE: The fuel must flow out of the nozzle for one
injection pump mounting surface.
firing cycle before timing can be attempted.
Remove the fuel lines and injectors. (See Fuel Injector
Remove the fuel shutoff solenoid. (See Fuel Shutoff

Solenoid Removal And Installation on Page 70-70-1.)
NOTE: The flywheel is rotated counterclockwise

when standing at the flywheel end of the
engine.
595 of 692 70-70-7

Fuel Injection Pump - Timing (Cont’d)
Figure 70-70-19
P-62662
P-62667 1
P13130
2 Add or subtract shim(s) (Item 1) [Figure 70-70-20] as

needed to adjust the fuel delivery timing.
P-69918
Figure 70-70-21
Continue to turn the engine slowly (for approximately one
and three-quarter turn after fuel stops flowing from the

injection pump nozzle), until the timing mark on the side
of the flywheel (Item 1) is at the bottom edge of the timing
hole (Item 2) [Figure 70-70-19] in the flywheel housing.
Slowly turn the engine counterclockwise: as soon as fuel

starts to flow at the top of the injection pump nozzle, stop 1
turning the engine.
At this point, look at the timing mark (Item 1) (located on

the flywheel) for proper alignment. When the timing mark
is aligned with the mark in the sight hole (Item 2) [Figure (1) (3)
(2)
70-70-19] the timing is correct for the injection pump,
which is 17° - 19° B.T.D.C. P-51280
The size of shims (Item 1) [Figure 70-70-21] are

identified by a symbol on the shims:
(1) Two holes means 0,20 mm (0.0079 in) shim.

(2) One hole means 0,25 mm (0.0098 in) shim.
(3) Without hole means 0,30 mm (0.0118 in) shim.
NOTE: Increasing the thickness of the shim pack by

0,050 mm (0.0020 in) retards the injection
timing by 0.500° (0.0087 rad). Decreasing the
shim pack by 0,050 mm (0.0020 in) advances
the timing by 0.500° (0.0087 rad).
596 of 692 70-70-8

Fuel Injector Removal And Installation

1
procedure:
MEL1485 - Socket
WARNING
Diesel fuel or hydraulic fluid under pressure can S6004
Use a piece of cardboard or wood to find leaks. Do Remove the injector tubelines (Item 1) [Figure 70-70-22]
not use your bare hand. Wear safety goggles. If fluid from the fuel injector pump.
from a doctor familiar with this injury. Installation: Tighten the high pressure fuel line nuts to
W-2072-EN-0909 24 - 33 N•m (18 - 25 ft-lb) torque.

Figure 70-70-23
IMPORTANT
1
when removing or installing them.
I-2029-0289
The following are some problems caused by faulty

injectors:
- Engine is hard to start or will not start

- Rough engine operation and idle 2
- Engine will not have full power S6003
- Excessive exhaust smoke
Remove the injector tubelines (Item 1) [Figure 70-70-23]

from the injectors.
Remove the fuel return hoses (Item 2) [Figure 70-70-23]

from the fittings.

24 - 33 N•m (18 - 25 ft-lb) torque.
597 of 692 70-70-9

FUEL SYSTEM (CONT’D) Fuel Injector Nozzle Pressure - Checking
Fuel Injector Removal And Installation (Cont’d) Remove the fuel lines and injectors. (See Fuel Injector
Figure 70-70-24
WARNING
W-2072-EN-0909
B-5970

Loosen the fuel injector with a special socket (MEL-1485) procedure:
[Figure 70-70-24].

MEL 4200 - Injector Nozzle Tester
Installation: Tighten the injectors to 49 - 68 N•m (36 - 50 MEL 4201 - Injector Nozzle Tester Adapter Set
ft-lb) torque.
Figure 70-70-26
Figure 70-70-25
A-2513
B-5971
Install the injection nozzle assembly onto the nozzle

Remove the fuel injector nozzle from the engine [Figure tester (MEL 4200) [Figure 70-70-26].
70-70-25].
Operate the hand lever at a slow rate and record the
opening pressure. If the pressure is not correct, replace
the adjusting spacer.
IMPORTANT Fuel Injection Pressure 13,73 - 14,71 MPa

(137 - 147 bar)
(1991 - 2134 psi)
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284
598 of 692 70-70-10

FUEL SYSTEM (CONT’D) Nozzle Spray Condition
Fuel Injector Nozzle Pressure - Checking (Cont’d) Figure 70-70-28
Figure 70-70-27 CORRECT WRONG
3
4
5
1
6
A-2621
P-62152
Connect the injection nozzle to the nozzle tester, and
check the nozzle spraying condition is correct [Figure
1. Nozzle Holder 70-70-28]. Also note the following conditions:
2. Adjusting spacer

3. Nozzle Spring 1. Fuel does not come out the side of the nozzle.
4. Push Rod 2. Drops of fuel are not present at the nozzle.
5. Distance Piece 3. The injector has an even flow coming from the nozzle.
6. Nozzle Piece
Tighten the Nozzle Holder (Item 1) [Figure 70-70-27] to

34,3 - 39,2 N•m (25.3 - 28.9 ft-lb) torque.
Tighten the Overflow pipe nut to 20 - 24 N•m (15 - 18 ft-

lb) torque.
Tighten the Nozzle Holder Assembly to 49,0 - 68,6 N•m

NOTE: You can adjust the release pressure of the

injector nozzle by adding or removing
spacers (Item 2) from the top of the nozzle
spring (Item 3) [Figure 70-70-27] Spacers are
available in different thicknesses.
599 of 692 70-70-11

FUEL SYSTEM (CONT’D)
Valve Seat Tightness
Figure 70-70-29
A-2513

WARNING
W-2072-EN-0909
Connect the injector nozzle to the tester with the nozzle

in the down position [Figure 70-70-29].
Check for inside leakage. Operate the hand lever until the
pressure reaches 12,75 MPa (127 bar) (1849 psi). Make
a record of the pressure. Release the hand lever. Check
the pressure decrease in 10 seconds.
If any fuel leak is found, replace or repair the injection

nozzle assembly.
NOTE: Injection nozzle gasket must be replaced

when the injection nozzle is removed for
checking.
600 of 692 70-70-12

CYLINDER HEAD Figure 70-80-3
Glow Plug - Testing
Figure 70-80-1
S6013
Use an ohmmeter to check the glow plugs [Figure 70-80-

3].
S6008 Touch one probe to the end of the glow plug and the
other probe to the body of the glow plug.

Disconnect the glow plug cables and leads. The reading should be approximately 0.9 ohm. If the
resistance is infinite, the coil of the glow plug is broken. If
Remove the nut and wire harness (Item 1) [Figure 70- the resistance is 0 the glow plug is short circuited.
80-1].
Repeat the procedure for each glow plug.
Figure 70-80-2
S6009
Remove the nuts (Item 1) [Figure 70-80-2] from the top

of the glow plugs.
Remove the glow plug connecting strap (Item 2) [Figure

70-80-2].
601 of 692 70-80-1

CYLINDER HEAD (CONT’D) Valve Clearance Adjustment
Glow Plug Removal And Installation NOTE: The valve clearance must be checked and
adjusted when engine is cold.
Remove the glow plug wire harness and strap. (See Glow
Plug - Testing on Page 70-80-1.) Remove the glow plugs. (See Glow Plug Removal And
Figure 70-80-4
Remove the valve cover. (See Cylinder Head Removal
Bring number 1 piston to “TDC” (Top Dead Center).
1 Figure 70-80-6
2
1
EM1493

Loosen and remove the glow plugs (Item 1) [Figure 70-
80-4].
Installation: Tighten the glow plugs to 7,8 - 14,7 N•m (69 P-62022
- 130 in-lb) torque.
Figure 70-80-5 Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [Figure 70-80-6].
Turn the adjustment screw (Item 2) [Figure 70-80-6] until

the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
70-80-6].
If adjustments are necessary, tighten lock nut before

moving on to the next rocker arm.
S6011
Photo [Figure 70-80-5] shows the glow plug removed

from the engine. Inspect the glow plugs and replace
when necessary.
602 of 692 70-80-2

CYLINDER HEAD (CONT’D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Remove the engine. (See Engine Removal And
Figure 70-80-7
Remove the timing gearcase cover. (See Timing
0,145-0,185 MM 100-1.)
(0.0057-0.0073”)
Figure 70-80-9
A-2730A
Make sure the piston is at TDC when adjusting the 1

clearance at the valves. The correct clearance is 0,145 -

0,185 mm (0.0057 - 0.0073 in) cold clearance [Figure P-69972
70-80-7].
Figure 70-80-8 Make sure the timing marks (Item 1) [Figure 70-80-9] are
in correct alignment.
P-62023A
With No. 1 piston at TDC (compression) both the intake

and exhaust valves are up. Set both No. 1 valves, No. 2
intake valve and No. 3 exhaust valve. [Figure 70-80-8].
Rotate the flywheel 360°, No.1 piston (overlap position).

Set No. 2 exhaust valve, No. 3 intake valve and both No.
4 valves [Figure 70-80-8].
603 of 692 70-80-3

CYLINDER HEAD (CONT’D) Figure 70-80-12
Cylinder Head Removal And Installation
Figure 70-80-10
1
1
P-47245
Installation: The push rod (Item 1) must be seated in the

P-51854 tappet (Item 2) [Figure 70-80-12] correctly or the push
rods will be damaged.
Remove the valve cover nuts (Item 1) [Figure 70-80-10].
After installing the rocker arm assembly and push rods,
the valve lash must be adjusted. (See Valve Clearance
Installation: Tighten the valve cover nuts to 6,9 - 11,3

Adjustment on Page 70-80-2.)
Figure 70-80-13
Remove the valve cover and replace the gasket if
needed.
Remove the fuel injector nozzles. (See Fuel Injector 2

Remove the glow plugs. (See Glow Plug Removal And

Figure 70-80-11 1
P-47246
Remove the clamps (Item 1) and remove the hose (Item

2) [Figure 70-80-13] from the thermostat housing.
2 Remove the intake and exhaust manifolds.

2
2
B-14332
Remove the rocker arm and shaft assembly (Item 1) and

the push rod tubes (Item 2) [Figure 70-80-11].
Installation: Tighten the nuts to 22 - 27 N•m (16 - 17 ft-

lb) torque.
604 of 692 70-80-4

Cylinder Head Removal And Installation (Cont’d)
Figure 70-80-14
14 6 3 11
18 10 2 7 15
B-3643B
17 9 1 8 16
13 4 12
5
Remove the four mounting bolts at the coolant housing
P-47247 (Item 1) [Figure 70-80-16].
Remove the coolant housing from the head.

Remove the cylinder head bolts in order of #18 to #1
[Figure 70-80-14].
Figure 70-80-17

NOTE: (A) is the gearcase side, (B) is the flywheel
side.
Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence to 64 - 69 N•m (47 - 51 ft-lb)
torque.
NOTE: Re-tighten the cylinder head bolts in the

correct sequence after the engine has been
run for 30 minutes.
Figure 70-80-15
1
P-47249A
When replacing just the gasket, use a new gasket that

has the same mark (Item 1) [Figure 70-80-17] as the
original gasket.
When replacing the gasket after an engine rebuild, the

piston protrusion must be measured.
1 (See Cylinder Head Top Clearance on Page 70-80-7.).
After the gasket and cylinder head have been installed,

B-14334
turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
Remove the cylinder head from the engine block.
Installation: Always use a new head gasket and new O-

ring. Make sure the O-ring (Item 1) [Figure 70-80-15] is
seated over the dowel.
605 of 692 70-80-5

CYLINDER HEAD (CONT’D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-18 Figure 70-80-20
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-20] on the
spring [Figure 70-80-18]. cylinder head.

Figure 70-80-19 NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-20] between

the straight edge and the surface of the cylinder head.
Figure 70-80-21
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

(Item 2) [Figure 70-80-18] and [Figure 70-80-19].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 70-80-18] and [Figure 70-80-19].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-18] and [Figure 70-80-19]. and two diagonal as shown in figure [Figure 70-80-21].
The maximum distortion of the head surface is ± 0,05

mm (± 0.002 in). If the measurement exceeds the
specification, replace the cylinder head.
606 of 692 70-80-6

CYLINDER HEAD (CONT’D) Valve Guide - Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly And Assembly on Page
Figure 70-80-22 70-80-6.)
Remove the carbon from the valve guide.
2 Figure 70-80-23
1 3
P-51631
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-22] being checked at T.D.C.
B-14335

Put three pieces of 1,5 mm (0.06 in) diameter solder
(Item 2) [Figure 70-80-22] on the top of the piston. Use Measure the valve stem O.D. [Figure 70-80-23].
grease to hold them in position.
Measure the valve guide I.D. [Figure 70-80-23].
NOTE: Put the solder in position so they do not touch
the valves. Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and / or valve guide.
Turn the piston to bottom dead center.
Valve Guide I.D 7,01 - 7,025 mm
Install the cylinder head. (See Cylinder Head Removal (0.2760-0.2765 in)
Valve Stem O.D 6,960 - 6,975 mm
Turn the crankshaft until the piston exceeds T.D.C. (0.2741 - 0.2764 in)
Remove the cylinder head. Clearance Between 0,035 - 0,065 mm
Valve Stem and guide (0.0014 - 0.0025 in)
Remove the solder wire (Item 3) [Figure 70-80-22] and Allowable Limit 0,1 mm (0.0039 in)
measure it.
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0,55 - 0,7 mm (0.0217 - 0.0276 in)
607 of 692 70-80-7

CYLINDER HEAD (CONT’D) Reconditioning The Valve And Valve Seat
Valve Guide - Checking (Cont’d) Figure 70-80-26
Figure 70-80-24
225 mm (8.86 in)
20 mm 70 mm (2.76 in) 15 mm
(0.787 in) (1.77 in)
11,7 - 11,9 mm
(0.460 - 0.468 in ) 6,5 - 6,6 mm
(0.256 - 0.259 in)
5,0 mm 8,9 - 9,1 mm 20,0 mm
(0.2 in) (0.350 - 0.358 in) (0.787 in)
6,7 - 7 mm PI-9993
25,0 mm 12,5 - 12,8 mm
(0.263-0.275 in) (0.98 in) (0.490 - 0.50 in)
MC-1364
Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-26].
To remove and replace the valve guide, make the driver
tool as shown in figure [Figure 70-80-24]. Clean the valve seat and combustion chamber.

Figure 70-80-25 Figure 70-80-27
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-25]. recessing or protrusion with a depth gauge [Figure 70-
80-27].
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-25], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.
608 of 692 70-80-8

Reconditioning The Valve And Valve Seat (Cont’d) 1 2

15° Exhaust
Figure 70-80-28 30° Intake
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-30].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-28].
If the seat surface (b) is too wide, use a 30 degree cutter

(Item 2) on the intake, and a 15 degree cutter on the
Protrusion 0,05 mm (0.002 in)
exhaust to get the correct width (Item 3) [Figure 70-80-
Recessing 0,25 mm (0.0098 in) 30].
Allowable Limit (Recessing) 0,4 mm (0.016 in)
Valve Seat Width
Figure 70-80-29
Intake 2,12 mm (0.0835 in)
Exhaust 2,12 mm (0.0835 in)
Valve Seat And Face Angle
Intake 60°
Exhaust 45°
45° Exhaust
15° Exhaust 60° Intake
30° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-29].
609 of 692 70-80-9

Valve Spring
Figure 70-80-31
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-32].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the spring.
measurement is less than the allowable limit, replace the

spring [Figure 70-80-31]. Setting Length 31,0 mm (1.22 in)
Setting Load 117,4 N (26.4 lbf)
Free Length 37 - 37,5 mm (1.457 - 1.476 in)
Allowable Limit 100,0 N (22.5 lbf)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-80-31].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 1,0 mm (0.039 in)
610 of 692 70-80-10

CYLINDER HEAD (CONT’D) Rocker Arm And Shaft - Checking
Valve Tappets Figure 70-80-35
Figure 70-80-33
1
2
B-3697
P-47267
Measure the rocker arm I.D. (Item 1) [Figure 70-80-35]

Remove the valve tappets (Item 1) [Figure 70-80-33].
with an inside micrometer.
Figure 70-80-34
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-

80-35] with an outside micrometer.
If the clearance exceeds the allowable limit, replace the

bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm

and Shaft 0,016 - 0,045 mm
(0.0006 - 0.0018 in)
Allowable Limit 0,10 mm
P-47268 (0.004 in)
Rocker Arm Shaft O.D. 11,973 - 11,984 mm
Measure the O.D. of the tappet [Figure 70-80-34]. (0.4714 - 0.4718 in)
Rocker Arm I.D. 12 - 12,018 mm
Measure the ID of the tappet bore [Figure 70-80-34]. (0.4724 - 0.4731 in)

tappets.
Tappet OD 19,959 - 19,980 mm

(0.7858 - 0.7866 in)
Tappet Bore ID 20 - 20,021 mm (0.7874 - 0.7882 in)
Clearance
Between Tappet 0,02 - 0,06 mm (0.0008 - 0.0024 in)
and Tappet
Bore
Allowable limit 0,07 mm (0.0028 in)
611 of 692 70-80-11

CYLINDER HEAD (CONT’D)
Push Rod Alignment - Checking
Figure 70-80-36
P-76926
Place the push rod on V blocks [Figure 70-80-36].

Measure the push rod alignment [Figure 70-80-36].
If the push rod exceeds the allowable limit, replace the

push rod.
Push rod Allowable 0,25 mm (0.0098 in)

alignment limit
612 of 692 70-80-12

CRANKSHAFT AND PISTONS Figure 70-90-2
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

Remove the top edge from the cylinder bore with a ridge
reamer.
1
Remove the oil pan. (See Oil Pan Removal And
Turn the flywheel and put a pair of connecting rods at

bottom dead center. A-2903
Remove the connecting rod bolts.

Installation: Make sure the marks on the connecting rod
Installation: Tighten the connecting rod bolts to 44 - 49 and bearing are aligned when installing the bearing cap
N•m (33 - 36 ft-lb) torque. (Item 1) [Figure 70-90-2].
Repeat the procedure to remove the other piston /
Figure 70-90-1 connecting rod assemblies from the engine block.

Figure 70-90-3
4
1 3
5 2
7 1
PI-10013
6 P-47270
Remove the rod cap and bearing [Figure 70-90-1].
Remove the snap ring (Item 1) and piston pin (Item 2)
Use a hammer handle and push the piston / connecting [Figure 70-90-3].
rod assembly out of the cylinder bore [Figure 70-90-1].
Separate the piston (Item 3) from the connecting rod
NOTE: Make sure the pistons are marked so they will (Item 4) [Figure 70-90-3].
be returned to the same cylinder bore. Remove the oil ring (Item 5) [Figure 70-90-3].
Remove the second compression ring (Item 6) [Figure
70-90-3].
Remove the first compression ring (Item 7) [Figure 70-
90-3].
NOTE: Mark the piston (Item 3) and connecting rod
(Item 4) [Figure 70-90-3] with the same
number to ensure correct installation and
proper cylinder placement.
613 of 692 70-90-1

CRANKSHAFT AND PISTONS (CONT’D) Piston And Connecting Rod - Servicing
Piston And Connecting Rod Removal And Figure 70-90-6

Figure 70-90-4
1
P-47272
3
PI-10015 Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 70-90-6].
Installation: When installing new rings, assemble the If the measurement exceeds the allowable limit, replace

ring so the mark (Item 1) near the gap faces the top of the the piston.
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
Piston Bore I.D. 22,0 - 22,013 mm
3) [Figure 70-90-4].
(0.8661 - 0.8667 in)
Figure 70-90-5 Allowable Limit 22,03 mm (0.8673 in)
3
1
2
5
6 4
P-47271
Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in clean engine oil to 80°C (176°F) and tap the
piston pin into position. Place the piston rings so that
there are gaps every 120° (Items 3, 4, and 5) [Figure 70-
90-5] with no gap facing the piston pin in the cylinder.
NOTE: Assemble the piston to the connecting rod

with the FW mark (Item 6) facing the flywheel
side and the connecting rod mark (Item 1)
[Figure 70-90-5] facing the injection pump
side.
614 of 692 70-90-2

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-90-8
Piston And Connecting Rod - Servicing (Cont’d) 35 mm (1.38 in)

27 mm (1.063 in)
Figure 70-90-7
162 mm (6.38 in)
1 35 mm
(1.378 in)
2
27,9 - 27,95 mm
(1.098 - 1.1004 in)
25,0 - 25,01 mm
(0.984 - 0.985 in)
MC-1366
To replace the connecting rod small end bushing, make a

P-47273 driver tool as shown in figure [Figure 70-90-8].
Figure 70-90-9
Measure the O.D. of the piston pin (Item 1) [Figure 70-
90-7]

Measure the I.D. of the connecting rod small end (Item 2)
[Figure 70-90-7].
Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 22,002 - 22,011 mm

(0.8662 - 0.8666 in)
Bushing I.D. 22,025 - 22,04 mm
(0.8671 - 0.8677 in)
Oil Clearance Between 0,014 - 0,038 mm PI-10016
Piston Pin and Bushing (0.00055 - 0.00150 in)
Allowable Limit 0,15 mm (0.0059 in) Use a press and special driver tool to remove the small
end bushing [Figure 70-90-9].
Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until
it is flush [Figure 70-90-9].
615 of 692 70-90-3

Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-10
PI-10017
Remove the carbon from the ring grooves. Measure the

B-3622 clearance between the ring and groove with a feeler
gauge [Figure 70-90-11].
Install a piston ring into the lower part of the cylinder If the clearance exceeds the allowable limit, replace the
bore. Measure the ring gap with a feeler gauge [Figure ring. If the clearance still exceeds the allowable limit,

70-90-10]. replace the piston.
If the gap exceeds the allowable limit, replace the ring. Compression Rings 0,085 - 0,112 mm
(0.0033 - 0.0044 in)
Top Ring Gap 0,3 - 0,45 mm Allowable Limit 0,2 mm (0.0079 in)
(0.0118 - 0.0177 in)
Oil Ring 0,02 - 0,06 mm
Oil Ring Gap 0,25 - 0,40 mm (0.0008 - 0.0021 in)
(0.0098 - 0.0157 in)
Second Ring Gap 0,30 - 0,45 mm
(0.0118 - 0.0177 in)
616 of 692 70-90-4

CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Alignment
Cylinder Bore Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-90-12 doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-90-14
B-4066
Use a gauge to check the inside measurement of the

cylinder bore [Figure 70-90-12].

Figure 70-90-13
B-4067
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-14].
If the measurement exceeds the allowable limit, replace

the connecting rod.
Rod Alignment 0,05 mm (0.002 in)
A-2717
Measure the six points as shown in figure [Figure 70-90-

13] to find the maximum wear.
The factory specifications are:
78,0 - 78,019 mm (3.0709 - 3.0716 in)
The wear limit is: 78,5 mm (3.077 in).
If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.
617 of 692 70-90-5

Crankshaft And Bearings Removal And Installation

2
Remove the piston and connecting rod assemblies (See
Piston And Connecting Rod Removal And Installation on
Page 70-90-1.)
Figure 70-90-15
1
2 5
4
P-47276
1 Install the bearing case cover (Item 1) with the casting

mark (Item 2) [Figure 70-90-17] in the upward position.
Tighten the bolts to 9,8 - 11,3 N•m (7.2 - 8.3 ft-lb) torque.
3
Figure 70-90-18
P-47274

Mark and remove the inside screws (Item 1) first, then
remove the outside screws (Item 2) [Figure 70-90-15].
NOTE: The inside bolts are different length than the

outside bolts.
Install two screws in the bearing case cover and remove

the cover (Item 3) [Figure 70-90-15].
Remove the two gaskets (Item 4) and oil seal (Item 5)

[Figure 70-90-15] from the cover.
P-47277
Figure 70-90-16
1 Before removing the crankshaft / mainbearings, check

2 the end play. Install a dial indicator. Move the crankshaft
[Figure 70-90-18] to the flywheel side, zero the dial
indicator. Measure the end play by pulling the crankshaft
toward the gear case side.
If the measurement exceeds the allowable limit, replace

the thrust washers [Figure 70-90-18].
End Play 0,15 - 0,31 mm

(0.0059 - 0.0122 in)
P-51872
Installation: Install the gaskets (Item 1 and 2) [Figure

70-90-16] as shown.
618 of 692 70-90-6

Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 70-90-19
2
B-4092
Remove the two bearing case bolts [Figure 70-90-21].
P-47278 Remove the bearing case and bearing.
Installation: Tighten the bearing case bolts to 29,4 -

Remove the mainbearing case bolt (Item 1) [Figure 70- 34,3 N•m (21.7 - 25.3 ft-lb) torque.

90-19].
Figure 70-90-22
Installation: Align the bearing case hole (Item 2) [Figure
70-90-19] with the hole in the block. Put oil on the bolt
threads and tighten to 49 - 53,9 N•m (36.2 - 39.8 ft-lb)
torque.
Figure 70-90-20
PI-10021
Installation: When installing the mainbearing case

assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [Figure 70-90-22]. The thrust
P-47279 washers oil grooves must face outward.
Remove the crankshaft / mainbearing assembly from the

engine block [Figure 70-90-20].
NOTE: Turn the crankshaft as needed to allow the

crank pin journals to pass through the cut out
(Item 1) [Figure 70-90-20] of the engine block.
Mark the bearing case halves for correct installation.
619 of 692 70-90-7

Crankshaft And Bearings - Servicing
Figure 70-90-23
A-2716
Measure the crankpin O.D. [Figure 70-90-25].

A-2763
Calculate the oil clearance.
Put the crankshaft on V-blocks. Install a dial indicator on Crankpin Bearing I.D. 40,004 - 40,050 mm
the center journal [Figure 70-90-23]. (1.5750 - 1.5768 in)

Crankpin O.D. 39,959 - 39,975 mm
Turn the crankshaft at a slow rate to obtain the (1.5732 - 1.5738 in)
misalignment (one half of the alignment measurement).
Oil Clearance 0,029 - 0,091 mm
(0.0011 - 0.0036 in)
If the misalignment exceeds the allowable limit, replace
the crankshaft. Allowable limit 0,2 mm (0.0079 in)
Alignment 0,02 mm (0.0008 in)
Tighten the connecting rod bolts to 27 - 30 N•m (20 - 22

ft-lb) torque.
Figure 70-90-24
120
A-2727
Measure the crankpin bearing I.D. [Figure 70-90-24].
620 of 692 70-90-8

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-26 2 2
1 1 3
PI-10023
Install the sleeve guide (Item 1) and stop (Item 2) [Figure

PI-10022 70-90-27].
Heat the sleeve to approximately 150°C (300°F). Install

Check the wear on the crankshaft sleeve (Item 1) [Figure the sleeve on the crankshaft using the special driver tool
70-90-26]. (Item 3) [Figure 70-90-27].

If the wear exceeds the allowable limit or the seal leaks NOTE: The sleeve is installed with the larger
oil, replace the sleeve. chamfered surface to the front of the
crankshaft (Item 1) [Figure 70-90-27].
Wear of Sleeve 0,1 mm (0.0004 in)
The special tool set will be needed to replace the

crankshaft sleeve.
Remove the sleeve.
621 of 692 70-90-9

Figure 70-90-28
B-3618
Measure the O.D. of the crankshaft journal [Figure 70-

B-3631 90-30].
Calculate the oil clearance.

Measure the I.D. of the No. 1 crankshaft bearing [Figure
70-90-28]. If the clearance exceeds the allowable limit, replace the

crankshaft bearing.
Figure 70-90-29
Bearing 1:
Bearing I.D. 47,984 - 48,048 mm

(1.8891 - 1.8916 in)
Journal O.D. 47,934 - 47,950 mm
(1.8872 - 1.8878 in)
(0.0013 - 0.0045 in)
P-73019
NOTE: Undersize dimensions of crankshaft journal

[Figure 70-90-29].
Undersize 0,2 mm (0.008 in) 0,4 mm (0.016 in)

Dim. A 2,3 - 2,7 mm 2,3 - 2,7 mm
radius (0.0906 - radius (0.0906 -
0.1063 in radius) 0.1063 in radius)
Dim. B 1,0 - 1,5 mm dia. 1,0 - 1,5 mm dia.
(0.0394 - 0.0591 (0.0394 - 0.0591
in dia.) in dia.)
Dim. C 47,734 - 47,750 47,534 - 47,550
mm dia. (1.8793 - mm dia. (1.8714 -
1.8799 in dia.) 1.8720 in dia.)
The crankpin must be fine-finished to higher than
(0.8-S)
622 of 692 70-90-10


1. Seam 4
Figure 70-90-31 2. Bearing
3. Engine Block
Removal Tool 4. Bearing Recession
3
135 mm (5.31”)
24 mm
(0.94”)
47,30-47,50 mm
(1.863-1.870”)
72 mm
(2.80”) 2 1 2
P-48778
20 mm (0.79”)
51,20-51,40 mm
40 mm 10 mm (2.016-2.023”) Remove the front bearing with the special removal tool
(1.6”) (0.4”) MC-1367 [Figure 70-90-31].
Installation: Clean the new bearing (Item 2) and bore,

To remove the front bearing make the tool as shown in apply oil to the bearing and bore. Install the new bearing
figure [Figure 70-90-31]. with the seam (Item 1) [Figure 70-90-33] toward the

exhaust manifold side, using the installation driver tool.
Figure 70-90-32
Installation Tool Check the depth (Item 4) of the bearing (Item 2) from the
face of the engine block (Item 3) [Figure 70-90-33]. This
130 mm (5.12 in)
will ensure proper bearing alignment with the crankshaft.
20 mm
4 mm (0.8 in)
Bearing Number 1 0,0 - 0,3 mm
(0.16 in) Recession (0.0 - 0.0118 in)
64,80 - 64,90 mm
72 mm (2.551 - 2.555 in)
(2.83 in) 68 mm
(2.68 in)
20 mm (0.8 in)
40 mm 10 mm 59,80 - 59,90 mm
(2.354 - 2.358 in)
(1.57 in) (0.4 in) MC-1365
To install the front bearing make the tool as shown in

figure [Figure 70-90-32].
623 of 692 70-90-11

Figure 70-90-34
P-73020
NOTE: Undersize dimensions of crankshaft journal

PI-10025 [Figure 70-90-35].
Undersize 0,2 mm (0.008 in) 0,4 mm (0.016 in)

Clean the crankshaft journal and bearing. Put a strip of Dim. A 2,3 - 2,7 mm 2,3 - 2,7 mm
press gauge on the center journal. (0.091 - 0.106 in) (0.091 - 0.106 in)

radius radius
Install the mainbearing case halves and tighten the bolts.
Dim. B 1,0 - 1,5 mm 1,0 - 1,5 mm
Remove the bearing case halves.
(0.0394-0.0591 in) (0.0394-0.0591 in)
dia. dia.
NOTE: DO NOT turn the crankshaft with the press
gauge installed. Incorrect measurements will Dim. C 47,734-47,750 mm 47,534-47,550 mm
be obtained. (1.8793-1.8799 in) (1.8714-1.8720 in)
dia. dia.
Measure the flattened press gauge [Figure 70-90-34]. Dim. D 51,721-51,740 mm 51,521-51,540 mm
(2.0362-2.0370 in) (2.0284-2.291 in)
If the clearance exceeds the allowable limit, replace the dia. dia.
crankshaft bearing. The crankpin must be fine-finished to higher than
(0.8-S)
Crankshaft Bearing 2
Crankshaft Journal O.D. 47,934 - 47,950 mm
(1.8872 - 1.8878 in)
Bearing I.D. 47,984 - 48,029 mm
(1.8891 - 1.8909 in)
(0.0013 - 0.0037 in)
Crankshaft Bearing 3
Crankshaft Journal O.D. 51,921 - 51,940 mm
(2.0441 - 2.0449 in)
Bearing I.D. 51,974 - 52,019 mm
(2.0462 - 2.0480 in)
(0.0014 - 0.0039 in)
624 of 692 70-90-12

CAMSHAFT AND TIMING GEARS Figure 70-100-3
Timing Gearcase Cover Removal And Installation 1
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 70-70-3.)
Remove the governor fork lever. 1

1 1
Figure 70-100-1
1 1
1
P13270
1
NOTE: The bolts can vary in length. Keep the bolts in
their original location

from the timing gear case cover, and remove the cover.

P13266 Installation: Tighten the mounting bolts to 10 - 11 N•m
(88.5 - 97.4 in-lb) torque.
Remove the crankshaft pulley bolt (Item 1) [Figure 70- Clean the gasket surface of timing cover.
100-1].
Figure 70-100-4
Installation: Tighten crankshaft pulley bolt to 137 - 157
Figure 70-100-2
1
P13271
2
Remove the timing cover gasket (Item 1) [Figure 70-100-
P13268
4].
Remove the crankshaft pulley (Item 1) [Figure 70-100-2]

from the crankshaft.
Installation: When installing the crankshaft pulley on the

crankshaft, align the timing marks (Item 2) [Figure 70-
100-2].
625 of 692 70-100-1

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-7
Timing Gearcase Cover Removal And Installation

(Cont’d)
1
Figure 70-100-5
1 2 P13279
1
Installation: Install the timing gear case cover, then
1
install the crankshaft collar with the tapered side (Item 1)
P13272 [Figure 70-100-7] toward the O-ring.
Figure 70-100-8
Installation: Install four new O-rings (Item 1) and the oil

seal (Item 2) [Figure 70-100-5] into the timing gear case
cover
Figure 70-100-6 1
2
P13276
1 NOTE: The idle adjustment spring (Item 1) [Figure 70-

100-8] is located inside the timing case cover.
P13345
Be careful not to damage.
Remove the crankshaft collar (Item 1) [Figure 70-100-6]

from the crankshaft.
NOTE: The collar can stay in the gearcase cover,

when the cover is removed.

crankshaft and replace with a new O-ring.
626 of 692 70-100-2

CAMSHAFT AND TIMTING GEARS (CONT’D) Idler Gear And Shaft Removal And Installation
Timing Gears Backlash - Checking Remove the timing gearcase cover. (See Timing
When the gears are installed, check the backlash of the 100-1.)
gears.
Figure 70-100-10
Figure 70-100-9
1 2
P13269
P-47264

Remove the snap ring (Item 1) and flat washer (Item 2)
Install a dial indicator [Figure 70-100-9]. from the idler gear shaft [Figure 70-100-10].
Hold one gear while turning the other gear [Figure 70- Remove the idler gear (Item 3) [Figure 70-100-10].
100-9].
Figure 70-100-11
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear. 2
Crank Gear and Idler Gear 1 0,032 - 0,115 mm

(0.0013 - 0.0045 in)
Cam Gear and Idler Gear 1 0,036 - 0,114 mm 1
1
(0.0014 - 0.0045 in)
Injection Pump Gear and 0,034 - 0,116 mm
Idler Gear 1 (0.0013 - 0.0046 in)
Injection Pump Gear and 0,030 - 0,117 mm P13346
Governor Gear (0.0012 - 0.0046 in)
from the idler shaft.
Remove the idler shaft (Item 2) [Figure 70-100-11].
Installation: Tighten the camshaft retainer bolts to 18 -

627 of 692 70-100-3

Camshaft - Servicing
Remove the timing gearcase cover. (See Timing

100-1.)
Remove the cylinder head. (See Cylinder Head Removal

Figure 70-100-12
PI-10002B
1
Installation: Check the camshaft end play. If clearance
exceeds the allowable limit, replace the camshaft retainer
plate [Figure 70-100-13].
1 Camshaft End Play 0,07 - 0,22 mm

(0.0028 - 0.0087 in)

P13344 Figure 70-100-14
Remove the tappets from the block.
Align the holes (Item 1) [Figure 70-100-12] in the gear

on the camshaft with the mounting plate bolts.
Remove the mounting bolts from the camshaft mounting

plate.

Remove the camshaft.

P-47263
Measure the cylinder block bore in the engine block

[Figure 70-100-14].
628 of 692 70-100-4

Camshaft - Servicing (Cont’d)
Figure 70-100-15
B-5001
Measure the cam lobes at their highest point [Figure 70-

A-2761 100-16].
If the measurement is less than the allowable limit,

Measure the camshaft journal [Figure 70-100-15]. replace the camshaft.

Calculate the oil clearance. If the clearance exceeds the Cam Height of Intake 28,8 mm (1.134 in)
allowable limit, replace the camshaft. Allowable Limit 28,75 mm (1.132 in)
Cam Height of Exhaust 29 mm (1.142 in)
Cylinder Block Bore I.D. 36 - 36,025 mm
(1.4173 - 1.4183 in) Allowable Limit 28,95 mm (1.140 in)
Journal O.D. 35,934 - 35,950 mm
Figure 70-100-17
(1.4147 - 1.4153 in)
Oil Clearance of Cam- 0,05 - 0,091 mm
shaft Journal (0.00197 - 0.00358 in)
A-2760
Put the camshaft in V-blocks. Install a dial indicator

[Figure 70-100-17].
Turn the camshaft at a slow rate. If the misalignment

exceeds the allowable limit, replace the camshaft.
Camshaft Alignment Allowable Limit 0,01 mm

(0.0004 in)
629 of 692 70-100-5

Idler Gear And Shaft Servicing 26 mm
(10 in)
Figure 70-100-18
196 mm (7.72 in)
150 mm (5.91 in)
28,8 - 28,9 mm 20 mm
(1.134 - 1.137 in) (0.79 in)
25,8-25,9 mm
(1.016-1.020 in) P-62615A
To replace the idler gear bushing, make a driver tool as

P13368
shown in figure [Figure 70-100-20].
Measure the outside diameter of the idler gear shaft (Item Figure 70-100-21
1) [Figure 70-100-18].

Idler Gear Shaft 25,967 - 25,98 mm
O.D. (1.0223 - 1.0228 in)
Figure 70-100-19
1
2
PI-10004
Use a press and the driver tool, to remove the old

bushing and install the new bushing [Figure 70-100-21].
P13365
Check the inside diameter of the idler gear bushing (Item

1) [Figure 70-100-19].
Idler Gear Bushing I.D. 26,000 - 26,021 mm

(1.0236 - 1.0244 in)
Oil Clearance Between Idler 0,020 - 0,054 mm
Gear and Bushing (0.0008 - 0.0021 in)
Allowable limit 0,10 mm (0.0039 in)

bushing.
Align the oil hole in the bushing (Item 2) [Figure 70-100-

19] with oil hole in the gear, when installing the new
bushing.
630 of 692 70-100-6

FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-110-2
Remove the drive belt. (See Belt Removal And

Remove the tensioner pulley. (See Tensioner Pulley

Figure 70-110-1
1
S2900
The ring gear (Item 1) [Figure 70-110-2] on the flywheel

is an interference fit. Heat the ring gear enough to
expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.

S2901 Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
Remove the six bolts (See inset) [Figure 70-110-1] from Clean the new ring gear and heat it to a temperature of
the flywheel. 232° - 260°C (450° - 500°F).
Remove the flywheel. Install the ring gear on the flywheel and be sure the gear
is seated correctly.
Installation: Coat the threads with a thread locking
adhesive Loctite® 242 or equivalent. Tighten the bolts to
63 - 80 N•m (46.5 - 59 ft-lb) torque.
631 of 692 70-110-1

FLYWHEEL AND HOUSING (CONT’D) Figure 70-110-4
Remove the drive belt shield. (See Shield Removal And

Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-8.)
Remove the drive belt. (See Belt Removal And

Remove the drive belt tensioner pulley. (See Tensioner

Pulley Removal And Installation on Page 30-50-2.) EM1453
Remove the starter. (See Removal And Installation on

Page 60-40-2.) Install a puller in the drive pulley and remove the pulley
from the hydrostatic pump shaft [Figure 70-110-4].
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-110-1.) Installation: Install the pulley key in the shaft before
installing the drive pulley.
Figure 70-110-3

Figure 70-110-5
1 1
1
EM1452
P-48650
Remove the hydrostatic pump drive pulley mounting bolt

(Item 1) [Figure 70-110-3] and washer. Remove the two mounting bolts (Item 1) [Figure 70-110-
5] from the drive belt housing which mount the
Installation: Apply Loctite® #242 and tighten the hydrostatic pump to the housing.
mounting bolt to 24 - 26 N•m (18 - 19 ft-lb) torque.
NOTE: Machines equipped with SJC option will have (65 - 70 ft-lb) torque.
a nut securing the pump pulley instead of the
bolt (Item 1) [Figure 70-110-3]. Apply Loctite®
#242 and tighten the nut to 258 - 325 N•m (190
- 240 ft-lb) torque.
632 of 692 70-110-2

FLYWHEEL AND HOUSING (CONT’D) Figure 70-110-7
Housing Removal And Installation (Cont’d)
Figure 70-110-6 2
1 P-48648
Remove the seven mounting bolts (Item 1) [Figure 70-

P-4231A 110-7] which fasten the housing on the engine.

Remove the mounting bolt (Item 1) [Figure 70-110-6] (35 - 40 ft-lb) torque.
from engine coolant tubeline mounting bracket which is

attached to the flywheel housing. Remove the two bolts (Item 2) [Figure 70-110-7] which
fasten the housing on the engine.
Installation: Tighten the mounting bolt to 34 - 38 N•m
(25 - 28 ft-lb) torque. Installation: Tighten the mounting bolts to 82 - 88 N•m
Remove the housing.
633 of 692 70-110-3

634 of 692
70-110-4
HEATER
HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-6
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-6
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1


BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1



HEATER SYSTEM Figure 80-10-3
Description
Figure 80-10-1 1
2 3
2
N-20876
1
Control Panel: The panel (Item 1) [Figure 80-10-3] has
EM1157 two separate components.
Fan Switch: This is a four position rotary switch (Item 2)

Heater Unit: The heater (Item 1) [Figure 80-10-1] is [Figure 80-10-3]. When the Fan switch is in the off
located behind the loader cab. The unit delivers the warm position the heat valve will operate, as it is controlled by

air for heat into the cab. The unit contains the blower and the ignition power.
heater coil.
Potentiometer: The potentiometer (Item 3) [Figure 80-
Figure 80-10-2 10-3] controls the Heater Valve (Item 1) [Figure 80-10-4]
from fully Off to fully On. This can be used for defrost of
the windows and temperature control.
Figure 80-10-4
2
1
N-22092
Heater Coil: The heater coil (Item 1) [Figure 80-10-2]

supplies the warm air into the cab by passing air through
EM1159
the coil.
Heater Blower: The blower (Item 2) [Figure 80-10-2] is Heater Valve: The heater valve (Item 1) [Figure 80-10-4]
used to push air through the heater and into the cab. is used to control the amount of engine coolant that flows
to the heater coil.
637 of 692 80-10-1

638 of 692
80-10-2
REGULAR MAINTENANCE Heater Coil
Filters Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 80-20-1 Figure 80-20-3
1
1
P-48012
P-76565
The Fresh Air Filter (Item 1) [Figure 80-20-1] is located
below the rear window outside the cab. Remove the
Remove the cover screws (Item 1) [Figure 80-20-3] and
clamping knobs, filter cover and filter.
remove the cover.
Shake the filter or use low pressure air to remove dirt.
Figure 80-20-4
This can be done several times before replacement is

required. Install the filter, filter cover and clamping knobs.
1
Figure 80-20-2
P-43852A
Use low pressure air or water to remove debris from the

1 P-48005 heater coil (Item 1) [Figure 80-20-4].
Install the cover and lower the operator cab. (See

The Recirculation Filter (Item 1) [Figure 80-20-2] is
Lowering on Page 10-30-2.)
located in front of the rear window inside the cab.
Remove the clamping knobs, filter cover, and filter.
Shake the filter or use a vacuum to clean. This can be

done several times before replacement is required. Install
the filter with the arrows pointing forward (Inset) [Figure
80-20-2], install the filter cover and clamping knobs.
639 of 692 80-20-1

640 of 692
80-20-2
TROUBLESHOOTING
Blower Motor Does Not Operate
POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse / wiring. Replace fuse / repair
wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Motor.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the Fan switch. Replace Fan switch.
malfunction.
Blower Motor Operates Normally, But Air Flow Is Insufficient
POSSIBLE CAUSE INSPECTION SOLUTION

1. Air leak. Check to make sure air hoses are properly hooked to Repair or adjust.
Louvers, and air ducts.

2. Plugged cab filters. Check cab filter condition. Clean or replace filters.
641 of 692 80-30-1

TROUBLESHOOTING (CONT’D) Figure 80-30-3
Electrical System
NOTE: The key must be put in the ON position when

checking for power in circuits.
Figure 80-30-1
1 1
P-68444
Check the loader harness (Item 1) [Figure 80-30-3] for

voltage. The voltage should be 12 volt.
If there is no voltage at the wiring harness, check the

P-66829 harness for broken wires or blown fuse.

If there is voltage at the wiring harness, check the
Remove the access cover (Item 1) [Figure 80-30-1] from resistance to the blower fan at the blower fan wiring
the operator cab. connector (Item 2) [Figure 80-30-3].
Figure 80-30-2 If there is no resistance value replace the blower fan.
If there is a resistance value check the climate controls at

the control panel inside the loader cab.
Figure 80-30-4
P-68118
1
Disconnect the blower fan wiring connector (Item 1)
[Figure 80-30-2] from the loader wiring harness.
N-20876
Remove the three mount screws (Item 1) [Figure 80-30-

4] from the cab control panel.
642 of 692 80-30-2

Electrical System (Cont’d)
Figure 80-30-5
C
H
B
M
N-22288
If there is voltage at the wiring harness, check the Blower

P-28920 switch [Figure 80-30-7] for resistance.
With the switch in the OFF position, there should be zero

Remove the control panel and wiring harness from the resistance between all terminals.
cab [Figure 80-30-5].

With the switch in the 1 position, there should be
Figure 80-30-6 resistance between C terminal and the B terminal,
between the C terminal and the L terminal and also
between the B terminal and the L terminal frame [Figure
80-30-7].
1
resistance between C terminal and the B terminal,
between the C terminal and the M terminal and also
between the B and the M terminal frame [Figure 80-30-
7].

resistance between C terminal and the B terminal,
between the C terminal and the H terminal and also
between the B terminal and the H terminal frame [Figure
P-28918 80-30-7].
If any of the above resistance tests fail, replace the

Disconnect the loader wiring harness (Item 1) [Figure Blower switch.
80-30-6] from the Blower switch.
If the above resistance tests are good, check the
Check the loader harness for voltage. The voltage should potentiometer.
be 12 volt.

harness for broken wires or blown fuse.
643 of 692 80-30-3

Figure 80-30-8
A C
N-22290
If there is voltage at the wiring harness, check the

P-28920 potentiometer [Figure 80-30-10] for resistance.
The resistance should be 10 K ohm between wire

The potentiometer will affect the operation of the heater. terminal A and wire terminal C frame [Figure 80-30-10].

If heater valve does not open, or close, check the If no resistance is found replace the potentiometer.
potentiometer.
Figure 80-30-11
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-8] from the potentiometer.
Figure 80-30-9
1
N-22201
The white wire B, (Item 1) [Figure 80-30-11], on the

P-28919 potentiometer, is a resistor wire.
Check the loader harness (Item 1) [Figure 80-30-9] for

voltage. The voltage should be 12 volt.

harness for broken wires or blown fuse.
644 of 692 80-30-4

Figure 80-30-12
N-22175
1
To check the resistance of the white wire, turn the

N-22175 potentiometer control (Item 1) [Figure 80-30-14] to the
full Heater position.
To check the resistance of the white wire, turn the Figure 80-30-15
potentiometer control (Item 1) [Figure 80-30-12] to the

full A/C position.
Figure 80-30-13
A C
A C
B
N-22290
B
Check the resistance between the wire terminal A and

N-22290 wire terminal B frame [Figure 80-30-15] should be
approximately 39 K ohm.
The resistance between the wire terminal A and wire Check the resistance between the wire terminal C and
terminal B frame [Figure 80-30-13] should be wire terminal B frame [Figure 80-30-15] should be
approximately 49 K ohm. approximately 49 K ohm.
Check the resistance between the wire terminal C and If the resistance is not found replace the potentiometer.
wire terminal B frame [Figure 80-30-13] should be
approximately 39 K ohm.
645 of 692 80-30-5

TROUBLESHOOTING (CONT’D) Heater Valve Not Opening Or Closing
Engine Coolant Bypassing The Heater Valve Figure 80-30-18
Figure 80-30-16
2
1
1
N-20876
N-20876
support device. (See Installing on Page 10-20-1.) Turn the Fan switch (Item 1) to position 1. Turn the

temperature control (Item 2) [Figure 80-30-18] to the
Turn the Fan switch (Item 1) [Figure 80-30-16] to the High cold position, with the loader Ignition switch OFF.
High Speed position, with the loader Ignition switch OFF.
Figure 80-30-17 Start Procedure on Page 10-60-4.)
Figure 80-30-19
EM1160
EM1160
Start Procedure on Page 10-60-4.)
Place the remote start tool on the left fender of the
Start the loader and run at high idle, for 10 minutes. loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-19], as the key of
Check the heater hose (Item 1) [Figure 80-30-17] for the remote start tool is turned to the ON position without
temperature. starting the loader. The heater valve should rotate. Place
a mark on the heater valve shaft.
If the hose is hot, the heater valve is leaking by, and
needs to be replaced.
646 of 692 80-30-6

TROUBLESHOOTING (CONT’D)
Heater Valve Not Opening Or Closing (Cont’d)
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 2) [Figure 80-30-18]

to the High Heater position, with the loader Ignition switch
OFF.
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-19], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-2.)

Replace the heater valve.
647 of 692 80-30-7

648 of 692
80-30-8
HEATER UNIT Figure 80-40-3

Figure 80-40-1
1 EM1161
Remove the two mounting nuts (Item 1) [Figure 80-40-3]

at the right side.
Figure 80-40-4

P-66829
1
Remove the access cover (Item 1) [Figure 80-40-1] from
the operator cab.
Figure 80-40-2
EM1162
1
Remove the two mounting nuts (Item 1) [Figure 80-40-4]
at the left side.
P-68118
Disconnect the blower fan wiring connector (Item 1)

[Figure 80-40-2] from the loader wiring harness.
649 of 692 80-40-1

HEATER UNIT (CONT’D)
Figure 80-40-5
EM1159
Remove the heater hoses (Item 1) [Figure 80-40-5] from

the heater coil.

Remove the heater unit from the loader.
Reverse the removal procedure to install the heater unit.
650 of 692 80-40-2

HEATER COIL Figure 80-50-2
Figure 80-50-1
1
1
2
N-22094
Remove the two mount bolts (Item 1) [Figure 80-50-2]

EM1159 from the heater coil.
Remove the heater coil from the unit.

support device. (See Installing on Page 10-20-1.) Reverse the removal procedure to install the heater coil.

Remove the heater unit from the cab.

Remove the heater valve (Item 1) [Figure 80-50-1].

Mark the heater hoses (Item 2) [Figure 80-50-1] for

proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil to prevent coolant loss
from the system.
Remove the rear cover from the heater unit. (See Heater
Coil on Page 80-20-1.)
651 of 692 80-50-1

652 of 692
80-50-2
BLOWER FAN Figure 80-60-3

Remove the heater unit from the back of the cab. (See
Figure 80-60-1
1 1
EM1038
Remove the two mount bolts (Item 1) [Figure 80-60-3]

from the blower fan housing.
1 Remove the blower fan housing from the heater unit.
Reverse the removal procedure to install the heater fan.

EM1037

side of the evaporator / heater unit.
Figure 80-60-2
EM1036

side of the evaporator / heater unit.
Remove the grommet (Item 2) and blower fan wiring

harness (Item 3) [Figure 80-60-2] from the side of the
evaporator / heater unit.
653 of 692 80-60-1

BLOWER FAN (CONT’D) Figure 80-60-6
Figure 80-60-4
1
1 1
EM1030
2
Check the blower housing (Item 1) [Figure 80-60-6] for
EM1029 wear and replace as needed.
Figure 80-60-7
Remove the eight mount screws (Item 1) [Figure 80-60-
4] from the blower wheel covers.

Remove the blower wheel covers from the fan housings.
Remove the two mount screws (Item 2) [Figure 80-60-4]

from the fan motor mount. 1
1
Remove the fan motor mount.
Figure 80-60-5
EM1031
Remove the outside rings (Item 1) [Figure 80-60-7] from

the fan motor and blower wheels.
Inspect the end rings for wear and replace as needed

1 [Figure 80-60-7].
EM1035
Remove the screw (Item 1) [Figure 80-60-5] from the

back of the fan motor assembly.
Remove the fan motor assembly from the housing.
654 of 692 80-60-2

BLOWER FAN (CONT’D) Figure 80-60-10
Disassembly And Assembly (Cont'd) 3

1
Figure 80-60-8
1 EM1034
NOTE: Before removing blower wheels, mark their

EM1032 orientation to ensure they are assembled
back on the correct side and the fins are
facing the same direction.
Figure 80-60-9
Remove the blower wheel (Item 1), washer (Item 2) and

inside ring (Item 3) [Figure 80-60-10] from the blower fan
motor shaft.
Repeat the procedure for the other blower wheel.
EM1033
Remove the outside blower wheel clamp (Item 1) [Figure

80-60-8] and [Figure 80-60-9] from the blower wheel.
655 of 692 80-60-3

BLOWER FAN (CONT’D)
Figure 80-60-11
P-68118
The wiring code for the blower fan connector [Figure 80-
60-11] is:

Number on Connector Wire Color
1 Orange
2 Red
3 Yellow
4 Black
Reverse the removal procedure to install the wire

connector.
656 of 692 80-60-4

HEATER VALVE Figure 80-70-2

Remove the Heater Unit from under the cab and place it
across the mainframe supported by blocks. (See
Remove any tie-straps that hold the heater hoses. 1
Figure 80-70-1 P-66922
Disconnect the loader wiring harness (Item 1) [Figure

80-70-2] from the heater valve.
1

2
3 EM1159
Remove the mount bolts (Item 1) [Figure 80-70-1] from

the heater valve mount.
Remove the heater hose clamps (Items 2 and 3) [Figure

80-70-1].
Remove the heater hoses from the heater valve.
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.
657 of 692 80-70-1

HEATER VALVE (CONT'D) Figure 80-70-5
Figure 80-70-3 1
1 2
P-66925

P-66923 5] from the heater valve mount plate.
Remove the mount plate (Item 2) [Figure 80-70-5] from

Remove the three mount bolts (Item 1) [Figure 80-70-3] the heater valve bracket.
from the heater valve actuator.

Figure 80-70-6
Figure 80-70-4
1
1 1
2
2
P-66926
P-66924

Remove the actuator (Item 1) and the three mounting from the heater valve.
spacers (Item 2) [Figure 80-70-4] from the heater valve
mount plate.
658 of 692 80-70-2

SPECIFICATIONS
(S100) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-3
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
659 of 692 SPEC-01 S100 Service Manual

660 of 692 SPEC-02 S100 Service Manual

(S100) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 1270 mm (50 in) Dirt bucket and can vary with other
bucket types.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
95.3°
3306 mm
(130.2 in)
43°
2633 mm
(103.6 in)

1878 mm
(73.9 in) 390 mm
(15.4 in)
2084 mm
(82.0 in)
25° 26°
167 mm
(6.6 in) 818 mm
2263 mm (32.2 in)
(89.1 in)
2800 mm
(110.2 in) S0114A
1167 mm
(45.9 in) 1270 mm
(50.0 in)
967 mm
(38.1 in)
1731 mm
(68.2 in)
S0129A
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
661 of 692 SPEC-10-1

(S100) LOADER SPECIFICATIONS (CONT’D)
Performance
STANDARD CONTROLS SELECTABLE JOYSTICK

CONTROLS (SJC)
Rated Operating Capacity (ISO) 453 kg (1000 lb) 453 kg (1000 lb)
Tipping Load (ISO) 908 kg (2002 lb) 951 kg (2097 lb)
Operating Weight 1856 kg (4091 lb) 1932 kg (4258 lb)
SAE Breakout Force - Lift 796 kg (1754 lb) 866 kg (1908 lb)
SAE Breakout Force - Tilt 867 kg (1911 lb) 897 kg (1976 lb)
Push Force 1131 kg (2493 lb) 1131 kg (2493 lb)
Travel Speed
- Single Speed Loader 0 - 10,3 km/h (0 - 6.4 mph) 0 - 10,3 km/h (0 - 6.4 mph)
- Two-Speed Loader (Opt.) Low / High --- 0 - 14 km/h (0 - 8.7 mph)
Engine
Make / Model KUBOTA / V1505-E2B Interim Tier II

Fuel / Cooling Diesel / Liquid

Horsepower (SAE Net) 25 kW (33.5 hp) @ 3000 rpm
Torque (SAE Net) 92,9 N•m (68.5 ft-lb) @ 2200 rpm
Number of Cylinders 4
Displacement 1,498 L (94.41 in³)
Bore / Stroke 78,0 mm / 78,4 mm (3.07 in / 3.09 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge w/separate safety element
Ignition Diesel - Compression
Low Idle 1200 rpm
High Idle 3200 rpm
Air Induction Naturally Aspirated
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Drive System
Main Drive Fully hydrostatic, 4-wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors.
Final Drive #80 HS endless roller chain & sprockets in sealed chaincase with oil lubrication.
Total Engine to Wheel Reduction 40:1
Axle Size 44,7 mm (1.76 in), Heat treated
Wheel Bolts Six - 9/16 in. Wheel bolts secured to axle hubs
662 of 692 SPEC-10-2

Controls
Machine Steering Direction and speed controlled by two hand operated steering levers or optional
joystick(s).
Loader Hydraulics - Lift and Tilt Controlled by separate foot pedals or optional Selectable Joystick Control (SJC).
- Front Auxiliary (Std.) Controlled by lateral movement of the right hand steering lever or optional Right
Hand Selectable Joystick Control (SJC).
Engine Hand lever speed control, key type Start switch or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Glow Plugs automatically activated as needed by Instrument Panel.
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers or optional joystick(s).
Secondary Brake One of the hydrostatic transmissions.
Parking Brake Mechanical disc, manually operated switch on front instrument panel
Hydraulic System
Pump Engine driven, gear type

Pump Capacity 49,6 L/min (13.1 U.S. gpm) @ 3000 Engine rpm @ 91% efficiency
Filter (Hydraulic) Full flow replaceable, 3 micron synthetic media element
System Relief Valve Setting 207 bar (3000 psi)
Hydraulic Cylinders Double acting; Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter: Lift Cylinder (2) 50,8 mm (2.00 in)
Tilt Cylinder (1) 57,2 mm (2.25 in)
Rod Diameter: Lift Cylinder (2) 31,8 mm (1.25 in)
Stroke: Lift Cylinder (2) 653,5 mm (25.73 in)
Control Valve 3-Spool, open center type with spring detent on lift float
and electrically controlled auxiliary spool.
Fluid Lines SAE standard tubelines, hoses and fittings.
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 2,8 Seconds
Lower Lift Arms 1,8 Seconds
Bucket Dump 1,6 Seconds
Bucket Rollback 1,2 Seconds
663 of 692 SPEC-10-3

Electrical
Alternator Belt driven, 90 amp ventilated

Battery 12 volt, 600 cold cranking amp @ -18°C (0°F);
115 minute reserve capacity at 25 amp
Starter 12 volt; Gear Reduction Type; 2,7 kW (3.62 hp)
Instrumentation Gauges: Engine Coolant Temperature, Fuel Level.
Warning lights: Fuel Level, Seat Belt, Engine Coolant Temperature, Engine
Malfunction, Hydraulic Malfunction, General Warning.
Indicators: BICS™ Functions, Turn Signals, Engine Preheat.
Data Display: Operating Hours, Engine rpm, Speed Management Setting,
Maintenance Clock Countdown, Battery Voltage, Service Codes, Engine
Preheat Countdown, Steering Drift Compensation Setting, Drive Response
Setting.
Other: Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:

*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock,
Attachment Control Information, High-Flow / Password Lockouts, Multi-language

Display, Help Screens, Diagnostic Capability and Engine / Hydraulic Systems
Shutdown Function.
Capacities
Cooling System
Without Heater 11,0 L (11.6 qt)
With Heater 12,0 L (12.7 qt)
Fuel 45,0 L (11.9 U.S. gal)
Engine Oil W/Filter 4,5 L (4.8 qt)
Hydraulic Reservoir 13,0 L (3.4 U.S. gal)
Hydraulic / Hydrostatic System 22,0 L (5.8 U.S. gal)
(Including Reservoir)
Chaincase Reservoir 22,0 L (5.8 U.S. gal)
Coolant Recovery Bottle 4,0 L (4.3 qt)
Tires
Standard Duty 27 x 8.50 - 15, 4 ply rating

Heavy Duty 27 x 8.50 - 15, 6 ply rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
664 of 692 SPEC-10-4

TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat Company that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9 - 10 13 - 14
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 21 - 23 24 - 27
(180 - 200) (215 - 240)
0.375 34 - 38 48 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 82 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 125 - 135
(65 - 70) (90 - 100)
0.5625 125 - 135 170 - 190
(90-100) (125 - 140)
0.625 170 - 190 240 - 190
(125 - 140) (175 - 190)

0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
N•m 0.875 450 - 490 645 - 710
(ft-lb) (330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)
665 of 692 SPEC-20-1

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 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 18 - 24 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)
666 of 692 SPEC-20-2

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Tightening Torque
O-ring Face Seal Connection
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
IMPORTANT 1/4”
3/8”
9/16” - 18
11/16” - 16
18 (13)
30 (22)
When repairing hydrostatic and hydraulic systems, 1/2” 13/16” - 16 54 (40)
clean the work area before disassembly and keep all 5/8” 1” - 14 81 (60)
3/4” 1-3/16” - 12 114 (84)
damage the system. 7/8” 1-3/16” - 12 133 (98)
I-2003-0888 1” 1-7/16” - 12 160 (118)
1-1/4” 1-11/16” - 12 209 (154)
Figure SPEC-30-1
1-1/2” 2” - 12 221 (163)

B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use petroleum jelly to hold the O-ring in
position until the fittings are assembled [Figure SPEC-
30-1].
667 of 692 SPEC-30-1

HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC-30-4
Straight Thread O-ring Fitting
Figure SPEC-30-3
1
Nut Nut
Washer
Washer
O-ring
O-ring
TS-1619A
A-1852 Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts

the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-30-4].
the washer is tight against the surface [Figure SPEC-30-
3]. Use the chart [Figure SPEC-30-5] to find the correct
tightness needed. If the fitting leaks after tightening,
Tubelines And Hoses disconnect it and inspect the seat area for damage.
Replace any tubelines that are bent or flattened. They will Figure SPEC-30-5
restrict flow, which will slow hydraulic action and cause
Flare Fitting Tightening Torque
heat.
Tubeline x TORQUE
Replace hoses which show signs of wear, damage or Outside x N•m
weather cracked rubber. Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
Always use two wrenches when loosening and tightening
5/16” 1/2” - 20 23 (17)
hose or tubeline fittings.
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)
668 of 692 SPEC-30-2

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-7
(CONT’D) Port Seal and O-ring Boss
Tightening Torque
Port Seal Fitting
x TORQUE
Figure SPEC-30-6 x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
Nut Seals
To Fitting 1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)
Nut Seals
To Port
Use the following procedure to tighten the port seal
fitting:
Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.
Secondary O-ring Seal P-13008
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-30-6].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
669 of 692 SPEC-30-3

670 of 692
SPEC-30-4
HYDRAULIC / HYDROSTATIC FLUID When temperatures below -18°C (0°F) are common, the
SPECIFICATIONS loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
Specifications cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
Use Bobcat hydraulic / hydrostatic transmission fluid of fluid flow to the hydrostatic transmission pump
(P/N 6903117 - 2, 2.5 U.S. gal), (P/N 6903118 - 5 US. (indicated by TRANS light ON) can cause transmission
gal), (P/N 6903119 - 55 U.S. gal). damage in less than 60 seconds.
Figure SPEC-40-1
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI) WARNING
During cold weather (0°C [32°F] and below), do not
operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
TEMPERATURE RANGE ANTICIPATED hydrostatic system will not get enough oil at low

DURING MACHINE USE temperatures. Park the machine in an area where the
[1] VG 100; Minimum VI 130 temperature will be above -18°C (0°F) if possible.
[2] VG 46; Minimum VI 150 W-2027-0311
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
Use only recommended fluid in the hydraulic system

[Figure SPEC-40-1].
WARNING
from a physician familiar with this injury.
W-2072-0807
671 of 692 SPEC-40-1

672 of 692
SPEC-40-2
CONVERSIONS
Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart
673 of 692 SPEC-50-1

674 of 692
SPEC-50-2
ALPHABETICAL INDEX
(S100) LOADER SPECIFICATIONS CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-80-1
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-15
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 DIAGNOSTIC SERVICE CODES . . . . .60-80-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-50-1
AUXILIARY HYDRAULIC INTERLOCK VALVE DRIVE COMPONENTS . . . . . . . . . . . .40-20-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
ELECTRICAL / HYDRAULIC CONTROLS
BACK-UP ALARM SYSTEM . . . . . . . 60-190-1 (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-120-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 ELECTRICAL SYSTEM INFORMATION
BLOWER FAN . . . . . . . . . . . . . . . . . . . 80-60-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
BOBCAT CONTROLLER (ACS) (SJC) . 60-72-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-210-1
BOBCAT CONTROLLER (AUXILIARY) (SJC) ENGINE COOLING SYSTEM . . . . . . .10-90-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1 ENGINE COOLING SYSTEM . . . . . . .70-50-1
BOBCAT CONTROLLER (DRIVE) (SJC) ENGINE INFORMATION . . . . . . . . . . .70-10-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1
ENGINE LUBRICATION SYSTEM . . .10-110-1
BOBCAT CONTROLLER (GATEWAY) . 60-70-1
ENGINE SPEED CONTROL (SJC) . . .70-21-1
BOBCAT INTERLOCK CONTROL SYSTEM
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 ENGINE SPEED CONTROL . . . . . . . .70-20-1

BOB-TACH (HAND LEVER) . . . . . . . . 10-140-1 FINAL DRIVE TRANSMISSION
(CHAINCASE) . . . . . . . . . . . . . . . . . .10-130-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
BOB-TACH (POWER) BLOCK . . . . . . 20-130-1
FLYWHEEL AND HOUSING . . . . . . .70-110-1
BOB-TACH (POWER) . . . . . . . . . . . . 10-141-1
FLYWHEEL RPM SENSOR . . . . . . . .60-150-1
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
FRONT AUXILIARY HYDRAULIC COUPLER
BUCKET POSITION VALVE . . . . . . . . 20-100-1 BLOCK (SJC) . . . . . . . . . . . . . . . . . . .20-111-1
CAB DOOR (SPECIAL APPLICATIONS KIT FRONT AUXILIARY HYDRAULIC COUPLER
DOOR) . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1 BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-130-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
CALIBRATION . . . . . . . . . . . . . . . . . . 60-140-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .70-70-1
CAMSHAFT AND TIMING GEARS . . 70-100-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1
CASE DRAIN FILTER . . . . . . . . . . . . . 30-60-1 HEATER COIL . . . . . . . . . . . . . . . . . . .80-50-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . 40-30-1 HEATER SYSTEM . . . . . . . . . . . . . . . .80-10-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-30-1 HEATER UNIT . . . . . . . . . . . . . . . . . . .80-40-1
CONTROL HANDLE / LEVER (SJC) . 50-111-1 HEATER VALVE . . . . . . . . . . . . . . . . . .80-70-1
CONTROL HANDLE / LEVER (STANDARD) HYDRAULIC / HYDROSTATIC FILTERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
CONTROL PANEL . . . . . . . . . . . . . . 50-100-1 HYDRAULIC / HYDROSTATIC FLUID
CONTROL PANEL (SJC) . . . . . . . . . . 50-101-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1
CONTROL PANEL SETUP . . . . . . . . 60-160-1 HYDRAULIC CONNECTION
CONTROL PEDALS AND LINKAGES . 50-90-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-30-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-50-1 HYDRAULIC CONTROL VALVE (SJC) 20-41-1
CRANKSHAFT AND PISTONS . . . . . . 70-90-1 HYDRAULIC CONTROL VALVE . . . . . .20-40-1
CYLINDER (BOB-TACH) . . . . . . . . . . . 20-22-1 HYDRAULIC FLUID RESERVOIR . . . .20-80-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC PUMP (SJC) . . . . . . . . . .20-61-1
675 of 692 INDEX-01 S100 Service Manual

HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-220-1
HYDRAULIC SYSTEM INFORMATION 20-10-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-14
HYDRAULIC / HYDROSTATIC SYSTEM SERVICE MANUAL REVISION . . . . . . SMR-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 SERVICE PC (LAPTOP COMPUTER)
HYDROSTATIC MOTOR . . . . . . . . . . .30-20-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
HYDROSTATIC PUMP (SJC) . . . . . . . .30-41-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-40-1 SPARK ARRESTER MUFFLER . . . . 10-170-1
HYDROSTATIC SYSTEM INFORMATION STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 STEERING DRIFT COMPENSATION 60-141-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 STOPPING THE ENGINE AND LEAVING THE
LIFT ARM BYPASS CONTROL VALVE 20-50-1 LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 TIRE MAINTENANCE . . . . . . . . . . . 10-160-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 TORQUE SPECIFICATIONS FOR BOLTS
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 TOWING THE LOADER . . . . . . . . . . . 10-50-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 TRACTION LOCK . . . . . . . . . . . . . . . 60-110-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16 TRANSPORTING THE LOADER ON A
LOADER STORAGE AND RETURN TO TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-190-1 TROUBLESHOOTING . . . . . . . . . . . . 80-30-1

LUBRICATING THE LOADER . . . . . .10-150-1 WINDOWS (CAB DOOR) . . . . . . . . . 50-123-1
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1 WINDOWS (REAR) . . . . . . . . . . . . . 50-120-1
MAIN RELIEF VALVE (SJC) . . . . . . . . .20-31-1 WINDOWS (SIDE) . . . . . . . . . . . . . . 50-122-1
MAIN RELIEF VALVE . . . . . . . . . . . . . .20-30-1 WINDOWS (TOP) . . . . . . . . . . . . . . . 50-121-1
MAINTENANCE CLOCK . . . . . . . . . .60-180-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . .70-30-1
OIL COOLER . . . . . . . . . . . . . . . . . . . .20-90-1
OPERATOR CAB . . . . . . . . . . . . . . . . .10-30-1
OPERATOR CAB . . . . . . . . . . . . . . . . .50-20-1
OPERATOR SEAT (SUSPENSION) . . .50-31-1
OPERATOR SEAT . . . . . . . . . . . . . . . .50-30-1
PASSWORD SETUP (DELUXE
INSTRUMENTATION PANEL) . . . . . .60-170-1
PASSWORD SETUP (KEYLESS START
PANEL) . . . . . . . . . . . . . . . . . . . . . . . .60-171-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . .10-180-1
REAR DOOR . . . . . . . . . . . . . . . . . . . .50-70-1
REAR GRILLE . . . . . . . . . . . . . . . . . . .50-60-1
REGULAR MAINTENANCE . . . . . . . . .80-20-1
REMOTE START TOOL (SERVICE TOOL) KIT
-7217666 . . . . . . . . . . . . . . . . . . . . . . .10-61-1
REMOTE START TOOL KIT-MEL1563 .10-60-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . 1-10
SEAT BAR SENSOR . . . . . . . . . . . . .60-100-1
SEAT BAR . . . . . . . . . . . . . . . . . . . . . .50-10-1
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PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: S100 - 1

Date: 5 October 2009
Product: Bobcat Loader
Model: S100
Manual No: 6987403 (10-09)

S100 Service Manual (P/N 6987403) Dated 10-09 contains updated service information which replaces the
previous S100 Service Manual (P/N 6987403) Dated 3-09.
The following Sections are a revision to the above Service Manual.
COVER
10-70
20-31
20-41
20-61
20-111
30-41
50-70
50-101
50-131
60-10
60-71
60-72
60-73
60-120
60-140
60-190
70-21
SPEC-10
677 of 692 SMR-1 S100 Service Manual


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SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X

Date: 26 March 2010
Model: S100
Manual No: 6987403 (04-10)

The following Sections are a revision to the above Service Manual.
COVER
20-70
20-110
30-20
50-111
50-131
60-10
60-30
60-190
70-90


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SERVICE MANAGER X

Date: 7 September 2012
Model: S100
Manual No: 6987403 (09-12)



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ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL REVISION

Model: S100
Manual No: 6987403 (09-12)


ROUTE TO
ATTENTION
SERVICE MANAGER X

Model: S100
Manual No: 6987403 (09-12)



ROUTE TO
ATTENTION
SERVICE MANAGER X

Model: S100
Manual No: 6987403 (09-12)



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ATTENTION
SERVICE MANAGER X

Model: S100
Manual No: 6987403 (09-12)



ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 11 October 2012
Model: S100
Manual No: 6987403 (10-12)



Service Manual S100 Skid-Steer Loader: S/N A8ET20001 & Above

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What safety precautions are mentioned regarding servicing the loader?

What safety precautions are mentioned regarding servicing the loader?

What does the manual cover regarding maintenance procedures?

What does the manual cover regarding maintenance procedures?

Service Manual

S100 Skid-Steer Loader

S/N A8ET20001 & Above

Dealer Copy -- Not for Resale

6987403-EN (10-12) Printed in U.S.A. © Bobcat Company 2012

CORRECT CORRECT CORRECT

P-90216 B-15590 B-15591

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

B-15600 B-15601 B-6589

3 of 692 1-1 S100 Service Manual

4 of 692 1-2 S100 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 692 1-3 S100 Service Manual

6 of 692 1-4 S100 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Dealer Copy -- Not for Resale

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7 of 692 1-5 S100 Service Manual

8 of 692 1-6 S100 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach™ wedges and

Dealer Copy -- Not for Resale

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

Dealer Copy -- Not for Resale

22. Check for any field

The Bobcat loader is highly maneuverable and compact.

The Bobcat loader has an internal combustion engine

The dealer explains the capabilities and restrictions of

Dealer Copy -- Not for Resale

The following publications and training materials provide

• The Delivery Report is used to assure that complete

• The Operation & Maintenance Manual delivered with

• Machine signs (decals) instruct on the safe operation

• An Operator’s Handbook is fastened to the operator

Dealer Copy -- Not for Resale

The Bobcat loader and attachment must be in good

Avoid Silica Dust

The machine and some attachments have components

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