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Manual
S/N 524611001 & Above
S/N 524711001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902680 (6-12) Printed in U.S.A. © Bobcat Company 2006
1 of 638
2 of 638
Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & M aintenance 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-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
3 of 638
4 of 638
Dealer Copy -- Not for Resale
ALPHABETICAL INDEX
5 of 638
ALPHABETICAL INDEX (CONT’D)
RADIATOR...............................................................70-
01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START.....................................................10-01
RPM SENSOR.........................................................70-01
TIRE MAINTENANCE..............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS ....... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ............................10-01
TROUBLESHOOTING.............................................70-01
6 of 638
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HEATER
SPECIFICATIONS
SPECIFICATIONS
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.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct fu nction of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
SI SSL-0206 SM
SI SSL-0206 SM
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of hi gh temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Figure 2
1
P-48387
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
Figure 4
B-16315
FRONT
OPERATOR SEAT LIGHTS
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDERS FRONT AUXILIARY
QUICK COUPLERS
STEPS
✝ BUCKET B-22498
● OPERATOR CAB
(ROPS / FOPS) LIFT ARM
SUPPORT
◆ REAR AUXILIARY DEVICE
QUICK COUPLERS
LIFT ARM
REAR
GRILL LIFT
CYLINDER
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT B-22499
✽ TIRES
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
Procedure
Figure 10-10-1
P-31849
Figure 10-10-3
WARNING
Put the floor jack under the front of the loader [Figure 10-
WARNING 10-3].
Lift the front of the lo ader and put jack stands under the
Put jack stands under the front axles and rear
axle tubes [Figure 10-10-3].
corners of t he frame before running the engine for
service. Failure to use jack stands can allow the
NOTE: Make sure the jack stands do not touch the
machine to fall or move and cause injury or death.
tires. Make sure tires clear floor or any
W-2017-0286
obstacles.
1
2
N-20525
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the seat bar and move pedals until both pedals
lock.
Figure 10-20-5
1 2
N-20524
Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [Figure 10-20-3].
Install pin (Item 1) [Figure 10-20-3] into the rear of the lift Raise the support device into storage position and insert
arm support device below the cylinder rod. pin (Item 1) through lift arm support device (Item 2)
[Figure 10-20-5] and bracket. Connect spring to pin.
Removing The Lift Arm Support Device
Remove jack stands.
Figure 10-20-4
N-20523
Description
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299
Figure 10-30-2
N-20120 N-20608A
N-20520 N-20519
Always stop the engine before raising or lowering the
cab.
Loosen the nut (both sides) at th e front corners of th e
operator cab [Figure 10-30-2]. NOTE: Make sure the seat bar is fully raised or
Figure 10-30-5
N-20608A
Emergency Exit
Figure 10-30-6
N-20171
Pull on the tag on the top of the rear window to remove Figure 10-30-9
the rubber cord [Figure 10-30-6].
Figure 10-30-7
X
P-30255
N-20606 Push the window out with your foot [Figure 10-30-9] at
any corner of the window.
Push the rear window out of the rear of the operator cab. Exit through the front door.
Procedure
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
N-19048 N-19073
Figure 10-40-1
Procedure
Figure 10-50-1
1
1
N-18409
Procedure
Figure 10-60-1
P-28823
P-28793
Procedure (Cont'd)
WARNING
Figure 10-60-4
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Sw itch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
1 service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-5
P-28806
N-20861
Procedure (Cont'd)
Figure 10-60-6 1
2
3 1
P-43215
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
■ Or every 12 months.
Checking
Figure 10-80-1
1
2
N-18409
Replace the inner filter every third time the outer filter is
replaced or as indicated. (See Replacing Filter
Element(s) on Page 10-80-2.)
OUTER FILTER
Figure 10-80-3
1 P-43240
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
P-43239
INNER FILTER
Figure 10-80-6
1 P-43242
Check the cooling system every day to prevent over- Figure 10-90-1
heating, loss of performance or engine damage.
EARLY MODELS
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
P-48494
P-54001
Open the rear door and raise the rear grill (remove the
rear grill on later style machines).
EARLY MODELS
P-48393
P-48495
Open the rear door.
Figure 10-90-4 Remove the c over from the c oolant recovery tank (Item
LATER MODELS 1) [Figure 10-90-5]. Check the coolant level. The coolant
Figure 10-90-6
LATER MODELS
MAX
MIN
MAX
P-45106
P-54003
Raise the oil cooler. Clean the top of the radiator [Figure
10-90-3] & [Figure 10-90-4].
Lower the oil cooler. Open the rear door and remove the rear grill.
Check cooling system for leaks. Check the coolant level [Figure 10-90-6]. The level
marks are on the outside of the tank. The coolant level
Lower the rear grill (reinstall the r ear grill on la ter style must be between the MIN and MAX marks on the coolant
machines) and close the rear door. recovery tank when the engine is cold.
Reinstall the rear grill and close the rear door before
operating the loader.
WARNING
IMPORTANT Do not remove radiator cap when the engine is hot.
You can be seriously burned.
AVOID ENGINE DAMAGE W-2070-1285
Always use the correct ratio of water to antifreeze.
Figure 10-90-7
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine EARLY MODELS
damage.
Figure 10-90-8
LATER MODELS
P-54001
Figure 10-90-9 Lower the r ear grill and close the rear door (install the
rear grill on later style machines).
1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
After all the coolant is removed, close the drain valve and
remove the hose.
Remove the cover from the coolant recovery tank. Fill the
tank until it i s between the MIN and MAX marks on th e
coolant recovery tank.
Fuel Specifications
WRONG
WARNING
WARNING
Always clean up spilled fuel or oil. Keep heat, flames, B-15602
Install and tighten the fue l fill cap (Item 1) [Figure 10-
100-1].
Fuel Filter
Figure 10-100-3
P-48388
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100- 3.)
After replacing the filter element or when the fuel tank Start the engine.
has run out of fuel, the air must be removed from the fuel
system before starting the engine. It may be necessary to open the vent (Item 3) [Figure 10-
100-4] briefly while the engine is running. Close the vent
Figure 10-100-4 when the engine runs smoothly.
P-48389
Figure 10-110-1
P-43247
P-43249
WARNING 1
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Stop the engine and check for leaks at the oil filter.
P-1575
Add oil until it reaches the top mark (Item 1) [Figure 10-
110-5] on the dipstick. DO NOT OVERFILL.
Figure 10-120-1
2
1
P-28802
Lower the lift arms and tilt the Bob-Tach fully back.
Figure 10-120-2
P-64023A
P10303
Add the correct fluid to the reservoir until the fluid level is
between the marks on the di pstick (Item 1) [Figure 10-
120-2]. Do not fill above the top mark on the dipstick
Figure 10-120-4
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a p erson’s body by
penetrating the skin. This can cause serious injury
1 and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
WARNING
P-48395
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
(See SERVICE SCHEDULE on Page 10-70-1.) for the Failure to use care around combustibles can cause
correct service intervals. explosion or fire which can result in injury or death.
W-2103-1285
Install and hand tighten the filter element. Drain the hy draulic fluid reservoir. (See Replacing
Hydraulic Fluid on Page 10-120-3.)
Close the rear door before operating the loader.
Figure 10-120-5
Start the e ngine, check for leaks and the p roper fluid
level in the reservoir.
1 P-43272
Figure 10-120-7
1
2
1 1
P-48520
(See SERVICE SCHEDULE on Page 10-70-1.) for the Raise the operator cab. (See Raising The Operator Cab
service interval. on Page 10-30-1.)
The fluid must be replaced if it becomes contaminated or Replace the hydraulic/hydrostatic filter element. (See
after major repairs. If the fluid is replaced, the hydrostatic Replacing Hydraulic/Hydrostatic Filter on Page 10-120-
filter and both case drain filters must be replaced. 2.)
Add the correct fluid to the reservoir until the fluid level is
Hydraulic fluid escaping under pressure can have
between the marks on the dipstick. DO NOT fill above the
sufficient force to e nter a person’s body by
top mark on the dipstick.
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
Lower the operator cab. (See Lowering The Operator
physician familiar with this injury is not received
Cab on Page 10-30-2.)
immediately.
W-2145-0290
Start the engine and operate the loader hydraulic
controls. Stop the engine and check for leaks.
Breather Cap
Figure 10-120-8
1
1
P-30011
(See SERVICE SCHEDULE on Page 10-70-1.) for the NOTE: Be sure the rubber gasket (Item 2) [Figure 10-
correct service interval. 120-9] is installed on the cap.
Figure 10-130-1
P-31287
P-3870
Remove the check plug (Item 1) [Figure 10-130-2] from
the front of the chaincase housing.
The chaincase contains the fi nal drive sprockets and
chains and uses the same type of oil as the hydraulic/ Figure 10-130-3
hydrostatic system. (See Specifications on Page SPEC-
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until P-31287A
the oil flows from the hole. Install and tighten the plug.
Figure 10-140-1
N-18460
Move the Bob-Tach levers to e ngage the wedges If the wedge does not contact the lower edge of the hole
[Figure 10-150-1]. The levers and wedges must move [Figure 10-150-2] and [Figure 10-150-3], the
freely.
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-2
TS-1062
Figure 10-151-1
2
1
P-43832
2
1
P-43831
Figure 10-151-4
Bob-Tach
Wedge
1
B-17460
If the wedge does not contact the lower edge of the hole Lubricate the wedges. ( See SERVICE SCHEDULE on
[Figure 10-151-4], the attachment will be loose and can Page 10-70-1 and See LUBRICATION OF THE BOBCAT
come off the Bob-Tach. LOADER on Page 10-160-1)
Procedure
Figure 10-160-1
P-48497
N-20579
Procedure (Cont'd)
Figure 10-160-5
8 8
P-43829 P-43830
N-20573
Figure 10-160-6
6 P-43831
7
P1564
Procedure (Cont'd)
Figure 10-160-8
P-48500
N-20575
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-9].
Check that the lock nuts are tightened to 25-28 ft.-lb. (34-
38 N•m) torque.
Mounting
Rotating IMPORTANT
Figure 10-170-2 Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
B-9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].
Servicing
WARNING
Figure 10-180-1
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do s o can cause injury or
death.
W-2006-0284
(See SERVICE SCHEDULE on Page 10-70-1.) for Close the rear door.
service interval for cleaning the spark arrestor muffler.
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
28
HYDRAULIC/HYDROSTATIC SCHEMATIC 29
PILOT
S130 (S/N 524611001 AND ABOVE)
(S/N 524711001 AND ABOVE)
Printable Version Click Here
INTEGRATED QUICK
30 26
(PRINTED SEPTEMBER 2004) FEMALE COUPLER BLOCK
F1 D1
V-0402 FEMALE
7 (FRONT AUXILIARY
MALE
24 7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
(REAR QUICK
1 COUPLERS)
MALE
23 25 27
MALE
F2 D2
4 37
DRAIN P1 P2
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20
BOB-TACH
AUXILIARY
CYLINDER
SPOOL
(OPTIONAL)
36 14
HYDRAULIC TILT CYLINDERS
44
POWERED BICS CONTROL VALVE
BOB-TACH
5 8 5
(OPTIONAL)
INLET OUTLET
D C 39
DR
A B 17
43 TILT
CYLINDER
50 SPOOL
48 47
46
51 11
DRIVE MOTOR 49 45 14
PP LIFT CYLINDERS
10
38
P2 18
P1
42 A B
LIFT
CYLINDER
SPOOL 35
15
14
4 37
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
78 of 638
HYDRAULIC SYSTEM INFORMATION
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Tighten Procedures
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of t he recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3,
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
By-pass valve stuck. 12
By-pass valve stem bent or broke. 13
Checking
WARNING 2
Engage the parking brake. Lower the seat bar. Start the
P-45265
Lower the lift arms. Stop the engine. Pull up on the lift WARNING
arm by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Check only one cylinder at a time. Open the rear door. Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
Disconnect the negative ground cable to the battery. W-2103-1285
Figure 20-20-3
1
P-45267
P-45258
Use a drift pin and hammer, remove the cylinder pivot pin
(Item 2) [Figure 20-20-5] (both sides).
Identification
1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring
7 8
14
1 13
2 12
3
11
10
B-13593
Disassembly
2
Use the following tools to disassemble the cylinder:
P-48033
4
3 P-48039
2
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-7].
1 Figure 20-20-12
P-48040
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-12].
Assembly (Cont'd)
Figure 20-20-13
1
2
P7425
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 16].
Install the rod seal on the rod seal tool [Figure 20-20-14].
Assembly (Cont'd)
Figure 20-20-17
1
2 3
P-48036
Figure 20-20-18
P-48035
Checking
Figure 20-21-1
Disconnect the hose (Item 1) [Figure 20-21-1] which Stop the engine. Move the tilt pedal to release the
goes to the base end of the tilt cylinder. hydraulic pressure. Raise the seat bar.
Figure 20-21-3
1
N-20739
Figure 20-21-6
N-20734
1
Remove the retainer nut (Item 1) [Figure 20-21-4] from
the cylinder rod end pivot pin.
N-20737
Figure 20-21-7
1 1
1
N-18556
N-00845
Remove the old seal (both sides) from the end of the tilt
cylinder [Figure 20-21-8].
Remove the base end pivot pin (Item 1) [Figure 20-21-
7]. Apply a li ght coat of grease on the new seals (Item 1)
Install the rod end of the tilt cylinder into the Bob-Tach.
Identification
1
15
7 12
13
8
5
10
14
20
11
MS1797
Disassembly
2
Figure 20-21-9 3 1
N-20554
Remove the nut (Item 1), piston (Item 2) and head (Item
Use the following tools to disassemble the cylinder: 3) [Figure 20-21-10].
N-20609
Figure 20-21-12
5
3
4
2
1
P7424
N-20611
Use the following tools to assembly the cylinder:
Remove the wi per seal (Item 1), and rod seal (Item 2), MEL1396 - Seal Installation Tool
the back up washer (Item 3), the thin O-ring (Item 4) and MEL1033 - Rod Seal Installation Tool
the thick O-ring (Item 5) [Figure 20-21-12] from the
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-13].
Assembly (Cont'd)
Figure 20-21-14
N-20613
Figure 20-21-17
Install the O-ring and seal on the piston (Item 1) [Figure
20-21-14].
Figure 20-21-15
P7425
Install the wiper seal with the wiper toward the outside of
the head.
N-20612
Install the rod seal on the rod seal tool [Figure 20-21-15].
Assembly (Cont'd)
Figure 20-21-18
2
3
P-48088
P-48089
Figure 20-21-21
Install the thin O-ring (Item 1) [Figure 20-21-18].
Figure 20-21-19
2
1 3
P7429
N-20554
Install the head (Item 1), and the piston (Item 2) [Figure
20-21-19]. The small diameter of the piston goes into the
cylinder tube first.
Checking
WARNING
Figure 20-22-1
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
WARNING
1 Diesel fuel or hy draulic fluid unde r pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
P-31514
Use a piece of c ardboard or wood to find le aks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
Tilt the Bob-Tach forward, so it is parallel to the floor from a physician familiar with this injury.
[Figure 20-22-1]. W-2072-0496
Figure 20-22-2
1
2
P-43211
Engage the parking brake. Lower the seat bar. Start the
engine.
Figure 20-22-3
1 1
1 2 P-31513
Parts Identification
1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod
15
PE1064
Disassembly
2
4 3 1
Use the following tools to disassemble the cylinder:
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Figure 20-22-7
3
2
1
P-43212
P-16295
Remove the wi per seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4) and
the thick O-ring (Item 5) [Figure 20-22-8] from the head.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-9].
Assembly (Cont’d)
Figure 20-22-10
3
1
2
4
N-20613
Figure 20-22-13
Piston: Install the O-ring (Item 1) and seal (Item 2) on the
piston (Item 3) [Figure 20-22-10].
Figure 20-22-11
P-7425
Install the wiper seal with the wiper toward the outside of
the head.
N-20612
Install the rod seal on the rod seal tool [Figure 20-22-11].
Assembly (Cont’d)
1 3
2 4
Figure 20-22-14
2
3
P-16294
Install the head (Item 1), and spacer (Item 2) [Figure 20-
P-7422 22-15].
NOTE: Clean and dry the threads before installing the Tighten the nut to 90 ft.-lb. (122 N•m) torque.
nut. Install the new nut from the seal kit.
Figure 20-22-16
P-43212
Checking
WARNING
When the engine is running during s ervice, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
WARNING
N-18409
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
The tools listed will be nee ded to do the fol lowing Failure to use jackstands can allow the machine to
procedure: fall or move and cause injury or death.
W-2017-0286
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Checking (Cont’d)
Figure 20-30-3
1
2
1
2
N-20863
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-30-5
P-43309
Figure 20-30-7
If the relief pressure is not correct, adjust the main relief
valve. Remove the end cap (Item 1) [Figure 20-30-5].
N-20907
P-28861
WARNING The fixed end main valve hose assembly (Item 1) [Figure
20-40-1] is connected to a fixed end fitting on the control
Never work on a machine with the lift arms up unless
valve. The hose is routed to the upright where the hose is
the lift arms are secured by an approved lift arm
connected to a tee fitting that feeds the base end of both
support device. Failure to use an approved lift arm
lift cylinders. The hose can only be removed by first
support device can allow the lift arms or attachment
removing it from the tee fitting located at the rear of
to fall and cause injury or death.
Raise the l ift arms and install an a pproved lift arm Cap all hoses and fittings.
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Figure 20-40-2
Figure 20-40-3
1
1
2
1
P-28858
1
2
P-28866
P-28895 Remove the clevis pin (Item 1) [Figure 20-40-6] from the
tilt spool linkage.
Remove the two mounting bolts and nuts (Item 1) Remove the clevis pin (Item 2) [Figure 20-40-6] from the
[Figure 20-40-4] from the lift arm by-pass mount. lift spool linkage.
Figure 20-40-7
1 1
2 P-28870A
P-28871
P-28869
Figure 20-40-11 1
P-28874
1
Disconnect the tubeline from control valve (Item 1)
[Figure 20-40-13].
P-28873
Figure 20-40-14
Disconnect the control valve drain hose (Item 1) [Figure
20-40-11].
P-28877
Figure 20-40-15
2 1 1
P-43310
P-43308
Figure 20-40-18
N-21005
1 1
Reverse the r emoval procedure to in stall the control
valve.
N-21006
1 1
N-21004
Figure 20-40-22
3 6
1 2
1
5 4
N-21013
N-21004
Remove the fi tting (Item 1) [Figure 20-40-23] from th e
valve.
Install the six mounting bolts [Figure 20-40-22].
Figure 20-40-24
N-21010
Figure 20-40-27
1 2
1
N-18685
N-18684
Using a fl at blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-24] & [Figure 20-40-
25]. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-27].
Orifice size is 0.078 inch.
Install new O-rings (Item 1) and back-up ring (Item 2)
* Reverse the removal procedure to install the lift arm [Figure 20-40-27] on the check valve.
by-pass orifice.
Check valve (Item 3) [Figure 20-40-27] has a rating of 5-
10 PSI.
Figure 20-40-28
N-21017
Figure 20-40-31
P-8956
Figure 20-40-29
N-21013
N-21004
Figure 20-40-32 1
1 N-18693A
Figure 20-40-33
N-21011
1
Remove the solenoid cartridge (Item 1) [Figure 20-40-
35].
N-21010
Figure 20-40-36
3
2
P9175
1
Figure 20-40-41
N-21159
1
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve Removal And Installation on Page
N-21006
1 1
N-21018
3
2 N-21008 Loosen the main relief valve (Item 1) [Figure 20-40-44].
1
B-6764
1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring
2
CD-15092
N-21009
Remove the O-rings, sleeve, and glide ring from the main
The auxiliary section (Item 1) uses an orifice load check relief valve [Figure 20-40-45].
poppet (Item 2) [Figure 20-40-43].
Figure 20-40-46
N-21013
Figure 20-40-47
4
3
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844
Figure 20-40-49
2 E-01509
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
N-18839
1
Remove the O -rings and back-up washer from the an ti-
cavitation valve [Figure 20-40-51].
N-21018
Plug
Figure 20-40-50 Figure 20-40-52
N-21019
N-21018
Remove the lift lock solenoid (Item 1) [Figure 20-40-49] Remove the plug (Item 1) [Figure 20-40-52] (Port F2).or
& [Figure 20-40-50] (Port F1). optional port relief valve from the control valve.
Remove the anti-cavitation valve (Item 2) [Figure 20-40- Installation: Always use new O-rings and back-up
49] & [Figure 20-40-50] (Port F1). from the control valve washers. Tighten to 35-40 ft.-lb. (47-54 N•m) torque.
for the lift section.
Figure 20-40-53
Plug
1 2
N-21020
1
Remove the rubber boot (Item 1) and retainer (Item 2)
1
[Figure 20-40-55].
N-18800
Figure 20-40-54
N-21018
Figure 20-40-56
1
N-21022
2
N-21018 NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Figure 20-40-57
2
1
N-21021
Figure 20-40-59
N-21013
Figure 20-40-60 2
N-21031
N-21023
Figure 20-40-63
3
2
1
1
N-21035
2
IMPORTANT
1
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
N-21036
Figure 20-40-64
Remove the s pool assembly and seal (Item 1) [Figure
20-40-66] from the control valve.
N-21034
1
N-18915
1
2
N-18916
P-8988
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-73].
N-19004
Figure 20-40-74
Remove the detent adapter (Item 1) [Figure 20-40-71]
from the spring assembly.
N-18918
Remove the stud from the end of the spool [Figure 20-
40-74].
N-19009
Figure 20-40-75
N-18963
1
Install the plastic plug and O-ring in the spool [Figure 20-
40-77].
N-18920
Figure 20-40-78
Removal of the plastic plug:
O-ring
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Figure 20-40-76 Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-78].
2
1
N-18961
Figure 20-40-79
N-18968
N-18967 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
Clamp the collar (Item 1) [Figure 20-40-79] in a vise. detent adapter and collar together to prevent
1
3
2
N-18958
N-19004
Figure 20-40-83
CD-15051
1
Install the detent balls and spring [Figure 20-40-85].
N-19007
N-19005
Figure 20-40-87
1
N-21031
N-21013
1
Figure 20-40-91
1 N-21018
2
1
N-21023
Figure 20-40-94
N-21013
Figure 20-40-95
2
1
N-21037
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Assembly: Always use a new spool seal.
20-40-95] from the tilt spool.
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-100].
N-18942
N-18942
Figure 20-40-101
Put the linkage end of the spool in t he vise [Figure 20-
40-98]. 2
Figure 20-40-99
N-21027 N-18943
N-19014
Figure 20-40-102
1 1
N-21040
Figure 20-40-103
2 1
N-21041
Figure 20-40-106
1
1
N-21042
Plug Check that the spools are not loose in their bore.
2
1
N-18843
Description Raise the l ift arms and install an a pproved lift arm
support device. (See Installing Lift Arm Support Device
The Advanced Control System (ACS) includes the on Page 10-20-1.)
Selectable Hand/Foot Control.
Stop the engine. Raise the seat bar.
Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-41-1 2
P-34986
Figure 20-41-2
1
1 P-34987
Remove the tu beline clamp (Item 1) [Figure 20-41-2] Remove the bolts (Item 3) [Figure 20-41-4] from the li ft
holding the fixed end main valve hose. The clamp is arm by-pass control valve bracket.
located behind fuel fill tube.
Remove the l ift arm by-pass control valve from the
loader.
Figure 20-41-5
2
1
P-34990
Figure 20-41-6 1
2 3
3
2
P-34991
Disconnect the o utlet tubeline (Item 1) [Figure 20-41-6] Disconnect the lift tubeline (Item 2) [Figure 20-41-8] from
from the control valve. the control valve.
Disconnect the tubeline (Item 2) [Figure 20-41-6] from Disconnect the tilt tubeline (Item 3) [Figure 20-41-8] from
the auxiliary section of the control valve. the control valve.
Figure 20-41-9
P-43308
1 1
P-43309
Figure 20-41-12
1 1
2 1
N-19112
N-19113
Figure 20-41-15
3 N-18695
2
N-18679
Figure 20-41-19
6
3
1 2
1
5
4
N-18686
N-18679
Remove the fi tting (Item 1) [Figure 20-41-20] from th e
valve.
Install the six mounting bolts [Figure 20-41-19].
N-18685
Figure 20-41-23
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-24].
Figure 20-41-25
1
N-18683 1
P-8956
Figure 20-41-26
1
1
N-18689
1 1
N-18688 2
2
2 N-18690
N-18692
Figure 20-41-31
N-18693A
Figure 20-41-33
3
2
P9175
1
Use an O hm meter to me asure coil resistance [Figure
N-18694 20-41-34].
Figure 20-41-38
N-21159
1
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve, Removal And Installation on Page
2
N-19099
Figure 20-41-39
1
1
N-19034
3
2 N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-41].
Figure 20-41-42
Remove the load check plugs (Item 1) [Figure 20-41-39].
Figure 20-41-40
N-19035
N-19102
Figure 20-41-43
1
2
3 4
5
1
B-06764
1. Relief Valve
2. O-ring
3. Sleeve N-19034
4. Glide Ring
5. O-ring
Loosen the port relief valve (Item 1) [Figure 20-41-44] &
[Figure 20-41-45] (Port E1 or F2). (See Port Relief Valve
CD-15092 on Page 20-41-15.)
Figure 20-41-44
N-18981
N-19000
Figure 20-41-47
4
1
3
2
1
1. O-ring
2. Back-up Washer N-18980
3. O-ring
4. Relief Valve
Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-41-49] from the control valve for the til t
N-18844 section.
Figure 20-41-50
Remove and install new O-rings and check back-up
washer from the port relief valve [Figure 20-41-47].
Figure 20-41-48 1
N-18843
N-19003
Anti-Cavitation Valve
Figure 20-41-51
E-1509
1
1. Anti-Cavitation Valve
2. O-ring
3. Back-up Washer
4. O-ring
N-18839
Figure 20-41-52
N-19036
Figure 20-41-54
N-18983
Figure 20-41-55
N-19003
Figure 20-41-57
1
N-18985
Figure 20-41-58
1
1
N-19003
N-18944A
N-18943 N-18943
Figure 20-41-64 1
1
N-18988
Figure 20-41-65
N-18987
Figure 20-41-67
3 2
1 N-18992
Figure 20-41-68
1
N-18795
Figure 20-41-71
1 2
N-18843
1
Check that the load check valve seats are not worn.
2
Check the load check poppets for damage.
Inspecting
2
WARNING
4
Never work on a machine with the lift arms up unless 1
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 5
to fall and cause injury or death.
W-2059-0598
P-43322
Raise the lift arms 6 fee t (2 m) off the ground. Stop the
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm By- Raise the operator cab. (See Raising The Operator Cab
Pass Control Knob while the lift arms slowly lower. on Page 10-30-1.)
Removal And Installation The lift lock by-pass valve (Item 1) [Figure 20-50-1] is
located under the right side of the control panel.
Install jackstands under the rear corners of the loader.
Figure 20-50-2
1
P-43324
P-43323
Remove the by-pass valve (Item 1) [Figure 20-50-3]
from the valve block. Inspect the by -pass valve for
Remove the two mounting bolts (Item 1) [Figure 20-50- damage and replace if necessary.
2].
1
WARNING
Put jackstands under the front axles and rear corners 2
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-37545
Figure 20-60-5
EXAMPLE: TESTER
1
CONNECTION
Reservoir
2
Hydraulic Pump
Out In
P-37418
Hydraulic Control
Valve
Connect the INL ET hose (Item 1) [Figure 20-60-2] & 1
[Figure 20-60-3] from the tes ter to the O UTLET fitting
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to f ull
RPM*.
Connect the OUTLET hose (Item 2) [Figure 20-60-2] & NOTE: Do not exceed system relief pressure,
[Figure 20-60-4] from the tester to the hose (Item 1) damage to the hydraulic system may occur if
[Figure 20-60-4] which was disconnected from the gear pressure is exceeded.
pump.
Record the flow (GPM) at system relief pressure. The
high pressure flow must be at least 80% of free flow.
WARNING
2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-37330
1 Figure 20-60-10
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
P-37415
Hydraulic Control
Valve
Connect the INL ET hose (Item 1) [Figure 20-60-7] & 1
[Figure 20-60-8] from the tes ter to the O UTLET fitting
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to f ull
RPM*.
Connect the OUTLET hose (Item 2) [Figure 20-60-7] & NOTE: Do not exceed system relief pressure,
[Figure 20-60-9] from the tester to the hose (Item 1) damage to the hydraulic system may occur if
[Figure 20-60-9] which was disconnected from the pressure is exceeded.
Power Bob-tach block.
Record the flow (GPM) at system relief pressure. The
high pressure flow must be at least 80% of free flow.
WARNING
P-48393
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-12
1.)
Figure 20-60-13
1
1
P-37357
Figure 20-60-16
Remove the right rear engine mount (Item 1) [Figure 20-
60-13].
Figure 20-60-14
1 P-37353
Loosen the hose clamps and remove the fuel fill hose
(Item 1) and the fuel vent hose (Item 2) from the loader
[Figure 20-60-16]
P-48505
Figure 20-60-17
1
1
N-21114
P-37339
P-37352
Installation: Tighten the engine mount bolt to 70 ft.-lb . NOTE: A s haft (Item 2) [Figure 20-60-20] with the
(95 N•m) torque. dimensions of 1 .5” diameter by 2.125” long
will be needed to push the engine/hydrostatic
pump assembly.
Figure 20-60-21
P-26347
1 2
1
P-26347
P-37336
Remove the O-ring (Item 1) [Figure 20-60-22].
Remove the two mounting bolts (Item 1) [Figure 20-60- Remove the coupler (Item 2) [Figure 20-60-22] from the
21] from the hydraulic pump. hydraulic pump shaft.
Remove the hydraulic pump (Item 2) [Figure 20-60-21] Installation: Use a ne w O-ring (Item 1) [Figure 20-60-
from the loader. 22] when installing the hydraulic pump.
Identification
15
8
7
6
12
13
11
7 9 10
1 4 5
3
B-16050A
P-26352
2
2
P-26353
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-60-25 1
P-26358
2
Figure 20-60-28
P-26354
1
Figure 20-60-26
1
P-26359
Figure 20-60-29
1
P-26391
Figure 20-60-32
P-26389
Figure 20-60-30
P-26362
1
1
P-26362
Figure 20-60-33
P-26394
Remove the dr ive gear (Item 1) [Figure 20-60-33] from Figure 20-60-36
the pump end section.
1 P-26395
P-26393
Figure 20-60-37
P-26398
P-26397
Figure 20-60-38
P-26374
IMPORTANT 2
P-28831
Stop the engine and open the rear door.
Figure 20-70-1 Disconnect the oil cooler tubeline (Item 1) [Figure 20-70-
2] from the filter housing.
3
1
2
1 1
P-28830
Figure 20-70-4
1 1
P-28833
1
1
WARNING
P-43185
P-43186
Figure 20-90-1
1
2
1
2
N-18191
Solenoid Testing
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-90-4
Figure 20-90-2
P9175
1
Use a test meter to measure coil resistance [Figure 20-
90-4]. Coil wires do not hav e polarity. Correct resistance
for the coil is 9.7 ohms ± 1 ohm @ 78° F.
P-30527
C
D
WARNING P-28882
1 1
P-28884
Figure 20-90-8 2
N-19070
Figure 20-90-9
1
N-19072
Remove the solenoid nut (Item 1) [Figure 20-90-9]. NOTE: Always install new O-rings before any parts
are installed into the valve. Check the parts
Installation: Tighten the nut to 60 in.-lb. (6,78 N•m) for wear or damage and replace as needed.
torque.
Figure 20-90-12
3
N-19042
Figure 20-90-13
N-19045
N-18339
Remove the plug [Figure 20-90-15].
Remove the plug (Item 1), and flow control spool (Item 2)
[Figure 20-90-13].
Figure 20-90-16
1
N-19046
WARNING P-30004
2
P-30079
1
Disconnect the dr ain hose (Item 1) [Figure 20-100-5]
P-30075 from the control valve.
Figure 20-100-4
1
2
2
P-30084
1
Figure 20-100-7
P-30085
P-30086
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 1
Figure 20-100-9
Figure 20-100-12
1
P16312
P16314
Figure 20-100-10
Remove the shuttle check valve (Item 1) [Figure 20-100-
1 11] & [Figure 20-100-12]from SH1 port.
P16313
Figure 20-100-13
P16319
1
1 Remove the nuts (Item 1) [Figure 20-100-15] & [Figure
P16316 20-100-16] from the solenoid valve.
3
2
2
1
1
2
P16317
2 1
P16321
Remove the pilot check valves (Item 1) [Figure 20-100-
13] & [Figure 20-100-14] from block ports PC1 and PC2.
Remove the seal washers (Item 2) and solenoid valve
Installation: Put oil on O -ring and back-up washers. coils (Item 3) [Figure 20-100-16].
Tighten to 30-35 ft.-lb. (40,7-47,5 N•m) torque.
Figure 20-100-17
P16322
Figure 20-100-20
P16323
Figure 20-100-18
1
P16325
Remove the diverter control solenoid valve (Item 1) Installation: Put oil on O-rings and ba ck-up washers.
[Figure 20-100-17] & [Figure 20-100-18] from the SV1 Tighten to 12-15 ft.-lb. (16,3-20,3 N•m) torque.
port.
Figure 20-100-21
P9137
P16326
Use a test meter to measure coil resistance [Figure 20-
100-23]. Coil wires do not have polarity. Correct
Figure 20-100-22 resistance is 7.7 ohms ± 1 ohm @ 78°F.
Inspection
P16327
3
WARNING 1
P-48393
Figure 20-110-2
P-48227
Installation: The harness connectors are marked with NOTE: There is an O-ring in-between the power Bob-
Red or Black tie straps. Be sure the connectors with the Tach block and the hydraulic pump. Inspect
same color are connected. and replace as needed.
Figure 20-110-3
P-48226
Figure 20-110-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-110-6].
IMPORTANT 1
Figure 20-110-8
1
1
P-48122
Figure 20-110-9
1
2
1
P-48384
3
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-110-
(Item 2) [Figure 20-110-9]. 11] to 12-14 ft.-lb. (16,3-19 N•m) torque.
Figure 20-110-12 3
2
1
P-48106
Remove the orifice screw (Item 2) located behind the NOTE: Remember the solenoid coil orientation for
plug (Item 1) [Figure 20-110-12]. ease of installation.
Figure 20-110-13
1 1
P-48386
Figure 20-110-16
1
P-48174
1
2 2
1 1
P-48138
P-48173
IMPORTANT 1
Figure 20-120-1
P-34661
2 Figure 20-120-3
6
2
4
5 3
P-43215
Remove the two mounting bolts (Item 3) [Figure 20-120- Remove the male coupler (Item 1) [Figure 20-120-2] &
1]. [Figure 20-120-3].
1
2
P-34665
P-34664
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
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, 10, 11
Hydraulic Service codes appear (Warnings, low charge pressure.) 8, 11, 12, 13
Figure 30-10-1
WARNING P-43309
WARNING 3
3
1
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause 3
explosion or fire which can result in injury or death.
W-2103-1285
Lift and block the loader. (See Procedure on Page 10-10- 3 N-20908
1.)
Mark the two hoses (Item 1) [Figure 30-20-2] before
Raise the operator cab. (See Raising The Operator Cab disconnecting them from the HYDROSTATIC MOTOR
on Page 10-30-1.) for correct installation.
Remove the front and rear wheel/tire assemblies. (See Remove the two hoses (Item 1) [Figure 30-20-2] from
TIRE MAINTENANCE on Page 10-170-1.) the drive motor.
Figure 30-20-3
P-4141
Parts Identification
10
11
9
8
13
3 16
5
14
6
15 3
24 26
12 23 25 2 D-3431A
Disassembly 1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Seal all open ports and clean the motor with solvent.
Lift and remove the mounting flange (Item 1) [Figure 30-
Figure 30-20-4 20-6] from the motor.
1
2
3
N-00621
N-00622
Disassembly (Cont'd)
1
Figure 30-20-8
N-00627
Figure 30-20-11
Turn the mounting flange back over and remove the seal
(Item 1) [Figure 30-20-8] from the mounting flange.
N-00628
Disassembly (Cont'd)
Figure 30-20-12
N-00631
1
Figure 30-20-15
Remove the square cut seal (Item 1) [Figure 30-20-12]
from the gerolor.
1
N-00632
Disassembly (Cont'd)
1
Figure 30-20-16
N-00635
Figure 30-20-19
Remove the square cut seal (Item 1) and small O-ring
(Item 2) [Figure 30-20-16] from the end cap.
1
2
N-00636
Turn the end cover over and remove the sh uttle valve
N-00634 plug from the end cover [Figure 30-20-19].
Disassembly (Cont'd)
3
Figure 30-20-20
2
1
1
2
3
N-00640
Figure 30-20-23
2
1
N-00639
N-00641
Remove the low pressure relief valve plug from the side
of the end cover [Figure 30-20-21].
The low pressure relief valve is made up of the poppet
(Item 1), the spring (Item 2) and the plug assembly (Item
3) [Figure 30-20-23].
Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-00643
Prior to assembly:
Clean all parts with solvent and dry with compressed air. Install the new O-ring on the plug and tighten to 300 in.-
lb. (34 N•m) torque [Figure 30-20-25].
Put grease on O-rings.
Figure 30-20-26
Lubricate parts with oil.
2
1
1
N-00644
Install the poppet (Item 1), the spring (Item 2) and the
N-00642
spring sleeve (Item 3) [Figure 30-20-26] in the end
cover.
Install the poppet (Item 1) and spring (Item 2) [Figure 30-
20-24] in the low pressure relief port in the end cover. NOTE: The tapered end of the poppet must face
towards the shuttle valve.
Assembly (Cont'd)
1
Figure 30-20-27
N-00648
Install the square cut seal (Item 1) and small O-ring (Item
N-00646 2) [Figure 30-20-29] in the end cover.
Figure 30-20-30
Install a ne w O-ring on th e plug [Figure 30-20-27] and
tighten to 260 in.-lb. (41 N•m) torque.
Figure 30-20-28
N-00649
3 1
N-00647
Install the shuttle valve (Item 1), poppet (Item 2), spring
(Item 3) and spring sleeve (Item 4) [Figure 30-20-28] in
the port hole in the end cap.
Assembly (Cont'd)
Figure 30-20-31
N-00652
Figure 30-20-34
Align the case drain ports in the valve plate with the case
drain port in the end cover [Figure 30-20-31].
1
N-00653
Assembly (Cont'd) 1
Figure 30-20-35
N-00656
N-00655 N-00657
Install the two ch eck balls (Item 1) [Figure 30-20-36] in Mark the case drain hole on the outer ring of the gerolor
their bores in the gerolor star. (as shown) [Figure 30-20-38].
Assembly (Cont'd)
1
Figure 30-20-39 2
3
4
5
N-00660
1 Install the square cut seal (Item 1), seal (Item 2), back-up
N-00658 seal (Item 3), seal (Item 4) and back-up ring (Item 5)
[Figure 30-20-41] in the mounting flange.
Align the case drain holes and install the balance plate Figure 30-20-42
(Item 1) [Figure 30-20-39] on the gerolor assembly.
N-00661
Assembly (Cont'd)
Figure 30-20-43
N-00664
Install the nine bolts into the motor. Make sure all the
N-00662 parts are in correct alignment [Figure 30-20-45].
Figure 30-20-46
Align the case drain port (Item 1) [Figure 30-20-43] in
the mounting flange with the case drain port in th e
balance plate (as shown).
MC-2230
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
P-4456
P-4455
P-4153 Use a s lide hammer to remove the seal from the motor
carrier shaft [Figure 30-20-49].
Figure 30-20-50
P-4149
P-4150
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-20-51].
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-4152
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-20-
53]. (See Disc Removal And Installation on Page 40-10-
Lift and block the loader. (See Procedure on Page 10-10- 1.)
1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the l oader operator cab. (See Raising The [Figure 30-20-53] from the inside of the chaincase.
Figure 30-20-55
1
P-4168
P-4165
Use one of the motor carrier mounting bolts (Item 1)
[Figure 30-20-56] and install partially into one mounting
Slide the motor carrier out of the chaincase [Figure 30- hole on the carrier.
20-55].
Fasten a chain hoist to the bolt on the motor carrier and
Installation: Check the motor carrier gasket (Item 1) remove the carrier from the loader.
[Figure 30-20-55] for wear or damage and r eplace if
4
3 7
6
1. Mount Assy.
2. Shaft
3. Bearing
4. Race
5. Housing
6. Snap Ring
7. Seal
8. Plug
MC-1937
Carrier Disassembly
Figure 30-20-57
7.000”
Length
(177,8 mm) P-4176
Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-20-59].
procedure. Refer to ph oto [Figure 30-20-57] for th e
correct dimensions of the tool needed.
Figure 30-20-58
2
1
P-4365
Figure 30-20-61
P-4369
P-4373
Put the motor carrier housing in the press as shown
[Figure 30-20-63].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30- Use 4-5/16 inch driver tool and press the new inner
20-61] facing up.
Figure 30-20-62
P-4368
P-4370
Turn the mot or carrier housing over as shown [Figure
30-20-64].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-20-62]. Use 4-5/16 inch driver tool and press the new ou ter
bearing race into the motor carrier housing [Figure 30-
Use a 3-7/8 inch driver tool and press the outer bearing 20-64].
race from the housing.
Press the bearing race in until it is fully seated in the
Check all parts for wear and damage. Replace the carrier housing.
bearing race when new bearings are to be installed.
Figure 30-20-65
1
1
Figure 30-20-67
P-4374 1
Put the snap ring (Item 1) [Figure 30-20-67] over the end
of the sprocket shaft.
Using the press and driver tools, press the s nap ring
(Item 1) [Figure 30-20-67] over the sprocket.
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-20-69].
1
Refer to Carrier Shaft Seal Replacement on Page 30-20-
15 for complete shaft seal installation procedure.
P-4376
Figure 30-20-70
N-15088
1
Check the end play of the motor carrier as follows:
N-15087
The carrier shaft must turn freely with end play not to
exceed 0.007 inch (0,17 mm).
Figure 30-30-1
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
fall or move and cause injury or death.
W-2017-0286
Remove the charge pressure sender (Item 2) [Figure 30- Install a gauge where the charge pressure sender was
30-1] from the fitting. removed.
Installation: Tighten the s ender to 7.4 -8.1 ft.-lb. (10-11 Start the engine.
N•m) torque.
The gauge must read as follows:
Adjusting
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-17231
Figure 30-30-2
Figure 30-30-4
1
If the charge pressure is not c orrect loosen the c harge
relief valve plug (Item 1) [Figure 30-30-2].
1 2
N-19566
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-4235
Figure 30-40-3
P-4236
Figure 30-40-5
P-28850
2
Installation: Install the key in the hydrostatic pump shaft Remove the two hydrostatic pump mounting bolts (Item
(Item 1) [Figure 30-40-5] before installing the pump drive 2) [Figure 30-40-5] from the pump and drive belt
pulley.
5
8
7 4
6 3
2
9 1
13 14
10 15
11 12
17
19
21
16
22
29
24
26
28
38
30 33
36
34
32
31
37
35
46
47 48
40
42 45
39 44
49
41
43
D-2427
4
17 6
16
8 1
11
14 13 10 3 2
12
5
7
15 9
22
23
19
18 21
20
24
30
25
32
26
34 27
29
36 31
38
35 33
47
37
39 46
45
44
48
43
49
42
50 40
51
58
52 41
53
57
52
53 60
59
54 55 56
D-2428
Figure 30-40-7
1
1
2
1
1 N-19569
1
N-22038
Remove the four mounting bolts (Item 1) [Figure 30-40-
9].
Remove the pump mounting bolts (Item 1) [Figure 30-
40-7] (both sides). Figure 30-40-10
Figure 30-40-8
2
N-19570
1
N-22036
Figure 30-40-11
3
1
1 N-19551
2
3 Remove the pump housing end cap (Item 1) [Figure 30-
N-19571 40-13].
Disassembly
Figure 30-40-12
1 1
N-17193
N-19550
Disassembly (Cont'd) 1
Figure 30-40-15
2
1
N-17198
Figure 30-40-16
N-17199
Disassembly (Cont'd)
Figure 30-40-19 1
4 3
4 2
4 2 1
4
3
N-17481
Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-22
2) [Figure 30-40-19] for wear and replace as needed.
Figure 30-40-20
N-17239
N-17201
Disassembly (Cont'd)
1
Figure 30-40-23
1
N-17242
Figure 30-40-26
Remove the snap ring (Item 1) [Figure 30-40-23] from
the pump housing and remove the driveshaft and bearing
from the housing.
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-40-26]
from the lower trunnion cover. Remove the cover.
N-17241
Disassembly (Cont'd)
Figure 30-40-27
1 1
1
N-17246
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-30
[Figure 30-40-27] from the pump housing.
1
2
N-17247
Disassembly (Cont'd)
Figure 30-40-31
1 N-17249
Figure 30-40-34
Inspect the seal (Item 1) [Figure 30-40-31] in the upper
trunnion cover and replace if needed.
1 N-17251
Figure 30-40-35
1
N-17253
N-17252
Install the lower bearing (Item 1) [Figure 30-40-36] on
the swashplate.
Tilt the swashplate (Item 1) [Figure 30-40-35] and
remove the swashplate and lower bearing from the pump Figure 30-40-37
housing.
Assembly (Cont'd)
Figure 30-40-38
1 1
N-17247
3
Install the upper trunnion seal (Item 1) [Figure 30-40-40]
N-17249 and cover.
Figure 30-40-41
Figure 30-40-39
N-17246
N-17248
Assembly (Cont'd)
Figure 30-40-42
2
N-17243
N-17244
N-17242
Install the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-40-42] at the lower trunnion as shown in
[Figure 30-40-43]. Install the snap ring (Item 1) [Figure 30-40-45] on th e
pump shaft.
Assembly (Cont'd) 1 2 1
Figure 30-40-46
3 4
1
1
1
N-17200
Install the bearing and snap ring (Item 1) [Figure 30-40- Apply a small amount of grease to t he washer (Item 3)
46] on the pump shaft. and install into the ball guide retainer (Item 4) [Figure 30-
N-17240
N-17199
Install the pump shaft into the pump housing [Figure 30-
40-47]. Install the ball guide retainer and washer (Item 1) [Figure
30-40-49] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-47].
Assembly (Cont'd)
2 1
Figure 30-40-50
N-17194
Figure 30-40-53
Assemble the piston assemblies into the slipper guide.
Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
Figure 30-40-51
N-17196
Assembly (Cont'd) 1 1
Figure 30-40-54
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-56] to 35-45 ft.-
lb. (47-61 N•m) torque.
Coat the backside of the valve plate with petroleum jelly Figure 30-40-57
to hold it in position and install the v alve plate onto the
pump, bronze face up [Figure 30-40-54].
Figure 30-40-55 1
2 1
N-19571
1
Install the two small O-rings (Item 1) [Figure 30-40-57].
Assembly (Cont'd)
1
Figure 30-40-58
1 N-19569
Shield Removal And Installation To adjust the drive belt between the flywheel and the
hydrostatic pump pulley, use the following procedure:
Figure 30-50-1
Stop the engine. Open the rear door.
Figure 30-50-3
P-48001
1
Remove the thr ee drive belt shield mounting clips (Item 2
1) [Figure 30-50-1].
1
P-48478
P-48000
Readjust if necessary.
Figure 30-50-5
P-48000
P-48480
Figure 30-50-7
1 2
P-48481
Remove the drive belt from the pump pulley and flywheel.
P-48478 Remove the drive belt from the loader [Figure 30-50-8].
Remove the belt tensioner assembly. Reinstall belt shield and connect the negative (-) cable to
the battery.
P-8760
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring
13
8 16
17
9
18
10
19
20
E-2296
Figure 30-50-11
3
1
1
4
P-8861
Remove the grease cover (Item 1) [Figure 30-50-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-50-13] with a plastic hammer.
Figure 30-50-12
2
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-50-14].
assembly (Item 5) [Figure 30-50-12].
Figure 30-50-15
1
1
P-8873
2
Figure 30-50-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-50-15] as shown.
2
3
P-8874
Figure 30-50-19
1
1
P-8877
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-50-19] over the roll pins. assembly, do not pr ess down on the arrow
2
1
P-8876
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hos es,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2 1
P-54001
Following tool is necessary to perform this procedure:
Open the rear door of the loader. Remove the rear grill from the loader. (See Removal And
Installation on Page 50-60-2 [S/N 524614399 & below] or
Figure 30-60-1 See Removal And Installation on P age 50-60-1 [S/N
524614400 & above)
EARLY MODELS
2 3 1
N-20727
Figure 30-60-3
N-19346
Figure 30-60-4 NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
N-19345
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Switch Operated Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . . . . . 40-30-3
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-3
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
DRIVE
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 SYSTEM
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Sprocket And Bearings Removal And Installation . . . . . . . 40-20-3
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 1
N-19105
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Inspect the traction lock guides (Item 1) [Figure 40-10-7]
and the brake disc for damage or wear and replace as
Raise the l oader operator cab. (See Raising The necessary.
Operator Cab on Page 10-30-1.)
A snap ring pliers with 90° tips are necessary for
Disconnect and r emove the engine speed control. (See removing the parking brake disc.
Figure 40-10-1
1
N-19081
Figure 40-10-3
1
2
P-21944
N-19082
The parking brake switch (Item 1) [Figure 40-10-10] is in
the front overhead panel. (See Front Accessory Panel
Figure 40-10-4 Removal And Installation on Page 60-50-10.)
N-19083
Figure 40-20-1
1 1
P-4159
Figure 40-20-3
P-4160
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
Place the new axle seal over the axle and into the axle
tube.
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
Figure 40-20-7
1
P-4170
Figure 40-20-10
2
1
P-4162
Installation: Pack both axle bearings with grease before Press the splined end of the axle free from the bearing
installing them. [Figure 40-20-10].
Figure 40-20-11
4
3
P-4175
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.
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 onto the axle during installation, as it will
slide freely along the axle shaft after the spline end has Use the long rod and bearing cup tool to r emove the
passed through the bearing and until it r eaches the inner bearing cup [Figure 40-20-13].
bearing mounting surface on the axle.
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-13].
Figure 40-20-14
P-4180
2
Use the slide hammer and remove the bearing cup from
1 the axle tube [Figure 40-20-15].
P-4179
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.
Figure 40-20-18
P-4174
Figure 40-20-17
P-4173
To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.
Secure the tool to the thr eaded rod with a nut ( Item 3)
[Figure 40-20-16].
WARNING
DO NOT exceed the recommended torque of 130 ft.-
lb. (176 N•m). The tool ma y fail under too muc h 1
torque. Put cloth around the tool to p rotect yourself
from flying debris.
W-2233-0296
P-4152
Figure 40-20-20
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Remove the center chaincase cover. (See Center Cover NOTE: It may be necessary to tie the front drive chain
Removal And Installation on Page 40-30-3.) up as shown in photo [Figure 40-20-20], so the
carrier/motor assembly can be moved enough
Remove the front (or rear) chaincase cover. (See Front
to free the rear drive chain (Item 1) [Figure 40-
Cover Removal And Installation on Page 40-30-2 or See
20-20] from the sprocket.
Rear Cover Removal And Installation on Page 40-30-3)
Remove the front (or rear) axle and sprocket. (See Axle Remove the front drive chain from the chaincase.
Sprocket And Bearings Removal And Installation on
Page 40-20-3.)
S130 Bobcat Loader
40-20-8 Service Manual
284 of 638
DRIVE COMPONENTS (CONT’D)
Figure 40-20-21
B-13504
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-21].
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 130 ft.-lb. (176 N•m)
torque.
Figure 40-30-1
P-31287
P-3870
Remove the check plug (Item 1) [Figure 40-30-2] from
the front of the chaincase housing.
The chaincase contains the fi nal drive sprockets and
chains and uses the same type of oil as the hydraulic/ Figure 40-30-3
hydrostatic system. (See Specifications on Page SPEC-
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until P-31287A
the oil flows from the hole. Install and tighten the plug.
1 1 1
1 1
1
WARNING P-4144
Never work on a machine with the lift arms up unless Remove the eight front chaincase cover mounting bolts
the lift arms are secured by an approved lift arm (Item 1) [Figure 40-30-4].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the front chaincase cover (Item 2) [Figure 40-
to fall and cause injury or death. 30-4] from the loader.
W-2059-0598
Figure 40-30-5
1 1
1
3 4 1
5
2
P-48561
P-28856
Disconnect the front steering linkage bars from the rear
linkage bars. (See Removal and Installation on Page 50-
Disconnect and remove the engine speed control from 100-1 or See Removal and Installation on Page 50-101-
the control panel. (See Removal And Installation on Page 2)
70-20-1.)
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
Figure 50-10-1
P10564 P10563
Figure 50-10-2
Figure 50-10-4
N-18463
Lower the seat bar. Lift on the grab handle and bottom of the o perator cab
slowly until the cab is all the way up a nd the latching
mechanism engages [Figure 50-10-4].
Figure 50-10-5
1
P-43382
Assembling Components
Figure 50-10-7
4 5 6
7
9
4 8
3 5
3 6
2 9 8
10 2 10
1
7
N-19383
Assemble the parts as shown for the left side of the seat 1
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Figure 50-10-9
5
4 6
3
4
5
2 7 2 3 6
1
N-19340 1
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
10].
Figure 50-10-11
4 5
2
2
1 N-19384
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
N-19222
WARNING 1
N-20616
N-20617A
Figure 50-20-4
2 1
P-48587
Figure 50-20-5 Remove the front screw (Item 1) [Figure 50-20-6] from
the gas cylinder mounting bracket.
DUAL GAS CYLINDER
1 2
P-43354
Figure 50-20-7
1 2
1
P1008
N-20618
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
P-39601
Remove the cylinder(s) from the retaining pin(s). Assembly: Install a r eplacement cylinder inside the
cylinder housing.
Reverse the removal procedure to i nstall the gas
cylinder(s). Apply a small amount of LOCTITE 242 on the threads of
the cylinder rod [Figure 50-20-10].
WARNING
AVOID INJURY OR DEATH 1
Attach a ch ain 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
P-43362
Figure 50-20-11
Remove screw (Item 1) [Figure 50-20-12] from the cab
ground.
Remove the heater unit from the cab (if equipped). (See
Removal And Installation on Page 80-50-1.)
Figure 50-20-13
1 1
P-43356
P-43358 P-43357
P-39601
Figure 50-20-17
N-20628 N-20628A
N-20619
Figure 50-30-1
1
1
1
2
N-20729A
N-20729
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Locate the s eat belt bolts under seat pan i nsulation
Figure 50-30-2
2 N-20655
Figure 50-31-1
1 2
N-20974
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)
Figure 50-31-2
N-20973
P10564 P10563
1 1
2 2
1
1 N-18582
Figure 50-31-8
N-18587
Figure 50-31-6
N-18579
Figure 50-31-9
1
N-18583
N-18580
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-10] and tilt the seat back all the way forward.
Inspect the seat ride adjustment [Figure 50-31-9].
Figure 50-31-11
Reverse the removal procedure to install the operator
1 1
N-18578
1
1
2
N-18586
1
N-18585
Figure 50-31-15
1
2
OUTSIDE OF CAB
P16131
3 Figure 50-31-18
Figure 50-31-16
INSIDE OF CAB
P16128
P16284
Figure 50-40-1
N-20739
1
Remove the rod end pivot pin (Item 1) [Figure 50-40-3].
N-20733
Remove the tilt cylinder rod end.
Figure 50-40-2
N-20734
Figure 50-40-4
1
1
P-3908
Installation:
Use a pun ch to push the pivot pin all the way into the
Bob-Tach frame. P-3909
Figure 50-40-7
3 3
2 1 2 P-3928
1
Remove the lever mounting bolt and nut (Item 1), washer
P-3912 (Item 2) and spring (Item 3) [Figure 50-40-9].
Figure 50-40-8 1
P-3924A
1
N-20735
Figure 50-40-11
1
2
4
3 P-3929
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
P-3925 or clevis (Item 4) are damaged, put the assembly in the
vise. Loosen and remove the bolt (Item 1) [Figure 50-40-
13] with a 5/16 inch allen wrench.
Use a punch and hammer, remove the roll pin (Item 1)
[Figure 50-40-11] from the Bob-Tach wedge and spring, Replace the worn or damaged parts as needed.
bolt and clevis assembly.
Bob-Tach Stops
Figure 50-40-14
1 1
P-3926
Figure 50-41-1
2
3
N-20734
1
2
Remove the retainer bolt (Item 1) [Figure 50-41-2] and
P-43823
nut from the tilt cylinder rod end pin.
Figure 50-41-3
1
2 1
P-3909
3
Figure 50-41-6 1
1 N-18560
Use the following procedure to remove and install the Figure 50-41-9
Bob-Tach lever (Item 1) [Figure 50-41-6], spring and
wedge.
1 4
P-43824
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-9].
Figure 50-41-10
3 2
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
or clevis (Item 4) [Figure 50-41-10] are damaged, put the
assembly in a vise.
Figure 50-41-11
N-18563
Figure 50-50-1
1
2
P-48506
Left Side
Figure 50-50-2
P-43215
Figure 50-50-4
1
N-20768
1
Remove the tubeline clamps (Item 1) [Figure 50-50-6]
N-20766 under the lift arms.
Figure 50-50-7
Right Side
Figure 50-50-5
2
1
N-20769
Remove the lift arm support device (Item 1) [Figure 50- Remove the retainer bolt (Item 2) [Figure 50-50-7] and
50-5]. nut from the lift cylinder rod end pivot pin.
Figure 50-50-8
1
1 2
P-4345
Wrap one of the 7 ft. lifting straps around the lift arm
N-20846 crossmember as shown [Figure 50-50-10].
NOTE: Put a piece of cardboard under the rod end of Remove the tilt cylinder (Item 2) [Figure 50-50-10] from
the lift c ylinders to pr otect the fender from the lift arm crossmember and put on the blocking.
scratches.
Figure 50-50-11
Remove the lift arm support device (Item 2) [Figure 50-
50-8].
Figure 50-50-9
1 2
P-4348
Figure 50-50-14
P-4346
Use the chain hoist and lower the lift arms so they rest on
the blocking.
Figure 50-50-13
N-20773A
Raise the lift arms with the chain hoist so the lift arms are
free from the loader [Figure 50-50-14].
2
N-20772
Figure 50-50-15
N-20774A
Pull the lift arms away from the loader [Figure 50-50-15].
N-21155
1
N-21154
Figure 50-60-4
P-48508
Open the rear door and raise the rear grill [Figure 50-60- 1
4].
N-19218
Figure 50-61-1
1
2
P-48130
Open the rear door. Reverse the removal procedure to install the grill.
Figure 50-61-2
P-48252
3
2
P-43360
1
Remove the top and bottom door hinge mounting bolts
P-48511 (Item 1) [Figure 50-70-3] and nuts.
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the engine harness.
hinge as shown.
Figure 50-70-2 Lift the door away from the loader frame and put the door
flat on the floor.
P-34588
Figure 50-70-4
WARNING
AVOID INJURY OR DEATH
1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-31126
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 2
3 Align the striker assembly in the center of t he mounting
holes.
Figure 50-70-7
1
P-31128
Figure 50-70-8
P-31127
Figure 50-80-1
P-4222
Figure 50-80-2
1
2
P-4225
P1619
Disconnect the fuel fill hose (Item 1) and the vent hose
(Item 2) [Figure 50-80-4] from the fuel tank.
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
Figure 50-80-5
P-4228
P-4229
Loosen the fuel level sender (Item 1) [Figure 50-80-7]
with a wrench.
Lift the fuel tank up and remove the tank from the loader
[Figure 50-80-5]. Turn the fuel level sender (Item 1) [Figure 50-80-7] out
P-4226
WARNING 1
1
Remove the two mounting bolts (Item 1) [Figure 50-90-
2] from the pedal mounting bracket.
Pedal Adjustment
P-28907
WARNING P-28941
1 P-28896
Figure 50-90-6
1
P-30150
1
Figure 50-90-7
P-28942
Figure 50-90-10
P-28907
Figure 50-91-1
1
2
P-21936
1 P-21927
Figure 50-91-2 1
P-21924
Figure 50-91-5
1
1 P-21931
P-28957
Remove the bolt (Item 1) holding the linkage (Item 2)
[Figure 50-91-7] to the side of the foot pedal.
Remove the pi n (Item 1) [Figure 50-91-5] holding the
linkage to the sensor. Figure 50-91-8
2
3
1
P-21932
P-28958
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) [Figure 50-91-8] from the foot pedal.
Tip the foot pedal up and remove the two nu ts (Item 1)
[Figure 50-91-6].
Figure 50-100-2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
2
1
3
P-28847
Figure 50-100-3
2 2
P-26325
1
1
Remove the fuse/relay block [Figure 50-100-5].
P-34166
Figure 50-100-4
2
1
1
P-26323
Figure 50-100-6
P-28952
Figure 50-100-7
P-28953
Figure 50-100-8
1 3
2
3
1
P-4146
P-4154
Figure 50-100-11
2 1
P-3729
1 2
3 2
P-3736
Slide the plate (Item 1) to the right and remove it from the
two guide pins (Item 2) [Figure 50-100-13].
Figure 50-100-14
1
2
5
6
4 2
1
N-15312
2
1
P-3733
Figure 50-100-17
1
3
2 1
P-34365
P-3734
Linkage Adjustment
WARNING
1
Never work on a machine with the lift arms up unless the lift
arms are secured by an ap proved lift arm support device. 2
Failure to use an approved lift arm support device can allow
1
the lift arms or attachment to fall and cause injury or death.
W-2059-0598 3
P-34365
Raise the l ift arms and install an ap proved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-10-
1.)
Figure 50-100-21
1
2
1
3
P-3723
2
3 Move the right side steering lever forward and install a
4 15/16 inch (24 mm) thick spacer (Item 1) between the
P-3726 center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-23].
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt This will allow the pintle arms to move freely while
(Item 2). The bolt (Item 2) is threaded into the linkage bar
4
2
1
3
3 1 2
4
P-3724
P-3730
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the pintle arm
arm cam (Item 2) and the centering block (Item 3) mounting bolt (Item 1) is tight, 25-28 ft.-lb. (34-38 N•m)
[Figure 50-100-22]. torque and that there is no pl ay between the pintle arm
(Item 2) and the square pump shaft (Item 3). Also check
that the cam mounting bolts (Item 4) are tight, 45-50 ft.-
lb. (62-68 N•m) torque [Figure 50-100-24].
Figure 50-100-25
P-3728
1
Move the left control lever to the full forward position
(until the lever hits the stop), then pull forward on the left
P-3727 rear linkage bar until the pintle arm is rotated to the front
as far as possible [Figure 50-100-26]. Use a locking plier
and clamp the two linkage bars together.
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
25] on each steering linkage bar.
Figure 50-100-27
P-3723
WARNING P-3731
2
3
4
P-3726
P-3725
Figure 50-100-31
P-3732
P16121 Move the r ight control lever until the tires do not t urn
(neutral position).
Start the engine and run at high RPM. Move the right centering block to the left until it contacts
Figure 50-100-33
1
1
P-34365
2
Tighten the two bolts to 11-13 ft.-lb. (15-17 N•m) torque,
then tighten the two nuts to 21-25 ft.-lb. (28-33 N•m)
P-3726 torque at the steering cross shaft (Items 1 & 2) [Figure
50-100-34].
Tighten the two bolts (Item 1) to 11-13 ft.-lb. (15-17 N•m)
torque, then tighten the two nut s (Item 2) to 21-25 ft.-lb.
Description
Figure 50-101-1
The steering system [Figure 50-101-1] consists of Pintle arms are of a two- piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the loader.
The steering system returns the levers to the ir 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 n ot 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
linkage bars are adjustable in length for “full travel Sequence of steering adjustments:
adjustment”.
1. Set neutral of pintle arms, “creep”
Steering linkage bars attach to the pintle arms where a 2. Set linkage travel at steering linkage bars
rubber torsion bushing is pressed into the pintle arms. 3. Set drift at drift adjustment bolts
P-54147
WARNING Raise the l ift arms and install an a pproved lift arm
support device. (See Installing Lift Arm Support Device
Never work on a machine with the lift arms up unless on Page 10-20-1.)
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising The Operator Cab
support device can allow the lift arms or attachment on Page 10-30-1.)
Remove the control knob (Item 2), jam nut (Item 1) and
Put jackstands under the front axles and rear corners rubber washer (Item 3) [Figure 50-101-3].
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Figure 50-101-3
fall or move and cause injury or death.
W-2017-0286
P-54146
1 1
2 3
2
P-26323
1 1
Remove the fuse/relay mounting bolts (Item 1) [Figure
50-101-5].
P-54145
Remove the fuse/relay cover (Item 2) and fuse/relay
block retaining bracket (Item 3) [Figure 50-101-5].
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-101-4] which are connected to the
P-26325
P-26329
P-54148 P-54136
1
1
P-54134
Figure 50-101-11
P-54149
3
Remove the mounting nut ( Item 1) [Figure 50-101-10]
from the end of the shock connected to the steering
Installation: Tighten the mounting bolts to 25 -28 ft.-lb. Remove Control Handle Lever (Item 1) [Figure 50-101-
(34-38 N•m) torque. 11]. (See Control Lever Removal And Installation on
Page 50-110-1.)
2 1
2
1
P-28845
2
To remove the steering shaft mounting bracket (Item 3)
[Figure 50-101-11], remove the three mounting bolts
P-4154 (Item 1) [Figure 50-101-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks Remove the steering shaft mounting bracket.
(Item 1) from the cross shaft assembly [Figure 50-101-
WARNING 2 2
Never work on a machine with the lift arms up unless the lift
arms are secured by an ap proved lift arm support device.
Failure to use an approved lift arm support device can allow 1 1
the lift arms or attachment to fall and cause injury or death.
W-2059-0598
P-54145
WARNING Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-101-14] which are connected to the
Put jackstands under the front axles and rear corners steering shaft on the control panel.
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Remove the four steering linkage mounting bolts (Item 2)
fall or move and cause injury or death. [Figure 50-101-14].
2
5
2
P-48630
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering 1 Bolt
spring shoulder bolt (Item 2) [Figure 50-101-15].
P-48632
Figure 50-101-18 2
1
3
3
6
2
5
1
2 4
1
1 P-48627
2
If the surface of any of the four solid pintle cams (Item 1)
are worn, loosen the bolt (Item 2) and rotate the cams 1/4
P-48629 turn [Figure 50-101-19].
Figure 50-101-20
2
ROLLER CAMS
2 1
P-54615
3
Loosen the bolt (Item 1) and remove the pintle base (Item
2) [Figure 50-101-22].
P-54617
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-101-20].
Figure 50-101-21
4
3
1
P-48624
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering linkage bar (Item 4) for damage and replace as
needed [Figure 50-101-21].
2
1
3
P-54625
1
P-48659 Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-101-24] and inspect the pintle solid cams
for damage or excessive wear.
NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft
1
P-54624
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-101-25].
Figure 50-101-26
1 3
4 2
2
P-48619
3
Figure 50-101-30
2 1
1
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
fall or move and cause injury or death.
W-2017-0286
Figure 50-101-31
2
P16121
Using the remote start tool, turn the key (Item 1) [Figure
2 50-101-33] to the run position.
P-54614
Move the traction lock override switch (Item 2) [Figure
50-101-33] so the traction function is unlocked. (The
Loosen the two bolts (Item 1) holding the right centering traction lock override switch light will be ON.) On a
block. Move the right hand centering block (Item 2)
P-48451
Figure 50-101-34
1 1
2
P-54610
Figure 50-101-36
2 1
2 1
P-48632
WARNING
P-48448
Never work on a machine with the lift arms up unless the lift
arms are secured by an ap proved lift arm support device.
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
Failure to use an approved lift arm support device can allow
(Item 2). Th e bolt (Item 2) [Figure 50-101-37] must be
the lift arms or attachment to fall and cause injury or death.
W-2059-0598
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Raise the l ift arms and install an a pproved lift arm Figure 50-101-38
support device. (See Installing Lift Arm Support Device
WARNING
2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Lift and block the loader. (See Procedure on Page 10-10- P-54613
1.)
Raise the operator cab. (See Raising The Operator Cab Loosen the nut (Item 1) only until the tension is released
on Page 10-30-1.) from the torsion bushing (Item 2) [Figure 50-101-38].
Pre-load tension in the torsion bushings must be The bolt must be loose enough to al low the tor sion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-101-38] to turn freely
between the torsion bushing and the linkage bar.
Figure 50-101-39
1 3 4
P-51174
3 2
2
4
1
P-51173 1
P-51133
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the base pintle
arm cam (Item 2) and the centering block (Item 3) arm mounting bolt (Item 1) and both of the up per pintle
[Figure 50-101-40]. mount bolts (Item 2) [Figure 50-101-42] and tighten to
35-40 ft.-lb. (48-54 N•m) torque. There should be no play
between the pintle arm and the square pump shaft.
Figure 50-101-43
1
1 1
P-51175
P-54609
Disconnect the remote start tool. (See REMOTE START
on Page 10-60-1.)
Loosen the two bolts and nuts (Item 1) [Figure 50-101-
43] on each steering linkage bar. Figure 50-101-46
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35-40
ft.-lb. (47,5-54,2 N•m) [Figure 50-101-46].
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
pintle arm is rotated to the front as far as possible
[Figure 50-101-44]. Use a lo cking plier, clamp the two
linkage bars together.
1 P-37574
Figure 50-110-1
1
1
P-28845
2 P-28843
To replace the rubber boot (Item 1) [Figure 50-110-2] on
the control panel, remove the control lever (See Control
Disconnect the electrical connectors from the control Lever Removal And Installation on Page 50-110-1.)
lever [Figure 50-110-1].
Figure 50-111-1
1
1
N-17773
2
P-21879
P-28963
Figure 50-111-5
1
P-21860
Figure 50-111-6 5
2
1 4
1 P-21862
P-21878
Figure 50-111-12
1
P-21880 2 3
Figure 50-111-10
1
P-21799
4
3 7
1 Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-111-11] & [Figure 50-
111-12] to assure proper return of the control handle to
4 neutral and minimize harness movement.
3
NOTE: Route wires (Item 2) [Figure 50-111-11] &
5 6 [Figure 50-111-12] as sh own away from stop
2 strap (Item 3) [Figure 50-111-11] & [Figure 50-
P-21882 111-12] to avoid wire damage.
N-17384
1
Remove the rubber handle cover (Item 1) [Figure 50-
111-15] from the handle.
2 2
N-17385
Figure 50-111-17
P-48736
2
1 Disconnect the electrical connectors (Item 1) [Figure 50-
N-17394 111-19] from the control lever switch handle.
N-22796
Figure 50-111-20
2
1
1
P13734
Figure 50-111-23
P-32595 1
nuts.
To replace the r ubber boot (Item 1) [Figure 50-111-23]
Installation: Tighten the u-bolts so the lever can not be
on the control panel, remove the c ontrol lever. (See
moved either right or left when seated in the operator
Control Lever Removal and Installation on Page 50-111-
seat. Control lever end (Item 2) [Figure 50-111-20]
5.)
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
Drill out the four rivets (Item 2) [Figure 50-111-23]
raising the cab. The distance between handles should be
located on the flange of the rubber boot and remove the
18.25 inches [Figure 50-111-21].
old boot.
Remove the control lever from the cross shaft and control
Install the new boot and reinstall the control lever. (See
panel.
Control Lever Removal and Installation on Page 50-111-
5.)
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
(NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C421
HEADLIGHTS
4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
7.7 ohm
GROUND
2370 2 2
GROUND
(NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
PWM
2380 2 2
BICS HYDRAULIC LOCK
G
C
D
E
B
A
K
E
F
J
WIRING SCHEMATIC Printable Version Click Here
C420
4410 A A 9.8 ohm
2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
(Without ACS Option) WIRES CONNECT BY LETTER
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
S130 (S/N 524611001 AND ABOVE) B A
2340 2 2 PWM
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
(PRINTED OCTOBER 2003)
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY HYDRAULIC
V-0396
C108
3300 A A TEMPERATURE
SWITCH
SENDER
BRAKE
3310 B B
1930
RED = RED 500-3000 ohm
2000
RNG = ORANGE
BLK = BLACK
C435
RIGHT
LBL = LIGHT BLUE 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN
SWITCHED POWER 1000-1999 RNG AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4470 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2470 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430
29 26 J1 J2 32 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15
C105
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 3700 42 9410 G See C492
B 1200 9200 4820 4310 4920
2410 REAR STATUS LH SKI FUEL PWM RH SKI
SEE J2 FRONT COMPUTER SEAT BAR
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
BASE ROD IN DOWN SENDER DOWN
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 4200 6210 8800
40
SENDER
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
ALTERNATOR 2010 6736515
4910
HOLD PULL
4730
4110
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
C
4300
4320
4310
4910
4920
4930
4940
4230
2530
2800
C101
1490
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
Dealer Copy -- Not for Resale
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B PULL 0.3 ohm
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
25A
P P
(ATTACHMENT)
(COMPUTER)
N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 7101088 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A
F
A
F
1080
1040
G
-
D
C
E
A
B
1300
F
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
COMPUTER ACS
ACD & REMOTE
1310 START CONNECTOR V-0396 (10-1-03)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
391 of 638
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
2 2 2430 2370 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
REAR BASE 2380 2
C414
1 1 4440 BICS HYDRAULIC LOCK
G
C
D
E
A
K
E
F
7.5 ohm
C420
2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
(With ACS Option) WIRES CONNECT BY LETTER
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
S130 (S/N 524611001 AND ABOVE) B A
2340 2 2 PWM
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
(PRINTEDOCTOBER 2003)
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY HYDRAULIC
V-0397
C108
3300 A A TEMPERATURE
SWITCH
SENDER
BRAKE
3310 B B
1930
RED = RED 500-3000 ohm
2000
RNG = ORANGE
BLK = BLACK
C435
RIGHT
LBL = LIGHT BLUE 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN AUX RELIEF
SWITCHED POWER 1000-1999 RNG
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4470 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2470 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430
29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A 3400 15
C105
HYDRAULIC CHARGE C
A 3400 4360 4330 2900 9100 4810 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
11 12 13 14 15 16 17 18 19 20 See C492 N K G L B R P S F E D C M A J H
2420 3700 42 9410 G
B 4440 1200 9200 4820 4310 4920
2410 REAR STATUS LH SKI FUEL PWM RH SKI
SEE J2 FRONT COMPUTER SEAT BAR
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
BASE ROD IN DOWN SENDER DOWN
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 4200 6210 8800
40
SENDER
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 17 41 4
B
B B 1800
FUEL
EXCITATION
SHUTOFF
J1
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
Dealer Copy -- Not for Resale
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
TO OPTIONS C465 C466
GLOW PLUGS 4100 B B PULL 0.3 ohm
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
C 7100 A TO OPTIONS C450
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
TO OPTIONS TO OPTIONS
C
B
A
L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
F 4730 CONNECTOR) CONNECTOR)
1510
4650
2650
D 4235
C488
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
(ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
J J
C489
25A
P A 1170
(ATTACHMENT)
(COMPUTER)
N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
FUSE 1 FUSE 3 FUSE 6
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
MAINFRAME HARNESS 7101088 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0397 (10-1-03)
BATTERY
392 of 638
WIRING SCHEMATIC TO ENGINE OR MAINFRAME AIR CONDITIONER SWITCH
THERMOSTAT
OPTIONS 7100 C 3100 A A
C630
2650 F
C612
S130 (S/N 524611001 AND ABOVE) OFF A 7010 B B
C103
6600 G
(S/N 524711001 AND ABOVE) LOW
2100
B 2310 2205 C C
BACK-UP
6400 E MEDIUM TO OPTIONS (AC)
ALARM 6310 A HIGH
(PRINTED OCTOBER 2003) 6500 D
V-0398 6200 H HERE OR TO OPTIONS
(HVAC JUMPER) HEATER VALVE
2600 B
DBL A A 3200 1300 A A RED 10
C613
Printable Version Click Here WHT B B 7200 D D WHT 8 M
6340
C614
2620
7000
2610
6610
6320
6620
6330
2640
C BLK C C 2110 2130 C C BLK 7
1110
POTENTIOMETER B B
B E E
2630 6210 1000
E F C A B D F E D C B A F F
C604 C605 REGISTRATION LEFT WORK RIGHT WORK L 5000 3 3 YEL BLOWER MOTOR
E F C A B D F E D C B A LAMP
M
1200 2 2 RED
C611
H 1010 1 1 RNG M
2200 4 4 BLK
DELUXE EUROPEAN BLOWER SWITCH
5 5
POWER RELAY TO OPTIONS 7 pin Octal ACD/Remote
(DELUXE ACCESSORY)
C617
30 SSL 7-PIN Control -
87A 1190 B CAN CONNECTOR Harness 6719431
D F C E A B G
HVAC HARNESS - 6725933 2740 C
Controller
DLX ACD W/Mag.
9800
1160
9700
1710
9500
9600
2710
667549
6675493
SSL 7-PIN
C426 To Mainframe TO HORN
C705
Harness CONNECTOR KEY "RUN" D 9800 PUR J1 - 8-PIN
CAN CONNECTOR D F C E A B G Instl DL Atch
UNSW POWER F 1160 RED/WHT 2720 H GROUND
C412
2750 B Control 6719450
HORN RELAY 1730 A CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
SW POWER E 1730 RNG 9 1720 B SW POWER ACD
9800
1160
9700
1710
9500
9600
2710
85 86 9 Machine
2770 7200 CAN LOW B 9620 PUR 9610 E CAN LOW
87 14 Connector to
2750 CAN HIGH A 9520 PUR 9510 D CAN HIGH
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN TO OPTIONS
(DELUXE ACCESSORY)
LEFT BLINKER RELAY 87A
30
2760 ADDITIONAL POWER
GROUND G 2730 BLK 13 C OPEN
Engine
Compartment
CONNECTOR
UNSW POWER 2 1160 RED/WHT 2720 H GROUND
Connector 7-PIN A OPEN
C666 ATTACHMENT
C490
E 85 86 2740 B
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD 2780 6415 on Loader
D 6410 6410
87
1740 A CONNECTOR G OPEN
SW POWER 1 1730 RNG 1720 B SW POWER 30 Boom
C411
87A 6020 10 J
CAN LOW B 9620 PUR 9610 E CAN LOW
C
BOOM-MOUNTED
N
CAN HIGH A 9520 PUR 9510 D CAN HIGH B 6000 ACD CONNECTORS
9 TO AWS TO MAINFRAME SW POWER K 1740
C401or
3 C A 6510 B C A
C402
GROUND 2730 BLK OPEN
RIGHT BLINKER CONTROLS GROUND B 2740 C703 J2 - 10-PIN BLACK
C489
7-PIN 2720 B
A OPEN RELAY C497
C666 ATTACHMENT
CONNECTOR G OPEN 85 86
1720 A E OUTPUT E 5100 5100 C E OUTPUT
2790 6515 F OUTPUT F 5350 5350 H F OUTPUT
J 6510
87
BOOM-MOUNTED 30 G OUTPUT G 5400 5400 J G OUTPUT
N 87A 6010
ACD CONNECTORS H OUTPUT H 5050 5050 B H OUTPUT ACD
SW POWER K 1740 Output
C OUTPUT C 5300 5300 G C OUTPUT
GROUND B 2740 C703 J2 - 10-PIN BLACK AWS HORN/BLINKER HARNESS - 6726662 D OUTPUT D 5150 5150 D D OUTPUT
Connector to
Engine
E OUTPUT E 5100 5100 C E OUTPUT No Rev. A OUTPUT A 5250 5250 F A OUTPUT Compartment
F OUTPUT F 5350 5350 H F OUTPUT
M OUTPUT M 5200 5200 E B OUTPUT
G OUTPUT G 5400 5400 J G OUTPUT ACCESSORY CONNECTOR ID (K TO L) L 5910 5000 A J OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT TO OPTIONS TO OPTIONS 12
(HVAC) ADDITIONAL POWER CONNECTOR
ID (K TO P) P 5510 5450 K K OUTPUT
C OUTPUT C 5300 5300 G C OUTPUT (DELUXE ACCESSORY)
11
C490
D OUTPUT D 5150 5150 D D OUTPUT C 2740 C 1740 A
C506 14-PIN
C704
C636
C642
2740 B ATTACHMENT J3 - 10-PIN GRAY
A OUTPUT A 5250 5250 F A OUTPUT B 1140 B Connector CONNECTOR
on Loader 5900 J ID #1
M OUTPUT M 5200 5200 E B OUTPUT A 1740 A
Boom 5500 A ID #2
ID (K TO L) L 5910 5000 A J OUTPUT TO MAINFRAME
(ACCESSORY CONNECTOR) B ID #3 ACD
ID (K TO P) P 5510 5450 K K OUTPUT BLOWER
(ASSEMBLY HVAC/ACCESSORY 1730 1720 A C ID #4 Input
C489
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
6674226-6664227)
HARNESS - 6725390
10
11
2720 B D ID #0 Connector to
Engine
CONNECTOR
5900 J ID #1 REV. A DELUXE ATTACHMENT E OPEN
Compartment
F OPEN
5500 A ID #2 ALARM
HORN TO HANDLE CONNECT0R CONTROL HARNESS - G OPEN
B ID #3
C412
2730 B
C ID #4
6675099
7200 A
6732730 H
K
OPEN
OPEN
D ID #0 FRONT WIPER Rev. none
M BOTTLE AND TANK
E OPEN 6664554 REV. A - PUMP 6677835 - 6668137
F OPEN 6725201 OR 6718627 NO
REV. OR 6718255 - TANK
FRONT WIPER
MOTOR
FRONT HORN HARNESS - 6727498
G OPEN Rev. D
V
DELUXE ATTACHMENT CONTROL HARNESS - 6729380
H OPEN
K OPEN Dealer Copy -- Not for Resale M
C622
7200 or YEL
7150 or DGN
2765 or BRN
LEFT TAILLIGHT
L X 6707789 RIGHT TAILLIGHT
6707789
BACK-UP
ALARM
6579858
TO OPTIONS
2745
(DELUXE ACCESSORY)
TO
POWER BOB-TACH MAINFRAME C 7310
SOLENOID C404 8 TO ENGINE OR
B
PARK
HIGH
TO OPTIONS B 2735 2755 B B A B C D E F REGISTRATION MAINFRAME RIGHT WORK A B C D E F
C610
6674305 LEFT WORK
C667
7100 A
C606
BACK-UP ALARM A B C D E F A B B A A B C A B C D E F G H A B C D E F
C F 7190 7180
SWITCHES 2 2 2 2
D
C607
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
TO
2530
2520
6310
2500
7100
6500
6400
6200
6250
2520
2510
6240
6230
6510
6710
6610
2550
6410
6810
6640
2540
2540
2530
6240
1720
2720
1740
2730
1730
6600
7100
6370
SOLENOID
E 2770 A A MAINFRAME
6674305
WIPER HARNESS - 6730885 REV. none
C402
1720 1730 A
9.8 ohms 2720 B
BACK-UP ALARM 9
12
12
11
C103
41 B B 6730 B B 6720
17
BACK-UP E 40 A A 2660 OPEN C C 6620
ALARM A 16 15
6579858
HARNESS 6713993 2630 D D 2620
REAR LIGHT HARNESS 6716419 M
FRONT WIPER
BOTTLE AND TANK BACK-UP ALARM D 40 A A 2640 OPEN E E OPEN
F H 42 B B 6330 F F 6320
RIGHT
WORKLIGHT
2620 6200 2600 B HARNESS - 6715659 B HARNESS 6713994 HARNESS 6731239
6210 6200 H
NO REV. 46 C C 6430 A A 6430
LEFT
WORKLIGHT
2630 6210 6310 A
TO MAINFRAME 41 B B 6730 B B 6830
18
E 40 A A 2660 OPEN C C 6630
RIGHT
TAILLIGHT
2610 6320 D HARNESS 6713993 2630 D D 2630
C622 FRONT WIPER
2650 G MOTOR TO ATTACHMENT 40 A A 2640 OPEN E E OPEN
LEFT L X
2640 6330 7100 C B 42 B B 6330 F F 6330
TAILLIGHT V 13
13
J HARNESS 6713994 HARNESS 6731239
BACKUP M
ALARM N
TO OPTIONS
2745
6800
2670
6700
2660
(DELUXE ACCESSORY) P
2640
6360
2650
1370
C 7310 M TO OLDER 2620
B 2735 2755 B B MODEL ATTACHMENTS 2630
A
C610
C506
C667
87A 87 86 87A 87 86
DOME LIGHT E 7160 C C D WHT S LEFT RIGHT 2640 87A 87 86 87A 87 86
TO OPTIONS SWITCH FLASHER FLASHER
A 7210 A A C BRN LT 2610 2650
C623
C608
6350
6340
TO OPTIONS
H YEL RT
1370
6210
6310
2790
2795
(EXTERIOR CAB)
L RNG
1020
1320
1020
1320
1020
1320
K
6440 1
C669
RNG
2785 2
TO OPTIONS (HVAC)
GRADER HARNESS - 6540 3 A B A B A B
C631
C612
B B 2310 2300 B
A A 7030
8
A 6707303 4 WAY FLASHER To Starter "B" Terminal
Left Marker Fuse 10A
STROBE OR
BEACON
HARNESS - 6718873 1010
8 8
Right Marker Fuse 10A Signal Fuse 10A
B A RNG = ORANGE
A C LETTER ACROSS
TO OPTIONS CAN SHIELD 9700 C BLK = BLACK
C632 (4 WAY FLASHER) C LBL = LIGHT BLUE CONNECTORS
ALARM SW POWER 1 1710 E To Mainframe A B
DBL = DARK BLUE
B A 2 2785 2780 D HORN TO HANDLE CONNECT0R Harness
CAN LOW B 9600 A LGN = LIGHT GREEN BATTERY FEED 1000-1999 RED, RED/WHT, RNG
C669
B A
C412
393 of 638
WIRING SCHEMATIC
OPTIONS 6676732-6674585
TO OPTIONS
(POWER BOB-TACH)
S130 (S/N 524611001 AND ABOVE) 6557904 POWER BOB-TACH 2770 E
FLASHER SWITCH
(S/N 524711001 AND ABOVE) 2760 D
C601
6668816-6665317 1
7000 A
BEACON SWITCH 2
(PRINTED OCTOBER 2003) C
6 6665316-6668815
V-0399 5 HAZARD SWITCH 3
7010 B
4
Printable Version Click Here TO LIGHT 1130
L
6010
2 1
6430 5
4
CONNECTOR 3 X 3
1180
RED = RED TO OPTIONS 1 2
WIRES CONNECT BY 4
6530
6
RNG = ORANGE (EXTERIOR CAB)
LETTER ACROSS 5 2750
BLK = BLACK 6 6676537 (AHC/AFC) TO MAINFRAME
CONNECTORS E 6700
LBL = LIGHT BLUE ACS SWITCH
2755
DBL = DARK BLUE A B D 2780 1
C670
LGN = LIGHT GREEN 4550 E
B A B 6540 2
DGN = DARK GREEN 3 R
YEL = YELLOW F 6440 2745
SOME CONNECTOR 4
PNK = PINK A 2755 4235 D
BODIES NOT SHOWN 5
WHT = WHITE 4275 C
C 6
BRN = BROWN FOR DRAWING CLARITY K
C488
TAN = TAN
PUR = PURPLE G
GRY = GRAY B
2730 J
1700 S
6400 L
6500 M
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1150 H
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL N
HYDRAULIC 4000-4999 LGN P
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK F
ACCESSORIES 7000-7999 WHT A
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR STANDARD ACCESSORY HARNESS - 6727468
TO OPTIONS
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH 2770 E
BEACON SWITCH V
2745
1
6420
SWITCH Dealer CopyD -- Not for
2760 M Resale
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
2 4 7220
3 5 SWITCH
4 1
4 5 2
6530 3
TO OPTIONS 5 6 1730
6 2750 2 1
(EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
D 2780 6 5
4
C670
7310
B 6540 5
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A
C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411
(FRONT WIPER)
PLUG
6000 B C
C F
E
C667
7210 A
ACS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2
3 R 2735 B
4
2755 4235 D
5 4275
6 C
K
G
B
C488
2730 J
6400 L
6500 M
1150 H
6300 N
6600 P
TO EUR0. LIGHTS 4730 F
CONNECTOR 1140 A
1700 S
V-0399 (10-1-03)
Printed in U.S.A.
394 of 638
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing a machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow ins tructions can
cause injury or death.
W-2003-0199
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Description
Figure 60-10-1
1
1
P-28840
Figure 60-10-2 The fuse panel cover (Item 1) [Figure 60-10-3] has a
decal inside to show the location and amp ratings.
P-13848A
Figure 60-10-4
P-28846
P-28903
F5 F1 E D C B F9
Remove the cover (Item 1) [Figure 60-10-4] to check or
replace the relays.
F10
E Not Used
F Glow Plugs Remove the cover (Item 1) [Figure 60-10-4] to check or
G Fuel Shutoff replace the fuses.
H Traction
J Starter The location and sizes are shown in [Figure 60-10-4] &
[Figure 60-10-5].
Solenoid Test
Figure 60-10-6
P9175
Correct resistance for the auxiliary, lift and tilt lock coils is
7.7 ohms ±1 ohm @ 76° F.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body. 1
If electrolyte is taken internally drink large quantities Disconnect the positive (+) battery cable (Item 1) [Figure
of water or milk! DO NO T induce vomiting. Get 60-20-2].
prompt medical attention.
W-2065-1296
Remove the battery from the loader.
Figure 60-20-1
P-48588
Figure 60-20-3
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Figure 60-20-5
Figure 60-20-4
When installing the battery in the loader, do not touch Clean the ter minals and cable ends as shown in fig ure
any metal parts with the battery terminal posts. [Figure 60-20-3] and [Figure 60-20-4].
Connect and tighten the battery cables. Connect the Check the electrolyte level in the battery. Add distilled
negative (-) cable last to prevent sparks. water as needed.
Install the battery holddown clamp. Put battery saver P/N (6664458) or grease on the battery
terminals and cable ends to prevent corrosion.
P-48509
Battery gas can explode and cause serious injury. Connect the end of the first cable (Item 1) to the positive
W-2066-1296 (+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-6] to th e
positive terminal on the loader starter.
Figure 60-30-1
2
P-24416A
1 2
4
1
3 P-24417
1
P-24543
The black cover has been removed to show alternator
rectifier/regulator assembly. The alternator contains field
Stop the engine. coil diodes (low current) (Item 1) [Figure 60-30-2],
grounded heat sink (Item 2) [Figure 60-30-2] & [Figure
Raise the operator cab. (See Raising The Operator Cab
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lb. (66 4
N) of force.
1 1
1
2 P-24542
1. If the test light does not light up, reattach the clamp
WARNING
and proceed to alternator voltage test. (See Charging
System Check on Page 60-30-2.) Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
2. If the test light lights up, there is a short (drain) in the make final connection (negative) at engine frame.
electrical system of the loader. The short must be
repaired before the charging system can be checked. Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Figure 60-30-6
1
P-30210
P-30210
Alternator Voltage Test
Figure 60-30-5 Turn engine OFF and remove the L & S ter minal
connector (Item 1) [Figure 60-30-6] off the alternator.
P-34676
Open tailgate.
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
Figure 60-30-7 1
P-24568
2
2
1 P-24566
P-24569 P-48825
P-48824
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Check the voltage across the “L” terminal (Item 1) and
ground (Item 2) [Figure 60-30-7]. The voltage should be Check the continuity between the “S” terminal (Item 1)
what the battery voltage is. If not, check wire harness,
WARNING P-30210
Never work on a machine with the lift arms up unless Disconnect the red wire (Item 1) [Figure 60-30-9] from
the lift arms are secured by an approved lift arm the alternator which comes from the battery.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Disconnect the wiring harness connector (Item 2) [Figure
to fall and cause injury or death. 60-30-9] from the alternator.
W-2059-0598
1
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove 2
both cables from the battery.) 3
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
P-24543
Place jackstands under the rear corners of the loader.
Raise the l ift arms and install an a pproved lift arm Remove the adjustment bolt (Item 1) [Figure 60-30-10]
support device. (See Installing Lift Arm Support Device from the mounting bracket.
on Page 10-20-1.)
Remove the alternator belt (Item 2) [Figure 60-30-10]
Raise the operator cab. (See Raising The Operator Cab from the alternator pulley.
on Page 10-30-1.)
Remove the mounting bolt (Item 3) [Figure 60-30-10].
Disconnect the negative (-) cable from the battery.
3 1
2
1 1
P-24527
Figure 60-30-12
1
1
P-24558
1
3
1 6
P-24533 47 13 14
2 12 5
Touch one probe to the “ L” terminal (Item 1) and the
other probe to the ground (Item 2) [Figure 60-30-15]. 10 11
19
18
17
16
15
C-3529B
P-24535
Remove the regulator cover.
Reverse the probes to check in the o ther direction Remove the four bolts holding halves together.
[Figure 60-30-16].
Pry the halves apart (use a press if needed).
There should be continuity in one direction only. Meter
readings should be different when probes are reversed. If Use a s oft jaw vise to h old rotor while removing pulley
there is no continuity or continuity in both directions, nut.
replace regulator.
Remove front case half from the rotor using a pl astic
hammer or press.
Figure 60-30-18
P-24524
P-24537
Touch the probes to the slip rings [Figure 60-30-20].
Use an ohmmeter to test the stator. The ohmmeter should read between 3.0-4.0 ohms.
Touch the probes to two of the bare stator wires [Figure
Move one of the probes to the third wire. Rotor Ground Test
Figure 60-30-19
P-24525
Assembly
Figure 60-30-22
P-24557
Checking
Figure 60-40-1
2
1
Bat
S
M
Cranking
Motor
P-34673
Figure 60-40-2 1
P-34675
1
Bat
S
M
Cranking
P-34674
Motor
Figure 60-40-5
4 2
1
P-34385
Remove the negative (-) and positive (+) cables from the
Parts Identification
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
32
7* 21
12 15
37
20
14
6
29
1 4
3
28
2
27
35 25. Holder
26. Bracket
27. Ring
22 26 28. Bolt
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
24 36. Bracket
37. Bearing
Figure 60-40-6
1
1
1
2
P-34596
Figure 60-40-7
1
1 2
4
3
3
N-00980
2 P-34600
Figure 60-40-11
3 2
1
P-34601
P-34599
Figure 60-40-14
1
3
2
2 2 4
P-34604
Figure 60-40-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Figure 60-40-17
N-00997
Figure 60-40-18
B-14458
Figure 60-40-21
N-00999
Check the commutator surface for burned spots which Replace the frame.
usually indicates an open-circuit, and correct it using
#400 sand paper. Figure 60-40-23
N-15005
S
M.T.
Starter B-14440
N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Clamp the starter in a vise. Using a 12 v olt battery and
Replace the brush holder and yoke if th e brushes need
Left Panel 2
1 3
The left instrument panel is the same for both Standard
and the Deluxe Instrument Panels [Figure 60-50-1]. 4 5
4 6 7 8
REF.
DESCRIPTION FUNCTION / OPERATION
NO
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY / HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES*
GLOW PLUG COUNTDOWN relating to the loader monitoring system. COUTNTDOWN - Glow Plug time remaining
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time
to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE CODES (Item 2).
(See BICS™ SYSTEM, Contents Page 60-01 Troubleshooting Guide for Troubleshooting
9 PRESS TO OPERATE LOADER Press to activate BICS™ System when the Seat Bar is down and operator is seated in operating position.
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE Button is pressed. The lift and tilt
functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can
be moved forward or backward when the light is ON.
13 TRACTION LOCK OVERRIDE (Function Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to
use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader
service. (See TRACTION LOCK OVERRIDE Page 60-01). Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or ◆SHUTDOWN condition.
* (See DIAGNOSTIC SERVICE CODES on Page 60-80-1.) for further description of SERVICE CODES.
29
B-15552B
OPT. OR ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
STD. LIGHT
System Voltage Std. ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt Std. ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine Std. ON 3 Beeps * Error Engine Oil Pressure sender out of range.
23 Oil Pressure Std. ON 3 Beeps * WARNING Engine oil level low.
Std. FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic Std. ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge Std. ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure Std. FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Engine coolant sender out of range
25 Coolant Std. ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature Std. FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic Std. ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil Std. ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature Std. FLASHING Continuous * SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter Std. FLASHING 3 Beeps * WARNING Air filter switch not connected.
Figure 60-50-3
1 3
ENTER PASSWORD
2
LANGUAGES
B-16165
4
The first screen you will see on your new loader will be as
6 5 B-15553B shown in [Figure 60-50-4].
(a) To enter a nu mber code (password) to allow Press and h old the START Button (Item 6) [Figure 60-
starting the engine (Keyless Start). 50-3] until the engine starts.
(b) To enter a num ber as directed for further use of Change Language: Press the Selection Button at the end
the Display Panel. of the arrow [Figure 60-50-4] to go to the next screen.
Figure 60-50-5
B-16655
Press
ADJUST CONTRAST
Press
UP OR DOWN
Arrow to
change contrast.
Press EXIT to
return to
previous level
menu.
B-16163/B16164/B-16161/B-16166/B-16167
Languages
TOOL/SETUP
LOADER FEATURES.
VITALS
Press SELECTION ARROW to select METRIC or
Enter Password on ENGLISH (M/E) readouts
Keypad
You can monitor real-time readouts of:
Press Enter to Continue Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Re-enter new password. System Voltage
Press Enter to Continue Engine Speed
(See left.)
The Display Panel is easy to use. Continue to set your
own preferences for running/monitoring your Bobcat
loader.
B-16163/B16164/B-16171/B-16172/B-16173/B-16174
2 3 4 5 6
POWER
FRONT
WIPER
WIPER
PLUG
USED
USED
REAR
USED
1
NOT
NOT
NOT
SIDE
CONSOLE
FRONT 12
CENTER 9
11
PANEL POWER TURN SIGNAL
BOB-TACH INDICATORS ROTATING
13 10 BEACON
8
PARKING HAZARD
NOT USED BRAKE LIGHTS
Side Console
Ref.
No. Description Function / Operation
1 POWER PLUG Provides a 12V receptacle for accessories.
2 NOT USED ---
3 FRONT WIPER Press the top of the switch to start the front wiper (press and hold for
wiper fluid). Press the bottom of the switch to stop the wiper.
4 REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of
the switch to provide washer fluid to clean the rear window.
5 NOT USED ---
6 NOT USED ---
Front Center Panel
7 ADVANCED CONTROL
Press the top to select Hand Controls; bottom to select Foot Controls.
SYSTEM (ACS)
8 NOT USED ---
9 TURN SIGNAL
Indicates left or right TURN SIGNALS are ON.
INDICATORS
10 HAZARD LIGHTS Press the left side to turn the HAZARD LIGHTS ON; right side to turn
OFF.
11 ROTATING BEACON Press the left side to turn the ROTATING BEACON ON; right side to
turn OFF.
12 POWER BOB-TACH Press and hold the top side to disengage the Bob-Tach wedges.
Press and hold the down side to engage the wedges into the
mounting frame holes.
13 PARKING BRAKE Press the top to engage the PARKING BRAKE; bottom to disengage.
Figure 60-50-9
RIGHT N-19353
1
Figure 60-50-12
RIGHT P-21769A
Figure 60-50-10
1
LEFT
N-19351
Remove the front light. (See Front Removal And Remove the panel.
Installation on Page 60-60-1.)
Reverse the removal procedure to install the instrument
Remove the three mounting bolts (Item 1) [Figure 60-50- panel.
9] or [Figure 60-50-10].
Figure 60-50-13
1 1
P-21944
Figure 60-50-14
P-21945
Figure 60-60-1
1
1
N-19351
Figure 60-60-2
N-19349
Figure 60-60-4
1 2
N-19339
Using care press the rear light and housing from the door
P-48511 [Figure 60-60-5].
Identification Chart
41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1
9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
Controller
J1
41 50
J2
41 50
31 40 31 40
21 30 21 30
11 20 11 20
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V-171/V-172
41
J1 50
1400 8000 X 9800 X X 3420 7200 3520 X
41 50
J2
4410 9410 4640 9340 3920 4500 X 3300 X X
1 2 3 4 5 6 7 8 9 10
V-172
WARNING 1
P-43390P
Lift and block the rear of the loader. (See Procedure on
Page 10-10-1.)
Remove the three mount bolts (Item 1) [Figure 60-70-2]
Raise the l ift arms and install an a pproved lift arm of the system controller mounting bracket.
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the system controller.
Stop the engine. Raise the seat bar. Installation: Tighten the nuts to 25-28 ft.-lb. (34-38 N•m)
Figure 60-70-1
P-43391
B-15551B
CODE CODE
01-16 Air filter not connected 11-05 Seat bar sensor short to battery
01-17 Air filter plugged 11-06 Seat bar sensor short to ground
02-16 Hydraulic charge filter not connected 12-21 Front auxiliary PWM switch out of range high
02-17 Hydraulic charge filter plugged 12-22 Front auxiliary PWM switch out of range low
12-23 Front auxiliary PWM switch not in neutral
03-09 Battery voltage low
03-10 Battery voltage high 13-05 Fuel shut-off hold solenoid short to battery
03-11 Battery voltage extremely high 13-06 Fuel shot-off hold solenoid short to ground
03-14 Battery voltage extremely low 13-07 Fuel shut-off solenoid open circuit
03-22 Battery voltage out of range low
14-02 Fuel shut-off pull solenoid error ON
04-09 Engine oil pressure low 14-03 Fuel shut-off pull solenoid error OFF
04-14 Engine oil pressure extremely low
04-15 Engine oil pressure shutdown level 15-02 Traction lock pull solenoid error ON
04-21 Engine oil pressure out of range high 15-03 Traction lock pull solenoid error OFF
04-22 Engine oil pressure out of range low
16-05 Traction lock hold solenoid short to battery
07-15 Hydraulic oil temperature shutdown level 20-02 Two-speed solenoid error ON
07-21 Hydraulic oil temperature out of range high 20-03 Two-speed solenoid error OFF
08-10 Engine coolant temperature high 21-03 Glow plug error OFF
CODE CODE
25-02 Rear auxiliary relief solenoid error ON 32-61 Handle lock short to ground
25-03 Rear auxiliary relief solenoid error Off 32-62 Handle lock short to battery
32-63 Pedal lock short to ground
26-02 Front base solenoid error ON 32-64 Pedal lock short to battery
26-03 Front base solenoid error OFF 32-65 Sensor supply voltage out of range
32-66 Battery voltage out of range
27-02 Front rod solenoid error ON 32-67 Switch flipped while operating
27-03 Front rod solenoid error OFF 32-68 Lift handle information error
32-69 Control pattern switch flipped while operating
28-02 Diverter solenoid error ON 32-70 Right drive handle short to ground
28-03 Diverter solenoid error OFF 32-71 Right drive handle short to battery
29-02 High flow solenoid error ON 33-23 Main Controller (Bobcat Controller) not
programmed
29-03 High flow solenoid error OFF
34-04 Deluxe panel no communication to Bobcat
controller
30-28 Controller Memory failure
32-04 ACS not communicating with Bobcat Controller 36-48 ACD multiple controllers present
32-23 ACS Not calibrated
32-31 Tilt actuator fault 37-02 Two-speed secondary error ON
32-32 Tilt actuator wiring fault 37-03 Two-speed secondary error OFF
32-33 Tilt handle wiring fault
32-34 Tilt actuator not in neutral
32-35 Tilt handle/pedal not in neutral
32-36 Lift actuator fault
32-37 Lift actuator wiring fault
32-38 Lift handle wiring fault
32-39 Lift actuator not in neutral
32-40 Lift handle/pedal not in neutral
32-41 No communication
32-49 Lift actuator short to ground
32-50 Tilt actuator short to ground
32-51 Lift actuator short to battery
32-52 Tilt actuator short to battery
32-53 Lift handle/pedal short to ground
32-54 Tilt handle/pedal short to ground
32-55 Lift handle/pedal short to battery
32-56 Tilt handle/pedal short to battery
32-57 Lift actuator reduced performance
32-58 Tilt actuator reduced performance
32-59 Lift actuator wrong direction
32-60 Tilt actuator wrong direction
CODE CODE
38-04 No communication from joystick controller 38-53 Left forward drive solenoid error OFF
38-05 Left joystick X axis not in neutral 38-54 Left reverse drive solenoid error OFF
38-06 Right joystick X axis not in neutral 38-55 Right forward drive solenoid error OFF
38-07 Left joystick Y as not in neutral 38-56 Right reverse drive solenoid error OFF
38-08 Right joystick Y axis not in neutral 38-57 Front right extend steering solenoid error OFF
38-09 Control pattern switch - Short to Battery or Ground 38-58 Front right retract steering solenoid error OFF
38-11 Lift actuator not in neutral 38-59 Front left extend steering solenoid error OFF
38-12 Tilt actuator not in neutral 38-60 Front left retract steering solenoid error OFF
38-13 Lift actuator fault 38-61 Rear right extend steering solenoid error OFF
38-14 Tilt actuator fault 38-62 Rear right retract steering solenoid error OFF
38-15 Right wheel speed fault 38-63 Rear left extend steering solenoid error OFF
38-16 Left wheel speed fault 38-64 Rear left retract steering solenoid error OFF
38-17 Tilt actuator reduced performance 38-65 Steering pressure solenoid error OFF
38-18 Lift actuator reduced performance 38-66 Back-up alarm error OFF
38-19 Left joystick X axis out of range high 38-67 No communication from Bobcat controller
38-20 Right joystick X axis out of range low 38-68 Wheel angles (alignment) not calibrated
38-21 Left joystick Y axis out of range high 38-69 Lift & tilt actuators not calibrated
38-22 Right joystick Y axis out of range high 38-70 Interrupted power
2. Raise the Seat Bar fully. All four BICS™ lights (Items
1, 2, 3, & 4) [PRESS TO OPERATE LOADER, SEAT
BAR, LIFT & T ILT VALVE and TRACTION*] on left
instrument panel should be OFF [Figure 60-90-1]
Troubleshooting Chart
WARNING
The following troubleshooting guide is provided for
assistance in lo cating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting guide. (See Troubleshooting Guide on Page 60-90-
3.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into
Troubleshooting Guide
2 Seat Bar is Seat Bar is up. Lift and tilt 2 11-05 Seat Bar sensor circuit shorted to battery
down. functions will voltage*.
not operate. 3 11-06 Seat Bar sensor circuit shorted to ground.
3 Control valve Control valve Lift, tilt and 1 17-07 Valve output circuit is open.
can be used. cannot be used. traction 2 17-05 Valve output circuit shorted to battery voltage*.
functions will 3 17-06 Valve output circuit shorted to ground.
not operate.
3 17-06 Controller not grounded or intermittent ground.
4 Loader can be Loader cannot Loader cannot 1 16-07 Traction lock hold solenoid circuit is open.
moved forward & be moved be moved 2 16-05 Traction lock hold solenoid circuit shorted to
backward forward and forward and battery voltage*.
backward. backward. 3 16-06 Traction lock hold solenoid circuit shorted to
ground.
5 15-02 Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be OFF).
6 15-03 Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
SEAT BAR LIFT & TILT VALVE TRACTION 03-09
Continuous System voltage low
Flashing 03-10 System voltage high
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and
both battery connections.
ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay.
*Normal BICS operating voltage is less than the electrical system voltage.
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL 1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
Test
Figure 60-100-1
1 P-4698
Figure 60-100-4
Use Sensor Tester (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
Figure 60-100-2
P-4699
1
If the above test fails, there is a problem with the seat bar
N-19558 sensor.
IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Figure 60-100-7
P-43382
N-19383
3
N-19219
Figure 60-100-8 NOTE: The sensor test light (Item 3) [Figure 60-100-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
Figure 60-100-10
N-18463
Figure 60-100-9
P-4699
2
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of traction lock. 8, 9, 10
SOLUTION SUGGESTIONS
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 doesn’t, check the brake 25 amp fuse.
When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of
4.
fuses. (See Fuse Location on Page 60-10-5.)
Inspecting
N-19077
Figure 60-110-3
N-19079
Figure 60-110-6
Remove the bracket (Item 1) [Figure 60-110-3] from the
chaincase cover.
1
Figure 60-110-4
P7926
1
Remove and inspect the compression spring (Item 1) and
spring cap washer (Item 2) [Figure 60-110-6] for wear or
damage. Replace if necessary. The spring may also stay
with the shaft when the electric solenoid and bracket are
removed from the chaincase.
Solenoid Removal And Installation (Cont'd) The part number listed will be needed to do the following
procedure:
Figure 60-110-7
P/N 6633583 - Polyurethane
2
3
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
1 support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-7964 Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Remove the shaft mounting bolt (Item 1), spring from the
assembly shaft (Item 2). Remove the wedge (Item 3) Raise the l oader operator cab. (See Raising The
[Figure 60-110-7] and inspect all parts for damage or
Figure 60-110-8 1
P11330
Figure 60-110-11
Remove the center chaincase cover [Figure 60-110-8].
(See Center Cover Removal And Installation on Page 40- 1
30-3.)
1 2
2
P11332
1 2
N-19106 N-19105
Apply a bead of polyurethane sealer (Item 1) [Figure 60- Do not tighten at this time.
110-12] around the bolt holes on the blocks.
2 1
3
2
4 4
1
P11337
P11334
NOTE: Bolt (Item 3) [Figure 60-110-13] & [Figure 60- After the bolts have been tightened recheck to make sure
110-14] represents the rear of the chaincase the shaft assembly is moving freely in the guides.
cover.
Remove the wedge assembly (Item 1) [Figure 60-110-
Install and tighten the two bolts (Item 4) [Figure 60-110- 15].
13].
NOTE: The wedge assembly must slide freely in the
grooves of the guides. Tighten the four guide
bolts to 90-100 ft.-lb. (123-135 N•m) torque.
Figure 60-110-16
1
2 1
2
N-19109
Remove the two bolts (Item 1) and remove the electric Install the gasket (Item 2) [Figure 60-110-18].
solenoid (Item 2) [Figure 60-110-16] from the center
chaincase cover.
N-19079
Figure 60-110-19
1
2
P11341
Figure 60-120-3
1
1
P-30209 P-21879
Figure 60-120-2
P-21767
1
Figure 60-120-5
P-21769A
Troubleshooting Guide
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then illuminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned on.
The following list shows the probable causes when the icon is illuminate.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature
Errors - lights solid with 3 beeps 32-54 - Tilt handle/pedal short to ground
32-04 - ACS in error 32-55 - Lift handle/pedal short to battery
32-23 - ACS not calibrated 32-56 - Tilt handle/pedal short to battery
32-31 - Tilt actuator fault 32-57 - Lift actuator reduced performance
32-34 - Tilt actuator not calibrated 32-58 - Tilt actuator reduced performance
32-35 - Tilt handle/pedal not calibrated 32-59 - Lift actuator wrong direction
32-36 - Lift actuator fault 32-60 - Tilt actuator wrong direction
32-39 - Lift actuator not calibrated 32-61 - Handle lock short to ground
32-40 - Lift handle/ pedal short not calibrated 32-62 - Handle lock short to battery
32-49 - Lift actuator short to ground 32-63 - Pedal lock short to ground
32-50 - Tilt actuator short to ground 32-64 - Pedal lock short to battery
32-51 - Lift actuator short to battery 32-65 - Sensor supply voltage out of range
32-52 - Tilt actuator short to battery 32-66 - Battery out of range
32-53 - Lift handle/pedal short to ground 32-67 - Switch flipped while operating
To see what error occurred, check the service code on the left instrument panel. (See DIAGNOSTIC SERVICE CODES
on Page 60-80-1.)
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2
Figure 60-120-6
P16578
P-28964
The wire connector (Item 1) [Figure 60-120-8] can be
removed from the handle sensor wires, use the following
Remove control Panel. (See Removal and Installation on procedure.
Page 50-100-1 and See Removal and Installation on
Figure 60-120-7
2
1
1
2 1
P13725 P13732
Handle Sensor Connector (Cont’d) Disconnect the h arness connector (Item 2) [Figure 60-
120-11] from the handle lock solenoid connector.
Figure 60-120-10
Figure 60-120-12
1 2
3
1
1
1
P13733
P13725 P13732
2-Terminal - Black
3-Terminal - Green
Figure 60-120-11
1
3
2
1
P13735
2 1
P-28961
Figure 60-120-14
1
P-48735
Figure 60-120-17
Remove the wedge (Item 1) [Figure 60-120-14] from the
harness connector (Black) that connects to th e handle
Figure 60-120-15 4
2
1
1
3 P-48736
2
1
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-120-17] from the loader wiring harness
P13735 connectors.
Figure 60-120-18
2 2
P-24234
1
Pull harness (Item 1) [Figure 60-120-20] out the bottom
of the control lever tube.
N-22783
Switch Handle Installation
Roll the pistol grip handle cover (Item 1) [Figure 60-120- Figure 60-120-21
18] down.
Figure 60-120-19
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
1
Switch Handle Installation (Cont’d) Install the wires into the connectors as listed below:
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
1
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/ Black
Three-Pin Connector
P-21700 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Install the new switch handle and wires from the top of
the control lever.
Three-Pin Connector
2 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
1 A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
P-21695
C-Terminal - Blank
D-Terminal - Yellow
Remove tape from wires for installation and install the 6 E-Terminal - Blank
inches of heat shrink tube (Item 1) [Figure 60-120-23]
approximately 3 inches into the control lever. Apply heat
heat to the exposed heat shrink tube.
Figure 60-120-24
1
3
2
P13735
1
N-17779 Left and Right Control Lever Switch Handle [Figure 60-
120-26]
1-Terminal - Red/White
Figure 60-120-25 2-Terminal - Black/White
Figure 60-120-27
1
1
3
2
N-17772
Figure 60-120-28 2
1
N-17742 N-17741
N-18940
Figure 60-120-31
2
1
P-21787
1
P-21836 Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-120-33].
Disconnect the ha rness connector (Item 1) [Figure 60- Installation: Apply a dr op of oil to the solenoid threads
120-31] from the handle sensor connector.
P-21789
1
P-21832
Check the O -ring (Item 1) [Figure 60-120-34] for
damage. Replace as necessary.
Remove the two screws (Item 1) [Figure 60-120-32]
holding the handle lock solenoid to the handle.
Figure 60-120-35
1
2 3
P-21802
1
1
P-21800 P-21801
Figure 60-120-38
B-16627
1
With the seat bar down, turn the ignition key on (keyless
panel choose RUN/ENTER) [Figure 60-120-39] and
P-24182 push the PRESS TO OPERATE button (Item 1) [Figure
60-120-40] to unlock the hand controls.
The new controller uses a calibration sequence to NOTE: Do not start the engine.
optimize the control system. The optimizing ensures full
Press RUN/ENTER
B-16626
Figure 60-120-42
2 1 2
B-16628
Fully press the heel of the lift and tilt pedals (Item 2)
[Figure 60-120-44] down and hold for one second.
Calibration is complete.
Figure 60-120-45
1
P-24271
1
P-24269 The wire connector (Item 1) [Figure 60-120-47] can be
removed from the s ensor wires, use the fol lowing
procedure.
Remove the two bolts (Item 1) [Figure 60-120-45] from
the end of the foot sensor.
4 P-24272 P-24273
3
2
Remove the wedge (Item 1) [Figure 60-120-48] from the
connector.
1 P-24270
2
3 1
2
P-30078
Figure 60-120-50
2
P-21790
Figure 60-120-53
1
1
P-21800 P-21801
1 3
2
P-21802
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
*3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
On earlier versions, the switch (Item 2) must be in the fourteen pin position. The current Version ACD
(Attachment Control Device) without switch, automatically recognizes the use of the seven or fourteen pin
connector when connected.
The ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab, must
be illuminated continuously.
If the ACD light flashes, check for diagnostic service codes. (See DIAGNOSTIC SERVICE CODES on Page
60-80-1.) for the proper procedure.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
NOTE: The key switch fully left position activates solenoids number 1 and 4.
Adjustment
Figure 60-140-1
2 P-48666
Turn the RP M sensor and the jam nut out from the
P-48665 flywheel. Set a c learance of 0 .050 inch (1,27 mm)
between the jam nut and the housing with a feeler gauge
(Item 1) [Figure 60-140-2].
When reinstalling the RPM sensor, turn the RPM sensor
(Item 1) [Figure 60-140-1] in until it makes contact with NOTE: New RPM sensors have a plastic tip which is
the engine flywheel.
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3,54
Engine will not start. 2, 5, 6, 7, 8, 9, 11,12,13,14,15,16,19,27,28,29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16,17,19,20,21,23,24,25,27,28,29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
Chart (Cont'd)
WARNING P-4072
Never work on a machine with the lift arms up unless Pull the speed control away from the loader frame and
the lift arms are secured by an approved lift arm disconnect the speed control rod (Item 1) [Figure 70-20-
support device. Failure to use an approved lift arm 2] from the control.
support device can allow the lift arms or attachment
to fall and cause injury or death. Installation: Be sure to install the c ontrol rod in the
W-2059-0598 bottom hole of the speed control.
2
1
P-4068
Figure 70-30-1
2 P-28913
Figure 70-40-1 1
P-48569
Disconnect the wire harness connector (Item 1) [Figure Remove the two upper mounting bolts (Item 3) [Figure
70-40-1] from the air cleaner sensor on the air cleaner. 70-40-2] from the top mount of the air cleaner.
P-48568
WARNING 1
2
Figure 70-50-1
P-48571
P-48567
P-48512
Figure 70-50-5
1
N-21148
Figure 70-50-8
Remove the right side radiator mounting bolt (Item 1) and
block off plate (Item 2) [Figure 70-50-5].
Figure 70-50-6
P-48574
1 1
WARNING
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
1 Figure 70-51-3
P-54001
Figure 70-51-4 2
P-54062
Figure 70-51-7
P-54048
P-54311
P0581
Loosen the idler pulley bolt (Item 1) [Figure 70-60-1]. Figure 70-60-4
1 4
3
2
1
5
N-00303
WARNING P-28921A
Never work on a machine with the lift arms up unless Remove the nu ts (Item 1) from the u-bolt which mounts
the lift arms are secured by an approved lift arm the fan belt shield (Item 2) [Figure 70-60-6] to the blower
support device. Failure to use an approved lift arm fan.
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the fan belt shield (Item 2) [Figure 70-60-6]
W-2059-0598 from the blower fan.
Figure 70-60-5
2
P-28922A
OIL LEVEL
P-43836 P-4301
NOTE: When checking the fan gearbox oil le vel, be Installation: Tighten the four mounting bolts to 25-28 ft.-
sure the level does not go above the top of the
Figure 70-60-9
1 4
1
3 2 P13920A
N-19376A
Lower the blower fan from the housing until it rests on the
steering linkage plate [Figure 70-60-11].
Remove the two m ounting bolts (Item 1) and t he two
spacer tubes (Item 2) [Figure 70-60-9] from the blo wer
fan.
Figure 70-60-12
P-43448
Installation: Use R.T.V. sealant to reseal the blower Blower Disassembly And Assembly
housing.
Figure 70-60-14
Loosen the el ectrical harnesses from the main frame of
the loader and the blower housing.
CD-9952
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
CD-9953
Figure 70-60-15
Remove the fan from the tapered shaft [Figure 70-60-
2 16].
Figure 70-60-17
1
P3006
1
Use the fol lowing procedure to remove the fan from the
shaft. CD-9954
1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.)
7. Long Key
8. Shaft (Short)
9. Short Key
10. Long Housing
11. Nut 1
12. Gear
13. Washer
14. Screw 18
15. Square Shim
*16. Short Housing 1 2
17. Bolt 6
3 4
18. Snap Ring (Large)
19. Cap 5 7 4
4
12
13
14
9
21
10 *16
11
15
20 17
12
4
13
14
18
19
Gearbox Disassembly
1. Complete Assembly
2. Long Housing Assembly Part Number
3. Long Housing Tag
4. Short Housing Assembly (See Note Below)
5. Internal Parts
NOTE: Be sure to count the number and thickness of Remove the four mounting bolts and the part number tag
shims during disassembly. Install the shims [Figure 70-60-19].
in the original location during assembly.
Remove the oil from the gearbox.
NOTE: Always replace seals during assembly.
Replace the parts in the gearbox as needed.
Figure 70-60-20
P3005A
P2999
Loosen the set screws (Item 1) and remove the pulley
(Item 2) [Figure 70-60-18].
Drill an 1/ 8 inch (3 mm) hole in th e seal. Use a sl ide
Remove the long key (Item 3) [Figure 70-60-18]. hammer tool to remove the seal [Figure 70-60-20].
Figure 70-60-21
P2966
Figure 70-60-24
Remove the small snap ring [Figure 70-60-21].
Figure 70-60-22
P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-24].
Remove the small shims [Figure 70-60-22]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
Figure 70-60-25
P2996
Figure 70-60-28
Support the bearing and press the shaft from the bearing
[Figure 70-60-25].
Figure 70-60-26
P2970
Remove the la rge snap ring from the fl ange end of the
housing [Figure 70-60-28].
P2997
WARNING
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
drilling or grinding.
W-2108-1186
Figure 70-60-29
P2973
Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-31].
Figure 70-60-32
Remove the large shims from the housing [Figure 70-60-
29].
Figure 70-60-30
1
P2998
Figure 70-60-33
P2972
P3001
Press the bearing, shims and gear from the shaft [Figure
70-60-34].
Gearbox Assembly
NOTE: (See Gearbox Disassembly on Page 70-60-7.)
when ordering parts for the Fan Gearbox.
P2961
Figure 70-60-37
P2963
P2960
Figure 70-60-40
P2967
Install the small snap ring in the groove above the shims Figure 70-60-43
[Figure 70-60-40].
P2966
Short Housing
Figure 70-60-44
P2970
Install the large snap ring in the groove above the shims
[Figure 70-60-46].
Figure 70-60-45
P2971
Align and press the gear on the shaft (teeth toward the
P2969 tapered end of the shaft) [Figure 70-60-47].
Figure 70-60-48
P2977
Install on the shaft, the same number and size shims that
P2975 were removed during disassembly [Figure 70-60-50].
Figure 70-60-51
After the g ear is seated, drive the key down inside the
gear key way [Figure 70-60-48].
Figure 70-60-49
P2974
P2976
P2973
P2987
P2978
P2981
Figure 70-60-56
Part Number
Tag 1
P2982
Figure 70-60-57
1.0”
(25,4 mm)
1 2
P2984A
Figure 70-60-59
P3089
Remove the bolts from the flanges and separate the two
Using a m agnetic based dial indicator mounted on a housings.
bench vise, touch the dial stem on the bolt (Item 1)
[Figure 70-60-59].
Figure 70-60-61
LONG HOUSING
P2985
Figure 70-60-62
SHORT HOUSING
NOTE: When filling the fan gea rbox with oil, be sure
the level does not go above the top of the
shaft in the gearbox. Use a light colored 90W
gear lube.
Compression Checking
Figure 70-70-2
P-51936
1
P-51939
Install the co rrect compression adapter (Item 1) [Figure Connect the fuel stop solenoid.
70-70-2] into the cylinder head.
Figure 70-70-5
1
2
P-51933
P-51934
Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-70-6] from the top of
each glow plug.
Touch one probe to the end of the gl ow plug and the
The reading must be between 1 and 2 ohms [Figure 70- Remove the glow plug connecting strap (Item 3) [Figure
70-5]. If the resistance is infinite, the coil of the glow plug 70-70-6].
is broken.
Figure 70-70-7
Repeat the procedure for each glow plug.
P-51935
Figure 70-70-8
P-51940
P-48708
Stop the engine and open the rear door [Figure 70-70-9].
Photo [Figure 70-70-8] shows the glow plug assembly Disconnect the connector (Item 1) [Figure 70-70-9] from
removed from the engine. Inspect the glow plugs and the fuel shut-off solenoid.
replace when necessary.
Figure 70-70-10
P-51941
P-51954
P-51943
Figure 70-70-14
1
1 2
1
3
3
P-51944
Disconnect the fuel inlet hose (Item 1) and the fuel return
P-51933 hose (Item 2) from the injection pump vent [Figure 70-
70-15].
Clean the area around the injection pump thoroughly. Cap the inlets on the injection pump vent where the
hoses were removed [Figure 70-70-15].
Disconnect the high pressure fuel lines (Item 1) [Figure
Figure 70-70-16
IMPORTANT 1
P-51945
Figure 70-70-17
P-51683
1
Remove the high-idling body (Item 1) [Figure 70-70-19]
from the engine block.
P-48820
Figure 70-70-20
P-51942
Figure 70-70-21
P-51952
1
P-4359
1
Figure 70-70-22
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1 2
P-4357
Figure 70-70-24
1
P-48779
2
The size of sh ims are identified by a symbol (Item 1)
1 [Figure 70-70-26] on the shims.
P-51944
(1) Two holes means 0.0008 in (0.20 mm) shim.
Installation: Remove the bolts (Item 1) that secure the (2) One hole means 0.0010 in (0.25 mm) shim.
fill cover (Item 2) [Figure 70-70-24] from the injection
Figure 70-70-25 (4) Three holes means 0.0014 in (0.35 mm) shim.
Figure 70-70-27
P-4364
2
P-4360
Install the sh im(s) (Item 1) [Figure 70-70-25] on the
injection pump mounting surface. For information on the
number of shims used. (See Timing The Injection Pump Install the injection pump in the engine.
on Page 70-70-9.)
Put the pin (Item 1) on the control rack in the slot of the
fork lever (Item 2) [Figure 70-70-27] located inside the
injection pump chamber.
IMPORTANT
If the pin is n ot correctly installed in t he fork lever,
the engine will run over maximum speed, resulting in
serious damage to the engine.
I-2086-1195
P-48823
P-54133
Rotate slowly until fuel just starts to flow upward into the
plastic tube.
2 1
At this instant, the 8.2° BTDC timing mark on the flywheel
should be aligned with the mark in the window (Item 1)
[Figure 70-70-30].
P-51949
IMPORTANT 1
Figure 70-70-33
P-48728
P-48727
1
Remove the four retainer bolts (Item 1) from the top of 2
the fuel injectors [Figure 70-70-33].
P-37583
Checking Nozzle Injection Pressure The tool listed will be n eeded to do th e following
procedure:
The tool listed will be ne eded to d o the following
procedure: OEM1064 - Injector Nozzle Tester
3EEABAC1P013A
Figure 70-70-38 2 1
3
B-5568
Set the injection nozzle to a nozzle tester. NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [Figure
Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/ 70-70-39].
cm², 2418 PSI) for 10 seconds.
Figure 70-70-40
4
3
1 2 3 4 5 6 7 8 1
2
(1) Idle Gear
(2) Idle Collar
(3) Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
B-05569
Stop the engine and open the rear door.
Valve
I=Intake I E I E I E I E
E=Exhaust
P-48604
WARNING
Mark the four drive motor hoses (Item 1) [Figure 70-80-
Never work on a machine with the lift arms up unless 1] for correct installation.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Disconnect the four drive motor hoses (Item 1) [Figure
support device can allow the lift arms or attachment 70-80-1] from the hydrostatic pump.
to fall and cause injury or death.
Figure 70-80-3
P-48605
Figure 70-80-4
1
1
P-43249
P-48655
Disconnect the hand pump (Item 1) [Figure 70-80-6]
from the fuel line connected to the fuel tank. Cap the fuel
Remove the mo unting bolt and nut (Item 1) [Figure 70- lines.
80-4] from the right front engine mount.
P-48612
Figure 70-80-10
P-48610
P-48611
Remove the belt from the cooling fan (Item 2) [Figure 70-
P-48616 80-9].
Figure 70-80-11
1
2
Note: The engine electrical harness (Item 6) [Figure 70-80-11] can remain on the engine while removing the
engine from the loader.
Figure 70-80-12
P-48606
Figure 70-80-15
Remove the mo unting bolt and nut (Item 1) [Figure 70-
80-12] from the left rear engine mount.
P-48393
Figure 70-80-16
2.5”
2.5”
1/4” (4)
1-1/2” Square Tubing
1 1/4” Wall Thickness Thick Gusset
1 1”
16”
4”
P-48737 2”
45° 9”
1”
Fasten a chain securely to each of the lifting brackets
(Item 1) [Figure 70-80-16] on the engine.
1”
.5”
.375”
Use Two 3/8”x 1-1/4” Bolts
for Drilled and Tapped Holes. MC-1799C
Figure 70-80-18 2
1
4
1
7
MC-1771
Replace all four engine mounts two front and two rear.
Figure 70-80-20
Engine
Mounting
Bracket
Washer
Loader Engine
Frame Mount
Spacer
Snubbing
Washer
MC-1765
Figure 70-90-1
1
P-4237
P-48651
Figure 70-90-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
P-48650 90-7] which fasten the housing on the engine.
P-4231
Figure 70-100-1
2 4 1
2
3
P-47243
Figure 70-100-2
2 2
2 2
P-47244
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-100-4].
2
17 9 1 8 16
13 5 4 12
P-47247
Figure 70-100-8
1
1
2
P-47246
P-47248
Remove the clamps (Item 1) and remove the hose (Item
2) [Figure 70-100-6].
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-100-8].
Figure 70-100-10 If the measurement is two sizes smaller than the selected
gasket or smaller than gasket size 15, th e engine must
be disassembled, clearances checked, and
reassembled.
1
After the gasket and cylinder head have been installed,
turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
P-47252
7
6
8
5 7
5 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
PI-9987 3) and thermostat (Item 4) [Figure 70-100-14].
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
1 3
P-51631
NOTE: Do not put the straight edge across NOTE: Put the solder in position so they do not touch
combustion chambers. the valves.
Put a feeler gauge (Item 2) [Figure 70-100-15] between Turn the piston to bottom dead center.
the straight edge and the surface of the cylinder head.
Install the cylinder head and tighten to the correct torque
Figure 70-100-16 in the correct sequence. (See Cylinder Head Removal
And Installation on Page 70-100-1.)
Figure 70-100-18
B-14335
1. Cylinder Head
Surface
2. Recessing
3. Protrusion
PI-9990
Figure 70-100-21
8.86” (225 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259” 2
(6,5-6,6 mm)
0.197” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
PI-9992
PI-9995
PI-9994
Valve Spring
Figure 70-100-26
A-2759
Rocker Arm And Shaft Checking Remove the fu el injection pump. Fuel Injection Pump
Removal And Installation 70-70-5
Figure 70-100-28
Remove the cylinder head, rocker arms and push rods.
(See Cylinder Head Removal And Installation on Page
70-100-1.)
Figure 70-100-29
1
2
B-3697
If the clearance still exceeds the allowable limit after the Figure 70-100-30
bushing is replaced, replace the rocker arm shaft.
P-47255
Figure 70-100-31
P-47258
1
1
2
1
B-14339
Remove the wi re (Item 1) [Figure 70-100-32] from th e Installation: Tighten the bolts to 13-15 ft.-lb. (18-20 nm)
springs. torque.
Figure 70-100-35
Oil Seal
O-Rings
B-3617B
3
2
B-14340
Figure 70-100-38
1
2
1
P-47262
Figure 70-100-39
PI-10002
Camshaft Servicing
Figure 70-100-42
B-5001
Figure 70-100-45
A-2761
1.650-1.652”
(41,9-41,95 mm)
1.494-1.495”
(37,95-37,97 mm)
MC-1366
Figure 70-100-48
Measure the O.D. of the idler gear shaft [Figure 70-100-
46].
Timing Gears Checking Backlash Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
When the gears are installed, check the backlash of the 100-10.)
gears.
Remove the idler gear. (See Idler Gear And Camshaft
Figure 70-100-49 Removal And Installation on Page 70-100-13.)
Figure 70-100-50
P-47264
1 1
Hold one gear while turning the other gear [Figure 70- Remove the three bolts (Item 1) [Figure 70-100-50].
100-49].
Remove the two bolts and fu el camshaft retainer plate
If the backlash exceeds the allowable limit, check the oil (Item 2) [Figure 70-100-50].
clearance of the shaft and gear. If th e oil clearance is
correct, replace the gear. Figure 70-100-51
Fuel Camshaft Governor Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
The governor serves to keep the engine speed constant 100-10.)
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. Remove the idler gear. (See Idler Gear And Camshaft
Removal And Installation on Page 70-100-13.)
Figure 70-100-52
Figure 70-100-53
1. Start Spring Remove the crankshaft gear with a puller [Figure 70-
2. Governor Spring 100-53].
3. Governor Spring
4. Fork Lever Remove the crankshaft key.
5. Fork Lever
6. Fork Lever Shaft
7. Fork Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball PI-10008
Figure 70-100-54
B-3616
2
Measure the clearance between the lobes of the in ner
rotor and outer rotor [Figure 70-100-55].
Figure 70-100-56
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-100-54].
A-2732
PI-10009 PI-10010
Put a piece of press gauge on the rotor face [Figure 70- Install a pressure gauge [Figure 70-100-58].
100-57].
Remove the c over carefully. Measure the width of th e If the oil pressure is less than the a llowable limit, check
press gauge [Figure 70-100-57]. the following items:
If the clearance exceeds the al lowable limit replace the * Engine Oil Level Low
oil pump. * Oil Pump Defective
* Oil Galley Plugged
End Clearance 0.004-0.006 inch (0,11-0,15 mm) * Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
Remove the top edge from the cylinder bore with a ridge
reamer.
Figure 70-100-61
1 1
P-47267 2
Figure 70-100-60
2
1
P-47270
P-51633A Remove the snap ring (Item 1) and piston pin (Item 2)
[Figure 70-100-64].
Remove the rod cap and bearing [Figure 70-100-62]. Separate the piston (Item 3) from the connecting rod
Figure 70-100-63
PI-10015
A-2903
Figure 70-100-66
3
1
2
5
P-47272
4
P-47271 Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 70-100-67].
Installation: When reassembling, align the marks (Item If the measurement exceeds the allowable limit, replace
1) on the connecting rod and piston (Item 2). Heat the
Figure 70-100-68
P-47273
1.098-1.100”
(27,9-27,95 mm)
0.984-0.985”
(25,0-25,01 mm)
MC-1366
Piston And Connecting Rod Servicing (Cont’d) NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-100-72 doing this check.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-100-73
P-51630
Figure 70-100-74
1
2 5
4
P-47276
1
Install the bearing case cover (Item 1) [Figure 70-100-
76] with the casting mark in the upward position. Tighten
the bolts to 17-20 ft.-lb. (23.5-27.5 N•m) torque.
3
Figure 70-100-77
P-47274
Remove the two gas kets (Item 4) and oil seal (Item 5)
[Figure 70-100-74] from the cover.
P-47277
Figure 70-100-75
Figure 70-100-78
2
B-4092
Figure 70-100-79
PI-10021
Figure 70-100-82
A-2716
Put the crankshaft on V-blocks. Install a dial indicator on Crankpin Bearing I.D. 1.8504-1.8522 inch
the center journal [Figure 70-100-82].
(47,000-47,046 mm)
Figure 70-100-83
120
A-2727
Figure 70-100-85 2 2
1 1 3
PI-10023
The special tool set will be needed to replace the Figure 70-100-87
crankshaft sleeve.
B-3631
Figure 70-100-90
Measure the O.D. of the crankshaft journal [Figure 70-
100-88]. Installation Tool
5.12” (130 mm)
Figure 70-100-91
1. Seam
2. Bearing 4
3. Engine Block
4. Bearing Recession 3
PI-10025
1
2
Measure the flattened press gauge [Figure 70-100-92].
P-48778
If the c learance exceeds the allowable limit, replace the
crankshaft bearing.
Remove the front bearing with the special removal tool
[Figure 70-100-89]. Crankshaft Journal O.D. 2.3591-2.3598 inch
Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
Figure 70-100-95
B-4066
A-2717
Figure 70-100-96
3
4
B-14424
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
TIGHTEN ALL HARDWARE PER SIZE TO GRAD E 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on
Page SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.
Identification
Figure 80-10-1
1
N-22100
1
Heater Blower: The blower (Item 1) [Figure 80-10-3] is
P-28906 used to push air through the heater and into the cab.
Figure 80-10-4
Heater Unit: The heater (Item 1) [Figure 80-10-1] is
located behind the loader cab. The unit delivers the warm
air for heat into the cab. The unit contains the blower and
Figure 80-10-2
2 3
1
N-20876
Identification (Cont'd)
Figure 80-10-5
P-43854
Figure 80-20-1
P-28820
1 Figure 80-20-4
P-28819
Figure 80-20-5
P-48008
P-48006
Figure 80-20-6
P-48007
Figure 80-30-1
P-43852
1 2
The heater coil (Item 1) [Figure 80-30-2], can now b e
cleaned with low pressure water or air. High pressure
may damage the fins of the heater.
Loosen the six mounting screws for the rear cover (Item
1) [Figure 80-30-1]. The screws do not ne ed to be
completely removed, they are secured on the back with
plastic retaining washers.
Figure 80-30-3
1
2
N-22260
Figure 80-30-4
1
N-22260
Disconnect the blower fan wiring connector (Item 1) If there is a resistance value check the climate controls at
[Figure 80-30-4] from the loader wiring harness. the control panel inside the loader cab.
Figure 80-30-7 1
P-28918
1
P-28920
Figure 80-30-10
C
H
B
M
L P-28920
Figure 80-30-13
A C
1
N-22175
B
N-22290
Figure 80-30-17
N-20876
N-22175
Raise the l ift arms and install an a pproved lift arm
support device. (See Installing Lift Arm Support Device
To check the resistance of the white wire, turn the on Page 10-20-1.)
potentiometer control (Item 1) [Figure 80-30-17] to the
full Heater position.
A C Figure 80-30-20
N-22290
Raise the l ift arms and install an a pproved lift arm Replace the heater valve. (See Removal and Installation
support device. (See Installing Lift Arm Support Device on Page 80-80-1.)
on Page 10-20-1.)
Figure 80-30-22
P-43855
P-43854
Figure 80-50-1
P-30104
1
Remove the two mounting nuts (Item 1) [Figure 80-50-
N-22130 3].
Figure 80-50-4
Raise the l ift arms and install an a pproved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Figure 80-50-2
P-30103
N-22129
Figure 80-50-5
1
1
P-30149
P-30108
Remove the six mount bolts (Item 1) [Figure 80-50-6]
from the heater unit rear cover.
Remove the heater unit from the rear of the cab. Support
heater unit by placing blocks across the fr ame [Figure Remove the rear cover from the unit.
80-50-5].
Figure 80-60-1
1 1
2
1
N-22093
Remove the he ater unit from the back of the cab. (See
Removal And Installation on Page 80-50-1.)
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent coolant loss from the system.
N-22100
Figure 80-70-2
2 N-22102
Figure 80-70-5
1
2 N-22109
Inspect the end rings and fan wheel covers for wear and
N-22107 replace as needed [Figure 80-70-7].
Figure 80-70-8
Check the blower housing (Item 1) and fan motor mount
(Item 2) [Figure 80-70-5] for wear and replace as
needed.
1 1
N-22110
2 Figure 80-70-9
N-22108
N-22112
Figure 80-70-10
N-22103
N-22111
Figure 80-70-13
1
1
2
N-22104
Figure 80-70-14
1
N-22106
1 1
The wiring code for the blower fan connector [Figure 80-
N-22105 70-15] is:
Figure 80-80-1
1
3
2
4
3
N-22155
1
Remove the three mount bolts (Item 1) [Figure 80-80-2]
P-43867 from the heater valve actuator.
Figure 80-80-3
Disconnect the loader wiring harness (Item 1) [Figure
80-80-1] from the heater valve.
Cap the hoses and the heater valve with caps and plugs
to prevent coolant loss from the system.
Figure 80-80-4
1
N-22159
Figure 80-80-7
Remove the three mounting bolts (Item 1) [Figure 80-80-
4] from the heater valve mount plate.
Figure 80-80-5
1
1
N-22160
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
TIRE DESCRIPTION WIDTH (OVER TIRES) WHEEL TREAD BUCKET WIDTH WIDTH (OVER BUCKET)
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.
Performance
Rated Operating Capacity (SAE) 1300 lb. (612 kg)
Tipping Load (SAE Rating) 2600 lb. (1179 kg)
Operating Weight 4740 lb. (2150 kg)
SAE Breakout Force - Lift 2750 lb. (12233 N)
- Tilt 2800 lb. (12455 N)
Axel Torque 4900 ft.-lb. (6644 N•m)
Travel Speed 0-7.3 MPH (11,7 km/hr.)
Controls
Hydraulic System
Pumps Engine driven, Gear type
Pump Capacity 16.9 GPM (64 L/min.) @ HIGH IDLE
System Relief at Quick Couplers 2500-2700 PSI (17237-18616 kPa)
Filter Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders Doubleacting;
Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter: Lift Cylinder (2) 2.00 (50,8)
Tilt Cylinder (1) 3.50 (88,9)
Rod Diameter: Lift Cylinder (2) 1.25 (31,8)
Tilt Cylinder (1) 1.50 (38,1)
Stroke: Lift Cylinder (2) 26.57 (668,5)
Tilt Cylinder (1) 14.50 (368,3)
Control Valve 3-spool, open center type w/float detent on lift and electrically controlled
auxiliary spool.
Fluid Lines SAE standard tubelines, hoses and fittings.
Fluid Type BOBCAT FLUID, Hydraulic/Hydrostatic
6903117 - (Two - 2.5 Gal. containers)
Electrical
Alternator Belt driven, 90 amp. open
Battery 12 volt, 600 cold cranking amps. @ 0°F. (-18°C);
115 minute reserve capacity at 25 amps.
Starter (Valeo) 12 volt; Gear Reduction Type; 4.02 HP (3,0 kW)
Instrumentation Gauges: Hourmeter, Fuel, Engine Temperature.
Warning lights: Engine Coolant Temperature, Engine Oil Pressure, Hydraulic
Oil Temperature & Charge Pressure, Hydraulic Filter, Engine Air Filter,
Seat Belt, uFel Level, General Warning, System Voltage.
Indicators: Attachment Control Device (ACD), Advanced Hand Controls (AHC)
or Advanced Control System (ACS), BICS Functions, glow plugs, Headlights,
Bucket Positioning, Attachment Auxiliary Hydraulics modes
Optional Deluxe Instrumentation:
* Same gauges and warning lights as standard Instrumentation.
*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Incl.: Keyless Start with password capability, Digital Clock,
Attachments, Attachments Information, Digital Tachometer, High Flow & Two-
Speed Lockouts, Multi-Language Display, Help Screens, Diagnostic Capability
& Engine/Hydraulic Systems Shutdown Function.
Drive System
Capacities
Cooling System W/O Heater 9.2 qt. (8,7 L)
With Heater 9.8 qt. (9,3 L)
Fuel 14 Gal. (53,0 L)
Engine Oil W/Filter 9.5 qt. (9,0 L)
Hydraulic Reservoir 14 qt.(13,0 L)
Hydraulic/Hydrostatic System 6 Gal. (22,0 L)
W/Reservoir
Chaincase Reservoir 8 Gal. (30,0 L)
Tires
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Head
Valves
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinders
Piston Rings
Connecting Rod
Oil Pump
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Crankshaft
Thermostat
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(N•m) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(N•m) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
NOTE: Use t he torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].
1
Nut Nut
Washer 2
Washer
O-ring
O-ring
TS-1619
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
TS-1619
1
P13573
1
Port Seal Fitting Port seal and nut, wa sher and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
Figure SPEC- 40-9
If a torque wrench cannot be us ed, use the fol lowing
method.
Tighten the nut with a wrench no more than one hex flat
maximum.
P13008
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
Diesel fuel or hy draulic fluid unde r pressure can five minutes at less than half throttle. This warm-up
penetrate skin or eyes, causing serious injury or period is necessary for foot pedal operation and safe
death. Fluid leaks under pressure may not be visible. stopping. Do not operate controls during warm-up
Use a piece of cardboard or wood to find le aks. Do period.
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention When temperatures are below -20°F (-30°C), the
from a physician familiar with this injury. hydrostatic oil m ust be heated or kept warm. The
W-2072-0496 hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
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